DeVillbiss Air Power Company C102D
Contents
1. O o o When you have finished using the air compressor 1 Set the ON OFF switch to OFF and unplug the 3 Protect the electrical cord and air hose from damage cord by winding them loosely around the air compressor 2 Relieveallpressurefromtheaircompressorheadand 4 Store the air compressor in a clean and dry location air hose by setting the adjustable pressure valve to 10 P S I DUTY CYCLE All DeVilbiss Air Power manufactured air compressors should be operated on not more than a 50 duty cycle This means an air compressor that pumps more than 50 of one hour is considered misuse because the air compressor is undersized for the required air demand Maximum compressor pumping time per hour is 30 minutes a DESCRIPTION OF OPERATION Air Compressor Pump To compress air the piston moves up and down in the cylinder On the downstroke airis drawn in through the air intake muffler valves The exhaust valve remains closed On the upstroke of the piston air is compressed The intake valves close and compressed air is forced out through the exhaust valve and then through the air hose Adjustable Pressure Valve The pressure valve controls the amount of pressure going from the air compressor to the accessory The pressure adjusting valve can be used to set approximate pressure between 10 and 125 P S I 125 P S I is the highest pressure this compressor will deliver Itis normal forthe adjustable pressure valve to releas2. CAC 1196 Cylinder Head Tube Seal Head Gasket CAC 4323 Valve Plate Assembly A 9 Ring CAC 1289 Outlet Tube Rod Assembly Screw 3 8 16 x 1 25 LG hex socket flat head torque to 350 in Ib Cylinder Sleeve CAC 4111 Endbell Assembly CAC 1342 Timing Belt Pump Isolator 5 required DAC 163 Shroud right for 102D 1 DAC 168 Shroud right for C102D 1 SSS 16 Switch Tank Isolator 4 required Motor Baffle right Motor Baffle left CAC 1285 Isolator tube CAC 4322 1 Cord Assembly DAC 162 Shroud left for 102D 1 DAC 167 Shroud left for C102D 1 Screws 5 used KK 4949 Isolator Kit includes Items 3 4 6 13 16 34 35 27 KK 4929 Fastener Kit includes items 1 9 22 25 KK 4980 Baffle Kitincludes items 17 18 KK 4926 Connecting Rod Kit includs items 8 10 Compressor Pump Diagram Parts List KEY NO PART NUMBER DESCRIPTION 23 CAC 1206 Clamp 2 used 24 CAC 4324 Pressure Valve Assembly for 102D 1 CAC 4076 Pressure Valve Assembly for C102D 1 Dn Ground Screw 26 SSP 6102 Male Connector mn Screw tank retention as required 28 SSP 3305 NI Pipe Cross 29 TIA 4150 Safety Valve 30 H 2105 Hose Connection 31 SS 1286 Nipple 33 SS 2707 Drain Cock 3A wees Screw self tapping 35 ooo Recess Bumper NOTILLUSTRATED SSH 8 Air Chuck H 2099 Adapter KK 49499 Isolator Kit includes items 3 4 6 13 16 34 35 27 12 Attach Sales Receipt Here Retain Original Sale
3. E ccccccccccccnnnncnnncnnnnn 8 UNPACKINGINSTRUCTIONS conocccccccoccccccccccccccnnos 5 AIR COMPRESSOR DIAGRAM STORAGE iii dial ibi 5 ANDPARTS LIST Trueni einai 9 10 DUTY GY CLE tien ik ee ict fee 5 COMPRESSOR PUMP DIAGRAM AND PARTS LIST ccccceesessseeeeeessseseeeeess 11 12 DESCRIPTION OF OPERATION cccceceeeeeeees 6 HOW TO ORDER REPAIR PARTS 13 INSTALLATION AND BREAK IN PROCEDURES 3 comicidad inici 6 In the unlikely event you should have a problem with this product or if you are missing any parts itis not necessary to return itto the store where you purchased it Simply call our toll free number and talk with our Service Representative OUR OFFICE HOURS ARE FROM 8 a m to 4 30 p m CST MONDAY THROUGH FRIDAY CALL TOLL FREE 1 800 888 2468 Ext 2 LIMITED WARRANTY ONE YEAR FROM DATE OF PURCHASE All merchandise manufactured by DeVilbiss Air Power Company is warranted to be free of defects in workmanship and material which occur during the first year from the date of purchase by the original purchaser initial user Products covered under this warranty include air compressors air tools accessories and service parts DeVilbiss Air Power will repair or replace at DeVilbiss s option products or components which have failed within the warranty period Repair or replacement and service calls on 60 and 80 gallon air compressors will be handled by Authorized Warranty Service Cent
4. OWNERS MANUAL FOR PERMANENTLY LUBRICATED AIR COMPRESSOR MODEL NO 102D 1 For Home Use Only SPECIFICATION CHART Model No 102D 1 C102D 1 Horsepower 3 4 SCFM 40 psig 3 0 3 0 SCFM 90 psig 2 2 2 2 Displacement CFM 4 0 4 0 Bore 1 3 4 13 4 Stroke 1 1 4 11 4 Voltage Single Phase 110 120 110 120 Minimum Branch Circuit Requirement 15AMPS 15AMPS Fuse Type Quick Acting Quick Acting Tank Size 2 Gallon 2 Gallon A circuit breakeris preferred Use only afuse or circuit breaker that is the same rating as the branch circuit the air compressor is operated on If the air compressor is connected to a circuit protected by fuses use quick acting fuses This unit is a continuous run unit It does not start and stop automatically NOTE IMPORTANT WARRANTY Foridentification of RepairParts Read and Retain the Safety For Warranty Information see separate Parts List Manual Guidelines and All Instructions see page 3 of this manual Carefully Before Operating DeVilbiss Air Power Company 213 Industrial Dr Jackson TN 38301 9615 MGP 102D 2 2 1 94 TABLE OF CONTENTS Page Page WARRANTY incisiones 3 Location of Air Compressor occcccincnnccncacnncnnnos 6 Extension Cords edson ease oeiy taraia inaa 6 SAFETY GUIDELINES rissin narii 4 Grounding Instructions s e 6 Air HOSE 2 nee ee 7 WARNING CHART cccccesessseeeeeesssseeeeeeeeeesseaes 4 5 OPERATING PROCEDURES onsas 7 GLOSSARY aiita ecient eit 5 TROUBLESHOOTING GUID
5. URES Do not modify the plug that has been provided If it Air Hose does not fit the available outlet the correct outlet should be installed by a qualified electrician The air hose attached to your comporessor has an integral pressure adjusting valve at the working end of the hose Should service or replacement be required make sure that the pressure adjusting valve is present in the air hose line wires Never connect the grounding wire to a flat blade DO NOTREPLACE THE HOSEWITH STANDARD HOSE plug terminal The grounding wire has insulation with an outer surface that is green with or without yellow ii A WARNING If these grounding instructions are not completely understood or if in doubt as to whether the compres sor is properly grounded have the installation checked by a qualified electrician If repairing or replacing cord or plug the grounding wire must be kept separate from the current carrying THAT IS NOT EQUIPPED WITH THE PRES SURE ADJUSTING VALVE 120 Volt Models White CAUTION f l Wire l Ground Donotallow hoseto become kinked orpinched atanytime This is importantto avoid damage to your compressor and to maintain pressure adjusting valve control 15 AMP PLUG OUTLET GROUNDED OUTLET GROUNDING 2 PIN 120 Volts 15 Amps OPERATING PROCEDURES 1 Before plugging in the air compressor set the adjust 5 Check the manufacturer s maximum pressure rating able pressure valve to 10 PSI Make sure
6. e air during operation A WARNING ALWAYS SET THE PRESSURE VALVE AT OR BELOW THE REQUIRED PRESSURE FORTHE ACCESSORY BEING USED BEFORE START ING YOUR COMPRESSOR FOR INFLATION OR OTHER USES REQUIRING ACCURATE PRESSURE USE A PRESSURE GAUGE Accumulator Tank Your accumulator tank is equipped with a relief pop off valve to prevent an over pressure condition in the tank This 2 gallon tank is not designed to store air but rather to provide the additional volume of compressed air necessary to operate a wide variety of air tools When starting your compressor attach the tool to the hose set the pressure adjusting valve at the required pressure wait a few moments until the tank fills with air You will know the tank is filled when you hear air bleeding through the pressure adjusting valve Depending on the type and size of tool being used you will occasionally need to wait for the tank to refill before continuing When you are finsihed or changing tools turn the compressor switch off and set the pressure adjusting valve to 10 PSI and wait for the tank to discharge completely INSTALLATION AND BREAK IN PROCEDURES Location of the Air Compressor Your compressor comes to you completely assembled and ready for use Operate the air compressor in a dry clean cool and well ventilated area The air compressor pump and case are designed to allow for proper cooling Clean or blow off dust or dirt that collects on the air compressor A c
7. em Read and follow the safety instructions provided on the label or safety data sheet for the material you are spraying Use a respirator mask if there is a chance of inhaling anything you are spraying Read all instruc tions be sure that the respirator mask is suitable for your application Unsuitable The solvents 1 1 1 Trichloroethane and Methylene Read the label or data sheet supplied with the material Solvents Chloride can chemically react with aluminum used in you intend to spray If it contains the solvents listed do paint spray guns paint pumps etc and cause an not use accessories that contain aluminum or galva explosion These solvents can also react with galva nized parts You must either change the material you nized components and cause corrosion and weaken intend to spray or use only stainless steel spray equip ing of parts This does not affect your air compressor ment but it may affect the equipment being used GLOSSARY SCFM or CFM Standard Cubic Feet per Minute a unit of measurement of air delivery PSIG or PSI Pounds per square inch gauge U L Listed Products with the U L mark are listed by Underwiters Laboratories Inc U L Samples of these products have been evaluated by U L and meet the applicable U L Standards of Safety UNPACKING INSTRUCTIONS Grasp the handle and lift the air compressor out of the carton Remove the styrofoam and or cardboard and STORAGE o o
8. ers and will be scheduled and serviced according to the normal work flow at the service center location and depending on the availability of replacement parts All decisions of DeVilbiss Air Power Company with regard to this policy shall be final This warranty gives you specific legal rights and you may also have other rights which vary from state to state RESPONSIBILITY OF ORIGINAL PURCHASER Initial User 1 Retain original sales receipts as proof of purchase for warranty work 1 Use reasonable care in the operation and maintenance of the product as described in the Owners Manual s 1 Deliver or ship the product to the nearest DeVilbiss Air Power Authorized Warranty Service Center Freight costs if any must be paid by the purchaser 1 Air compressors with 60 and 80 gallon tanks only will be inspected at the site of installation Contact the nearest Authorized Warranty Service Center that provides on site service calls for service call arrangement 1 If the purchaser does not receive satisfactory results from the Authorized Warranty Service Center the s Air Power Company THIS WARRANTY DOES NOT COVER L Merchandise sold as reconditioned floor models and or display models sold as is any damaged or incomplete equipment sold as is 1 Merchandise used as rental equipment 11 Merchandise that has become inoperative because of ordinary wear misuse negligence accident improper and or unauthorized repai
9. know and understand This information relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS To help you recognize this information we use the following symbols Please read the manual and pay attention to these sections Information for preventing damage to equip URGENT SAFETY INFORMATION A HAZARD THAT WILL CAUSE SERIOUS INJURY OR LOSS OF LIFE CAUTION A WARNING IMPORTANT SAFETY INFORMATION A HAZARD THAT MIGHT CAUSE SERIOUS INJURY OR LOSS OF LIFE NOTE Information that you should pay special ment attention to HAZARDS CAN OCCUR IF EQUIPMENT IS NOT USED PROPERLY PLEASE READ THE FOLLOWING CHART WHAT TO WHAT LD HAPPEN LOOKFOR COU HOW TO PREVENT IT Hot Parts When operated continuously the air hose gets hot Never touch the air compressor head during or imme especially near the compressor If you maintain con diately after operation tact by grasping you may suffer minor burns or dis comfort On tank mounted units the plumbing between the On tank mounted units avoid prolonged contact with pump and tank gets hot the pump to tank plumbing Flammable Itis normal forthe motor and pressure switch to spark The air compressor must only be used in well ventilated Vapors A spark can ignite flammable vapors from gasoline or areas free of gasoline or solvent vapors solvents causing a fire or explosion Do not operate the compressor while you are carrying it or in the spray area Com
10. lean air compressor runs cooler and provides longer service The ventilation openings on your air compressor are necessary to maintain proper operat ing temperature Do not place rags or other containers on or near these openings Extension Cords Use extra air hose instead of an extension cord to avoid voltage drop and power loss to the motor If an extension cord must be used be sure it is e a 3 wire extension cord that has a 3 blade grounding plug and a3 slot receptacle that will accept the plug on the compressor e in good condition e no longer than 50 feet e 14 gauge AWG or larger Wire size increases as gauge number decreases 12 AWG 10 AWG and 8 AWG may also be used DO NOT USE 16 OR 18 AWG o GROUNDING INSTRUCTIONS A WARNING RISK OF ELECTRICAL SHOCK In the event of a short circuit grounding reduces the risk of shock by providing an escape wire for the electric current This air compressor must be properly grounded The air compressor is equipped with a cord having a grounding wire with an appropriate grounding plug The plug must be used with an outlet that has been installed and grounded in accordance with all local codes and ordinances The outlet must have the same configuration as the plug See illustration DO NOT USE AN ADAPTER Inspect the plug and cord before each use Do not use if there are signs of damage IMPROPER GROUNDING CAN RESULT IN ELEC TRICAL SHOCK INSTALLATION AND BREAK IN PROCED
11. pressed Compressed air can propel dust dirt or loose particles Never point any nozzle or sprayer toward a person or Air itcomes in contact with These propelled particles may any part of the body cause serious injury or damage Too much air pressure applied to air tools or accesso ries can cause damage or risk of bursting Always wear safety goggles or glasses when using the air compressor Always turn the air compressor off before attaching or removing accessories Check the manufacturer s pressure rating for air tools and accessories Regulator outlet pressure must never exceed the maximum pressure rating WHATTO WHAT COULD HAPPEN HOW TO PREVENT IT LOOKFOR Always unplug the air compressor prior to maintenance Electricity Your air compressor is powered by electricity Likeany or repair other electrically powered device if it is not used properly it may cause electrical shock Never use the air compressor in the rain Always plug the cord into an electrical outlet with the specified voltage and adequate fuse protection Toxic Vapors It is normal for compressed air to contain toxic or Never directly inhale the compressed air produced by irritating vapors Such vapors are harmful if inhaled this unit Certain materials you are spraying like paint weed Read labels and safety data for all materials you spray killer sand or insecticide can be harmful if youinhale Follow all safety precautions th
12. r or alterations including failure to operate the product in accordance with the instructions provided in the Owners Manual s supplied with the product 1 An air compressor that pumps air more than 50 during a one hour period is considered misuse because the air compressor is undersized for the required air demand Maximum compressor pumping time per hour is 30 minutes 1 Merchandise sold by DeVilbiss Air Power which has been manufactured by and identified as the product of another company The product manufacturer s warranty will apply 1 Repair and transportation costs of merchandise determined not to be defective 1 Cost associated with assembly required oil adjustments or other installation and start up cost T ANY INCIDENTAL INDIRECT OR CONSEQUENTIAL LOSS DAMAGE OR EXPENSE THAT MAY RESULT FROM ANY DEFECT FAILURE OR MALFUNCTION OF THE PRODUCT Some states do not allow the axclusion or limitation of incidental or consaqtentialriagmagesiveobiidesabovesidaitaticinao vic asic mhere oye they are warranted for a period of 45 dayapfrom per Cho RO WARF GED compan NESS FOR A PAS IGULA 213 Industrial Drive _ Jackson TN 38301 9615 Telephone _ 1 800 888 2468 Ext 2 FAX 1800 388 DI IRPC AR gt ON AR RON dal R NLA DI IRC HA Ome states do not 3 allow limitations on how long an implied warranty lasts so the above limitations may not apply to SAFETY GUIDELINES This manual contains information that is important for you to
13. s Receiptas OWNERS MANUAL FOR Proof of Purchase for Warranty PERMANENTLY Repair Work LUBRICATED AIR COMPRESSOR WARRANTY This product is covered by the MODEL NOS DeVilbiss one year limited 102D 1 warranty SP 100 C The For Home Use Only warranty can be found in the General Manual or is available upon request An Authorized Warranty Service Center Directory is included with your unit When ordering repair parts from your local Authorized Service Center always give the following information e Model number of your compressor e Part number and description of the item you wish to purchase If you have any questions or need the location of the nearest Authorized Service Center call our Customer Service Hotline Toll Free 1 800 888 2468 Ext 2 Monday thru Friday 8 00 a m to 4 30 p m CST and talk with our Trained Customer Service Representatives The Model number can be The Date Code number can The Manufactures found on the maintenance be found on the foil label on Number ASME code label on the side of the tank the air tank compressors only is located on the metal data plate which is welded on to the backside of the air tank DeVilbiss Air Power Company 213 Industrial Drive Jackson TN 38301 9615
14. se of air Hole in hose Air leaks Decrease the amount of air usage Your com pressor is not large enough for the air require ment Replace the hose Tighten fittings Motor will not run Fuse blown circuit breaker tripped Extension cord is wrong length or gauge Loose electrical connections Faulty motor _ Check fuse box for blown fuse and replace as necesssary Reset circuit breaker Do not use a fuse or circuit breaker with higher rating than that specified for your particular branch circuit Check for proper fuse You should be using a Quick Acting fuse Check for low voltage problem Check the extension cord Disconnect the other electrical appliances from circuit or operate the compressor on its own branch circuit Check the extension cord Check wiring connection inside terminal box Have checked at a local Service Center High discharge pressure Cannot be adjusted lower Adjustable pressure valve notfunc tioning A WARNING RISK OF BURSTING DO NOT OPER ATE THE COMPRESSOR IF THIS PROB LEM EXISTS ADJUSTABLE PRESSURE VALVE MUST BE REPLACED Air Compressor Diagram POWER CORD GREEN GROUND WIRE Slide 19 over 7 as shown Make sure that no part of 7 tube touches 21 or 14 shroud when assembled Parts List 10 K N on 00 JJOO AODON vo PARTNUMBER DESCRIPTION Screw 10 24 x 7 8 LG hex head thd forming 4 required
15. the ON for the air tool accessory or vehicle tire being used OFF switch is in the OFF position The air compressor outlet pressure must never exceed the maximum pressure rating 2 Connect the air tool or accessory to the air hose Tighten securely 6 Slowly increase the pressure setting of the adjustable pressure valve You should be able to hear and feel air 3 Plug the power cord into the grounded outlet pressure being relieved by the adjustable pressure valve If pressure is not being relieved turn the air 4 Start the compressor by setting the ON OFF switch compressor off immediately The pressure valve must to the ON position be replaced A WARNING Compressed air from the outfit may contain TOO MUCH AIR PRESSURE COULD CAUSE AN water condensation Do not spray unfiltered air AIR TOOL OR VEHICLE TIRE TO RUPTURE OR at an item that could be damaged by moisture EXPLODE CAREFULLY FOLLOW STEPS5 AND Some air operated tools or devices may require 6 EACH TIME YOU USE YOUR COMPRESSOR filtered air Read the instructions for the air tool or device TROUBLESHOOTING GUIDE A WARNING VOLTAGE SOURCES MOVING PARTS OR COMPRESSED AIR SOURCES ARE EXPOSED WHEN REPAIRING THE COMPRESSOR PERSONAL INJURY CAN OCCUR UNPLUG THE COMPRESSOR BEFORE ATTEMPTING ANY REPAIRS PROBLEM CAUSE SOLUTION Air Leaks Hose fitting loose Tighten fitting Compressor is not delivering enoughair Prolonged excessive u
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