2 HP / 4 GALLON AIR COMPRESSOR - Northern Tool

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2 HP / 4 GALLONAIR COMPRESSOROWNER'S MANUALWARNING:Read carefully and understand all INSTRUCTIONS beforeoperating. Failure to follow the safety rules and other basicsafety precautions may result in serious personal injury.Item # 123008

READ ALL INSTRUCTIONSBEFORE OPERATINGSPECIFICATIONSMotor.120V 60HzHP.2Weight.59.5 lbsTank Capacity .4 GallonAir Pressure .115 psiCFM .5.5 CFM@40 PSI.3.5 CFM@90 PSICSA Listed .SAVE THESE INSTRUCTIONSThank you for purchasing your Northern IndustrialTMAir Compressor. Before attempting to operate yournew tool please read these instructions thoroughly.You will need these instructions for the safetywarnings, precautions, assembly, operation andmaintenance procedures.WARNING: The warnings, cautions andinstructions discussed in this instruction manualcannot cover all possible conditions or situationsthat could occur. It must be understood by theoperator that common sense and caution arefactors which cannot be built into this product, butmust be supplied by the operator.TABLE OF CONTENTSDescriptionPage #Specifications .1Safety rules .2Know Your Tool.3Getting Started .3Assembly .3Operation.4Maintenance .6Troubleshooting.7Parts List and Diagram.81

SAFETY RULES16. Check for damage. Check your tool regularly. Ifpart of the tool is damaged it should be carefullyinspected to make sure that it can perform itsintended function correctly. If in doubt, the partshould be repaired. Refer all servicing to a qualifiedtechnician. Consult your dealer for advice.17. Keep away from flammables. Do not attempt tooperate this tool near flammable materials orcombustibles. Failure to comply may causeserious injury or death.18. Store idle tools out of the reach of children anduntrained persons. Tools may be dangerous inthe hands of untrained users.19. Maintain tools with care. Keep tools sharp andclean. Properly maintained tools, with sharpcutting edges, are less likely to bind and areeasier to control.20. Never exceed the pressure rating of anycomponent in system.21. Protect material and air lines from damage orpuncture. Keep hose and power cable awayfrom sharp objects, moisture, chemicals, oil, etc.22. Check condition of hoses before each use. Donot use a damaged hose. If hose is damaged,replace immediately.23. Read, understand and comply with all warninglabels on unit.24. Drain tank of moisture after each use. IfCompressor is not to be used for extendedperiods of time, leave tank drain valve open toallow moisture to completely drain from tank.25. Do not tamper with Safety Valve. The SafetyValve is factory set for your model aircompressor. Any user adjustments to SafetyValve will automatically void warranty.26. Air compressors get hot while in operation.NEVER touch the motor, discharge tubing orcompressor pump while in operation.27. The Compressor operates automatically whilethe motor is turned on.28. Compressed air from the unit may containcarbon monoxide. Air produced is not suitablefor breathing purposes.29. Always use a respirator when spraying paintor chemicals.30. The air pressure switch is set at the factory foroptimum performance of your equipment. Neverattempt to bypass or remove this switch asserious damage to equipment or personal injurycould result from excessive air pressure.1. Know your tool. Read this manual carefully.Learn the tool’s applications and limitations, aswell as specific potential hazards peculiar to it.2. Ground all tools. If the tool is equipped with threepin plug, it should be plugged into a three-pinelectrical socket. Never remove the ground pin.3. Avoid body contact with grounded surfaces suchas pipes, radiators, ranges, and refrigerators.There is an increased risk of electric shock ifyour body is grounded.4. Do not expose tool to moisture. Don’t use thistool in damp or wet locations. Keep out of rain.5. Do not abuse cord. Never use the cord to carrytools or pull the plug from an outlet. Keep cordaway from heat, sharp edges or moving parts.Replace damaged cords immediately. Damagedcords increase the risk of electric shock.6. Remove adjusting keys or wrenches beforeturning the tool on. A wrench or key that is leftattached to a moving part of the tool may resultin personal injury.7. Keep work area clean and well lit. Cluttered ordark work areas invite accidents.8. Keep children away. All children should be keptaway from the work area. Never let a childhandle a tool without strict adult supervision.9. Do not operate this tool if under the influence ofalcohol or drugs. Read warning labels onprescriptions to determine if your judgment orreflexes are impaired while taking drugs. If thereis any doubt, do not attempt to operate.10. Use safety equipment. Eye protection should beworn at all times when operating this tool. UseANSI approved safety glasses. Everydayeyeglasses are NOT safety glasses. Dust mask,non-skid safety shoes, hard hat, or hearingprotection should be used in appropriate conditions.11. Wear proper apparel. Loose clothing, gloves,neckties, rings, bracelets, or other jewelry maypresent a potential hazard when operating thistool. Please keep all apparel clear of the tool.12. Don’t overreach. Keep proper footing andbalance at all times when operating this tool.13. Always disconnect the tool from power sourcebefore making any adjustments, storing,servicing, or changing accessories. Suchpreventative safety measures reduce the risk ofstarting the tool accidentally.14. Do not force tool. Use the correct tool for yourapplication. The correct tool will do the job betterand safer at the rate for which it was designed.15. Do not use the tool if the switch does not turn iton and off. Any tool that cannot be controlled withthe switch is dangerous and must be repaired.2

KNOW YOUR COMPRESSORHandlePowerSwitchAir Filter: This heavy duty metal air filter keepsyour compressor running cleanly, by filtering outimpurities.Oil Breather Cap: As the compressor motoroperates pressurized air must be released from thecrank case. The oil breather cap allows built up airto escape, while shielding your air compressor fromairborne impurities.Power Switch: The red tipped power switch turnsthe air compressor on and off. When switch ispulled up, compressor is turned ON. When switch ispushed down, compressor is turned OFF.Note: Always make sure that compressor PowerSwitch is in the OFF position beforeperforming any maintenance or plugging thecompressor into a power supply.Pressure Gauges: These dual gauges indicate theamount of air pressure built up in the air tank, aswell as the air pressure being delivered to the airchuck.Safety Valve: The Safety Valve device relievespressure from the Air Tank in the event of excessivepressure build up. The Safety Valve is preset atfactory. Do not attempt to make any adjustments tothe Safety Valve. Periodically pull the ring on theSafety Valve end to check that it is working properly.Air Tanks: Two powder coated steel tanks, with a 4gallon capacity, stores the compressed air until it isneeded.Air tyValueAirChuckPressureGaugesAirTanksGETTING STARTEDBefore operating your tool, check the contents ofthe box to make sure you have everything youwill need.Items included in the box:Air CompressorAir FilterOil Breather CapBottle of OilOwner’s ManualFigure 1. Air CompressorHandle: Convenient, rubber gripped handle allowsfor easy transport of your air compressor.Air Regulator: The air regulator controls the airflow pressure. Turn regulator clockwise to increaseair pressure, counter-clockwise to decrease airpressure.Air Chuck: Convenient quick disconnect air chuckallows for fast easy connection to an air hose.Tank Drain Valve: The Tank Drain Valve can beopened to allow moisture and compressed air to bereleased from the Air Tank.ASSEMBLYNOTE: Before performing any assembly ormaintenance make sure compressor is turned offand unplugged from the power supply.Installing the Oil and Oil Breather CapYour air compressor is shipped without oil in thecrankcase. BEFORE STARTING THE AIRCOMPRESSOR YOU MUST ADD OIL TO THECRANKCASE AS DESCRIBED BELOW:1. Place compressor on level ground.2. Remove the Oil Shipping Plug from the Oil Fillhole, located on the top of the crankcase coverat the rear of the air compressor.WARNING! Tank Drain Valve should always beopened slowly to avoid damage to equipment andpossible injury.3

Installing the Air FilterThe metal Air Filter is installed into the threadedport of the cylinder head.1. Thread the Air Filter into the Cylinder Head byturning the Air Filter clockwise.2. Securely tighten the Air Filter in place with awrench.(See Figure 4)3. Slowly pour the oil into the Oil Fill hole, until theoil level rises to the center of the red dot on theOil Sight Glass.Note: This compressor uses only SAE 5W-30motor oil.4. Install the Oil Breather Cap into the Oil Fill hole.5. Firmly hand tighten the Oil Breather Cap byturning clockwise.(See Figure 2)OilFillCrankcaseOilSightGlassFigure 4. Installing the Air FilterDrainPlugNote: DO NOT over tighten Air Filter.OPERATIONFigure 2. Installing the Oil & Oil Breather CapBEFORE OPERATING YOUR NEW AIRCOMPRESSOR please check the following pointscarefully:1 Check that all nuts and bolts are secure.2. Make sure oil has been properly added tocompressor. (See Installing Oil and Oil BreatherCap section.)Installing the Air ChuckNote: The use of a sealant tape is recommendedon the threads of the Air Chuck to prevent airleakage.1. Thread the Air Chuck into the Air Regulator byturning the Air Chuck clockwise.2. Securely tighten the Air Chuck in place with awrench. (See Figure 3)Initial Start-Up Procedure1. Open the Air Tank Drain Valve to permit air toescape, preventing air pressure buildup in theair tank.2. Run the compressor for a minimum of 20minutes in this “no-load” position to lubricate thepiston and bearings.3. Close Air Tank Drain Valve. Your compressor isready for use.Depending on the CFM draw of the tools beingoperated, your new Air Compressor can be used foroperating paint sprayers, air tools, grease guns,airbrushes, caulking guns, abrasive blasters, tire &plastic toy inflation, spraying weed killer andinsecticides, etc. Proper adjustment of the AirPressure Regulator is necessary for all of theseoperations. Refer to the air pressure specificationsprovided with the tool you are using.Figure 3. Installing the Air ChuckNote: DO NOT over tighten Air Chuck.4

General OverviewTo compress air, the piston moves up and down inthe cylinder. On the down stroke air is drawn inthrough the valve inlet. The discharge valve remainsclosed. On the upstroke of the piston air iscompressed. The inlet valve closes and air is forcedout through the discharge valve, through the checkvalve, and into the air tank. Working air is notavailable until the compressor has raised the tankpressure above that required at the air serviceconnection. The air inlet filter openings must bekept clear of obstructions, which could reduce airdelivery of the compressor.Attaching an Air HoseYour Air Compressor is supplied with a 1/4" QuickDisconnect Air Chuck. Once you have correctlyinstalled the Air Chuck (See Installing the Air Chuckon p.4) your compressor will be ready to accept airhoses equipped with 1/4" male air couplers.Note: Use only air hoses rated for use with 115psiair pressure or higher.To install an air hose, equipped with a 1/4" malecoupler:1. Pull back on Air Chuck outer sleeve to allowcoupler to be fully inserted into Air Chuck.2. Insert coupler into Air Chuck.3. Release outer sleeve of Air Chuck.4. Verify that air hose is securely connected to AirChuck by pulling lightly on air hose.(See Figure 5)Installation and LocationLocate the compressor in a clean, dry and wellventilated area. The compressor should be located12 to 18 inches from walls or any other obstructionwhich would interfere with airflow. Place thecompressor on a firm, level surface. Thecompressor is designed with heat dissipation finswhich allow for proper cooling. Keep the fins (andall other parts which collect dust or dirt) clean. Aclean compressor runs cooler and provides longerservice. Do not place rags, containers or othermaterial on top of the compressor.Figure 5. Attaching an Air HoseAdjusting the Air PressureYour Air Compressor is supplied with an AirPressure Regulator. This Regulator adjusts the airpressure.To increase air pressure, turn Air Regulatorclockwise.To decrease air pressure, turn Air Regulatorcounterclockwise.Connecting to Power SourceThis air compressor is designed to operate on aproperly grounded 120 volt, 60Hz, single phase,alternating current (ac) power source with a fused20 amp time delayed fuse or circuit breaker. It isrecommended that a qualified electrician verify theACTUAL VOLTAGE at the receptacle into which theunit will be plugged and confirm that the receptacleis properly fused and grounded. The use of theproper circuit size can eliminate nuisance circuitbreaker tripping while operating your air compressor.Extension CordsFor optimum Air Compressor performance anextension cord should not be used unlessabsolutely necessary. If necessary, care must betaken in selecting an extension cord appropriate foruse with your specific Air Compressor. Select aproperly grounded extension cord which will matedirectly with the power source receptacle and theAir Compressor power cord without the use ofadapters. Make certain that the extension cord isproperly wired and in good electrical condition.Maximum length of extension cord should be 50feet. Minimum wire size of extension cord should be12 gauge.(See Figure6) 6. Adjusting the Air PressureFigureCold Weather StartingTemperatures below freezing (32 F) cause themetal parts of your Air Compressor to contract andthat makes starting more difficult. To assist the AirCompressor in starting in cold weather, follow5

compressor.Changing the Air Compressor OilNote: This compressor uses only SAE 5W-30motor oil.1. Remove the Drain Plug under the Oil SightGlass by turning the nut counter-clockwise withwrench. (See Figure 2.)Note: Oil will begin to drain as Drain Plug isloosened. Place a funnel and oil pan in placeBEFORE loosening Drain Plug.2. Once Drain Plug is removed, tilt Air Compressorbackwards to allow all of the oil to drain out ofthe crankcase.3. Once oil is drained, replace Drain Plug andsecurely tighten in place with a wrench. Becareful not to overtighten the Drain Plug, as thiscould damage the rubber seal.4. Place Air Compressor on level surface.5. Remove the Oil Breather Cap.6. Slowly pour the oil into the Oil Fill hole, until theoil level rises to the center of the red dot on theOil Sight Glass.7. Install the Oil Breather Cap into the Oil Fill hole.Firmly hand tighten the Oil Breather Cap byturning clockwise.these tips:1. Try to keep Air Compressor stored intemperatures above 32 fahrenheit.2. Open the Air Tank Drain Valve and release allair pressure from the Air Tank before attemptingto start in cold weather. (After air is released3. Plug Air Compressor directly into a 120 voltelectrical outlet. Do not use an extension cordwhen starting your Air Compressor in coldweather.MAINTENANCEDaily (or before each use)1. Check oil level2. Drain condensation from the air tank.3. Check for any unusual noise or vibration.4. Be sure all nuts and bolts are tight.Weekly1. Clean breather hole on Oil Breather Cap.Monthly1. Inspect air system for leaks by applying soapywater to all joints. Tighten these joints if leaksare discovered.Always inspect the tool before use, and make sureit is in good working condition. Make sure all airvents are clear, (use compressed air to clean themachine where possible). Check the power cable tomake sure it is intact and free from cracks, barewires etc. Avoid using solvents when cleaningplastic parts. Most plastics are susceptible todamage from the various types of commercialsolvents.6 Months (or after 250 hours of operation whichever comes first)1. Change Air Compressor Oil.Note: Change oil more often if Air Compressor isused near paint spraying operations or in dustyenvironments.Checking the Air Compressor Oil1. Place Air Compressor on level surface. The oillevel should be at the red dot on the Oil SightGlass.2. If oil level is low, remove Oil Breather Cap andadd enough oil to bring the oil level to the reddot on the Oil Sight Glass.3. Replace Oil Breather Cap before starting6

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Part criptionPlastic HousingSpring WasherWasherScrew M5x14FanScrew M5x115Rear CapWasherBearing 6202StatorRotorStarting CapacitorRunning CapacitorBearing 6204Oil SealNut M8CrankcaseCrankshaftScrew M8x16 (lefthand)GasketCrankcase CoverOil Sight GlassPart escriptionDrain PlugPan Head ScrewOil Breather CapSpring Washer 8Washer 8Screw M8x20Connecting RodPistonSpring WasherPiston PinCylinder GasketCylinderSpring Washer 6Washer 6Screw M6x40GasketSealer RingValve GasketValve Plate AssyAir Intake ValveLimit PinCylinder GasketMetal Air Filter8Part iptionCylinder HeadElbow ExhaustExhuast PipeCheck ValveUnload PipeAir TankTank Drain ValveRubber FeetScrew M6x20/ Nut M6Power CordRubber GasketCentrifugal SwitchRubber GripSafety ValvePressure GaugePressure SwitchConnectorPressure GaugeRegulatorAir ChuckFrame Assy

Air Tanks:Two powder coated steel tanks, with a 4 gallon capacity, stores the compressed air until it is needed. GETTING STARTED Before operating your tool, check the contents of the box to make sure you have everything you will need. Items included in the box: Air Compressor Air Filter Oil Breather Cap Bottle of Oil Owner’s Manual ASSEMBLY /p div class "b_factrow b_twofr" div class "b_vlist2col" ul li div strong File Size: /strong 331KB /div /li /ul ul li div strong Page Count: /strong 10 /div /li /ul /div /div /div

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