Instruction Manual

2.5HP 40 Litre Air Compressor

Introduction 3Environmental Responsibilities 3General Safety Instructions 3Electrical Safety 4Use of Extension Cords 4Additional Safety Instructions 4-5The Compressor & Its Components 5Assembly & Operating Instructions 6-7Automatic On/Off Switch 7Overload Protection / Reset Procedure 7Pressure Gauges 8Pressure Regulator 8Safety Valve 8Compressor Set-Up 8Shutting Down Your Compressor 9Maintenance 9Trouble Shooting 9Exploded Diagram 10Parts Listing 10Warranty Details 11If You Have a Problem 12Supplier Contact Details 12

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Index

Introduction.

Project Air Compressors have been manufactured under stringent Quality Standards to meet the performance criteria set by Spear & Jackson.After familiarization you will find this compressor both easy and safe to operate.

Read the instruction manual completely before using your new Project Air Compressor.

Project Air compressors have many features which will make your DIY projects faster and easier.

Please ensure all waste and unwanted products and are disposed of in a safe and environmentally friendly manner.

Environmental Responsibilities.

When using this product, basic safety precautions should always be followed:

DO NOT OPERATE A COMPRESSOR WHEN UNDER THE INFLUENCE OF ALCOHOL OR DRUGS.

1. Read all instructions prior to using the product.2. To reduce the risk of injury, close supervision is necessary when the compressor is in use

near children or infirm persons.3. Know how to stop the compressor and be able to reduce the pressure immediately.4. Be completely familiar with all the controls.5. Please secure or cover any long hair, clothing or jewelry prior to using this compressor.6. Do not reach over machines with moving parts when in operation.7. Please ensure that any potential trip or slip hazard is removed prior to operating this

compressor.8. Do not use the compressor if the power cord shows any signs of damage or wear. Repair or

replace the damaged cord before use. 9. Do not pull forcefully on the cord to disconnect it from the power point.10. Keep the cord away from heat sources, oil and sharp edges.11. NEVER move the unit by pulling on the air hose. Use the handle provided at the front and on

the rear of the tank.12. Please ensure that the work area is well lit, ventilated and clean and tidy.

General Safety Instructions

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This product should only ever be connected to a properly manufactured, fitted and earthed power outlet that complies with National and regional electrical authority regulations and requirements.

Extension cables are not to be used with this product, as it may cause damage to the Compressor, Power Outlet and Home wiring. Such actions will void the warranty. Please use a longer Air Hose.

Warning ! To reduce the risk of electrocution keep all connections dry and off the ground. Do not use if wet or in a

wet environment.

Electrical Safety Instructions

Additional Safety Instructions

1. Always wear ear and eye protection when using any compressor, air tool or power tool, or are in the vicinity of the product when it is use.

2. Do not use the compressor in areas near combustible materials, combustible fumes or dust.

3. Always use a respirator or mask when spray painting or whenever there is a possibility vapors may be inhaled.

4. DO NOT ALLOW CHILDREN TO OPERATE THE COMPRESSOR AT ANY TIME.

5. DO NOT MAKE ANY MODIFICATIONS OR ADJUSTMENTS TO THE UNIT OR ANY OF ITS COMPONENTS.

7. UNITS WITH BROKEN OR MISSING PARTS OR WITHOUT THE PROTECTIVE HOUSING OR COVERS SHOULD NEVER BE OPERATED.

8. Do not leave the compressor unattended while the pressure switch is in the “I” (on) position.

9. Do not add or change oil while the compressor is in operation.

10. Use only the supplied or recommended lubricating oil for the compressor. Spear & Jackson Compressor Oil is available from Bunnings Stores (Product Code CA-CAP721-04). Recommended viscosity ISO 0046.

11. This compressor is fitted with a pressure activated “On/Off” switch. When the switch is in the “on” position, the compressor may start operating at any time when the pressure in the tank falls below the preset level of the pressure switch.

12. When not in use, we recommend that all tools and hoses be disconnected and the tanks drained of air and moisture. We also recommend that you leave the tank drain open when the compressor is not in use.

13.To reduce the risk of fire or explosion, never spray flammable liquids in a confined area.

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14.Do not ever directly inhale compressed air. Serious injury could occur.

15.Do not use the air from the compressor for any re-breathing apparatus.

16.Never apply the outlet air of this compressor directly on to any part of a person’s body. Do not attempt to block the air outlet with your finger or any part of your body. Severe injury may occur.

17.Do not weld anything to the air tank of the compressor. This could result in tank failure and will void the warranty.

18. Do not operate the compressor with the shield, cowling or cover removed.

18.Before transporting the compressor it is recommended that the tank be drained of pressurized air.

19.This air compressor is a duty cycle tool. It is not designed to run 100% of the time. If it is run on a continuous basis this may result in overheating or activation of the thermal cut out. Continual use of this type will void the warranty.

20.The manufacturer will not be responsible for any damage or injury resulting from cases of misuse or negligence.

21.The manufacturer will not be liable for any changes made to the compressor nor for any damage resulting from such changes.

Additional Safety Instructions

Warning !In the event that an air line is cut or broken, the air supply must be turned off at the

compressor.

The Compressor and Its Parts

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1. Remove all parts from the carton and layout in a clear, level and dust free space.

2. Attach wheels and axle assemblies using Bolts, washers and nuts supplied.

Wheel Assembly

3. The handle on the 2.5hp compressor is Bolted to the tank and comes with a rubber grip.

4. Attach rubber feet with hardware supplied .

Rubber Foot Assembly

Assembly & Operating Instructions

5. Attach Air filter supplied (as shown) to air inlet on the side of the pump.

No Air Filter Fitted Air Filter Air Filter Fitted

6. Ensure oil is added from the bottle supplied until the marker in the sight glass is level with the red indicator line. Additional oil can be purchased from Bunnings if required (Spear & Jackson Compressor Oil CA-CAP721-04).

Sight Glass Empty

Sight Glass Over full

Sight Glass Correct Level

Sight Glass Located Here

7. When the correct amount of oil has been added, screw the BREATHER PLUG SUPPLIED back into position as shown below. DO NOT OVERTIGHTEN .

Correct Position of Breather Plug

8. Before connecting the compressor to the power outlet, check for broken components and any damage to the power cord.

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9. Make sure the pressure switch is in the “O” or OFF position.

10. Plug the unit into a properly fitted and earthed power outlet.

Assembly & Operating Instructions

11. Attach the desired tool to the end of the air hose.

12. Switch the compressor on by moving the lever on the side of the pressure switch.

Automatic On / Off

The compressor is equipped with a pressure activated on/off switch. The compressor will only run when the switch is in the “I” or ON position (as per previous page).

Once the tank has reached the maximum preset pressure (115 PSI), the pump will automatically shut off.

The pump will automatically restart once the pressure in the tank drops below the minimum preset pressure (85 PSI).

The maximum and minimum pressures are set at the factory. Any attempt by the operator to change them will void the warranty of the product.

Overload Protection / Reset Procedure1. Switch “On/Off” Switch to “Off” Position.2. Disconnect compressor from Power source.3. Press the reset button located on the pump, next to the cylinder head beneath the edge

of the protective cowl. (as shown in image below)

4. Reconnect to power source.5. Re activate compressor using the “On/Off” Switch.

Reset switch located here

Possible causes of motor overload are as follows -1. Inadequate power supply.2. Use of extension leads.3. Overheating.4. Lack of lubricating oil.5. Use outside the standard operating parameters for this compressor.

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When Red lever is UP compressor is OFF

When Red lever is DOWN compressor is ON

The Tank Pressure Gauge supplies the reading of the air pressure inside the tank.

Pressure Gauges

NOTE. If you do not allow the air to discharge whilst you are setting the regulator, the pressure as indicated on the regulated outlet gauge will be incorrect.

This gauge ONLY indicates the correct pressure while air is being discharged from the outlet.

This compressor is fitted with an Air Pressure Regulator. It allows regulation of the output air pressure. Some air tools require a higher operating pressure than others. Please refer to the air pressure requirements of your tools for the proper settings for the regulator.

Pressure Regulator

The compressor is equipped with a safety valve that will engage when the pressure in the tank exceeds the maximum pressure setting, releasing any excess built up.

DO NOT REMOVE OR ATTEMPT TO ADJUST THE SAFETY VALVE.

Safety Switch

Safety Valve

Compressor Set Up

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When you have finished using your compressor, follow these steps:-

1. Close the air outlet taps.2. Switch off the compressor.3. Disconnect unit from power outlet (power point).4. Disconnect tools and / or Accessories from the air hose.5. Disconnect the Air Hose. 6. Locate the drain valve on the underside of the tank.7. Open the drain valve to release remaining pressurized air from within the tank. Moisture build

up in the tank is normal with air compressors, so a small amount of water may come out while draining. (Draining the tank is vital for the longevity and safety of your air compressor).

8. Store the compressor in a cool, dry place.

Shutting Down Your Compressor

1. The tank will require accumulated moisture to be drained from it on a regular basis. It is recommended that the tank be drained of moisture after every 5 Hours of use. The drain valve is located on the underside of the tank.

2. Check Oil level before each use. 3. Wash air filter insert in a mild soapy solution after 50 hours use. Operation in extreme

conditions e.g., dust, paint residue etc, may require more frequent cleaning.4. Check handle is attached properly prior to use.6. Check power cord for signs of wear and tear before each use.7. Never use caustic agents to clean any part of the compressor.8. Remove dust and dirt regularly. Wipe down compressor with a damp rag. Do not use alcohol,

petrol or other cleaning agent as this presents a fire hazard.

Maintenance

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Trouble Shooting

Problem Probable Cause Possible SolutionNot connected to power supply Check ConnectionPower supply not switched on Check switched OnTank full of air Motor will restart when pressure drops below preset minimumOn/Off switch in Off position set switch to "on" position

Problem Probable Cause Possible SolutionPower Fault or supply voltage too low Check the Power supplyPower cord too long or too thin Do not use extension leadsLack of lubricating oil Check oil level and adjust as necessaryCompressor running non stop. Reduce air consumption and allow compressor to cool.

Problem Probable Cause Possible SolutionLoose Part Tighten ComponentWheel or mounting feet loose Tighten Component

Problem Probable Cause Possible SolutionDirty air filter Clean air filterAir Leaking Return to point of purchase for assessmentAir consumption beyond capability of the unit Reduce air consumption.

Problem Probable Cause Possible SolutionOil Level too high Maintain the oil at the correct levelOil filler hole blocked Check and cleanIncorrect grade of oil used Use recommended oil only

Inability to maintain required operating pressure

Oil Consumption too high

Motor will not run Motor Running too slow Motor becoming excessively hot

Compressor will not start

Excessive vibration or noise

Exploded Diagram

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Part No. Description Qty Part No. Description Qty Part No. Description Qty Part No. Description Qty

1 HEAD BOLT 4 22 BOLT 1 43 REAR CAP 1 64 PLUG 12 SPRING WASHER 4 23 BREATHER 1 44 FAN 1 65 CABLE CONNECTOR(O) 13 CYLINDER HEAD 1 24 BOLT 4 45 BOLT 4 66 CABLE CONNECTOR(U) 24 ELBOW 1 25 OIL SIGHT GLASS 1 46 SPRING WASHER 4 67 HANDLE 15 GASKET 1 26 O-RING 1 47 WASHER 1 68 CHECK VALVE 16 VALVE ASSEMBLY 2 27 CRANK CASE COVER 1 48 CIRCLIPS 1 69 BOLT 17 VALVE PLATE 2 28 GASKET 1 49 PLASTIC COVER 1 70 RUBBER FOOT 28 GASKET 1 29 OIL SEAL 1 50 BOLT 6 71 BOLT 29 PISTON 1 30 CRANK CASE COVER 1 51 GASKET 6 72 DRAIN VALVE 110 GASKET 1 31 NUT 7 52 AIR COCK 2 73 PNEUMATIC WHEEL 211 CYLINDER HEAD 1 32 WASHER 8 53 PRESSURE GAUGE 40mm 1 74 AXLE 212 BOLT 2 33 LOCK WASHER 1 54 PRESSURE GAUGE 50mm 1 75 SPRING WASHER 213 SPRING WASHER 2 34 BOLT 4 55 REGULATOR 1 76 NUT 214 GASKET 1 35 CAPACITOR 1 56 CONNECTOR 1 77 TANK 115 PISTON RING 2 36 WASHER 2 57 PRESSURE SWITCH 1 78 DISCHARGE PIPE 116 OIL RING 1 37 SPRING WASHER 2 58 CONNECTOR 1 79 DISCHARGE NUT 217 PISTON PIN 1 38 BOLT 2 59 NUT 1 80 AIR FILTER 118 CIRCLIPS 2 39 BEARING 1 60 GASKET 1 81 HANDLE GRIP 119 CONNECTING ROD 1 40 ROTOR 1 61 SAFETY VALVE 1 82 BOLT 420 CRANK SHAFT 1 41 BEARING 1 62 UNLOADING NUT 121 NUT 1 42 STATOR 1 63 UNLOADING PIPE 1

Parts Listing

Compressors:One Year Home Use Warranty

Warranty providor:Spear & Jackson PTY LtdPO Box 4400Dandenong SouthVictoria Australia3164Telephone: 1300 731 818Facsimile: 1300 735 858

What Products are Covered By this Warranty:Project Air Branded air compressor.

What is covered under this Warranty:Substantial defects due to material and workmanship.

What is not covered under this warranty:

1. If this compressor is used for commercial, industrial or rental purposes, the warranty will be void.

2. Any failure that results from an accident, purchaser’s abuse, neglect or failure to operate products in accordance with instructions provided in the owner’s manual(s) supplied with compressor.

3. Pre-delivery service, i.e. assembly, oil or lubricants, and adjustment. 4. Items or service that are normally required to maintain the product, i.e. lubricants, filters and

gaskets, etc. 5. Any failure caused by installing or operating unit under conditions not in accordance with

installation and operation guidelines or damaged by contact with surroundings.6. Pump or valve failure caused by rain, excessive humidity, corrosive environments or other

contaminants.7. Cosmetic defects that do not interfere with compressor functionality. 8. Damage due to incorrect voltage or improper wiring to which the compressor is connected. 9. Other items not listed but considered general wear parts. 10. Pressure switches, air governors and safety valves modified from factory settings.11. Damage caused by use of incorrect oil. 12. Pump wear or valve damage caused by any oil contamination. 13. Damage from inadequate filter maintenance.

Responsibilities of the Warranty provider under this warranty:

To repair or replace, at manufacturers option, compressor or component which is defective, has malfunctioned and/or failed to conform within duration of the warranty period.

Responsibilities of the Purchaser under this warranty:

Provide dated proof of purchase and maintenance records. Use reasonable care in the operation and maintenance of the products as described in the

owner’s manual (s).

Warranty

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If You Have a Problem

Before returning this product for a Warranty Claim or any other reason Please Call

1300 731 818 (Australia)

0800 652 652 (New Zealand)

When you make your call, please have the following information at hand:• Product Type • Product Code• Place of Purchase• Date of Purchase•Concise description of the problem

A Spear & Jackson Customer Service Officer will take your call and, in most cases, will be able to solve your problem over the phone.

With continuing product development changes may have occurred which render the product received slightly different to that shown in this instruction manual. The manufacturer reserves the right to change specifications without notice.

Note: Specifications may differ from country to country.

The Helpline operates from 8am to 8pm, 5 days a week (EST). This allows you to contact Spear & Jackson directly with any queries and technical questions you have regarding our products.

P.O Box 4400Dandenong South, Victoria3164

Spear & Jackson Contact Details

Due to continuous product development and improvement, Spear & Jackson reserves the right to modify product design and materials without prior notice.

Tel :- 1300 731 818 Fax :- 1300 735 858Email :- sales@spear-and-jackson.com.au

Customer Service Contact Details

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