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OWNERS MANUAL FOR PERMANENTLY LUBRICATED AIR COMPRESSOR MODEL NO . , RlO2D - 1 ( For Home Use Only ) tl'r SPECIFICATION CHART Model No . 102D - 1 C10 ' 2D - 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 " 1 3 / 4 " Stroke 1 1 / 4 " 1 1 / 4 " Voltage - Single Phase 110 - 120 110 - 120 Minimum Branch Circuit Requirement 15AMPS 15AMPS * Fuse Type QuickActing QuickActing Tank Size 2 Gallon 2 Gallon * A circuitbreaker ispreferred . Useonly 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 . IMPORTANT : WARRANTY : NOTE : For identificationofRepair Parts , Read and Retain the Safety For Warranty Information Guidelines and All Instructions see separate Parts List Manual . see page 3 of this manual . Carefully Before Operating . DeVilbiss Air Power Company , 213 Industrial Dr . , Jackson , TN 38301 - 9615 I MGP - 102D - 2 2 / 1 / 94 I
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TABLE OF CONTENTS I Page Page WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Locationof Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ExtensionCords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SAFETYGUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 GroundingInstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 AirHose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 WARNING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 OPERATINGPROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTINGGUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 UNPACKINGINSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 AIRCOMPRESSOR DIAGRAM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 AN D PARTSLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 DUTYCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 COMPRESSOR PUMP DIAGRAM AN D PARTSLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12 DESCRIPTION OFOPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 HOWTO ORDER REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATIONAN DBREAK - IN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 In the unlikely event you should have a problem with this product or if you are missing a ny parts , it is not necessary to return it to 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 2
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LIMITED WARRANTY ONE YEAR FROM DATE OF PURCHASE All merchandise manufactured by De VilbissAir Power Company is warranted to be free ofdefects 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 , * airtools , accessories and serviceparts . De Vilbiss 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 80gallon air compressors , will be handled by Authorized Warranty Service Centers 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 . i RESPONSIBILITYOFORIGINALPURCHASER ( InitialUser ) : I Q Retain original sales receipts as proof of purchase for warranty work . [ 3 Use reasonable care in the operation and maintenance of the product as described in the Owners Manual ( s ) . { 3 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 . [ 3 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 . [ 3 If the purchaser does not receive satisfactory results from the Authorized Warranty Service the Center , I I I I . . . . ; Air Power Company . I THIS WARRANTYDOESNOTCOVER : I q [ 3 Merchandise sold as , reconditioned , floor models and / or display models sold " as is " , any damaged or incomplete equipment sold " as is " . [ 3 Merchandise used as " rental " equipment . [ 3 Merchandise that has become inoperative because of ordinary wear , misuse , negligence , accident , improper and / or unauthorized repair or alterations including failure to operate the product in accordance with the instructions provided in the Owners Manual ( s ) supplied with the product . [ 3 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 . [ 3 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 . [ 3 Repair and transportation costs of merchandise determined not to be defective . { 3 Cost associated with assembly , required oil , adjustments or other installation and start - up cost . { 3 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 . _ xclusion or limitation of incidental or con _ e _ lT . _ t _ tiale _ ien , _ ve _ bta'wsaJ _ o _ i | oldilati _ tt _ aqr _ l _ e , tbf _ y are warranted for a period of 45 da _ lp # or WAR , MEFSOASR PA _ ' OI _ _ 213 IndustrialDrive • Jackson TN 38301 - 9615 • Telephone : 1o800 _ 88 - 2468 , Ext . 2 • FAX : 1 - 800 - 888 - 3 states do not allow limitations on how long an implied warranty lasts , so the above limitations may not apply to
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SAFETY GUIDELINES I I Thismanual contain s information that is important for you to know and understand . This information relatesto 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 . URGENT SAFETY INFORMATION - A IMPORTANT SAFETY INFORMATION - HAZARD THAT WILL CAUSE A HAZARD THAT MIGHT CAUSE SERIOUS INJURY OR LOSS OF LIFE . SERIOUS INJURY OR LOSS OF LIFE . NOTE Information for preventingdamage to equip - informationthat you should pay special ment , attentionto . HAZARDS CAN OCCUR IF EQUIPMENT IS NOT USED PROPERLY . PLEASE READ THE FOLLOWING CHART . WHAT TO WHAT COULD HAPPEN HOW TO PREVENT IT LOOK FOR Never touch the air compressor head during or imme - Hot Parts When operated continuously , the air hose gets hot , diately after operation . especially near the compressor . If you maintain con - tact by grasping you may suffer minor burns or dis - comfort . On tank mounted units , avoid prolonged contact with On tank mounted units , the plumbing between the pump and tank gets hot . the pump to tank plumbing . Itis normal for the motor and pressure switch to spark , i Flammable The air compressor must onlybe used in wellventilated A spark can ignite flammable vapors from gasoline or areas , free of gasoline or solvent vapors . Vapors solvents , causing a fire or explosion . Do not operate the compressor whileyou are carrying it , or in the spray area . Corn pressed air can propel dust , dJrtorloose particles Never point any nozzle or sprayer toward a person or Compressed Air it comes in contact with . These propelledparticles may any part of the body . cause serious injury or damage . Always wear safety goggles or glasses when using the air compressor . Always turn the air compressor off before attaching or removingaccessories . Too much air pressure appliedto air toolsoraccesso - Check the manufacturer's pressure rating for air tools ripscan cause damage or risk of bursting , and accessories . Regulatoroutlet pressure must never exceed the maximum pressure rating . 4
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WHAT TO WHAT COULD HAPPEN HOW TO PREVENT IT LOOK FOR AJways unplug the air compressor prior to maintenance EJectricity Your air compressor is powered by electricity . Like any 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 erectrical 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 this unit . irritating vapors . Such vapors are harmful if inhaled . 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 you inhale Follow all safety precautions . them . Read andfollowthe safetyinstructions provided onthe 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 sheetsupplied 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 - ment . ing of parts . This does not affect your air compressor - but it may affect the equipment being used . GLOSSARY I SCFMorCFM : StandardCubicFeetperMinute ; aunitof U . L . Listed : Products with the U . L mark are listed by measurement of air delivery . Underwiters Laboratories , Inc . ( U . L . ) . Samples of these products have been evaluated by U . L . and meet the PSIG or PSh Pounds per square inch gauge , applicable U . L . Standards of Safety . UNPACKING INSTRUCTIONS I I Grasp the handle and lift the air compressor out of the carton . Remove the styrofoam and / or cardboard and discard . I STORAGE I When you have finished using the air compressor 1 . Set the " ON / OFF " switch to " OFF " and unplug the 3 . Protecttheelectricalcordandairhosefromdamage cord , by winding them loosely around the air compressor , 2 . Relieveallpressurefromtheaircompressorheadand 4 . Storetheaircompressorinacleananddrylocation . 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 . 5
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DESCRIPTION OF OPERATION I I Air Compressor Pump : To compress air , the piston Accumulator Tank : Your accumulator tank isequipped moves up and down in the cylinder . On the downstroke , with a relief ( pop - off ) valve to prevent an over pressure air isdrawn inthroughthe air intake muffler ( valves ) . The condition inthe tank . This 2 gallontank isnot designed to exhaust valve remains closed . On the upstroke of the store air , but rather to provide the additional volume of piston , air is compressed . The intake valves close and compressed airnecessaryto operate a wide varietyof air compressed air is forced out through the exhaust valve tools . When startingyour compressor , attach the tool to and thenthrough the air hose . the hose , set the pressureadjustingvalve at the required pressure , wait a few moments untilthe tank fills withair . Adjustable Pressure Valve : The pressurevalvecontrols You willknow the tank is filledwhen youhear airbleeding the amount of pressuregoing from the air compressor to through the pressure adjusting valve . Depending onthe the accessory . The pressureadjustingvalve can be used type and size of tool being used , you will occasionally to set approximate pressure between 10 and 125 P . S . I . need to wait for the tank to refill before continuing . When ( 125 P . S . I . is the highest pressure this compressor will you are finsihed or changing tools , turn the compressor deliver ) . It is normal for the adiustable oressure valve to switch off and set the pressure adjusting valve to 10 PSI release air during ooeration . and wait for the tank to discharge completely . ALWAYS SET THE PRESSURE VALVE AT OR BELOW THE REQUIRED PRESSURE FOR THE ACCESSORY BEING USED BEFORE START - ING YOUR COMPRESSOR . FOR INFLATION OR OTHER USES REQUIRING ACCURATE PRESSURE , USEA PRESSURE GAUGE . INSTALLATION AND BREAK - IN PROCEDURES I GROUNDING INSTRUCTIONS 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 ventilatedarea . The air compressor RISK OF ELECTRICAL SHOCKI In the event of a pump and case are designed to allowfor proper cooling . short circuit , grounding reduces the riskof shock by Clean or blow off dust or dirt that collects on the air providing an escape wire for the electdc current . compressor . A clean air compressor runs cooler and This air compressor must be properly grounded . provides Iongerservice . The ventilationopeningsonyour The aircompressor is equipped with a cord having a air compressor are necessaryto maintain properoperat - grounding wire with an appropriate grounding plug . ingtemperature . Do notplaceragsorother containerson The plug must be used with an outlet that has been or nearthese openings . 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 Extension Cords USE AN ADAPTER . use extra air hose instead of an extensioncord to avoid voltage drop and power lossto the motor . Inspectthe plug and cord before each use . Do notuse if there are signs of damage . If an extension cord must be used , be sure it is : • a 3 - wire extension cord that has a 3 - blade grounding plug , and a3 - slot receptacle that will accept the plug on the compressor IMPROPER GROUNDING CAN RESULT IN ELEC - • in good condition TRICAL SHOCK . • no longer than 50 feet • 14gauge ( AWG ) or larger . ( Wire size increases as gauge number decreases . ) 12AWG , 10AWG and8 AWG may also be used . DO NOT USE 16 OR 18 AWG . 6
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INSTALLATION AND BREAK - IN PROCEDURES I I 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 airhoseattached to you rcomporessor has an integral pressure adjusting valve at the working end of the hose . If repairing or replacing cord or plug , the grounding Should service or replacement be required , make sure that wire must be kept separate from the current - carrying the pressure adjusting valve is present inthe air hose line . wires . Never connect the grounding wire to a flat blade DONOTREPLACE THE HOSE WITH STANDARD HOSE plug terminal . The grounding wire has insulation with an outer surface that is green - with or without yellow stripes . If these grounding instructions are notcompletely THAT IS NOT EQUIPPED WITH THE PRES - understood , or if in doubt as to whether the compres - SURE ADJUSTING VALVE . sor is properly grounded , have the installation checked by a qualified electrician . 120VoltModels White Do notallow hose to become kinked or pinched at any time . This is importantto avoid damage to your compressor and to maintain pressure adjusting valve control . lS AMP PLUG OUTLET _ E _ G " ROUNDED _ GROUNDING . jI _ PIN 120 Volts , 15 Amps OPERATING PROCEDURES I 5 , 1 . Before plugging inthe air compressor , set the adjust - Check the manufacturer's maximum pressure rating for the air tool , accessory or vehicle tire being used . able pressure valve to " 10 " PSI . Make sure the " ON / OFF " switch is in the " OFF " position . The aircompressoroutlet pressure must never exceed the maximum pressure rating . 2 . Connect the air tool or accessory to the air hose . 6 . Slowly increasethe pressure settingof the adjustable Tighten securely . pressure valve . You should be ableto 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 compressor offimmediately . The pressurevalvemust 4 . Start the compressor by setting the " ON / OFF " switch to the " ON " position . be replaced . Compressed air from the outfit may contain TOO M UCH 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 FOLLOWSTEPS 5AND Some air operated tools or devices may require 6 EACH TIME YOU USE YOUR COMPRESSOR . filtered air . Read the instructions for the air tool ordevice . 7
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TROUBLESHOOTING GUIDE I VOLTAGE SOURCES , MOVING PARTS OR COMPRESSED AIR SOURCES ARE EXPOSED WHEN REPAIRING THE COMPRESSOR . PERSONAL INJURY CAN OCCUR . UNPLUG THE COMPRESSOR BEFORE AI - rEMPTING ANY REPAIRS . PROBLEM CAUSE SOLUTION Air Leaks Hose fitting loose . Tighten fitting . Compressor isnot delivering Prolonged excessive use of air . Decrease the amount of air usage . Your com - 3ressor is not large enough for the air require - enough air . meat . Hole in hose . Replace the hose . Air leaks . Tighten fittings . 1 , Motor will not run . Fuse blown , circuit breaker tripped . Check fuse box for blown fuse andreplace as necesssary . Reset circuit breaker . Do not use afuse or circuit breaker with higher rating than that specified for your particular branch circuit . 2 . Check for proper fuse . You should be using a Quick Acting fuse . 3 . Check for low voltage problem . 4 . Check the extension cord . 5 . Disconnect the other electrical appliances from circuit or operate the compressor on its own branch circuit . Check the extension cord . Extension cord is wrong length or gauge . Loose electrical connections . Check wiring connection inside terminal box Have checked at a local Service Center . Faultymotor . High discharge pressure . Adjustable pressu revalve not func - Cannot be adjusted lower . tioning . RISK OF BURSTING . DO NOT OPER - ATE THE COMPRESSOR IF THIS PROB - LEM EXISTS . ADJUSTABLE PRESSURE VALVE MUST BE REPLACED . 8
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I I Air Compressor Diagram 7 1 TO TANK 9 2 4 10 5 6 21 12 11 18 13 14 Y / 17 15 * POWER CORD ( GREEN ) / GROUND WIRE 27 o Slide # 19 over # 7 as shown . Make sure that no part of # 7 tube touches # 21 or # 14 shroud when assembled . 9
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Parts List I I KEY NO . PART NUMBER DESCRIPTION / 1 Screw # 10 - 24 x 7 / 8 LG hex head thd . forming ( 4 required ) 2 CAC - 1196 Cylinder Head * 3 Tube Seal * 4 Head Gasket 5 CAC - 4323 Valve PlateAssembly * 6 " O " Ring 7 CAC - 1289 Outlet Tube + 8 Rod Assembly / 9 Screw 3 / 8 - 16 x 1 / 25 LG hex socket flat head ( torque to 350 in / Ib ) + 10 Cylinder Sleeve 11 CAC - 4111 EndbellAssembly 12 CAC - 1342 Timing Belt * 13 Pump Isolator ( 5 required ) 14 DAC - 163 Shroud ( right ) for 102D - 1 DAC - 168 Shroud ( right ) for C102D - 1 Switch 15 SSS - 16 * 16 Tank Isolator ( 4 required ) > 17 Motor Baffle ( right ) > 18 Motor Baffle ( left ) 19 CAC - 1285 Isolator ( tube ) 20 CAC - 4322 - 1 CordAssembly 21 DAC - 162 Shroud ( left ) for 102D - 1 DAC - 167 Shroud ( left ) for C102D - 1 / 22 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 Kit includes items 17,18 . KK - 4926 + Connecting Rod Kit includs items 8 , 10 . 10
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Compressor Pump Diagram I I TO PUMP - , _ - - - t I \ 11
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Parts List I I KEY NO . PARTNUMBER DESCRIPTION 23 CAC - 1206 Clamp ( 2 used ) 24 CAC - 4324 Pressure Valve Assembly for 102D - 1 CAC - 4076 Pressure Valve Assembly for C102D - 1 Ground Screw 25 Male Connector 26 SSP - 6102 * 27 Screw ( tank retention ) ( as required ) 28 SSP - 3305 - NI Pipe Cross 29 TIA - 4150 SafetyValve Hose Connection 3O H - 2105 SS - 1286 31 Nipple Drain Cock 33 SS - 2707 * 34 Screw , self tapping * 35 Recess Bumper NOT ILLUSTRATED SSH - 8 Air Chuck H - 2099 Adapter * KK _ 4949 Isolator Kit includes items 3 , 4 , 6 , 13 , 16 , 34 , 35 , 27 12
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Service Notes I I 13
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I Service Notes I 14
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Service Notes I I 15
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Attach Sales Receipt Here . Retain Original Sales Receipt as OWNERS MANUAL FOR Proof of Purchase for Warranty Repair Work . PERMANENTLY LUBRICATED AIR COMPRESSOR WARRANTY This product is covered by the MODEL NOS , DeVilbiss one year limited 102D - 1 warranty ( SP - 100 - C ) . The warranty can be found in the ( For Home Use Only ) 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 : • Model number of your compressor • 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 Manufactures The Model number can be The Date Code number can 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 . Model Date MFG No . Code No . No . DeVilbiss Air Power Company • 213 Industrial Drive • Jackson , TN 38301 - 9615