CALIFORNIA AIR TOOLS 20040SM (01) PDF DOCUMENT

The safety messages and signal words in the manual for your CALIFORNIA AIR TOOLS 20040SM are as follows:

DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury to the operator or to bystanders.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to the operator or to bystanders.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury to the operator or to bystanders.

NOTICE: Indicates a situation which, if not avoided, may result in damage to product components or other property.

Moving parts can cause severe trauma. Keep hands and feet away from rotating parts, tie up long hair, remove jewelry, and DO NOT wear loose clothing when operating the CALIFORNIA AIR TOOLS 20040SM.

To avoid the danger of electric shock with your CALIFORNIA AIR TOOLS 20040SM, follow these instructions:

Use only undamaged electrical cords.

DO NOT touch bare wires or receptacles.

DO NOT operate the air compressor in wet weather or in wet conditions.

DO NOT touch the air compressor or cords if your hands or feet are wet.

Ensure that all cords are free of damage before connecting to the power supply.

Ensure that you have a sufficient electrical supply for supporting the requirements of the motor.

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electrical shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with local codes and ordinances.

This product is for use on a nominal 220-V circuit and has a grounding plug. Only connect the product to an outlet having the same configuration as the plug. Do not use an adapter with this product.

Dust or dust-like particulates caused by power-sanding, sawing, grinding, drilling or any other construction-like activities can contain contaminants that are harmful to breathe.

Always use your CALIFORNIA AIR TOOLS 20040SM air compressor in a well-ventilated and clean area.

Never breathe the air that comes directly out of the air compressor or air hose. This air is not suitable for breathing.

Always wear approved safety equipment. When performing dust-creating activities, securely wear properly-fit face masks or respirators.

If you feel ill from breathing while operating your air compressor, stop and seek medical attention immediately.

Flying objects can cause injury to the eyes, head, and other parts of the body. Air-powered equipment and power tools are capable of propelling items like metal chips and fasteners at high speed.

Always wear approved head and eye protection.

Never point the air stream at any part of the body, or at another person or animal.

When operating the air compressor, make sure all other people and animals maintain a safe distance.

Do not move the air compressor when the air tank is under pressure.

Never use the air hoses to pull or move the air compressor.

Keep the air compressor on a flat surface.

Air compressor surfaces on the CALIFORNIA AIR TOOLS 20040SM become hot during operation.

DO NOT touch hot surfaces, because they can cause severe burns.

Do not touch the air compressor’s cylinder head. The cooling fins of the cylinder head and delivery pipe become hot during operation.

Allow the air compressor to cool before touching it.

DO NOT place a storage cover on the unit during operation. Only place a cover on the air compressor after it has thoroughly cooled down.

The CALIFORNIA AIR TOOLS 20040SM compressor is designed for intermediate usage and should not be allowed to run continuously (i.e., where the motor/pump continuously runs) for more than 60 minutes at a time. Intermediate ON/OFF usage during a standard workday is acceptable with an average 70/30 operating duty cycle.

To prevent injury and for your general safety, only use high-pressure hoses, fittings, and couplings designed for use with air compressors. Inspect all hoses, fittings, and couplings for leaks and wear. If leaks or wear are detected, stop use and replace those items immediately. Do not repair them. Never leave pressurized air in the air tank when performing maintenance. Never leave the air compressor unattended with the power supply in use and the air hose connected.

Improper care can lead to the air tank bursting or exploding. Drain the air tank daily or after each use to prevent moisture buildup. Rust can weaken the air tank and cause leaks or bursting. If rust is detected, replace the tank immediately. Do not try to repair the air tank by welding, drilling, or modifying it in any way. If the air tank develops a leak, replace it immediately. Never repair, weld, or make modifications to the air tank or its attachments. Never make adjustments to the factory-set pressures and never exceed the manufacturer’s maximum-allowable pressure rating for attachments. Because of extreme heat, do not use plastic pipe or lead tin solder joints for a discharge line.

It is normal for the air compressor motor and pressure switch to produce sparks while operating. If sparks contact vapors from gasoline or solvents, they may ignite. Abrasive tools like grinders and drills can also make sparks that ignite flammable materials.

Always operate the air compressor a safe distance away from flammable items.

Use the compressor in well-ventilated areas.

Never exceed the maximum rated pressure.

The power requirements for the CALIFORNIA AIR TOOLS 20040SM are:

220v 60hz 1-phase (215v – 250v range).

13-14 Amps (20 Amp breaker minimum suggested).

The included NEMA 6-15P plug (6-foot power cable) may be connected to either a 6-15R or 6-20R electrical receptacle.

It is recommended to use a dedicated 20 (or 25/30) Amp Circuit. A low voltage and/or an overload circuit can cause the motor’s overload protection system circuit breaker to trip.

Yes, but with caution. If you must use an extension cord with your CALIFORNIA AIR TOOLS 20040SM, follow these guidelines:

Use an extension cord that is no more than 25 feet (7.6 m) long.

The cord must be at least 14 gauge.

Use only a 3-wire extension cord that has a 3-blade grounding plug.

Using an excessively long or thin-wired extension cord will cause severe damage to the motor, a drop in line voltage, loss of power, and overheating. When in doubt, use a heavier gauge cord (the smaller the gauge number, the more current the cord can carry).

The package contents for the CALIFORNIA AIR TOOLS 20040SM include:

Air Compressor

20040SM Owner’s Manual

MDR2i Smart Controller Owner’s Manual

Air Filters (4)

Air Filter Intake Tubes (4), 8mm OD

To install the 4 air filters and 4 air intake tubes on your CALIFORNIA AIR TOOLS 20040SM:

1. Attach the air filters to the top rear sides of BOTH motor head’s threaded ½” ports.

2. Screw the air filters clockwise until secure (hand tighten only).

3. Push (press fit) the 4″ air filter intake tube into the air filter port/hole (8mm OD). Repeat for the other intake tubes. The orientation of the intake tubes does not matter; they may point in any direction.

Before operating your CALIFORNIA AIR TOOLS 20040SM, perform the following checks:

Inspect for Damage: Make sure the air tank is not damaged, inspect all parts for damage, and check that all pipes are firmly connected. Do not use the compressor if any damage is found.

Save Packaging: It is important to save all outside packaging in case you need to return the product for service or repair.

Compressor Location:

Place the compressor on a flat surface with an incline no greater than 15 degrees. It is suggested to secure the compressor by bolting it down or using earthquake strapping to prevent it from falling over.

Maintain a clear area with at least 2 feet of obstacle-free space surrounding and above the compressor for adequate airflow.

Use in areas with clean air. Do not use in areas where dust or particulates are in the air, as this will damage the motor. Always use the air filter, properly installed.

Before using the air compressor for the first time, complete a test run as follows:

1. Plug the power supply cord into a 220 volt 60hz 1-phase power supply socket (215v – 250v range).

2. Attach an air hose gun or pneumatic tool to the 1/4″ Industrial Female Push-To-Connect air port.

3. Ensure the Manual Ball Drain Valve, at the bottom of the tank, is closed (turned 90 degrees).

4. PRESS & HOLD the SMART switch OK button for 4 seconds to turn ON the air compressor.

5. Both motor/pumps should start. The pressure will slowly rise. When the pressure reaches 120 PSI (+/- 5 PSI), the Smart pressure switch will automatically turn the motor/pumps off. This indicates the compressor is working normally.

6. Unplug the power supply cord and release the air in the tank by either pulling the Safety Relief Valve ring or expelling air through the connected air hose/tool.

Starting the compressor:

1. Attach an air hose gun or tool to the 1/4″ Industrial Female Push-To-Connect Air Port.

2. Close the Manual Ball Drain valve and ensure both air filters are attached to the motor/pump.

3. Plug the power supply cord into a power supply socket.

4. PRESS & HOLD the SMART switch OK button for 4 seconds to turn ON.

5. Allow the two motors to run and the tank to fill until the motors/pumps stop and turn off.

To regulate the air flow:

While the air compressor is running, turn “On” your tool and turn the regulator knob to the right to increase the pressure. Turn the pressure up until the desired pressure is reached.

Shutting down the compressor:

1. PRESS & HOLD the SMART switch OK button for 4 seconds to turn compressor OFF.

2. Unplug the power supply cord.

3. Remove the pressure and water in the air tank through the manual drain valve (or by using a connected air hose/tool to release air pressure from the tank).

Remove Water from Tank Daily: Turn the Manual Ball Drain Valve lever to be inline with the tubing; water/air will eject. Close the lever (90-degree angle) when water is no longer draining/visible.

Cleaning or Changing the Air Filter: The air filter reduces noise and prevents particulates from damaging the compressor. After a period of use, the filter will become clogged, reducing performance. It must be cleaned or replaced regularly.

1. Open the lid on the air filter, then remove the air filter element.

2. To clean the element, blow off or brush off the dirt and dust.

3. If clogged, replace it with a new air filter.

Testing for Leaks: Make sure all connections are tight but do not overtighten. To test for small leaks, spray a small amount of soapy water on the suspected area. If soap bubbles appear, replace the broken part.

Cleaning: Clean items with a soft brush, or wipe with a moistened cloth using a biodegradable solvent. Do not use flammable liquids like gasoline or alcohol. Keep parts clean from dirt and dust.

The MDR2i OLED Smart Pressure Switch (SMART Controller) for your CALIFORNIA AIR TOOLS 20040SM has the following features for remote monitoring and control:

Programmable ON/OFF Times

Pressure ON Level (i.e., re-start pressure)

Pressure OFF Level (i.e., shutdown pressure)

Unloader Relay Delay: Delay time for activation of the unloader valves during compressor start-up (load reduction).

AutoDrain Time: Select the time between each drain activation.

Drain Valve Time: AutoDrain valve opening duration.

Overcurrent Limit: (i.e., functions as an electrical trip/breaker).

Pressure Units: Select [bar] or [PSI]

Total Active (Motor-Pump) Running Hours

Before storing the CALIFORNIA AIR TOOLS 20040SM for a prolonged period, follow these steps:

1. Turn off the power supply.

2. Disconnect the power cord from the power supply and wrap it around the air compressor handle to reduce the risk of damage.

3. Pull the safety relief valve and release all the pressure from the air tank.

4. Clean the air compressor to remove all dirt and dust.

5. Cover the air compressor with a cover to protect the unit from dust and moisture.

6. Do not stack or store any items on top of or around the air compressor, as damage could occur.

To reduce the risk of electric shock, do not expose to rain. Store indoors.

Here are common problems and solutions for the CALIFORNIA AIR TOOLS 20040SM:

Problem: Pressure drop in the tank.

Possible Cause: Air leaks at connections.

Possible Solutions: Let the compressor build pressure to the maximum. Brush soapy water on air connections and look for air bubbles. Tighten leaky connections.

Problem: The unloader valve leaks when the compressor is idle.

Possible Cause: Unloader valve seal is defective.

Possible Solutions: Let the air in the tank flow out until all pressure is released. Then remove the unloader valve plug and clean the valve seal. If necessary, replace the seal and reinstall all components. Replace the Unloader.

Problem: The compressor stopped and does not start.

Possible Causes: The motor/pump thermal protector turned on because the motor is overheating. Motor windings are burned out.

Possible Solutions: Check that the main voltage corresponds to the specifications. An extension cord that is too thin or long can cause a voltage drop and motor overheating. Excessive use (over 1 hour continuous) can also cause overheating. Allow the motors to cool down. If windings are burned out, contact Customer Support.

Problem: The motor does not start and makes a humming noise.

Possible Causes: Head Pressure. Low voltage supply to the motors (220 volts 60hz 1-phase required, acceptable range 215v – 250v).

Possible Solutions: Perform a Check Valve Adjustment. Drain the air tank. Remove the check valve cap. Take out the check valve spring, clean inside the check valve, and elongate the spring. Replace the spring and cap.

Problem: The motor does not start or starts slowly.

Possible Cause: Low voltage supply to the motor.

Possible Solutions: Check that the main voltage corresponds to specifications. An extension cord that is too thin or long can cause a voltage drop; use heavy duty extension cords. Ensure the compressor is plugged into a fully functional power outlet.

Problem: The compressor is noisy with metallic clangs.

Possible Cause: Compressor motor/pump head gasket or reed valve is damaged.

Possible Solutions: Stop the compressor and contact Customer Support for service or replacement of the motor/pump.

Problem: The compressor does not reach the maximum pressure.

Possible Cause: Compressor head gasket or reed valve is faulty.

Possible Solutions: Stop the compressor and contact Customer Support for service or replacement of the motor/pump.

Problem: The compressor doesn’t provide as much air as it did when new and/or it cuts off within a much shorter time period.

Possible Causes: The pressure switch needs adjusting. The tank is full of water due to condensation.

Possible Solutions: For the pressure switch, stop the compressor and contact Customer Support. For water in the tank, open the drain valve and release the water. Clean the Auto Drain-Manual Drain Strainer (filter).

Problem: The motor pump unit does not stop when the tank pressure reaches its maximum working pressure (120 PSI) (+/- 5 PSI).

Possible Cause: SMART Controller (Pressure) Switch is defective or needs adjusting.

Possible Solutions: Stop the compressor immediately and contact Customer Support.