THE HOME DEPOT CTA6590412 4 Gal. 155 PSI Kohler Gas Powered Oil Free Portable Air Compressor User Manual

CTA6590412 4 Gal. 155 PSI Kohler Gas Powered Oil Free Portable Air Compressor
User Manual

The product style and configuration may vary.

SPECIFICATION CHART

MODEL NO.| RUNNING
H.P. (CV)| TANK CAPACITY
GALLONS| VOLTAGE/AMPS/
PHASE| KICK-IN
PRESSURE
(PRESSION| KICK-OUT
PRESSURE
---|---|---|---|---|---
TA6590412| 6.5| 4 (15)| KOHLER
SH270-3155| 125
(8,62 bar)| 155
(10,69 bar)

WARNING:
Read and understand all safety precautions in this manual before operating. Failure to comply with instructions in this manual could result in personal injury, property damage,  and/or voiding of your warranty. The manufacturer WILL NOT be liable for any damage because of failure to follow these instructions.

SAFETY GUIDELINES

The following 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.
DANGER: – A POTENTIAL HAZARD THAT WILL CAUSE SERIOUS INJURY OR LOSS OF LIFE.
WARNING: – A POTENTIAL HAZARD THAT COULD CAUSE SERIOUS INJURY OR LOSS OF LIFE.
CAUTION:– A POTENTIAL HAZARD THAT MAY CAUSE MODERATE INJURY OR DAMAGE TO EQUIPMENT.

IMPORTANT SAFETY INSTRUCTIONS

WARNING:

RISK OF FIRE OR EXPLOSION. | Never spray flammable liquids in a confined area. If sparks come into contact with vapors from gasoline or other solvents, they may ignite,  causing fire or explosion.  Always operate the compressor in a well–ventilated area. Do not smoke while spraying. Do not spray where sparks or flames are present. Keep the compressor as far from the spray area as possible. Store flammable materials in a secure location away from the compressor. Equip the area of operation with a fire extinguisher.
---|---
RISK OF BURSTING.| Do not weld, drill or modify the air tank of this compressor. Welding or modifications on the air compressor tank can severely impair tank strength and cause an extremely hazardous conditions.
Welding or modifying the tank in any manner will void the warranty. If tank develops a leak, replace it immediately with a new tank or replace the entire compressor.
RISK OF BURSTING.| Check the manufacturer’s maximum pressure rating for air tools and accessories. Compressor outlet pressure must be regulated so as to never exceed the maximum pressure rating of the tool. Relieve all pressure through the hose before attaching or removing accessories.  Never use a compressor to inflate small low-pressure objects such as children’s toys, footballs, basketballs, etc.
RISK OF BURNS.| High temperatures are generated by the gasoline engine, transfer tube, and pump. To prevent burns or other injuries, DO NOT touch these items while the engine is running. Allow them to cool before handling or servicing. Keep children away from the compressor at all times. Do not reach around protective shrouds or attempt to maintain them until the unit has been allowed to cool.
RISK TO BREATHING/ INHALATION  HAZARD. | Always wear MSHA/NIOSH-approved, properly fitting face mask or respirator and work in a well-ventilated area when using tools that generate dust.  Some dust created by power sanding, grinding, drilling and other construction activities contains chemicals known (to the  State of California) to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
• lead from lead-based paints
• crystalline silica from bricks and cement and other masonry products
• arsenic and chromium from chemically treated lumber.
RISK TO BREATHING.| Be certain to read all labels when you are spraying paints or toxic materials, and follow the safety instructions provided on the label or safety sheets for the materials you are spraying. Use an MSHA/NIOSH- approved respirator mask if there is a chance of inhaling anything you are spraying. Read all instructions and be sure that your respirator mask will protect you. Work in an area with good cross ventilation.
RISK OF EYE INJURY.| Always wear ANSI Z87.1-approved safety goggles when using an air compressor. Never point any nozzle or sprayer toward a person,  animal or any part of the body. Equipment can cause serious injury if the spray penetrates the skin.
RISK OF BURSTING.| • Do not adjust the tank safety valve for any reason. Doing so voids all warranties. The safety valve has been pre-set at the factory for the maximum pressure of this unit. Personal injury and /or property damage may result if the relief valve is tampered with.
• Do not use plastic or pvc pipe for compressed air. Use only galvanized steel pipe and fittings for compressed air distribution lines.
RISK TO BREATHING.| Risk of carbon monoxide poisoning. Engine exhaust contains carbon monoxide, an odorless and deadly poison. DO NOT operate in an enclosed area. DO NOT mount or operate in an enclosed vehicle, such as a van.
RISK OF FIRE OR EXPLOSION.| Never operate the gasoline engine without the muffler properly installed; doing so allows hot engine exhaust or sparks to vent directly  toward the gasoline tank.
RISK OF FIRE OR EXPLOSION.| Gasoline is flammable and gasoline vapors are explosive. Sparking or heat from engine, or from other sources, can ignite gasoline.
–  DO NOT start or operate with fuel cap removed.
–  DO NOT refuel while engine is running or still hot.
–  DO NOT overfill the tank––there should be no fuel in the filler neck.
–  DO NOT start or operate if spilled gasoline or smell of gasoline is present.
– Operate and refuel only in a well–ventilated area.
–  DO NOT store where gasoline vapors can reach:
–  an open flame
–  a pilot light, such as in a stove, furnace or water heater
– a spark.
RISK OF FIRE.| Unattended operation of this compressor could result in personal injury or property damage. To reduce the risk of fire, do not allow the compressor to operate unattended.
RISK TO BREATHING.| Air obtained directly from the compressor should never be used to supply air for human consumption. The air stream may contain carbon monoxide, toxic vapors, or solid particles from the tank. Breathing these contaminants can cause serious injury or death. In order to use air produced by this compressor for breathing, suitable filters, and in-line safety equipment must be properly installed. In-line filters and safety equipment must be properly installed. In-line filters and safety equipment used in conjunction with the compressor must be capable of treating the air to all applicable local and federal codes prior to human consumption.
RISK OF INJURY.| Always operate the compressor in a stable secure position to prevent accidental movement of the unit.
RISK TO HEARING.| Always wear hearing protection when using an air compressor. Failure to do so may result in hearing loss.
WARNING:| CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer, birth defects, and/or reproductive harm.

CAUTION:

Drain the moisture from the tank on a daily basis. A clean, dry tank will help prevent corrosion.
Pull the tank safety valve ring daily to ensure that the valve is functioning properly, and to clear the valve of any possible obstructions.
To provide proper ventilation for cooling, the compressor must be kept a minimum of 12 inches (31 cm) from the nearest wall, in a well–ventilated area. Restricting any of the compressor ventilation openings will cause overheating and could cause fire, never place objects against or on top of the compressor.
Fasten the compressor down securely if transport is necessary. Pressure must be released from the tank before transporting.
Protect the air hose from damage and puncture. Inspect them weekly for weak or worn spots, and replace if necessary.

OVERVIEW

BASIC AIR COMPRESSOR COMPONENTS
The basic components of the air compressor are the gasoline engine, pump, tank(s), and unloader.
The gasoline engine (see A) powers the pump.
The pump (see B) compresses the air and discharges it into the tank. As the piston in the pump cylinder moves downward, air enters the cylinder through the filter and air intake valves at atmospheric pressure. As the piston moves upward, it compresses the air and discharges it into the tank through a check valve.
The tanks (see C) store the compressed air. A check valve at the tank inlet prevents the compressed air in the tank from flowing back into the pump.
When the air pressure in the tank reaches the factory–set limit, the unloader (see D) relieves air pressure in the pump and transfer tubes and switches the engine to idle. As compressed air is used and the pressure level in the tank drops to a pre-set level, the unloader stops relieving pressure in the pump and transfer tube and switches the engine to full speed.![THE HOME DEPOT CTA6590412 4 Gal. 155 PSI Kohler Gas Powered Oil Free Portable Air Compressor

• Figure 1](https://manuals.plus/wp-content/uploads/2022/10/THE-HOME-DEPOT- CTA6590412-4-Gal.-155-PSI-Kohler-Gas-Powered-Oil-Free-Portable-Air-Compressor- Figure-1.jpg)

ASSEMBLY

ASSEMBLING THE COMPRESSOR

1. Unpack the air compressor. Inspect the unit for damage. If the unit has been damaged in transit, contact the carrier and complete a damage claim. Do this immediately because there are time limitations to damage claims. The carton should contain:
   • Air compressor
   • Operator/parts manual
   • Engine Manual

2. Check the compressor’s serial label to ensure that you have received the model ordered and that it has the required pressure rating for its intended use.

3. Locate the compressor according to the following guidelines:
   WARNING: Always operate the compressor in a well-ventilated area.
   a. Position the compressor as close as possible to the place where the air will be used.
   b. The compressor must be at least 12 inches (31 cm) from any wall or obstruction, in a clean, well–ventilated area, to ensure sufficient airflow and cooling.
   c. In cold climates, store portable compressors in a heated building when not in use, to reduce problems with engine starting, and freezing of water condensation.
   d. Place the compressor on the floor or a hard, level surface.

4. Connect an air hose (not included) to the compressor.

COMPRESSOR CONTROLS

Tank Pressure Relief Valve (see A)
If the unloader valve does not open when the pressure reaches the preset level, this valve will pop open automatically to prevent overpressurization. To operate manually, pull the ring on the valve to relieve air pressure in the tank.
Tank Pressure Gauge (see B)
This gauge measures the pressure level of the air stored in the tank. It is not adjustable by the operator and does not indicate line pressure.
Air Pressure Regulator (see C)
This air pressure regulator enables you to adjust line pressure to the tool you are using.
WARNING:
Never exceed the maximum working pressure of the tool.
Turn the knob clockwise to increase pressure, and counterclockwise to decrease pressure.

Regulated pressure gauge (see D)
This gauge measures the regulated outlet pressure.

OPERATING INSTRUCTIONS

BREAK-IN OF THE PUMP
NOTE: When references are made to gasoline engine operations, refer to the engine manual for proper procedure.

1. Before starting the compressor for the first time, ensure the proper oil level in the gasoline engine crankcase.
   WARNING: Risk of carbon monoxide poisoning. Engine exhaust contains carbon monoxide, an odorless and deadly poison. DO  NOT operate in an enclosed area. DO NOT mount or operate in an enclosed vehicle, such as a van.

2. Fill the tank of the gasoline engine with unleaded gasoline.
   DO NOT MIX OIL WITH THE GASOLINE.

3. Move the unloader lever to the manual start position (see A).

4. Open the petcocks on the bottom of the tanks (see B).
   NOTE: There are two petcocks on twin tank models.
   CAUTION:
   Escaping air and moisture can propel debris that may cause eye injury. Wear safety goggles when opening the petcock.

5. Start the gasoline engine according to the instructions in the engine manual. Move the unloader lever to the run position (see C). Run the compressor for about 30 minutes  to break in the internal parts.
   NOTE: If the unit does not operate properly, SHUT DOWN IMMEDIATELY, and contact your nearest Service Center or call the factory’s Customer Service Department. DO NOT return the unit to the store where it was purchased.

6. Shut off the gasoline engine. Close the petcocks (see B).
   Connect your air hose to the tank outlet. Check that all connections are tight. A small leak in any of the hoses, transfer tubes, or pipe connections will substantially reduce the performance of your air compressor.

DAILY START-UP

1. Check the oil level in the gasoline engine crankcase. Add oil as necessary. See instructions in the engine manual.

2. Fill the tank of the gasoline engine with unleaded gasoline.

3. Move the unloader lever to the start position (see A).

4. Close the petcocks on the bottom of the tanks. (see B).
   NOTE: There are two petcocks on twin tank models.

5. Start the gasoline engine according to the instructions in the engine manual. Run the engine for about one minute to warm up the pump, then move the unloader lever to the run position (see C). The pump will begin to fill the tank with air.
   WARNING:
   High temperatures are generated by the gasoline engine, transfer tube, and pump. To prevent burns or other injuries, DO NOT touch these items while the engine is running. Allow them to cool before handling or servicing. Keep children away from the compressor at all times.

NOTE: If the unit does not operate properly, SHUT DOWN IMMEDIATELY, and contact your nearest Service Center or call the factory’s Customer Service Department.
DO NOT return the unit to the store where it was purchased.

REPEATED STARTUPS
Move the unloader lever to the start position (see A), to relieve pressure in the pump and lines. It is important to do this because if air remains trapped in the pump, it creates a  blockage that makes restarting the compressor difficult or impossible.

SHUTDOWN

1. Shut off the gasoline engine.

2. Reduce pressure in the tank through the outlet hose. You can also pull the relief valve ring (see D) and keep it open to relieve pressure in the tank.
   CAUTION:
   Escaping air and moisture can propel debris that may cause eye injury. Wear safety goggles when opening the petcock.

3. Wear protective eyewear and open the petcocks (see B) at the bottom of the tanks to allow moisture to drain from the tanks.
   NOTE: There are two petcocks on twin tank models.
   

MAINTENANCE

MAINTENANCE
WARNING:
To avoid personal injury, always shut off the gasoline engine and relieve all air pressure from the system before performing any service on the air compressor. Do not use the unit with the shrouds or belt guard removed. Serious injury could occur from contact with moving parts.
Regular maintenance will ensure trouble-free operation.
Your gas-powered air compressor represents high–quality engineering and construction; however, even high–quality machinery requires periodic maintenance. The items listed below should be inspected on a regular basis.

WARNING:
To avoid personal injury, always shut off the gasoline engine and relieve all air pressure from the system before performing any service on the air compressor. Do not use the unit with the shrouds or belt guard removed. Serious injury could occur from contact with moving parts.
Regular maintenance will ensure trouble-free operation.
Your gas-powered air compressor represents high–quality engineering and construction; however, even high–quality machinery requires periodic maintenance. The items listed below should be inspected on a regular basis.

DRAINING THE TANK
Drain the moisture from the tank (for instructions, see “Shutdown” in the operating instructions section).
WARNING:
Condensation will accumulate in the tank. To prevent corrosion of the tank from the inside, this moisture must be drained at the end of every workday. Wear protective eyewear.
NOTE: Tilt unit to drain tanks (see B).
NOTE: In cold climates, drain the tanks after each use to reduce problems with freezing of water condensation.

CLEANING THE AIR FILTERS

A dirty air filter will reduce the compressor’s performance and life. To avoid any internal contamination of the pump, the filters should be cleaned frequently, and replaced on a regular basis. Felt filters should be cleaned in warm, soapy water, rinsed, and allowed to air dry before reinstallation. Paper filters should be replaced when dirty. Do not allow the filters to become filled with dirt or paint. If the filter becomes filled with paint, it should be replaced. Direct exposure to dirty conditions or painting areas will void your warranty.

CHECKING THE RELIEF VALVE
Pull the tank safety valve daily to ensure that it is operating properly and to clear the valve of any possible obstructions.
TESTING FOR LEAKS
Check that all connections are tight. A small leak in any of the hoses, transfer tubes, or pipe connections will substantially reduce the performance of your air compressor. If you suspect a leak, spray a small amount of soapy water around the area of the suspected leak with a spray bottle. If bubbles appear, repair or replace the faulty component. Do  not over-tighten any connections.

STORAGE
Before storing the compressor for a prolonged period, use an air blow gun to clean all dust and debris from the compressor.
Pull the tank safety valve to release all pressure from the tank.
Drain all moisture from the tank. Clean the filter elements and filter housings; replace the elements if necessary. Drain the oil from the pump crankcase and replace it with new  oil. Cover the entire unit to protect it from moisture and dust.
NOTE: For gasoline engine storage procedures, refer to the engine manual.

SERVICE INTERVAL

Perform the following maintenance at the intervals indicated below.| Daily
or after
each use| Every 200
operating
hours| Every 250
operating
hours| After the first 8 hours
and then every 100
operating hours
---|---|---|---|---
Inspect air filters (clean or replace as necessary)| •| |
Check engine oil level| •| | |
Change engine oil| see ENGINE MANUAL (supplied)
Operate the tank safety valve| •| | |
Drain tank| •| | |
Check and tighten all bolts (do not over-tighten)| | | | •
Gasoline engine maintenance| see ENGINE MANUAL (supplied)

TROUBLESHOOTING

Note: Troubleshooting problems may have similar causes and solutions.

fittings. DO NOT OVER TIGHTEN.
Restricted air intake| Clean or replace air filter element.
Restricted check valve| Remove and clean or replace.
Hole in air hose| Check and replace if necessary
Tank leaks| Immediately replace the tank. DO NOT attempt to repair.
Blown seals| Replace any faulty seals
Valve leaks| Replace worn parts and reassemble with new seals.
Leaking or worn piston seal| Replace piston and cylinder sleeve assemblies.
Excessive unloader cycling| Fittings leak| Check fittings with soapy water. Tighten or reseal leaking fittings. DO NOT OVER-TIGHTEN.
Air leaks from regulator, or regulator do not regulate pressure| Dirty or damaged regulator internal parts.| Clean or replace regulator or internal parts.
The regulated pressure gauge reading drops when air accessory is being used.| This is normal| If pressure drops too low, adjust the regulator while the accessory is used.
Compressor not large enough| Check the air requirement of the accessory. If it is higher than CFM and the pressure is supplied by the compressor, you need a larger compressor. Most accessories are rated at a 25% duty cycle.
The compressor won’t start in cold temperatures| Engine flooded| Remove the spark plug and dry it. Reinstall.
Compressor too cold| Move the compressor to a warmer location.
Overheating| Poor ventilation| Relocate the compressor to an area with cool, dry, and well-circulated air.
Dirty cooling surfaces| Clean all cooling surfaces of the pump and engine thoroughly.
Leaking valve| Replace worn parts and reassemble with new seals.

PARTS DRAWING

PARTS AND SERVICE

Replacement parts and service are available from your nearest authorized Service Center. If the need arises, contact Product Service as listed at right.
When consulting with a Service Center or Product Service, refer to the model number and serial number located on the serial label of the compressor. Proof of purchase is required for all transactions and a copy of your sales receipt may be requested.
Record the model number, serial number, and date purchased in the spaces provided below. Retain your sales receipt and this manual for future reference.
When needing service, please contact the nearest authorized Service Center or call:

PRODUCT SERVICE
In U.S.A. or Canada
Toll-Free Fax
1-888-895-4549
1-507-723-5013

Made in the USA of domestic and global components.
©2022 Sanborn Mfg.
A Division of MAT Industries, LLC.
Springfield, MN 56087
1-888-895-4549
For Service Parts: www.matoemparts.com
All Rights Reserved.

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