PANCAKE AIR COMPRESSOR
2 HP - 4 GALLON
Model 95499
ASSEMbLy ANd OPERAtION INStRuCtIONS
CAutION!
your Warranty Is Voided If:
a. you do not put compressor oil in the Compressor’s crankcase prior to its first use.
Before each use, check the oil level. Never run the Compressor with low or no compressor oil.
Running the Compressor with low or no oil will permanently damage the unit.
b. you drop the Air Compressor.
Always lift the Air Compressor using its Handle.
tO PREVENt SERIOuS INjuRy, REAd ANd uNdERStANd
ALL WARNINGS ANd INStRuCtIONS bEfORE uSE.
Copyright© 2007 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork
contained herein may be reproduced in any shape or form without the express written consent of Harbor
FreightTools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements,
actual product may differ slightly from the product described herein. Tools required for assembly and service
may not be included.
for technical questions or replacement parts, please call 1-800-444-3353.
Revised Manual 09j
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PERSONAL SAfEty
1.
Stay alert. Watch what you are doing, and use common sense when operating
an air tool. do not use an air tool while tired or under the influence of drugs,
alcohol, or medication. A moment of inattention while operating air tools may
result in serious personal injury.
2.
3.
dress properly. do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
Avoid accidental starting. be sure the Pressure Switch (63) is in its “StOP”
position, all pressure is safely released, and the unit is unplugged before
moving the Compressor and before performing any service, maintenance, or
cleaning procedures on the unit.
4.
Remove adjusting keys or wrenches before turning the Compressor on. A
wrench or a key that is left attached to a rotating part of the machine may result in
personal injury.
5.
6.
do not overreach. Keep proper footing and balance at all times. Proper footing
and balance enables better control of the air tool in unexpected situations.
use safety equipment. Always wear eye protection. Always wear ANSI-approved
safety impact glasses and hearing protection under a full face shield during use.
tOOL uSE ANd CARE
1.
2.
do not force the tool. use the correct tool for your application. The correct
tool will do the job better and safer at the rate for which it is designed.
do not use the Compressor if the Compressor’s Pressure Switch (63) does
not turn it on or off. Any tool that cannot be controlled with its Pressure Switch is
dangerous and must be replaced.
3.
4.
Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
Maintain tools with care. Properly maintained tools are less likely to bind and are
easier to control. Do not use a damaged tool. Tag damaged tools “do not use”
until repaired.
5.
6.
Check for misalignment or binding of moving parts, breakage of parts, and any
other condition that may affect the tool’s operation. If damaged, have the tool
serviced before using. Many accidents are caused by poorly maintained tools.
use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
SKU 95499
for technical questions, please call 1-800-444-3353.
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SERVICE
1.
2.
tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. follow instruc-
tions in the “Inspection, Maintenance, And Cleaning” section of this manual.
Use of unauthorized parts or failure to follow maintenance instructions may create
a risk of electric shock or injury.
SPECIfIC SAfEty RuLES ANd PRECAutIONS
1.
2.
CAutION! your Warranty is voided if:
a. you do not put compressor oil in the Compressor’s crankcase prior to
its first use. Before each use, check the oil level. Never run the Compressor
with low or no compressor oil. Running the Compressor with low or no oil will
permanently damage the unit.
b. you drop the Air Compressor. Always lift the Air Compressor using its Han-
dle.
dANGER! this Air Compressor is NOt equipped and should not be used
“as-is” to supply breathing air. For any application of air for human consump-
tion, you must fit the Air Compressor with suitable in-line safety and alarm equip-
ment (not included). This additional equipment is necessary to properly filter and
purify the air to meet minimal specifications for Grade D breathing as described
in Compressed Gas Association Commodity Specification G 7.1-1966, OSHA 29
CFR 1910. 134, and/or Canadian Standards Associations (CSA). In the event the
Air Compressor is used for the purpose of breathing air application and proper in-
line safety and alarm equipment is not simultaneously used, existing warranties
are void, and Harbor Freight Tools disclaims any liability whatsoever for any loss,
personal injury, or damage.
3.
4.
5.
dANGER! Never attempt to repair or modify the Air Tank (50). Welding, drilling,
or any other modification will weaken the Tank resulting in damage from rupture or
explosion. Always replace worn, cracked, or damaged Tanks.
Maintain labels and nameplates on the Air Compressor. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a replace-
ment.
WARNING! Never use plastic (PVC) pipe for compressed air;serious injury or death
could result. Any tube, pipe, or hose used must have a pressure rating higher than
150 PSI. Minimum recommended pipe size: Up to 50 feet long use 1/2” diameter.
Greater than 50 feet use 3/4” diameter. Larger diameter pipe is always better.
SKU 95499
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6.
7.
Make sure all tools and equipment used with the Air Compressor are rated to
the appropriate capacity. Do not use any tool or equipment that does not operate
from 85 PSI to 115 PSI.
drain the Air Compressor every day. Do not allow excessive moisture to build
up inside the Air Compressor’s Tank. Do not open the Drain Valve (54) with more
than 10 PSI of air pressure in the Tank. Do not unscrew the Drain Valve so that
more than four threads are showing.
8.
Avoid injury. Never direct the Air Outlet Valve (67) at people or animals.
do not alter or remove the Safety Release Valve (61).
9.
10.
Make sure the Air Compressor is located on a flat,level,sturdy surface capable
of supporting the weight of the Compressor, operator(s), and any additional
tools and equipment.
11.
do not move or transport the Compressor if the Air tank (50) is under pres-
sure.
12.
13.
Industrial applications must follow OSHA guidelines.
Never stand on the Air Compressor. Serious injury could result if the Compres-
sor is tipped.
14.
15.
16.
17.
Never leave the Air Compressor unattended when it is plugged in and running.
Turn off the Compressor, and unplug the unit before leaving.
do not allow children and other unauthorized people to handle or play with
the Air Compressor.
do not modify the factory set pressure shutoff or startup switches. This tool will
do the work better and safer at the speed and capacity for which it was designed.
Avoid body contact with oils and lubricants used in the Compressor. If swal-
lowed, seek medical treatment immediately. For skin contact, immediately wash
with soap and water. For eye contact, immediately flush eyes with clean water.
18.
19.
20.
WARNING: the brass components of this product contain lead, a chemical
known to the State of California to cause birth defects (or other reproductive
harm). (California Health & Safety code § 25249.5, et seq.)
People with pacemakers should consult their physician(s) before use. Elec-
tromagnetic fields in close proximity to heart pacemaker could cause pacemaker
interference or pacemaker failure.
WARNING! The warnings and precautions discussed in this manual cannot cover
all possible conditions and situations that may occur. It must be understood by the
operator that common sense and caution are factors which cannot be built into this
product, but must be supplied by the operator.
07d
SKU 95499
for technical questions, please call 1-800-444-3353.
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SAVE tHESE INStRuCtIONS
GROuNdING
WARNING!
Improperly connecting the grounding wire can result in the risk of electric shock.
Check with a qualified electrician if you are in doubt as to whether the outlet is
properly grounded. do not modify the power cord plug provided with the tool.
Never remove the grounding prong from the plug. do not use the tool if the
power cord or plug is damaged. If damaged, have it repaired by a service facil-
ity before use. If the plug will not fit the outlet, have a proper outlet installed by
a qualified electrician.
GROuNdEd tOOLS:tOOLS WItH tHREE PRONG PLuGS
1.
Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a
properly grounded outlet. If the tool should electri-
cally malfunction or break down, grounding pro-
vides a low resistance path to carry electricity away
from the user, reducing the risk of electric shock.
(See 3-Prong Plug and Outlet.)
2.
3.
The grounding prong in the plug is connected
through the green wire inside the cord to the
grounding system in the tool. The green wire in the
cord must be the only wire connected to the tool’s
grounding system and must never be attached to an electrically “live” terminal. (See
3-Prong Plug and Outlet.)
3-Prong Plug and Outlet
Your tool must be plugged into an appropriate outlet, properly installed and grounded
in accordance with all codes and ordinances. The plug and outlet should look like
those in the following illustration. (See 3-Prong Plug and Outlet.)
SKU 95499
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SyMbOLOGy
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
Volts Alternating Current
V~
A
Amperes
No Load Revolutions per Minute (RPM)
n xxxx/min.
0
uNPACKING
When unpacking, check to make sure all the parts shown on the Parts List on page
13 are included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the cover of this manual as soon as possible.
SKU 95499
for technical questions, please call 1-800-444-3353.
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ASSEMbLy INStRuCtIONS
1.
CAutION! Always make sure the Compressor’s Pressure Switch (63) is in its
“StOP” position prior to performing any service, maintenance, or cleaning of the
Compressor.
REGuLAtOR
AIR
COMPRESSOR
tO
tOOL
WAtER
fILtER
OILER
fIGuRE C
2.
to extend the life of your tools and equipment, it is recommended that you install
an oiler and water filter in-line with the Air
Outlet Valve (67) of the Air Compressor.
(See figure C.)
AIR OutLEt
VALVE (67)
3.
Prior to using the Air Compressor, the unit
requires the attachment of a 1/4”-18 NPt
female Quick Connector (not included). To
do so, wrap approximately 3” of pipe thread
sealant tape (not included) around the male
threads of the Air Outlet Valve (67). Then
firmly screw the Quck Connector into the Air
QuICK
CONNECtOR
(NOt INCLudEd)
Outlet Valve (67). (See figure d.)
fIGuRE d
07d
SKU 95499
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PRE-StARt INStRuCtIONS – Adding Compressor Oil
1.
IMPORtANt! Prior to first using the Compressor, the Compressor MuSt be filled
with a high quality S.A.E. 15W-30W grade non-detergent compressor oil.
fIGuRE E
OIL bREAtHER CAP
(24)
OIL SIGHt GLASS
(21)
dESIREd LEVEL
2.
To do so, unscrew and remove the Oil Breather Cap (24). Pour approximately 1/2
quart of compressor oil into the Oil Breather Cap hole. do not overfill.
(See figure E.)
3.
4.
Observe the level of compressor oil through the Oil Sight Glass (21). The optimal
oil level is at the center of the glass.
When finished adding compressor oil, re-install the Oil Breather Cap (24) back into
the Oil Breather Cap hole. (See figure E.)
SKU 95499
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OPERAtING INStRuCtIONS
to Start the Compressor:
PRESSuRE SWItCH
(63)
tOOL PRESSuRE
GAuGE (65)
REGuLAtOR (66)
AttACH AIR HOSE HERE
tANK PRESSuRE
GAuGE (62)
AIR OutLEt
VALVE (67)
SAfEty RELEASE
VALVE (61)
fIGuRE f
tANK dRAIN VALVE (54)
1.
Check to make sure the Air Tank’s Drain Valve (54), located at the bottom of the Air
Tank (50), is fully closed. Pull on the Safety release valve to verify that it is unstuck.
(See figure f.)
2.
3.
Turn the Air Outlet Valve (67) to its closed position. (See figure f.)
Connect an air hose (not included) to the previously installed Quick Connector.
Then, connect the other end of the air hose to the pneumatic tool (not included)
that is to be used. (See figure f, next page.)
4.
5.
Plug the Power Cord (55) into the nearest 120 volt, grounded, electrical outlet.
Pull up on the Pressure Switch (63) to its “StARt” position to turn on the unit.
(See figure f.)
6.
7.
When the Tank Pressure Gauge (62) reaches at least 85 PSI, turn the Air Outlet
Valve to its open position to allow air to the pneumatic tool. (See figure f.)
Once the air pressure reaches the pneumatic tool, observe theTool Pressure Gauge
(65). Adjust the Regulator (66) to feed the proper PSI to the tool. To do so, turn
the Regulator clockwise to increase the PSI. Turn the Regulator counterclockwise
to decrease the PSI. (See figure f.)
8.
NOtE: When the maximum air pressure,115 PSI, is reached as indicated by the
Tank Pressure Gauge (62), the motor will stop. The Compressor will automatically
restart when the air pressure drops below 85 PSI. (See figure f.)
07d
SKU 95499
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to Stop the Compressor:
1.
2.
3.
Push down on the Pressure Switch (63) to its “StOP” position. (See figure f.)
Unplug the Air Compressor from its electrical outlet.
Squeeze the trigger on the pneumatic tool to release any remaining air pressure
from the tool. Then disconnect the air hose from the tool, and store the tool in a
clean, dry, safe location out of reach of children.Turn the Air Outlet Valve (67) to its
closed position.
4.
5.
6.
7.
Disconnect the other end of the air hose from the Compressor’s Air Outlet Valve
(67), and store the air hose in a clean, dry, safe location out of reach of children.
Pull out on the Safety Release Valve (61) to release all remaining air pressure from
the Air Tank (50). (See figure f.)
Remove any moisture in the Air Tank (50) by opening the Tank Drain Valve (54).
Then, retighten the Drain Valve. (See figure f.)
Allow the Air Compressor to completely cool. Then store the unit in a clean, dry,
safe location out of reach of children.
INSPECtION, MAINtENANCE, ANd CLEANING
1.
2.
WARNING! Make sure the Pressure Switch (63) of the Air Compressor is in its
“StOP” position and the unit is unplugged from its electrical outlet before perform-
ing any inspection, maintenance, or cleaning procedures or leaving it unattended.
before each use, inspect the general condition of the Air Compressor. Check for
loose screws, misalignment or binding of moving parts, cracked or broken parts,
damaged electrical wiring, loose air fittings, and any other condition that may affect
the safe operation of the Compressor. If abnormal noise or vibration occurs, have
the problem corrected before further use.
do not use damaged equipment.
3.
4.
before each use, check the compressor oil level in the Oil Sight Glass (21). If
necessary, fill the crankcase of the Air Compressor with the proper amount and
type of compressor oil.
daily, purge the Air Tank (50) of all air and moisture to prevent corrosion. To do so,
slowly and carefully unscrew (no more than four threads) the Tank Drain Valve (54)
until the compressed air and condensation begins to be released from the Tanks.
Allow sufficient time for all of the air and condensation to escape from the Tanks.
Then, firmly re-tighten the Drain Valve.
5.
CAutION! All maintenance, service, or repairs not mentioned in this manual
must only be performed by a qualified service technician.
SKU 95499
for technical questions, please call 1-800-444-3353.
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tROubLESHOOtING
Problem
Compressor will not start.
Possible Cause
Possible Solution
1. Blown fuse or circuit breaker tripped.
2. Loose electrical connections.
3. Bad Capacitors.
1. Replace or reset fuse/circuit breaker.
2. Make sure Compressor is plugged into a
working, 120 volt, grounded, electrical outlet.
3. Replace capacitors.
1. Replace air filter.
Low pressure.
1. Restricted air filter.
2. Defective check valve.
3. Air leak in safety valve.
4. Defective Valve Plate.
2. Have a qualified service technician replace
check valve.
3. Check valve by pulling on ring. If condition
persists, have a qualified service technician
replace valve.
4. Replace Valve Plate.
Safety valve releasing.
Oil discharge in air.
1. Defective pressure switch.
2. Defective Safety Valve.
1. Have a qualified service technician replace
pressure switch.
2. Replace Safety Valve.
1. Drain crankcase and refill to proper level on
sight glass.
1. Too much oil in crankcase.
2. Compressor overheated.
3. Restricted oil breather cap.
2. Reduce air pressure regulation.
3. Clean or replace oil breather cap.
Immediately unplug Compressor from its
electrical outlet. Do not operate Compressor
until a qualified service technician can replace
pressure switch.
Pressure switch will not turn off
Compressor.
Defective pressure switch.
PLEASE REAd tHE fOLLOWING CAREfuLLy
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTATION ORWARRANTY OF ANY KINDTOTHE BUYERTHAT HE
OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER
AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS
SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER.
THE BUYER ASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE
ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER
INSTALLATION OF REPLACEMENT PARTS THERETO.
SKU 95499
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PARtS LISt ANd ASSEMbLy dIAGRAM
Part
1
2
3
4
5
6
7
8
description
Part
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
description
Part
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
description
Plastic Cowling
Oil Breather Cap
Exhaust Pipe Assy.
Spring Washer
Washer (#5)
Pan Head Screw (M5 x 14)
Turbo Fan
Screw (M5 x 15)
Motor Rear Cover
Wave Washer
Bearing (6202)
Stator Assy.
Spring Washer (#8)
Washer (#8)
Screw (M8 x 20)
Connecting Rod
Piston
Circlip (#12)
Piston Pin
Cylinder Gasket
Cylinder
Spring Washer (#6)
Washer (#6)
Screw (M6 x 40)
Oil Clean Ring
Seal Ring
Valve Plate Gasket
Valve Plate Assy.
Air Intake Valve
Limit Pin
Cylinder Head Gasket
Air Filter Element Assy.
Cylinder Head
Square Elbow Connector
Non-Return Valve Assy.
Unload Pipe Assy.
Tank
Nut (M6)
Rubber Foot
Screw (M6 x 20)
Tank Drain Valve
Power Cord
Rear Motor Cover Gasket
Seal Washer
Connector Seat
Connector
Wheel Sleeve
Safety Release Valve
Tank Pressure Gauge
Pressure Switch
Connector
Tool Pressure Gauge
Regulator
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Rotor Assy.
Capacitor 150uf/250V
Bearing (6204)
Oil Seal
Nut (M8)
Crankcase
Crank
Screw (M8 x 16 – Left Hand)
Crankcase Gasket
Crankcase Cover
Oil Sight Glass
Hex Head Screw
Pan Head Screw (M6 x 14)
Air Outlet Valve
44
45
46
61
62 63 64
65 66 67
43
42
41
60
59
40
39
38
37
36
58
57
47
48
49
35
34
33
32
56
55
50
51
31
30
29
52
53
28
27
54
26
25
24
23
21
17
15 14 13 12
11
9
8
22
20
18
16
10
7
1
19
6
5
4
3
2
Note: Some parts are listed and shown for illustration purposes only, and are not available
individually as replacement parts.
SKU 95499
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LIMItEd 1yEAR / 90 dAy WARRANty
Harbor Freight Tools Co. makes every effort to assure that its products meet high
quality and durability standards, and warrants to the original purchaser that for a period of
one year from date of purchase that the tank is free of defects in materials and workman-
ship (90 days if used by a professional contractor or if used as rental equipment). Harbor
Freight Tools also warrants to the original purchaser, for a period of ninety days from date
of purchase, that all other parts and components of the product are free from defects
in materials and workmanship. This warranty does not apply to damage due directly or
indirectly to misuse, abuse, negligence or accidents, repairs or alterations outside our fa-
cilities, normal wear and tear, or to lack of maintenance. We shall in no event be liable for
death, injuries to persons or property, or for incidental, contingent, special or consequential
damages arising from the use of our product. Some states do not allow the exclusion or
limitation of incidental or consequential damages, so the above limitation of exclusion may
not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRAN-
TIES, EXPRESS OR IMPLIED, INCLUDINGTHEWARRANTIES OF MERCHANTABILITY
AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with
transportation charges prepaid. Proof of purchase date and an explanation of the com-
plaint must accompany the merchandise. If our inspection verifies the defect, we will either
repair or replace the product at our election or we may elect to refund the purchase price
if we cannot readily and quickly provide you with a replacement. We will return repaired
products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning
the product.
This warranty gives you specific legal rights and you may also have other rights
which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
SKU 95499
for technical questions, please call 1-800-444-3353.
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