Harbor Freight Tools Air Compressor 95499 User Manual

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.  
Visit our website at: http://www.harborfreight.com  
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  
 
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.  
Page 3  
 
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  
for technical questions, please call 1-800-444-3353.  
Page 4  
 
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.  
Page 5  
 
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 t 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  
for technical questions, please call 1-800-444-3353.  
Page 6  
 
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.  
Page 7  
 
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  
for technical questions, please call 1-800-444-3353.  
Page 8  
 
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  
for technical questions, please call 1-800-444-3353.  
Page 9  
 
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  
for technical questions, please call 1-800-444-3353.  
Page 10  
 
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, ll 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.  
Page 11  
 
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  
for technical questions, please call 1-800-444-3353.  
Page 12  
 
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  
for technical questions, please call 1-800-444-3353.  
Page 13  
 
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.  
Page 14  
 

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