Harbor Freight Tools 10 gal 2.5 HP 125 PSI Oil Lube Air Compressor Product manual

Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
REV 15a
10gal oil lubricated
air compressor
Visit our website at: http://www.harborfreight.com
Email our technical support at: productsupport@harborfreight.com
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright© 2013 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 Freight Tools.
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.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Table of Contents
Safetye��������������������������������������������������������� 2
Maintenancei���������������������������������������������� 14
Specifications.............................................. 6
Parts List and Diagram............................... 18
Setup........................................................... 7
Warranty..................................................... 20
Safety
Operationa��������������������������������������������������� 12
Setup
WARNING SYMBOLS AND DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Operation
Addresses practices not related to personal injury.
Maintenance
Page 2
For technical questions, please call 1-888-866-5797.
Item 61490
IMPORTANT SAFETY INFORMATION
WARNING Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The warnings, precautions, and instructions discussed in this instruction 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.
4. Compressor use and care
c. Keep children and bystanders away
from an operating compressor.
2. Electrical safety
a. Compressor plugs must match the outlet.
Never modify the plug in any way.
Do not use any adapter plugs with grounded
compressors. Standard plugs and matching
outlets will reduce risk of electric shock.
b. Do not expose compressor to rain or wet
conditions. Water entering a compressor
will increase the risk of electric shock.
c. Do not abuse the cord. Never use the
cord for unplugging the compressor.
Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled
cords increase the risk of electric shock.
3. Personal safety
a. Stay alert, watch what you are doing and
use common sense when operating this
compressor. Do not use this compressor
while you are tired or under the influence
of drugs, alcohol or medication. A moment
of inattention while operating a compressor
may result in serious personal injury.
b. Use personal protective equipment.
Always wear ANSI-approved eye
protection during setup and use.
c. Prevent unintentional starting. Ensure the
switch is in the off‑position before connecting
to power source or moving the compressor.
Item 61490
b. Disconnect the plug from the power source
before making any adjustments, changing
accessories, or storing the compressor.
Such preventive safety measures reduce the
risk of starting the compressor accidentally.
c. Store an idle compressor out of the reach
of children and do not allow persons
unfamiliar with the compressor or these
instructions to operate it. A compressor is
dangerous in the hands of untrained users.
d. Maintain the compressor. Keep the
compressor clean for better and safer
performance. Follow instructions for
lubricating and changing accessories.
Keep dry, clean and free from oil and grease.
Check for misalignment or binding of moving
parts, breakage of parts and any other
condition that may affect the compressor’s
operation. If damaged, have the compressor
repaired before use. Many accidents are
caused by a poorly maintained compressor.
e. Use the compressor in accordance with
these instructions, taking into account
the working conditions and the work to
be performed. Use of the compressor for
operations different from those intended
could result in a hazardous situation.
Setup
b. Do not operate the Compressor in explosive
atmospheres, such as in the presence
of flammable liquids, gases or dust.
Compressor motors produce sparks
which may ignite the dust or fumes.
a. Do not use the compressor if the switch
does not turn it on and off. Any compressor
that cannot be controlled with the switch
is dangerous and must be repaired.
Operation
a. Keep work area clean and well lit.
Cluttered or dark areas invite accidents.
5. Service
a. Have your compressor serviced by a
qualified repair person using only identical
replacement parts. This will ensure that the
safety of the compressor is maintained.
For technical questions, please call 1-888-866-5797.
Page 3
Maintenance
1. Work area safety
Safety
General Safety Warnings
Air Compressor Safety Warnings
Safety
1. Risk of fire or explosion - do not spray
flammable liquid in a confined area or towards a
hot surface. Spray area must be well‑ventilated.
Do not smoke while spraying or spray where
spark or flame is present. Arcing parts - keep
compressor at least 20 feet away from explosive
vapors, such as when spraying with a spray gun.
2. Risk of bursting - do not adjust regulator higher
than marked maximum pressure of attachment.
3. Risk of injury - do not direct air
stream at people or animals.
15. USE OF AN EXTENSION CORD IS NOT
RECOMMENDED. If you choose to use an
extension cord, use the following guidelines:
Table A: RECOMMENDED MINIMUM WIRE
GAUGE FOR EXTENSION CORDS
(120 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD
LENGTH
25′
50′
100′ 150′
0–6
18
16
16
14
4. Do not use to supply breathing air.
6.1 – 10
18
16
Do not use.
10.1 – 12
16
16
Do not use.
5. Do not leave compressor unattended
for an extended period while plugged in.
Unplug compressor after working.
12.1 – 16
14
12
Do not use.
Setup
6. Keep compressor well-ventilated.
Do not cover compressor during use.
7. Drain tank daily and after use. Internal rust causes
tank failure and explosion.
8. Add correct amount of compressor oil before first
use and every use. Operating with low or no oil
causes permanent damage and voids warranty.
a. Make sure your extension cord
is in good condition.
b. Be sure to use an extension cord which
is heavy enough to carry the current your
product will draw. An undersized cord will
cause a drop in line voltage resulting in loss
of power and overheating. Table A shows the
correct size to use depending on cord length
and nameplate ampere rating. If in doubt,
use the next heavier gauge. The smaller
the gauge number, the heavier the cord.
Operation
9. Do not remove the valve cover or
adjust internal components.
16. Industrial applications must follow OSHA guidelines.
10. Compressor head gets hot during operation.
Do not touch it or allow children nearby
during or immediately following operation.
17. Maintain labels and nameplates on the
compressor. These carry important safety
information. If unreadable or missing, contact
Harbor Freight Tools for a replacement.
11. Do not use the air hose to move the compressor.
12. Release the pressure in the
storage tank before moving.
13. The use of accessories or attachments not
recommended by the manufacturer may
result in a risk of injury to persons.
14. All air line components, including hoses, pipe,
connectors, filters, etc., must be rated for a minimum
working pressure of 150 PSI, or 150% of the
maximum system pressure, whichever is greater.
18. This product is not a toy.
Keep it out of reach of children.
19. Operate unit on level surface. Check oil level
daily and fill to marked level if needed.
20. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields in
close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
Maintenance
21. WARNING: The brass components of this product
contain lead, a chemical known to the State
of California to cause cancer and birth defects
or other reproductive harm. (California Health
& Safety Code § 25249.5, et seq.)
22. WARNING: The cord of this product contains
lead and/or di (2-ethylhexyl) phthalate (DEHP),
chemicals known to the State of California
to cause cancer, and birth defects or other
reproductive harm. Wash hands after handling.
(California Health & Safety Code § 25249.5, et seq.)
SAVE THESE INSTRUCTIONS.
Page 4
For technical questions, please call 1-888-866-5797.
Item 61490
TO PREVENT ELECTRIC SHOCK AND DEATH
FROM INCORRECT GROUNDING WIRE CONNECTION:
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 compressor.
Never remove the grounding prong from the plug. Do not use the compressor if the power cord or plug
is damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the outlet,
have a proper outlet installed by a qualified electrician.
Safety
Grounding
110-120 VAC Grounded Compressors: Compressors with Three Prong Plugs
5. Use only 3-wire extension cords that have
3-prong grounding plugs and 3-pole receptacles
that accept the compressor’s plug.
Setup
6. Repair or replace damaged or
worn cord immediately.
2. Do not modify the plug provided –
if it will not fit the outlet, have the proper
outlet installed by a qualified electrician.
3. Improper connection of the equipment-grounding
conductor can result in a risk of electric shock.
The conductor with insulation having an outer
surface that is green with or without yellow
stripes is the equipment-grounding conductor.
If repair or replacement of the electric cord or
plug is necessary, do not connect the equipmentgrounding conductor to a live terminal.
4. Check with a qualified electrician or service
personnel if the grounding instructions are
not completely understood, or if in doubt as to
whether the compressor is properly grounded.
125 VAC 3-Prong Plug and Outlet
(for up to 125 VAC and up to 15 A)
7. This compressor is intended for use on a
circuit that has an outlet that looks like the one
illustrated above in 125 VAC 3-Prong Plug
and Outlet. The compressor has a grounding
plug that looks like the plug illustrated above
in 125 VAC 3-Prong Plug and Outlet.
8. The outlet must be properly installed and grounded
in accordance with all codes and ordinances.
9. Do not use an adapter to connect this
compressor to a different outlet.
Symbology
PSI
Grounding
Pin
Canadian Standards Association
CFM
Cubic Feet per Minute flow
Underwriters Laboratories, Inc.
SCFM
Cubic Feet per Minute flow
at standard conditions
NPT
National pipe thread, tapered
NPS
National pipe thread, straight
V
~
A
Maintenance
Pounds per square inch of pressure
Volts
Alternating Current
Amperes
Double Insulated
Item 61490
Operation
1. In the event of a malfunction or breakdown,
grounding provides a path of least resistance for
electric current to reduce the risk of electric shock.
This compressor is equipped with an electric
cord having an equipment-grounding conductor
and a grounding plug. The plug must be
plugged into a matching outlet that is properly
installed and grounded in accordance
with all local codes and ordinances.
For technical questions, please call 1-888-866-5797.
Page 5
Specifications
Safety
Electrical Rating
120VAC / 60Hz / 14A (dedicated
circuit recommended)
Air Outlet Size
1/4″ 18 NPT
Air Pressure
Shut-off 125 PSI
Restart 95 PSI
Air Tank Capacity
10 Gallons
Sound Level
5.3 SCFM @ 90 PSI
6.2 SCFM @ 40 PSI
89dB(A) @ 1m
Oil Capacity
5.6 oz.
Oil Type
30W non-detergent Air Compressor Oil
(sold separately)
Air Flow Capacity
Setup
224876
Operation
Maintenance
Page 6
For technical questions, please call 1-888-866-5797.
Item 61490
Instructions for putting into use
Safety
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch “OFF” and unplug the Air Compressor from its electrical
outlet before assembling or making any adjustments to the compressor.
Note: For additional information regarding the parts listed in the following pages,
refer to the Assembly Diagram near the end of this manual.
Functions
Safety
Valve (73)
Setup
Output Pressure
Gauge (77)
Quick
Coupler
(76)
ON
Pressure
Regulator (74)
Power Switch
(on Pressure Switch - 54)
Tank Pressure
Gauge (53)
Output
Pressure
Gauge (77)
Pressure
Regulator
(74)
Safety
Valve (73)
Drain
Valve (66)
Figure A
For technical questions, please call 1-888-866-5797.
Page 7
Maintenance
Quick
Coupler
(76)
Oil Sight
Glass (33)
Item 61490
Operation
Tank Pressure
Gauge (53)
PRESSURE SWITCH (54)
(Top View)
Power
Switch
OFF
Assembly/Mounting
1. Attach two Wheels (63) to the Tank (70), using two
Bolts (64) and two Nuts (65). See Figure B.
3. Thread the Air Filter (6) onto the side of
the Cylinder Head (7). See Figure C.
Safety
Cylinder
Head (7)
2. Slide the Handle (72) into the two slots on the top of
the Tank and secure in place with four Bolts (71).
Bolt (64)
Handle
(72)
Bolt
(71)
Nut (65)
Air
Filter (6)
Wheel (63)
Figure C
Tank (70)
Setup
Figure B
Checking the Oil
1. Check the oil level before operation. Fill the Pump
Crankcase with premium quality SAE 30-weight,
non-detergent, air compressor oil (sold separately).
Operation
IMPORTANT: Running the Air Compressor with
the incorrect amount of oil will cause damage
to the equipment and void the warranty. To
prevent damage, do not use with overfilled or
low oil. Slowly fill to full line, wait 2 minutes
and fill back up to full line. Compressor
has small passages that will fill slowly.
2. The oil level should be at the center of the “full” level
on the Oil Sight Glass (33), as shown in Figure D.
Add oil as needed to maintain this level.
Do not let the oil level go below the center
dot on the Sight Glass (LOW) and do not
overfill the oil so that it is above the center
dot on the Sight Glass (OVERFILL).
Crankcase Cover (31)
Oil Sight Glass (33)
3. To add oil:
a. Remove the Oil Breather Plug (37).
b. Using a funnel to avoid spills, pour enough
oil into the Pump Crankcase to reach
the “full” level in the Oil Sight Glass.
c. Replace the Oil Breather Plug.
Note: 30W non-detergent Air Compressor Oil
(sold separately) is recommended
for use with this compressor.
4. If uncertain which oil to use for this compressor,
call Harbor Freight Tools customer service
at 1-888-866-5797 for assistance.
5. Change the compressor oil after the first
hour of use to remove any debris.
CAUTION! TO PREVENT INJURY FROM BURNS:
Do not add or change the oil while the compressor
is in operation. Allow the compressor to cool before
replacing oil.
Maintenance
OVERFILL
FULL
LOW
Figure D: Oil Sight Glass
Page 8
For technical questions, please call 1-888-866-5797.
Item 61490
Break-In Procedure
2. Insert a male coupler (sold separately) into the Quick
Coupler (76) and fully open all regulators and valves.
3. Plug in the Power Cord.
5. Let the unit run for 30 minutes.
Air will expel freely through the Coupler.
6. Turn the Power Switch OFF.
Safety
1. Turn the Power Switch OFF and unplug the unit.
7. Unplug the Power Cord and
remove the male coupler.
4. Turn the Power Switch ON.
Note: Change the compressor oil after the
first hour of use to remove any debris.
Sample Air Line Setup
1. Connect a regulator valve, an inline shut off valve
and a 1/4″ NPT air hose to the Quick Coupler
(all sold separately). The air hose must be long
enough to reach the work area with enough extra
length to allow free movement while working.
2. Depending on the tool that will be used
with this compressor, incorporate additional
components, such as an in-line oiler, a filter,
or a dryer (all sold separately). Consult the air
tool’s manual for needed accessories.
Maintenance
Operation
Setup
Note: An in-line shutoff ball valve is an important
safety device because it controls the air supply even
if the air hose is ruptured. The shutoff valve should
be a ball valve because it can be closed quickly.
Item 61490
For technical questions, please call 1-888-866-5797.
Page 9
For technical questions, please call 1-888-866-5797.
Description
Non-lubricated
Tools
A
Air Hose
Filter
Regulator
Lubricator (optional)
Coupler and Plug
Leader Hose (optional)
Air Cleaner / Dryer (optional)
Air Adjusting Valve (optional)
Maintenance
A
B
C
D
E
F
G
H
Operation
Lubricated
Tools
B
B
C
C
A
A
E
E
F
H
Connects air to tool
Prevents dirt and condensation from damaging tool or workpiece
Adjusts air pressure to tool
For air tool lubrication
Provides quick connection and release
Increases coupler life
Prevents water vapor from damaging workpiece
For fine tuning airflow at tool
G
D
Function
Setup
Figure E: Portable Air Supply Setup
Safety
Page 10
Item 61490
Item 61490
For technical questions, please call 1-888-866-5797.
Page 11
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
F
Description
F
E
I
I
J
K
N
Operation
J
H
Setup
Function
H
L
L
M
O
Safety
For noise and vibration reduction
Secures air compressor in place
Isolates sections of system for maintenance
For vibration reduction
Distributes air to branch lines
To drain moisture from system
Brings air to point of use
Connects air to tool
Prevents dirt and condensation from damaging tool or workpiece
Adjusts air pressure to tool
For air tool lubrication
Provides quick connection and release
Increases coupler life
Prevents water vapor from damaging workpiece
For fine tuning airflow at tool
Non-lubricated Tools
C
C
Vibration Pads
Anchor Bolts
Ball Valve
Isolation Hose
Main Air Line - 3/4″ minimum recommended
Ball Valve
Branch Air Line -1/2″ minimum recommended
Air Hose
Filter
Regulator
Lubricator (optional)
Coupler and Plug
Leader Hose (optional)
Air Cleaner / Dryer (optional)
Air Adjusting Valve (optional)
B
A
Maintenance
B
A
C D
G
Lubricated
Tools
Slope
Figure F: Stationary Air Supply Setup
F
Operating Instructions
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
Safety
Compressor Area Set Up
1. Designate a work area that is clean and well‑lit.
The work area must not allow access by
children or pets to prevent injury.
2. Locate the Compressor on a flat level surface to
ensure proper pump lubrication and to prevent
damage to the unit. Keep at least 12″ of space
around the unit to allow air circulation.
3. Route the Power Cord from the compressor
to the grounded wall outlet, along a safe path
without creating a tripping hazard or exposing
the power cord to possible damage.
General Operation
Setup
1. IMPORTANT: First, turn the Power Switch OFF.
This releases tank pressure and allows the motor
to start freely, without tripping the Circuit Breaker.
2. Close the Drain Valve. (See Draining
Moisture from the Tank on page 15.)
3. Check for oil leaks and check the oil level
(See Checking the Oil on page 8).
WARNING! TO PREVENT SERIOUS
INJURY AND DEATH FROM
EXPLOSION:
Do not adjust the internal
pressure switch. Any change to the
automatic pressure levels may cause excess pressure to
accumulate, causing a hazardous situation.
6. Turn the Power Switch ON.
8. Adjust the Pressure Regulator (74) so that
the air output is enough to properly power the
tool, but the output will not exceed the tool’s
maximum air pressure at any time. Turn the
Regulator clockwise to increase the pressure
and counter-clockwise to decrease pressure.
Adjust the pressure gradually, while checking the
Output Pressure Gauge to set the pressure.
7. Allow the Air Compressor to build
up pressure until it cycles off.
9. Make sure the air tool’s throttle or switch is in the
off position. Connect the air tool to the air hose.
Note: At the beginning of the day’s first use
of the Air Compressor, check for air leaks by
applying soapy water to connections while the
Air Compressor is pumping and after pressure cutout. Look for air bubbles. If air bubbles are present
at connections, tighten connections. Do not use the
Air Compressor unless all connections are air tight,
the extra air leaking out will cause the compressor to
operate too often, increasing wear on the compressor.
10. Open the in-line shutoff valve.
Note: As long as the Power Switch is ON, the
operation of the Air Compressor is automatic,
controlled by an internal pressure switch.
The Compressor will turn on automatically when
the air pressure drops to 95 PSI, and will turn off
automatically when the air pressure reaches 125 PSI.
14. Close the in-line shutoff valve.
4. Close the in-line shutoff valve between
the compressor and the air hose.
5. Plug the Power Cord into a grounded
120VAC electrical outlet.
Operation
11. Use the air tool as required.
12. After the job is complete, turn the Power Switch OFF.
Note: Turn the switch off before
unplugging the compressor.
13. Unplug the Air Compressor.
Maintenance
15. Bleed air from the tool then disconnect the tool.
16. Turn the Drain Valve two turns to release
the internal tank pressure and any built-up
moisture. Close the valve after moisture has
drained out. Do not remove the Drain Valve.
17. Clean, then store the Air Compressor indoors.
Page 12
For technical questions, please call 1-888-866-5797.
Item 61490
Start compressor in heated area if outdoor temperatures
drop below 32° F.
If this is not practical, drain out the old pump oil
and use SAE 10W Non-detergent Air Compressor
Oil in the pump crankcase instead whenever the
compressor’s temperature will fall below 40°.
•
Do not use multi-viscosity oil (such as
10W-30) - they leave carbon deposits on pump
components and lead to accelerated failure.
•
Heavy operation may require heavier viscosity oil.
Emergency Depressurization
Safety
Cold Weather Operation
If it is necessary to quickly depressurize the Compressor:
1. Move the ON/OFF Power Lever to the OFF position.
2. Pull on the ring on the Safety Valve (73)
to quickly release stored air pressure.
Automatic Shut off System
b. Wait until the Compressor cools down
(about 10 minutes);
c. If the unit does not start up again on its own,
press the Reset Button to start the compressor;
a. Using an extension cord that is too
long or too small a gauge;
b. An air leak or open hose causing the compressor
to cycle too often and build up heat.
Setup
a. Shut off all tools.
2. Possible causes of repeated automatic
shut off of the compressor are:
Correct any issues before further use to
avoid damage to the compressor.
Operation
1. If the Compressor automatically shuts off
before reaching its normal cutoff pressure:
Reset Button
Maintenance
d. Resume operation.
Item 61490
For technical questions, please call 1-888-866-5797.
Page 13
Maintenance and Servicing
Procedures not specifically explained in this manual must
be performed only by a qualified technician.
Safety
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch “OFF” and unplug the Compressor from its electrical outlet
before performing any inspection, maintenance, or cleaning procedures.
TO PREVENT SERIOUS INJURY FROM COMPRESSOR FAILURE:
Do not use damaged equipment. If abnormal noise or vibration occurs,
have the problem corrected before further use.
Cleaning, Maintenance, and Lubrication
1. BEFORE EACH USE, inspect the general
condition of the air compressor. Check for:
Setup
• loose hardware,
• misalignment or binding of moving parts,
• cracked or broken parts,
2. AFTER USE, wipe external surfaces of
the compressor with a clean cloth.
3.
WARNING! If the supply cord of this
compressor is damaged, it must be replaced
only by a qualified service technician.
• damaged electrical wiring, and
• any other condition that may
affect its safe operation.
Maintenance Schedule
Following are general guidelines for maintenance checks of the Air Compressor.
Operation
Note: The environment in which the compressor is used, and the frequency of use will affect how often
you will need to check the Air Compressor components and perform maintenance procedures.
Daily:
Weekly:
a. Check oil level.
a. Inspect Air Filter.
b. Check for oil leaks.
b. Inspect Oil Breather Plug.
c. Make sure all nuts and bolts are tight.
d. Drain moisture from air tank.
e. Check for abnormal noise or vibration.
f. Check for air leaks.*
g. Inspect belt (if provided).
h. Wipe off any oil or dirt from the compressor.**
Monthly:
Inspect Safety Valve.
Every 6 months or 100 Operation Hours:
Replace Pump oil.***
Maintenance
* To check for air leaks, apply soapy water to joints while
the Air Compressor is pressurized. Look for air bubbles.
** To clean the compressor surface, wipe with
a damp cloth, using a mild detergent or mild solvent.
Page 14
*** Use 30W non-detergent Air Compressor Oil
(sold separately) only.
For technical questions, please call 1-888-866-5797.
Item 61490
Oil Maintenance
Check the oil periodically for clarity. Replace oil if it appears milky or if debris is present,
or every 6 months, or 100 operation hours, whichever comes first.
Replace the oil more frequently if compressor is used in harsh environments such as high heat or high humidity.
1. Place a container under the Drain Plug (35).
2. Remove the Oil Breather Plug (37)
to allow air flow into the Pump.
3. Remove the Oil Drain Plug, allowing
the oil to drain into the container.
4. When the oil is completely drained from the Pump,
replace the Oil Drain Plug.
Safety
CAUTION! TO PREVENT INJURY FROM BURNS:
Allow Air Compressor to cool before changing the oil.
5. Fill the Pump with new 30W non-detergent
Air Compressor Oil (sold separately) to the
FULL level on the Oil Sight Glass (5.6 oz.).
6. Replace and tighten the Oil Breather Plug.
7. Discard the old oil according to local,
state and federal regulations.
The Drain Valve (66) is located under the Tank. It must be used daily to release all trapped air and
moisture from the Tank. Doing this will eliminate condensation and prevent tank corrosion.
CAUTION! Do not open the Drain Valve so that more than four threads are showing.
2. Place a collection pan under the Drain Valve.
3. Open the Drain Valve two or three turns ONLY.
•
To open the Drain Valve, turn the
Drain Valve knob on the bottom of
the Tank counterclockwise.
4. When all the pressure and moisture is released,
close the Drain Valve.
To close the Drain Valve, turn the Drain
Valve knob on the bottom of the Tank
clockwise until you feel tension and the
knob is down as far as it can go.
Clockwise:
Drain Valve Closed
Inside of Tank
Tank Wall
Drain Valve
Knob
Figure G: Drain Valve Operation
Maintenance
•
Counterclockwise:
Drain Valve Open
Operation
1. Turn the Power Switch OFF.
Setup
Draining Moisture from the Tank
Item 61490
For technical questions, please call 1-888-866-5797.
Page 15
Troubleshooting
Problem
Compressor does
not start or restart
Safety
Compressor builds
pressure too slowly
Setup
Compressor not
building enough
air pressure
Operation
Overheating
Possible Causes
Likely Solutions
1. Tank already pressurized.
1. No problem. Compressor will start when needed.
2. Power cord not plugged in properly.
2. Check that cord is plugged in securely.
3. Incorrect power supply.
3. Check that circuit matches compressor requirements.
4. No power at outlet.
4. Reset circuit breaker, or have outlet
serviced by a qualified technician.
5. Thermal overload switch tripped.
5. Turn off Compressor and wait for it to cool down.
Press reset button. Resume operation.
6. Building power supply circuit tripped or
blown fuse.
6. Reset circuit or replace fuse. Check for low voltage
conditions. It may be necessary to disconnect
other electrical appliances from the circuit or
move the compressor to its own circuit.
7. Extension cord wire size is
too small or cord is too long to
properly power compressor.
7. Use larger diameter or shorter extension cord or
eliminate extension cord. See Recommended Wire
Gauge for Extension Cords in Safety section.
8. Compressor needs service.
8. Have unit inspected by a qualified technician.
1. Incorrect power supply.
1. Check that circuit matches compressor requirements.
2. Crankcase oil overfilled or oil too thick.
2. Drain oil and refill to proper level with recommended oil.
3. Working environment too cold.
3. Move compressor to a warmer location.
Check that recommended oil is in crankcase.
4. Safety valve leaking.
4. Listen for air leaking from valve.
If leaking, replace with identical valve with same rating.
DO NOT SEAL OR TAMPER WITH SAFETY VALVE.
5. Loose fittings.
5. Reduce air pressure, then check all fittings with
a soap solution for air leaks and tighten as needed.
Do not overtighten.
1. Air filters need cleaning/replacing.
1. Check inlet and outlet filters.
Clean and/or replace as needed.
2. Check Valve needs service.
2. Have technician clean or replace, as needed.
3. Compressor not large enough for job.
3. Check if accessory CFM is met by Compressor.
If Compressor cannot supply enough air flow (CFM),
you need a larger Compressor.
4. Loose fittings.
4. Reduce air pressure, then check all fittings with
a soap solution for air leaks and tighten as needed.
Do not overtighten.
5. Hose or hose connections too narrow.
5. Replace with wider hose and/or hose connections.
6. Crankcase oil too thick.
6. Drain oil and refill to proper level with recommended oil.
7. High altitude reducing air output.
7. Higher altitudes require compressors with greater output.
1. Air filters need cleaning/replacing.
1. Check inlet and outlet filters.
Clean and/or replace as needed.
2. Crankcase oil too thin or incorrect type. 2. Drain oil and refill to proper level with recommended oil.
Maintenance
Compressor
starts and stops
excessively
3. Crankcase oil level too low.
3. Add oil to proper level, check for leaks.
4. Unusually dusty environment.
4. Clean and/or replace filters more often or
move unit to cleaner environment.
5. Extension cord used.
5. Eliminate extension cord.
6. Unit not on level surface.
6. Reposition unit on a level surface.
1. Loose fittings.
1. Reduce air pressure, then check all fittings with a soap
solution for air leaks and tighten as needed.
Do not overtighten.
2. Compressor not large enough for job.
2. Check if accessory CFM is met by Compressor.
If Compressor doesn’t reach accessory CFM,
you need a larger Compressor.
Follow all safety precautions whenever diagnosing or servicing the compressor.
Disconnect power supply before service.
Page 16
For technical questions, please call 1-888-866-5797.
Item 61490
Troubleshooting (cont.)
Likely Solutions
1. Loose fittings.
1. Reduce air pressure, then check all fittings with a soap
solution for air leaks and tighten as needed.
Do not overtighten.
2. Crankcase overfilled with oil or oil
is incorrect thickness or type.
2. Drain oil and refill to proper level with recommended oil.
3. Crankcase oil level too low.
3. Add oil to proper level, check for leaks.
4. Unit not on level surface.
4. Reposition unit on a level surface.
Moisture in
discharge air
Too much moisture in air.
Install in-line air filter/dryer, and/or relocate
to less humid environment.
Safety Valve “pops”
Safety valve needs service.
Pull on test ring of safety valve. If it still pops,
replace with identical valve of same rating.
Air leaks from
pump or fittings
Loose fittings.
Reduce air pressure, then check all fittings with a soap
solution for air leaks and tighten as needed.
Do not overtighten.
Air leaks from Tank
Defective or rusted tank.
Have tank replaced by a qualified technician.
Drain moisture from tank daily to prevent future corrosion.
Oil in discharge
air or high oil
consumption
1. Crankcase oil too thin or
crankcase overfilled with oil.
1. Drain oil and refill to proper level with recommended oil.
2. Unit not on level surface.
2. Reposition unit on a level surface.
3. Crankcase vent clogged.
3. Clean Crankcase vent.
Safety
Excessive noise
Possible Causes
Setup
Problem
Maintenance
Operation
Follow all safety precautions whenever diagnosing or servicing the compressor.
Disconnect power supply before service.
Item 61490
For technical questions, please call 1-888-866-5797.
Page 17
Parts List and Diagram
PLEASE READ THE FOLLOWING CAREFULLY
Safety
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 OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT 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 RISK 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.
Parts List
Part
Setup
Operation
Maintenance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
26a
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Page 18
Description
Cover
Elbow
Start Valve
Spring Washer M6
Screw M6 x 50
Air Filter
Cylinder Head
Head Gasket
Valve Plate
Metal Gasket
Valve
Valve Plate Gasket
Cylinder
Bolt M8 x 30
Spring Washer M8
Cylinder Gasket
Pin
Compression Ring
Oil Ring
Wrist Pin Retainer
Piston
Connecting Rod
Screw M6 x 20
Nut M6
Crank Shaft
O-Ring
Cable Tie
Capacitor
Screw M8 x 20
Capacitor Bracket
Nut M8
Crank Case Cover
O-Ring
Oil Sight Glass
O-Ring
Oil Drain Plug M5 x 10
O-Ring
Oil Breather Plug
Crankcase Cover Gasket
Pump Crankcase
Washer M5
Screw M5 x 16
Qty
1
1
1
8
4
1
1
1
2
1
2
1
1
2
3
1
1
2
1
2
1
1
5
3
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
10
Part
42
43
44
45
46
47
48
49
50
51
51a
51b
51c
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
Description
Manual Overload Protector
Oil Seal
Bearing
Rotator
Bearing
Stator
Automatic Thermal Protector
End Cover
Fan
Circlip
Flat Washer 5
Spring Washer 5
Bolt
Connector
Tank Pressure Gauge
Pressure Switch
Unloader Tube
Nut
Ferrule
Check Valve
Ferrule
Nut
Exhaust Tube
Cooling Fin
Wheel
Bolt M12 x 55 (washer/
bushing assembly)
Hex Nut M12
Drain Valve
Foot Pad
Washer
Screw M6 x 25
Tank
Bolt M6 x 10
Handle
Safety Valve
Pressure Regulator
Motor Cord
Quick Coupler
Output Pressure Gauge
Plug
For technical questions, please call 1-888-866-5797.
Qty
1
1
1
1
1
1
1
1
1
1
4
4
4
1
1
1
1
1
1
1
2
2
1
1
2
2
2
1
2
2
2
1
4
1
1
1
1
1
1
1
Item 61490
Maintenance
Operation
Setup
Safety
Assembly Diagram
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.
Item 61490
For technical questions, please call 1-888-866-5797.
Page 19
Limited 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 this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, 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
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES 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 complaint 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 • 1-888-866-5797