Harbor Freight Tools Air Compressor 95498 User Manual

AIR COMPRESSOR  
2 HP - TWIN TANK - 4 GALLON  
95498  
SET uP ANd OPERATING 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 compres-  
sor 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.  
Read this material before using this product.  
Failure to do so can result in serious injury.  
SAVE THIS MANuAL.  
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 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.  
For technical questions or replacement parts, please call 1-800-444-3353.  
Cover revised 08k, 09j  
 
2. 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.  
3. Avoid accidental starting. Be sure the Compressor Control Knob (83) is in  
its “OFF” position 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. do not overreach. Keep proper footing and balance at all times. Proper foot-  
ing and balance enables better control of the power tool in unexpected situations.  
6.  
use safety equipment. Always wear eye protection. Always wear  
ANSI-approved safety impact glasses and full face shield when using  
this product. ANSI-approved hearing protection must also be used.  
TOOL uSE ANd CARE  
1. 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.  
2. do not use the Compressor if the Compressor’s Pressure Switch (64) does  
not turn it on or off. Any tool that cannot be controlled with its Pressure Switch is  
dangerous and must be replaced.  
3. Store idle tools out of reach of children and other untrained persons. Tools  
are dangerous in the hands of untrained users.  
4. 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. 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.  
6. 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.  
SERVICE  
1. Tool service must be performed only by qualified repair personnel. Service or  
maintenance performed by unqualified personnel could result in a risk of injury.  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 3  
 
2. 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.  
SAVE THESE INSTRuCTIONS  
SPECIFIC SAFETY RuLES ANd PRECAuTIONS  
1. 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 perma-  
nently damage the unit.  
b. You drop the Air Compressor. Always lift the Air Compressor using its Handle.  
2. Maintain labels and nameplates on the Air Compressor. These carry important  
information. If unreadable or missing, contact Harbor Freight Tools for a replace-  
ment.  
3. This Air Compressor is NOT equipped and should not be used “as-is” to supply  
breathing quality air. For any application of air for human consumption, you must  
fit the Air Compressor with suitable in-line safety and alarm equipment (not in-  
cluded). 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 Compres-  
sor 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.  
4. Never attempt to repair or modify the Air Tanks (51). Welding, drilling, or any other  
modification will weaken the Tanks resulting in damage from rupture or explosion.  
Always replace worn, cracked, or damaged Tanks.  
5. 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.  
6. 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 oper-  
ate from 85 PSI to 115 PSI.  
7. drain the Air Compressor every day. Do not allow excessive moisture to build  
up inside the Air Compressor’s Tanks. Do not open the Drain Valves (52) with  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 4  
 
more than 10 PSI of air pressure in the Tanks. Do not unscrew the Drain Valves so  
that more than four threads are showing.  
8. Avoid injury. Never direct the Air Outlet Valve (68) at people or animals.  
9. do not alter or remove the Safety Release Valve (62).  
10. Make sure the Air Compressor is located on a flat, level, sturdy surface ca-  
pable of supporting the weight of the Compressor, operator(s), and any ad-  
ditional tools and equipment.  
11. Industrial applications must follow OSHA guidelines.  
12. Never stand on the Air Compressor. Serious injury could result if the Compres-  
sor is tipped.  
13. Never leave the Air Compressor unattended when it is plugged in and run-  
ning. Turn off the Compressor, and unplug the unit before leaving.  
14. do not allow children and other unauthorized people to handle or play with  
the Air Compressor.  
15. do not move or transport the Compressor if the Air Tanks (51) are under  
pressure.  
16. do not force the Compressor. This tool will do the work better and safer at the  
speed and capacity for which it was designed.  
17. 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. Prolonged exposure to noise levels above 85 dBA is hazardous to hearing.  
Always wear hearing protection when operating or working around the Compressor  
when it is running.  
19. 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.)  
20. People with pacemakers should consult their physician(s) before use. Electromag-  
netic fields in close proximity to heart pacemaker could cause pacemaker interfer-  
ence or pacemaker failure.  
21. 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.  
SAVE THESE INSTRuCTIONS  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
GROuNdING  
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 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 facility 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 electrically malfunction or break down, grounding provides a low  
resistance path to carry electricity away from the user, reducing the risk of electric  
shock. (See 3-Prong Plug and Outlet.)  
2. 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. The tool must be plugged into an appropriate outlet, properly installed and ground-  
ed in accordance with all codes and ordinances. The plug and outlet should look  
like those in the preceding illustration. (See 3-Prong Plug and Outlet.)  
Symbology  
Double Insulated  
Canadian Standards Association  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 6  
 
Symbology  
Underwriters Laboratories, Inc.  
Volts Alternating Current  
Amperes  
V~  
A
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 95498  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
ASSEMBLY INSTRuCTIONS  
1. Turn the Compressor’s Pressure Switch (64) is in its “OFF” position prior to per-  
forming any service, maintenance, or cleaning of the Compressor.  
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 (68) of the Air Com-  
pressor. (See Figure C.)  
WRAP  
WITH  
AIR OuTLET VALVE  
(68)  
PIPE SEALANT TAPE  
(NOT INCLudEd)  
HERE  
QuICK CONNECTOR  
(NOT INCLudEd)  
FIGuRE d  
3. Prior to using the Air Compressor, the unit requires the attachment of a 1/4”-18  
NPT Male Quick Connector (not included). To do so, wrap approximately 3” of  
pipe thread sealant tape (not included) around the male threads of the Quick Con-  
nector. Then firmly screw the Quick Connector into the Air Outlet Valve (68).  
(See Figure d.)  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 8  
 
PRE-START INSTRuCTIONS  
To Add Compressor Oil:  
FIGuRE E  
OIL BREATHER CAP  
(25)  
OIL SIGHT GLASS  
(22)  
dESIREd LEVEL  
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.  
(See Figure E.)  
2. To do so, unscrew and remove the Oil Breather Cap (25). Pour approximately 1/2  
quart of compressor oil into the Oil Breather Cap hole. Do not overfill.  
(See Figure E.)  
3. Observe the level of compressor oil through the Oil Sight Glass (22). The oil level  
should appear between the “MINIMuM” and “MAXIMuM” marks on the Indicator.  
(See Figure E.)  
4. If necessary, continue adding compressor oil, while re-checking the Oil Sight Glass  
(22). Maintain oil level at the center of indicator in the Oil Sight glass.  
5. When finished adding compressor oil, re-install the Oil Breather Cap (25) back into  
the Oil Breather Cap hole.  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
OPERATING INSTRuCTIONS  
To Start The Compressor:  
REGuLATOR  
(67)  
PRESSuRE SWITCH  
(64)  
AIR  
OuTLET  
VALVE  
(68)  
TANK  
PRESSuRE  
GAuGE  
(63)  
AIR HOSE  
(NOT INCLudEd)  
TOOL  
PRESSuRE  
GAuGE  
(66)  
SAFETY  
RELEASE  
VALVE  
(62)  
TANK dRAIN VALVE  
(52)  
FIGuRE F  
1. Check to make sure the Air Tank’s Drain Valve (52), located on the bottom Air Tank  
(51), is fully closed.  
2. Turn the Air Outlet Valve (68) to its closed position.  
3. 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).  
4. Plug the Power Cord (55) into the nearest 120 volt, grounded, electrical outlet.  
5. Pull up on the Pressure Switch (64) to its “START” position to turn on the unit.  
6. When the Tank Pressure Gauge (63) reaches at least 85 PSI, turn the Air Outlet  
Valve to its open position to allow air to the pneumatic tool.  
7. Once the air pressure reaches the pneumatic tool, observe the Tool Pressure  
Gauge (66). Adjust the Regulator (67) to feed the proper PSI to the tool. To do so,  
turn the Regulator clockwise to increase the PSI. Turn the Regulator counterclock-  
wise to decrease the PSI.  
Note: When the maximum air pressure, 115 PSI, is reached as indicated by the Tank  
Pressure Gauge (63), the motor will stop. The Compressor will automatically re-  
start when the air pressure drops below 85 PSI.  
IMPORTANT: To decompress the air pressure in the Air Tanks (51), push down on the  
Pressure Switch (64) to its “STOP” position. Then, pull out on the Safety Release  
Valve to immediately release air pressure from the Air Tanks.  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 10  
 
To Stop The Compressor:  
1. Push down on the Pressure Switch (64) to its “STOP” position.  
2. Unplug the Air Compressor from its electrical outlet.  
3. Turn the Air Outlet Valve (68) to its closed position. (See Figure F.)  
4. 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.  
5. Disconnect the other end of the air hose from the Compressor’s Air Outlet Valve  
(68), and store the air hose in a clean, dry, safe location out of reach of children.  
6. Pull out on the Safety Release Valve (62) to release all remaining air pressure from  
the Air Tanks (51). (See Figure F.)  
7. Remove any moisture in the Air Tanks (51) by opening the Tank Drain Valve (52).  
Then, retighten the Drain Valve. (See Figure F.)  
8. Allow the Air Compressor to completely cool. Then store the unit in a clean, dry,  
safe location out of reach of children.  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 11  
 
INSPECTION, MAINTENANCE, ANd CLEANING  
Procedures not specifically explained in this manual must be performed  
only by a qualified technician.  
TO PREVENT SERIOuS INjuRY FROM ACCIdENTAL  
OPERATION:  
Turn the Power Switch of the tool to its “OFF” position and unplug the  
tool from its electrical outlet before performing any inspection,  
maintenance, or cleaning procedures.  
1. 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.  
2. Before each use, check the compressor oil level in the Oil Sight Glass (22). If  
necessary, fill the crankcase of the Air Compressor with the proper amount and  
type of compressor oil.  
3. daily, purge the Air Tanks (51) of all air and moisture to prevent corrosion. To do  
so, slowly and carefully unscrew (no more than four threads) the Tank Drain Valve  
(52) 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.  
TROuBLESHOOTING  
Possible Solution  
1. Replace or reset fuse/circuit breaker.  
Problem  
Compressor will not  
start.  
Possible Cause  
1. Blown fuse or circuit  
breaker tripped.  
2. Loose electrical  
connections.  
2. Plug Compressor into a working, 120 volt,  
grounded, electrical outlet.  
3. Bad capacitors.  
3. Replace capacitors.  
Low pressure.  
1. Restricted air filter.  
1. Replace air filter.  
2. Defective check valve.  
3. Air leak in safety valve.  
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. Defective valve plate.  
4. Replace valve plate.  
Safety valve releasing. 1. Defective pressure  
switch.  
1. Have a qualified service technician replace  
pressure switch.  
2. Defective safety valve.  
2. Replace safety valve.  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 12  
 
Possible Solution  
1. Drain crankcase and refill to proper level on  
sight glass.  
Problem  
Oil discharge in air.  
Possible Cause  
1. Too much oil in  
crankcase.  
2. Compressor overheated. 2. Reduce air pressure regulation.  
3. Restricted oil breather  
cap.  
3. Clean or replace oil breather cap.  
Pressure switch will not Defective pressure switch.  
turn off Compressor.  
Immediately unplug Compressor from its  
electrical outlet. Do not operate Compressor  
until a qualified service technician can replace  
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 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  
description  
Part  
description  
Part  
description  
1
2
3
4
5
6
7
8
9
Plastic Housing  
24 Pan Head Screw  
46 Cylinder Head  
Spring Washer  
Washer  
Screw (M5 x 14)  
Fan  
Screw (5 x 115)  
Rear Cap  
Washer  
25 Oil Breather Cap  
26 Spring Washer (#8)  
27 Washer (#8)  
28 Screw (M8 x 20)  
29 Connecting Rod  
30 Piston  
31 Spring Washer  
32 Piston Pin  
33 Cylinder Gasket  
34 Cylinder  
35 Spring Washer (#6)  
36 Washer (#6)  
37 Screw (M6 x 40)  
38 Gasket  
39 Sealer Ring  
40 Valve Gasket  
47 Elbow Exhaust  
48 Exhaust Pipe  
49 Check Valve  
50 Unload Pipe  
51 Air Tank  
52 Tank Drain Valve  
53 Rubber Foot  
54 Screw (M6 x 20)/Nut (M6)  
55 Power Cord  
56 Rubber Gasket  
61 Rubber Grip  
62 Safety Release Valve  
63 Tank Pressure Gauge  
64 Pressure Switch  
65 Connector  
Bearing (6202)  
10 Stator  
11 Rotor  
13 Running Capacitor  
14 Bearing (6204)  
15 Oil Seal  
16 Nut (M8)  
17 Crankcase  
18 Crankshaft  
66 Tool Pressure Gauge  
67 Regulator  
19 Screw (M8 x 16 – Left hand) 41 Valve Plate Assy.  
20 Gasket  
42 Air Intake Valve  
43 Limit Pin  
44 Cylinder Gasket  
45 Air Filter  
68 Air Outlet Valve  
79 Frame Assy.  
21 Crankcase Cover  
22 Oil Sight Glass  
23 Drain Plug  
Note: Some parts are listed and shown for illustration purposes only, and are not avail-  
able individually as replacement parts.  
REV 08k  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 13  
 
ASSEMBLY dIAGRAM  
REV 08k  
SKU 95498  
For technical questions, please call 1-800-444-3353.  
Page 14  
 
LIMITEd 1 YEAR / 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 work-  
manship (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 di-  
rectly or indirectly to misuse, abuse, negligence or accidents, repairs or alterations out-  
side our facilities, 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 limita-  
tion 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 com-  
plaint must accompany the merchandise. If our inspection verifies the defect, we will ei-  
ther 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 re-  
paired 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 95498  
For technical questions, please call 1-800-444-3353.  
Page 15  
 

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