Manual For The 62803 21 Gal. 2 1/2 HP 125 PSI Cast Iron Vertical Air Compressor
User Manual: Manual for the 62803 21 gal. 2-1/2 HP 125 PSI Cast Iron Vertical Air Compressor 21 gal. 2-1/2 HP 125 PSI Cast Iron Vertical Air Compressor
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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 15h 21 GAL cast iron vertical 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© 2015 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 Safety Safety.......................................................... 2 Maintenance............................................... 14 Setup........................................................... 6 Parts List and Diagram............................... 18 Specifications.............................................. 6 Warranty..................................................... 20 Operation.................................................... 11 WARNING SYMBOLS AND DEFINITIONS Setup 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. Addresses practices not related to personal injury. Operation Maintenance Page 2 For technical questions, please call 1-888-866-5797. ITEM 62803 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 62803 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 62803 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 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. 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. Grounding Pin 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. 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. PSI Pounds per square inch of pressure Double Insulated CFM Cubic Feet per Minute flow Canadian Standards Association SCFM Cubic Feet per Minute flow at standard conditions Underwriters Laboratories, Inc. NPT National pipe thread, tapered NPS National pipe thread, straight ITEM 62803 VAC A Volts Alternating Current Amperes For technical questions, please call 1-888-866-5797. Page 5 Maintenance Symbology Specifications Safety Electrical Rating 120VAC / 60Hz / 14A (Dedicated circuit required) Air Outlet Size 1/ ″ 4 Air Pressure Shut-off Restart -18 NPT 125 PSI 95 PSI Air Tank Capacity 21 Gallons Air Flow Capacity 4.7 CFM @ 90 PSI 5.8 CFM @ 40 PSI Oil Capacity 5.6 oz. 4001244 SAE 30W, non‑detergent, Air Compressor Oil (sold separately) 93.5 dB @ 3′ Oil Type Sound Level Instructions for putting into use Setup 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. ON/OFF Power Lever (On Pressure Switch (58)) Operation Oil Sight Glass (33) Pressure Regulator (56) OFF ON/OFF Power Lever ON Tank Pressure Gauge (64) Quick Coupler (55) for attaching in-line shutoff valve, air hose and tool Tank Pressure Gauge (64) Pressure Regulator (56) Quick Coupler (55) Safety Valve (59) Safety Valve (59) Maintenance Drain Valve (73) Pressure Switch (58) Output Pressure Gauge (63) Figure B: Controls Output Pressure Gauge (63) Figure A: Functions Page 6 For technical questions, please call 1-888-866-5797. ITEM 62803 Assembly Nut (72) Cylinder Head (7) Spring Washer (71) Nut (79) Spring Washer (78) Washer (77) Wheel (70) Foot Pad (76) Screw (69) Washer (75) Safety Tank (68) Air Filter (8) Screw (74) Figure C Figure E 3. Thread the Air Filter (8) onto the side of the Cylinder Head (7). 4. Break in the new Air Compressor as follows: a. Turn the Power Switch off and unplug the unit. Insert a male coupler (sold separately) into the female Quick Coupler and fully open all regulators and valves. Handle (67) Setup 1. Attach the Wheels (70) to the Tank (68), using the Nuts (72), Screws (69), and Spring Washers (71). Attach the Foot Pads (76) to the bottom of the Tank (68) using the Screws (74), Washers (75 & 77), Spring Washers (78), and Nuts (79). b. Plug in the Power Cord. c. Turn the Power Switch ON. d. Let the unit run for 30 minutes. Air will expel freely through the Coupler. Tank (68) Figure D Bolts (66) 2. Slide the Handle (67) into the two slots on the top of the Tank (68) and secure in place with four Bolts (66). 5. 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. 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. 6. Depending on the tool which you will be using with this compressor, you may need to incorporate additional components, such as an in-line oiler, a filter, or a dryer (all sold separately), as shown on Figure F on page 8 and Figure G on page 9. Consult your air tool’s manual for needed accessories. ITEM 62803 For technical questions, please call 1-888-866-5797. Page 7 Maintenance f. Unplug the Power Cord and remove the male coupler. Operation e. Turn the Power Switch OFF. 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 F: Portable Air Supply Setup Safety Page 8 ITEM 62803 ITEM 62803 For technical questions, please call 1-888-866-5797. Page 9 A B C D E F G H I J K L M N O B A F Description F E Operation I I J N K 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) Maintenance B A C D G Lubricated Tools Slope Figure G: Stationary Air Supply Setup F Checking the Oil 1. Check the oil level before operation. Fill the Pump Crankcase (38) with SAE 30W, non‑detergent, Air Compressor Oil (sold separately). Safety 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. Crankcase Cover (30) Oil Sight Glass (33) OIL LEVEL OVERFILL FULL Setup LOW Tank (68) Figure H: Oil Sight Glass 2. The oil level should be at the center of the “full” level on the oil level sight glass, as shown in Figure H. Add oil as needed to maintain this level. Do not let the oil level go below the center dot (LOW as shown above) and do not overfill the oil so that it is above the center dot (OVERFILL as shown above) on the sight glass. 3. To add oil: a. Remove the Oil Plug (31). b. Using a funnel to avoid spills, pour enough oil into the Pump Crankcase (38) to reach the “full” level in the Oil Sight Glass (33). c. Replace the Oil Plug. Cold Weather Operation Premium quality 30-weight, non-detergent air compressor oil (sold separately) is recommended for use with this compressor. 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. 4. If uncertain which oil to use for this compressor, please 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. Operation Maintenance Page 10 For technical questions, please call 1-888-866-5797. ITEM 62803 Operating Instructions 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. Maintenance Operation Setup 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. 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. ITEM 62803 For technical questions, please call 1-888-866-5797. Page 11 General Operation 1. IMPORTANT: First, turn the Power Switch OFF. This releases tank pressure and allows the motor to start freely, without tripping the Circuit Breaker. Safety 2. Close the Drain Valve by turning it clockwise. 3. Check for oil leaks and check the oil level (See Checking the Oil). 4. Close the in-line Shutoff Valve between the compressor and the air hose. 5. Plug the Air Compressor Power Cord into a grounded 120 VAC electrical outlet. 6. Turn the Power Switch ON. 7. Allow the Air Compressor to build up pressure until it cycles off. Setup 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. 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. 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. 8. Adjust the Air Compressor’s Pressure Regulator 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 knob clockwise to increase the pressure and counter-clockwise to decrease pressure. Adjust the pressure gradually, while checking the air output gauge to set the pressure. 9. Make sure the air tool’s throttle or switch is in the off position. Connect the air tool to the air hose. 10. Open the in-line Shutoff Valve. 11. Use the air tool as needed. 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. 14. Close the in-line Shutoff Valve. 15. Bleed air from the tool then disconnect the tool. Operation 16. Turn the Drain Valve, at the bottom of the Tank, two turns counterclockwise to release any built‑up moisture and the internal tank pressure. Close the valve after moisture has drained out. Do not remove the Drain Valve. 17. Clean, then store the Air Compressor indoors. Maintenance Page 12 For technical questions, please call 1-888-866-5797. ITEM 62803 Emergency Depressurization If it is necessary to quickly depressurize the Compressor, turn the Power Switch OFF. Then, pull on the ring on the Safety Valve to quickly release stored air pressure. Safety Automatic Shut off System 1. If the Compressor automatically shuts off before reaching its normal cutoff pressure: a. Shut off all tools. 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; d. Resume operation. 2. Possible causes of repeated automatic shut off of the compressor are: a. Using an extension cord that is too long or narrow; b. An air leak or open hose causing the compressor to cycle too often and build up heat. Maintenance Operation Figure I: Reset Button 3. Correct any issues before further use to avoid damage to the compressor. Setup Reset Button ITEM 62803 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: • loose hardware, Setup • misalignment or binding of moving parts, • damaged belts, 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. • cracked or broken parts, • 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. Note: The environment in which the compressor is used, and the frequency of use can affect how often you will need to check the Air Compressor components and perform maintenance procedures. Operation 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 SAE 30W, non‑detergent, Air Compressor Oil only (sold separately). For technical questions, please call 1-888-866-5797. ITEM 62803 Oil Maintenance CAUTION! TO PREVENT INJURY FROM BURNS: Allow Air Compressor to cool before changing the oil. 1. Place a container under the Drain Plug. 2. Remove the Oil Breather Plug to allow air flow into the Pump. 3. Remove the Drain Plug, allowing the oil to drain into the container. 4. When the oil is completely drained from the Pump, replace the Drain Plug. 5. Fill the Pump with new SAE 30W, non‑detergent, Air Compressor Oil to the FULL level on the Oil Sight Glass (5.6 oz.). Safety Check the oil periodically for clarity. Replace oil if it appears milky or if debris is present, or every 6 months, or 100 hours of runtime, whichever comes first. In harsh environments such as high heat or high humidity, you will need to replace the oil more frequently. 6. Replace and tighten the Oil Breather Plug. 7. Discard the old oil according to local, state and federal regulations. The Drain Valve is located under the Tank. It must be used daily to release all trapped air and moisture from the Tank. This will eliminate condensation which can cause tank corrosion. Counterclockwise Drain Valve Open Clockwise Drain Valve Closed Inside Compressor CAUTION! Do not open the Drain Valve so that more than four threads are showing. Setup Draining Moisture from the Tank Compressor Wall 1. Turn the Power switch of the compressor off. 2. Place a collection pan under the Drain Valve. Knob 3. Unthread the Drain Valve two or three turns ONLY. Figure J: Drain Valve Operation To open the Drain Valve, turn the knob on the bottom of the Compressor counterclockwise. To close the Drain Valve, turn the knob on the bottom of the compressor clockwise until you feel tension and the knob is down as far as it can go. Air Filter Maintenance Operation 4. When all the pressure and moisture is released, close the Drain Valve. Check the Air Filter weekly to see if it needs replacement. If working in dirty environments, you may need to replace the filter more often. 3. Replace with a new Air Filter. 2. Remove the Air Filter. 4. Replace the Cover. Maintenance 1. Remove the Cover. ITEM 62803 For technical questions, please call 1-888-866-5797. Page 15 Troubleshooting Problem Compressor does not start or restart Possible Causes Likely Solutions Safety 1. Tank(s) 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. Cord wire size is too small or cord is too 7. Use larger diameter or shorter extension cord or long to properly power compressor. eliminate extension cord. See Recommended Wire Gauge for Extension Cords in Safety section. Compressor builds pressure too slowly Setup Compressor not building enough air pressure Operation High Oil Consumption 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. Crankcase oil too thin. 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. Maintenance 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 62803 Troubleshooting (cont.) Likely Solutions 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. 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. 1. Crankcase overfilled with oil or oil is incorrect thickness or type. 1. Drain oil and refill to proper level with recommended oil. 2. Crankcase oil level too low. 2. Add oil to proper level, check for leaks. 3. Loose or damaged belt guard. 3. Replace belt guard. 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. Unit not on level surface. 5. Reposition unit on a level surface. Moisture in discharge air Too much moisture in air. Install inline air filter/dryer, and/or relocate to less humid environment. Oil in discharge air 1. Crankcase oil too thin or crankcase overfilled with oil. 1. Drain oil and refill to proper level with recommended oil. 2. Crankcase vents clogged. 2. Clean Crankcase vents. Safety Valve “pops” Safety valve needs service. Pull on test ring of safety valve. If it still pops, replace. 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. Excessive noise Follow all safety precautions whenever diagnosing or servicing the compressor. Disconnect power supply before service. 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. ITEM 62803 For technical questions, please call 1-888-866-5797. Page 17 Setup Compressor starts and stops excessively Safety 1. Air filters need cleaning/replacing. Operation Overheating Possible Causes Maintenance Problem Parts List and Diagram Parts List Safety Part Setup Operation 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 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Description Cover Start Valve 3-Way Screw M6*55 Spring Washer Ø6 Plain Washer Ø6 Cylinder Head Air Filter Head Gasket Valve Plate Valve Al. Gasket Valve Plate Gasket Cylinder Cylinder Gasket Bolt M8*25 Spring Washer Ø8 Piston Ring Piston Piston Pin Wrist Pin Retainer Ø12 Connecting Rod Crank Shaft Screw M8*22 Zip Tie Capacitor Adhesive Sticker Bolt M8*20 Capacitor Bracket Crankcase Cover Gasket Oil Plug Crankcase Cover Screw M6*20 Oil Gauge Oil Gauge Gasket Drain Plug M6*10 O-Ring Crankcase Screw M6*16 Overload Protector Qty 1 1 1 4 4 4 1 1 1 2 2 1 1 1 1 2 2 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 4 1 1 1 1 1 10 1 Part 41 42 43 44 45 46 47 48 49 50 51 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 79 Description Oil Seal Bearing Rotator Bearing Stator Wave Pad Bolt M5*8 Spring Washer Ø5 Ground Connection End Cover Fan Circlip Ø14 Spring Washer Ø5 Bolt M5*115 Quick Couple Regulator Connector Pressure Switch Safety Valve Unloader Tube Exhaust Tube Check Valve Output Pressure Gauge Tank Pressure Gauge Plug Screw M6*10 Handle Tank Wheel Axle Wheel Spring Washer Ø10 Nut M10 Drain Valve Bolt M8*25 Plain Washer Ø8*Ø24*2 Foot Pad Plain Washer Ø8 Spring Washer Ø8 Nut M8 Qty 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 2 2 2 2 2 2 Maintenance 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. Page 18 For technical questions, please call 1-888-866-5797. ITEM 62803 Maintenance Operation Setup Safety Assembly Diagram ITEM 62803 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
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