Manual For The 68740 Portable Air Compressor, 2 Horsepower, 8 Gallon, 125 PSI
Central Pneumatic Air Compressor Air Compressor 67501 68740
User Manual: Manual for the 68740 Portable Air Compressor, 2 Horsepower, 8 Gallon, 125 PSI 8 gal. 2 HP 125 PSI Oil Lube 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 16h 8 GAL 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© 2011 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. Contents IMPORTANT SAFETY INFORMATION���������������������������������������������������������������������������������������������������������������������������3 GENERAL COMPRESSOR SAFETY WARNINGS���������������������������������������������������������������������������������������������������3 AIR COMPRESSOR SAFETY WARNINGS��������������������������������������������������������������������������������������������������������������5 GROUNDING�������������������������������������������������������������������������������������������������������������������������������������������������������������������6 110-120 VAC GROUNDED COMPRESSORS: COMPRESSORS WITH THREE PRONG PLUGS�������������������������6 SYMBOLOGY������������������������������������������������������������������������������������������������������������������������������������������������������������7 SPECIFICATIONS������������������������������������������������������������������������������������������������������������������������������������������������������������8 UNPACKING��������������������������������������������������������������������������������������������������������������������������������������������������������������������8 INSTRUCTIONS FOR PUTTING INTO USE�������������������������������������������������������������������������������������������������������������������8 FUNCTIONS��������������������������������������������������������������������������������������������������������������������������������������������������������������8 WORK PIECE AND WORK AREA SET UP��������������������������������������������������������������������������������������������������������������9 ASSEMBLY/MOUNTING�������������������������������������������������������������������������������������������������������������������������������������������9 CHECKING THE OIL�����������������������������������������������������������������������������������������������������������������������������������������������10 GENERAL OPERATING INSTRUCTIONS�������������������������������������������������������������������������������������������������������������������� 11 EMERGENCY DEPRESSURIZATION��������������������������������������������������������������������������������������������������������������������12 AUTOMATIC SHUT OFF SYSTEM�������������������������������������������������������������������������������������������������������������������������12 MAINTENANCE AND SERVICING��������������������������������������������������������������������������������������������������������������������������������13 CLEANING, MAINTENANCE, AND LUBRICATION����������������������������������������������������������������������������������������������13 MAINTENANCE SCHEDULE����������������������������������������������������������������������������������������������������������������������������������13 OIL MAINTENANCE�����������������������������������������������������������������������������������������������������������������������������������������������14 DRAINING MOISTURE FROM THE TANK�������������������������������������������������������������������������������������������������������������14 AIR FILTER MAINTENANCE����������������������������������������������������������������������������������������������������������������������������������14 TROUBLESHOOTING��������������������������������������������������������������������������������������������������������������������������������������������15 PARTS LIST�������������������������������������������������������������������������������������������������������������������������������������������������������������������17 ASSEMBLY DIAGRAM��������������������������������������������������������������������������������������������������������������������������������������������������18 WARRANTY�������������������������������������������������������������������������������������������������������������������������������������������������������������������19 Page 2 For technical questions, please call 1-888-866-5797. Item 68740 compressor. Standard plugs and matching outlets will reduce risk of electric shock. Important Safety Information b. Do not expose the compressor to rain or wet conditions. Water entering a compressor will increase the risk of electric shock. In this manual, on the labeling, and all other information provided with this product: 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. c. Do not abuse the cord. Never use the cord for pulling or 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. 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. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. b. Use personal protective equipment. Always wear eye protection. Safety equipment such as a dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. c. Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source or moving the compressor. d. Only use safety equipment that has been approved by an appropriate standards agency. Unapproved safety equipment may not provide adequate protection. Eye protection must be ANSIapproved and breathing protection must be NIOSHapproved for the specific hazards in the work area. NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices not related to personal injury. General Compressor Safety Warnings 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. 1. Work area safety a. Keep work area clean and well lit. Cluttered or dark areas invite accidents. 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. 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 a grounded Item 68740 Personal safety 4. Compressor use and care 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. b. Disconnect the plug from the power source of the compressor before making any adjustments, changing accessories, or storing it. 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. Following 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 For technical questions, please call 1-888-866-5797. Page 3 conditions and the work to be performed. Use of the compressor for operations different from those intended could result in a hazardous situation. RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS (120 VOLT) Service 5. NAMEPLATE AMPERES 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. (at full load) Air Compressor Safety Warnings 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 maximum stated pressure of attachment. 3. Risk of injury - Do not direct air stream at people or animals. 4. To reduce the risk of electric shock, do not expose to rain. Store indoors. 5. Wear ANSI-approved safety goggles during use. 6. Do not use to supply breathing air. 7. Do not use the air hose to move the compressor. 8. Drain Tank daily and after use. Internal rust causes tank failure and explosion. 9. EXTENSION CORD LENGTH 25’ 50’ 100’ 150’ 0–6 18 16 16 14 6.1 – 10 18 16 14 12 10.1 – 12 16 16 14 12 12.1 – 16 14 12 Do not use. TABLE A 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. 17. Industrial applications must follow OSHA guidelines. 18. Maintain labels and nameplates on the compressor. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 19. Add correct amount of compressor oil before first use and every use. Operating with low or no oil causes permanent damage and voids warranty. This product is not a toy. Keep it out of reach of children. 20. Operate unit on level surface. Check oil level daily and fill to marked level if needed. 10. Do not remove the Pressure Switch (54) cover or adjust the internal components. 21. 11. Do not use the air hose to move the compressor. 12. Compressor head gets hot during operation. Do not touch it or allow children nearby during or immediately following operation. 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. 22. 13. Release the pressure in the storage tank before moving. 14. The use of accessories or attachments not recommended by the manufacturer may result in a risk of injury to persons. 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.) 23. 15. 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. 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.) 16. USE OF AN EXTENSION CORD IS NOT RECOMMENDED. If you choose to use an extension cord, use the following guidelines: 24. 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. SAVE THESE INSTRUCTIONS. Page 4 For technical questions, please call 1-888-866-5797. Item 68740 6. 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 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. Grounding Pin 120 VAC 3-Prong Plug and Outlet (for up to 120 VAC and up to 15.5 A) 7. This compressor is intended for use on a circuit that has an outlet that looks like the one illustrated above in 120 VAC 3-Prong Plug and Outlet. The compressor has a grounding plug that looks like the plug illustrated above in 120 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. 110-120 VAC Grounded Compressors: Compressors with Three Prong Plugs 1. 2. 3. 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. Repair or replace damaged or worn cord immediately. Symbology Double Insulated Do not modify the plug provided – if it will not fit the outlet, have the proper outlet installed by a qualified electrician. 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. Item 68740 Canadian Standards Association Underwriters Laboratories, Inc. VAC A Volts Alternating Current Amperes No Load Revolutions n0 xxxx/min. per Minute (RPM) For technical questions, please call 1-888-866-5797. Page 5 Functions Specifications Electrical Requirements 120 VAC / 60 Hz / 2 HP Amperage 14A (Dedicated circuit recommended) Air Outlet Size 1/4″-18 NPT Air Pressure Auto Shut-Off @ 125 PSI Restart @ 95 PSI Air Tank Capacity 8 Gallons Air Flow Capacity 4.5 SCFM @ 90 PSI 5.5 SCFM @ 40 PSI Oil Capacity 5.6 oz. Oil Type SAE 30W non-detergent Air Compressor Oil (Sold separately) Decibel Level 88 dB @ 1m Oil Sight Glass (33) Pressure Tank Pressure Output Gauge (53) Pressure Regulator Gauge (74) (77) ON/OFF Power Lever (On Pressure Switch (54)) Safety Coupler for Valve (73) attaching in-line shutoff valve, air hose and tool Drain Valve (66) (Top View) Pressure Switch (54) Instructions for putting into use TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Turn the Power Lever “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. Page 6 ON Tank Pressure Gauge (53) 263525 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. OFF ON/OFF Power Lever Output Pressure Gauge Pressure (77) Regulator (74) Figure 1 Work Piece and Work Area Set Up 1. Designate a work area that is clean and welllit. 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. For technical questions, please call 1-888-866-5797. Item 68740 Assembly/Mounting 4. a. Make sure the Power Lever is OFF and the unit is unplugged. Insert a male coupler (sold separately) into the female Quick Coupler (76) and fully open all regulators and valves. Bolt (64) Wheel (63) Bolts (71) Tank (70) Break in the new Air Compressor as follows: Hex Nuts (65) b. Plug in the Power Cord. c. Turn the Power Lever ON. d. Let the unit run for 30 minutes. Air will expel freely through the Coupler. Handle (72) Wheel (63) e. Turn the Power Lever OFF. Bolts (71) Bolt (64) f. Unplug the Power Cord and remove the male coupler. Figure 2 1. Attach the Wheels (63) to the Tank (70), using the Bolts (64) and Hex Nuts (65). 2. Slide the Handle (72) into the two slots on the top of the Tank and secure in place with four Bolts (71). Cylinder Head (7) 5. Connect a regulator valve, an in-line shut off valve and a 1/4″ NPT air hose to the Quick Coupler (76) (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. Air Filter (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). Consult your air tool’s manual for needed accessories. See typical Air Line Set up Charts on the following pages. This compressor is a portable type compressor. Figure 3 3. Thread the Air Filter (6) onto the side of the Cylinder Head (7). Item 68740 For technical questions, please call 1-888-866-5797. Page 7 Page 8 A B C D E F G H Air Hose Filter Regulator Lubricator (optional) Coupler and Plug Leader Hose (optional) Air Cleaner / Dryer (optional) Air Adjusting Valve (optional) Description Non-lubricated Tools A Lubricated Tools B B C C A Function A E E F H Connects air to tool Prevents dirt and condensation from damaging tool or work piece Adjusts air pressure to tool For air tool lubrication Provides each connections Increases coupler life Prevents water vapor from damaging work piece For fine tuning airflow at tool G D Air Tool & Spray Gun Portable Setup For technical questions, please call 1-888-866-5797. Item 68740 B A Item 68740 A B C D E F G H I J K L M N O Description F E F C C H H J I K J L Function L M M O N 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 Prevents dirt and condensation from damaging tool or work piece Prevents water vapor from damaging work piece Adjusts air pressure to tool For air tool lubrication Connects air to tool Provides each connections For fine tuning airflow at tool Increases coupler life Non-lubricated Tools Vibration Pads Anchor Bolts Ball Valve Isolation Hose Main Air Line - 3/4″ minimum recommended Ball Valve Branch Air Line -1/2″ minimum recommended Filter Air Cleaner / Dryer (optional) Regulator Lubricator Air Hose Coupler and Plug Air Adjusting Valve Leader Hose B A C D G Lubricated Tools Slope F Air Tool & Spray Gun Stationary Setup For technical questions, please call 1-888-866-5797. Page 9 Checking the Oil 1. 3. a. Remove the Oil Plug (37). Check the oil level before operation. Fill the Pump Crankcase (39) with premium quality SAE 30-weight, non-detergent air compressor oil. 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. b. Using a funnel to avoid spills, pour enough oil into the Pump Crankcase (39) 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. Crankcase Cover (31) Oil Sight Glass (33) OIL LEVEL OVERFILL Tank (70) FULL LOW Figure 5 2. The oil level should be at the center of the “full” level on the oil level sight glass, as shown in Figure 5. 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. Page 10 To add 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. WARNING! To prevent serious injury from burns: Do not add or change the oil while the compressor is in operation. Allow the compressor to cool before replacing oil. For technical questions, please call 1-888-866-5797. Item 68740 Adjust the pressure gradually, while checking the air output gauge to set the pressure. General 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. IMPORTANT: First, turn the Power Switch OFF. This releases tank pressure and allows the motor to start freely, without tripping the Circuit Breaker. 1. 2. Close the Drain Valve (66). 3. Make sure all nuts and bolts are tight. 4. Check for oil leaks and check the oil level (See Checking the Oil). 5. Close the in-line Shutoff Valve between the compressor and the air hose. 6. Make sure the air tool’s throttle or switch is in the off position. 7. Connect the air tool to the air hose. 8. Plug the Air Compressor Power Cord into a grounded 120 V electrical outlet. 9. Open the in-line Shutoff Valve. 10. Turn the Power Lever ON. 11. Allow the Air Compressor to build up pressure until it cycles off. 13. Use the air tool as needed. 14. After the job is complete, turn the Power Lever OFF. Note: Turn the switch off before unplugging the compressor. 15. Unplug the Air Compressor. 16. Close the in-line Shutoff Valve. 17. Bleed air from the tool then disconnect the tool. 18. Turn the Drain Valve (66), at the bottom of the Tank, two turns to release any builtup moisture and the internal tank pressure. Close the valve after moisture has drained out. Do not remove the Drain Valve. 19. Clean, then store the Air Compressor indoors. Emergency Depressurization If it is necessary to quickly depressurize the Compressor, turn the Power Lever OFF. Then, pull on the ring on the Safety Valve (73) to quickly release stored air pressure. Automatic Shut off System 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 cut-out. 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 Lever 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 as indicated on the Tank Pressure Gauge (53), and will turn off automatically when the air pressure reaches 125 PSI as indicated. IMPORTANT: The internal pressure switch is not user adjustable, do not make changes to the air pressure settings of the internal pressure switch. Any change to the automatic pressure levels may cause excess pressure to accumulate, causing a hazardous situation. 12. Adjust the Air Compressor’s 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 knob clockwise to increase the pressure and counter-clockwise to decrease pressure. Item 68740 Reset Button Figure 4 1. If the Compressor automatically shuts off: 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 it’s 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. 3. Correct any issues before further use to avoid damage to the compressor. For technical questions, please call 1-888-866-5797. Page 11 Maintenance and Servicing 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 Lever “OFF” and unplug the Compressor from its electrical outlet before performing any inspection, maintenance, or cleaning procedures. TO PREVENT SERIOUS INJURY FROM TOOL FAILURE: Do not use damaged equipment. If abnormal noise or vibration occurs, have the problem corrected before further use. Cleaning, Maintenance, and Lubrication 1. 2. 3. 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. Daily: a. Check oil level. b. Check for oil leaks. 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. Wipe off any oil or dirt from the compressor.** Weekly: a. Inspect Air Filter (6). b. Inspect Oil Plug (37). BEFORE EACH USE, inspect the general condition of the Air Compressor. Check for loose hardware, misalignment or binding of moving parts, cracked or broken parts, damaged electrical wiring, and any other condition that may affect its safe operation. Monthly: AFTER USE, wipe external surfaces of the tool with a clean cloth. Every 6 months or 100 Operation Hours: WARNING! If the supply cord of this power tool is damaged, it must be replaced only by a qualified service technician. Inspect Safety Valve (73). Replace Pump oil.*** * 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. *** Use Air Compressor Oil only (sold separately). Page 12 For technical questions, please call 1-888-866-5797. Item 68740 Oil Maintenance Draining Moisture from the Tank Check 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. WARNING: Risk of personal injury hazard. Allow Air Compressor to cool before changing the oil. To drain the oil from the Pump Crankcase (39): The Drain Valve (66) is located under the Tank (70). It must be accessed daily to release all trapped air and moisture from the Tank. This will eliminate condensation which can cause tank corrosion. Note: Do not open the Drain Valve so that more than four threads are showing. To empty the air and condensation: a. Make sure the Power Lever of the compressor is off. a. Place a container under the Drain Plug (35). b. Place a collection pan under the Drain Valve. b. Remove the Oil Plug (37) to allow air flow into the Pump. c. Unthread the Drain Valve two or three turns ONLY. c. Remove the Drain Plug, allowing the oil to drain into the container. d. When the oil is completely drained from the Pump, replace the Drain Plug. e. Fill the Pump with new compressor oil to the FULL level on the Oil Sight Glass (33). f. Replace and tighten the Oil Plug. g. Discard the old oil according to local, state and federal regulations. d. When all the pressure is released, close the Drain Valve. Air Filter Maintenance 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. To replace the Air Filter: a. Remove the Cover (1). b. Remove the Air Filter (6). c. Replace with a new Air Filter. d. Replace the Cover. Item 68740 For technical questions, please call 1-888-866-5797. Page 13 Troubleshooting Problem Compressor does not start or restart Possible Causes 1. Incorrect power supply. 2. No power at outlet. 3. Power cord not plugged in properly. 4. Thermal overload switch tripped. 5. Building power supply circuit tripped or blown fuse. 6. Tanks are pressurized. 7. Cord wire size is too small or cord is too long to properly power compressor. 8. Compressor needs service. Compressor builds pressure too slowly High Oil Consumption 4. Turn off Tool. Turn off Compressor and wait for it to cool down. Press reset button. Resume operation. 5. 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. 6. Fully bleed tanks of air. 7. Use larger diameter or shorter extension cord or eliminate extension cord. See Recommended Wire Gauge for Extension Cords in Safety section. 8. Have unit inspected by a qualified technician. 1. Incorrect power supply. 1. Check that circuit matches compressor requirements. 2. Crankcase overfilled with 2. Drain oil and refill to proper level oil or oil too thick. with recommended oil. 3. Working environment too cold. 3. Move unit to a warmer location. Check that recommended oil is in crankcase. 4. Safety valve needs service. 4. Listen for air leaking from valve. If leaking 5. Loose fittings. Compressor not building enough air pressure Likely Solutions 1. Check that circuit matches compressor requirements. 2. Reset circuit breaker, or have outlet serviced by a qualified technician. 3. Check that cord is plugged in securely. replace with identical valve with same rating. 5. Reduce air pressure, then check all fittings with a soap solution for air leaks and tighten as needed. Do not overtighten. 1. Filters need cleaning/replacing. 1. Check inlet and outlet filters. Clean and/or replace as needed. 2. Crankcase oil too thick. 2. Drain oil and refill to proper level with recommended oil. 3. Check Valve needs service. 3. Clean or replace, as needed. 4. Compressor not large enough 4. Check if accessory SCFM is met by Compressor. for job. If Compressor cannot supply enough air flow (SCFM), you need a larger Compressor. 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. 6. Hose or hose connections 6. Replace with larger hose and/or hose connections. not adequate. 7. High altitude reducing 7. You may need a larger compressor if you air output. are situated in a high altitude location. 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 vents clogged. 3. Clean Crankcase vents. Follow all safety precautions whenever diagnosing or servicing the compressor. Disconnect power supply before service. Page 14 For technical questions, please call 1-888-866-5797. Item 68740 Problem Overheating Possible Causes Likely Solutions 1. Filters need cleaning/replacing. 1. Check inlet and outlet filters. Clean and/or replace as needed. 2. Crankcase oil too thin 2. Drain oil and refill to proper level or incorrect type. with recommended oil. 3. Crankcase oil level too low. 3. Add oil to proper level, check for leaks. 4. Unusually dusty environment. 5. Compressor starts and stops excessively 6. 1. 2. Excessive noise Moisture in discharge air Oil in discharge air Safety Valve “pops” Air leaks from pump or fittings Air leaks from tank 4. Clean and/or replace filters more often or move unit to cleaner environment. Cord is too small of a gauge or 5. Increase cord size or use shorter length extension too long to handle compressor. cord, or eliminate extension cord. See Recommended Wire Gauge for Extension Cords in Safety section. Unit not on level surface. 6. Reposition unit on a level surface. Compressor not large enough 1. Check if accessory SCFM is met by Compressor. for job. If Compressor doesn’t reach accessory SCFM, you need a larger Compressor. Loose fittings. 2. Reduce air pressure, then check all fittings with a soap solution for air leaks and tighten as needed. Do not overtighten. 1. Crankcase overfilled with oil or oil is incorrect thickness or type. 2. Crankcase oil level too low. 3. Loose or damaged belt guard. 4. Loose fittings. 5. Unit not on level surface. Too much moisture in air. 1. Crankcase oil too thin or crankcase overfilled with oil. 2. Crankcase vents clogged. Safety valve needs service. Loose fittings. Defective or rusted tank. 1. Drain oil and refill to proper level with recommended oil. 2. Add oil to proper level, check for leaks. 3. Replace belt guard. 4. Reduce air pressure, then check all fittings with a soap solution for air leaks and tighten as needed. Do not overtighten. 5. Reposition unit on a level surface. Install inline air filter/dryer, and/or relocate to less humid environment. 1. Drain oil and refill to proper level with recommended oil. 2. Clean Crankcase vents. Pull on test ring of safety valve. If it still pops, replace. Reduce air pressure, then check all fittings with a soap solution for air leaks and tighten as needed. Do not overtighten. Have tank replaced by a qualified technician. Follow all safety precautions whenever diagnosing or servicing the compressor. Disconnect power supply before service. Item 68740 For technical questions, please call 1-888-866-5797. Page 15 Parts List Part 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 Page 16 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 Hex Nut M6 Crank Shaft O-Ring Zip Tie Capacitor Screw M8 x 20 Capacitor Bracket Hex Nut M8 Crank Case Cover O-Ring Oil Sight Glass O-Ring Drain Plug M5 x 10 O-Ring Oil Plug Crankcase Cover Gasket Pump Crankcase Washer M5 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 Part 41 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 Screw M5 x 16 Manual Overload Protector Oil Seal Bearing Rotator Bearing Stator Automatic Thermal Protector End Cover Fan Circlip Plain 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 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 10 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 68740 ASSEMBLY DIAGRAM Item 68740 For technical questions, please call 1-888-866-5797. Page 17 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. 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 68740 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. Item 68740 For technical questions, please call 1-888-866-5797. Page 19 3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797
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