®
AIR COMPRESSOR
2 HP-8 GALLON
40400
ASSEMBLY & OPERATING INSTRUCTIONS
Due to continuing improvements, actual product may differ slightly from the product described herein.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.
©
®
Copyright 1999 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.
For technical questions and replacement parts, please call 1-800-444-3353.
REV 08/01
Safety Warnings (continued)
7.
Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving parts.
Protective, electrically non-conductive clothes and non-skid footwear are recommended when working.
Wear restrictive hair covering to contain long hair.
8.
9.
Use eye and ear protection. Always wear ANSI approved impact safety goggles. Wear an ANSI
approved dust mask or respirator when working around metal, wood, and chemical dusts and mists.
Do not overreach. Keep proper footing and balance at all times. Do not reach over or across running
machines.
10. Maintain tools with care. Keep tools sharp and clean for better and safer performance. Follow
instructions for lubricating and changing accessories. Inspect tool cords periodically and, if damaged,
have them repaired by an authorized technician. The handles must be kept clean, dry, and free from oil
and grease at all times.
11. Disconnect power. Unplug tool when not in use.
12. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are removed from
the tool or machine work surface before plugging it in.
13. Avoid unintentional starting. Be sure the switch is in the Off position when not in use and before
plugging in.
14. Stay alert. Watch what you are doing, use common sense. Do not operate any tool when you are tired.
15. Check for damaged parts. Before using any tool, any part that appears damaged should be carefully
checked to determine that it will operate properly and perform its intended function. Check for
alignment and binding of moving parts; any broken parts or mounting fixtures; and any other condition
that may affect proper operation. Any part that is damaged should be properly repaired or replaced by
a qualified technician. Do not use the tool if any switch does not turn On and Off properly.
16. Guard against electric shock. Prevent body contact with grounded surfaces such as pipes, radiators,
ranges, and refrigerator enclosures.
17. Replacement parts and accessories. When servicing, use only identical replacement parts. Use of
any other parts will void the warranty. Only use accessories intended for use with this tool. Approved
accessories are available from Harbor Freight Tools.
18. Do not operate tool if under the influence of alcohol or drugs. Read warning labels on
prescriptions to determine if your judgment or reflexes are impaired while taking drugs. If there is any
doubt, do not operate the tool.
19. Use proper size and type extension cord. If an extension cord is required, it must be of the proper
size and type to supply the correct current to the tool without heating up. Otherwise, the extension cord
could melt and catch fire, or cause electrical damage to the tool. This tool requires use of an extension
cord of 0 to 15 amps capability (up to 50 feet), with wire size rated at 16 AWG. Longer extension cords
require larger size wire. If you are using the tool outdoors, use an extension cord rated for outdoor use
(signified by “WA” on the jacket).
20. Maintenance. For your safety, service and maintenance should be performed regularly by a qualified
technician.
21. Drain compressor every day. Do not allow moisture to build up inside the compressor.
22. Make sure all equipment is rated to the appropriate capacity.
23. Avoid explosions and fire. Never place flammable objects near the compressor. Never spray water or
any flammable liquids towards the compressor.
SKU 40400
For technical questions, please call 1-800-444-3353.
Page 3
Unpacking
When unpacking, check to make sure all parts are included. Refer to the Assembly Drawing and Parts List at
the end of this manual. If any parts are missing or broken, please call Harbor Freight Tools at the number on
the cover of this manual as soon as possible.
Assembly
The Wheels need to be assembled to the Air Compressor. Insert the Axle (#54) through one of the Wheels
(#55). With these two assembled together, insert Axle (#54) through the bracket on the bottom of the Tank
Assembly (#50). Slide on Washer (#56) and the Lock Washer (#57) and tighten with the Nut (#58). Once
assembled, roll the Air Compressor to test the operation of the wheels. Periodically check to insure that
wheel and axle hardware is secure.
Operation
To assist you with operation, please refer to the Assembly Diagram and Parts List located on pages 6, 7 and 8.
Warning: Fill with compressor oil before using;
running with NO or LOW OIL voids warranty.
Checking the Oil
Make certain to add compressor oil prior to operation. The Oil Fill Plug and Oil Sight is shown on the
illustration on page 6. Only use a good quality, 30-weight, non-detergent compressor oil.
Change the oil after every 500 hours of operation.
1.
2.
By checking the level of fluid in the Oil Sight (part #20), you will be able to determine the oil level. The
oil level should be even with the dot in the center of the Oil Sight (part#20). If low, add oil until it is at
the proper level.
Oil is added by removing the Oil Plug (part #14) and, using a funnel to avoid spills, adding oil to the
Compressor. After Oil is added, replace the Oil Plug.
Compressor Operation
1.
2.
Plug the power cord into an electrical outlet with a grounding prong.
Pull up on the ON/OFF switch to turn on (see illustration on page 6). Push down on the switch to shut
the compressor off.
3.
Allow the tank to fill to 80 PSI before using. With the Air Compressor on, its operation is automatic
and under the control of the internal pressure switch.
Warning: Do not remove the factory sealed Air Control Valve (see illustration on page 6); removal of
this valve voids warranty.
Hose Connections
1.
Close the Air Control Valve (turn to right or left).
2.
Connect the high pressure air hose to the air outlet. The outlet is 1/4” NPT. Note: For easy
connection or removal, a quick coupler (not included) should be installed on the end of the outlet.
3.
Turn the Air Control Valve to the middle position to allow the air to pass.
REV 03/06
SKU 40400
For technical questions, please call 1-800-444-3353.
Page 4
Compressor Operation (continued)
Caution: The pressure switch is adjustable but changes to the pressure levels are not recommended;
any change to the automatic On/Off pressure levels will cause additional stress on the motor which
may result in shortened motor life.
Using the Safety Valve
The Safety Valve (see illustration on page 6 for location) is used when decompression is needed quickly and
efficiently.
1.
Press the ON/OFF switch down.
2.
Pull on the Safety Valve ring to release pressure.
Empty Air and Condensation
The Petcock (#53) release valve is located underneath the Tank Assembly (#50). It must be used daily to
release all trapped air and moisture through this valve. It will also get rid of any condensation that may cause
tank corrosion.
Warning: Do not open the Petcock (#53) so that more than four threads are showing.
1.
2.
3.
Push down on the ON/OFF switch to turn the compressor off.
Unscrew the Petcock (#53) two to three turns.
When all pressure is released, close the Petcock (#53) again.
NOTE: IF THE COMPRESSOR SUDDENLY SHUTS OFF, check and reset the unit’s
Overload Protection (59). To reduce the chance of this occurring, eliminate the
use of an extension cord.
Warning: To reduce the risk of fire or explosion, never spray flammable liquids in a
confined area. Always operate the compressor in a well ventilated area. Do not smoke
while spraying. Do not spray where sparks or flames are present. Keep compressor as
far from spray area as possible.
Never directly inhale the compressed air produced by a compressor. It is not
suitable for breathing purposes.
Never weld on the air tank of this Compressor. Welding of the tank could affect
tank strength and result in an extremely hazardous condition.
To avoid the potential for electric shock, never use this Compressor outdoors
when it is raining, and never use the Compressor on a wet surface.
Never point any nozzle or sprayer toward a person or animal.
REV 01/06
SKU 40400
For technical questions, please call 1-800-444-3353.
Page 5
Air Compressor Diagram
SHROUD
CYLINDER HEAD
FILTER SCREW
HANDLE
AIR PRESSURE SWITCH
REGULATED VALVE
DRAIN VALVE
CONTROL VALVE
AIR PRESSURE METER
AIR PRESSURE METER
SAFETY VALVE
TANK ASSEMBLY
Hex Head Bolt
part # 11
To drain the oil
remove this bolt.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES
ANY REPRESENTATION OR WARRANTY OF ANY KINDTO THE BUYERTHAT HE OR SHE IS QUALIFIED
TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY
PARTS OFTHE 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.
REV 03/06
SKU 40400
For technical questions, please call 1-800-444-3353.
Page 6
Parts List
Part
1
Description
Socket Screw
Qty
4
1
1
1
1
1
1
2
1
1
1
1
4
1
1
1
1
6
1
1
1
1
1
1
1
1
1
1
1
1
Part
Description
Qty
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
1
30 Capacitor
31 Back Cover
2
Cylinder Head
Cylinder Head Gasket
Valve
3
32 Forced Air Fan
33 Stem Ring
34 Shroud
4
5
Cylinder Gasket
Cylinder
6
35 Stem Ring
36 Pin
7
Gasket
8, 8-1 Compression Ring
8-2 Piston
37 Strip Valve
38 Filter/Filter Screw
39 Elbow 90 degree
40 Drain Tube
41 Check Valve
42 Tube
9
Wrist Pin Piston
10 Piston
11 Hex Head Nut
12 Crossed Screw
13 Handle
43 Drain Valve
44 Regulated Valve
45 Outlet
14 Oil Retainer
15 Connecting Rod
16 Gasket Crankcase
17 Hex Head Bolt
18 End Cover Assembly
19 Washer
46 Air Pressure Switch
47 Air Pressure Meter
48 Air Pressure Meter
49 Safety Valve
50 Tank Assy
51 Screw
20 Oil Sight
21 Stem Ring
22 Washer
52 Rubber Washer
53 Petcock
23 Crankshaft Cone Assy
24 Inner Hex Head Bolt
25 Crank Case
26 Crossed Self Tapping Screw
27 Motor Drive
28 Nut
54 Axle
55 Wheel
56 Washer
57 Lock Washer
58 Nut
29 Washer
59 Overload Protection
Note: Some parts listed and shown on this page are for illustration purposed only and are not
available individually as replacement parts.
REV 01/06
SKU 40400
For technical questions, please call 1-800-444-3353.
Page 7
Assembly Diagram
REV 01/06
SKU 40400
For technical questions, please call 1-800-444-3353.
Page 8
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