4 Gallon, 2 HP Peak
Pancake Compressor
Model 38898
ASSEMBLY and OPERATING INSTRUCTIONS
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
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 11/04; 10/05; 02/06
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SAFETY WARNING & CAUTIONS
WARNING: When using pneumatic equipment, basic safety precautions should always be followed
to reduce the risk of personal injury and hazards.
READ ALL INSTRUCTIONS BEFORE USING THIS TOOL!
1. KEEP WORK AREA CLEAN. Cluttered areas invite injuries.
2. OBSERVE WORK AREA CONDITIONS. Do not use tools in damp, wet, or poorly lit locations.
Don’t expose to rain. Keep work area well lit. Do not use electrically powered air compressors in
the presence of flammable gases or liquids.
3. KEEP CHILDREN AWAY. Children must never be allowed in the work area. Do not let them
handle machines, tools, or hoses.
4. STORE IDLE EQUIPMENT. When not in use, tools must be locked up in a dry location to inhibit
rust. Always lock up tools and keep out of reach of children.
5. DO NOT FORCE THE TOOL. It will do the job better and more safely at the rate for which it was
intended. Do not use inappropriate attachments in an attempt to exceed the tool’s capacities.
6. USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force a small tool or attachment to do
the work of a larger industrial tool. Do not use a tool for a purpose for which it was not intended.
7. DRESS PROPERLY. Do not wear loose clothing or jewelry as they can be caught in moving parts.
Nonskid footwear is recommended. Wear restrictive hair covering to contain long hair.
8. USE EYEAND EAR PROTECTION. Always wearANSI-approved chemical splash goggles when
working with chemicals. Always wear ANSI-approved impact safety goggles at other times. Wear
a full face shield if you are producing metal filings or wood chips. Wear an ANSI-approved dust
mask or respirator when working around metal, wood, and chemical dusts and mists.
9. 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 hydraulic lines and seals
periodically and, if damaged, have them repaired by an authorized technician. Inspect all hoses for
leaks prior to use. The handles must be kept clean, dry, and free from oil and grease at all times.
11. REMOVE ADJUSTING KEYSAND WRENCHES. Make it a habit to check that keys and adjust-
ing wrenches are removed from the tool or machine work surface before plugging it in.
12. STAY ALERT. Watch what you are doing, use common sense. Do not operate any tool when you are
tired.
13. CHECK 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.
14. 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.
15. 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.
16. MAKE SURE ALL EQUIPMENT IS RATED TO THE APPROPRIATE CAPACITY. Do not at-
tempt any operations or hook up any equipment that would not meet the rated capacities of this tool.
Page 3 SKU # 38898
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Handle
ON / OFF Power Switch
Pressure Gauge
Compressor
Oil Dipstick
Oil Reservoir
Oil Drain Plug
Air Tank
Air Flow Valve
Pressure Release Valve
Tank Drain Valve
Foot
Power Cord
ELECTRICAL SET UP
Your compressor has a grounded, three-prong plug. If using an extension cord, it must be a
three-prong type. You must connect to a three-prong receptacles only. The third prong is for grounding;
do not remove or disable the third prong, as this will create an unsafe condition.
Common household current is 110-120 Volts. As long as your compressor is rated from 110-
120 Volts, there will be no complications in using power from a household receptacle. Never try to plug
a tool designed for 110-120 Volts into a 220-240 Volt receptacle. 220V plugs and outlets are shaped
differently to prevent this.
Only use rounded jacket extension cords, preferably listed by Underwriter’s Laboratories (UL).
Make sure the cord is rated for outdoor use, even if your application is indoors. Outdoor use
cords have the letters “WA” on the cord jacket.
The extension cord must have a minimum wire size depending on the amperage of the tool and
the length of the extension cord. The size is signified by its AWG (American Wire Gauge) rating; the
smaller the gauge, the greater the cable’s capacity.
Note: When using extension cords - To avoid circuit breaker and voltage
drop problems when using extension cords, we recommend using only
12 gauge x 50 foot extension cords (Item #41444 or #45287), available from
Harbor Freight Tools).
Page 4 SKU # 38898
Rev 01/02
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SET UP & OPERATION
Your compressor is fully assembled when you receive it. Before using it, perform the following set up
operations.
Before using your compressor for the first time,
check to be sure the oil reservoir is filled.
Note: Optimal oil tank capacity is 7.8 ounces.
1.
2.
Unscrew the threaded Oil Dipstick to re-
move it from the oil reservoir.
Look at the oil level on the dip stick. The
proper oil level is shown on the illustration
to the right.
Oil
Dipstick
3.
4.
If the oil level is low, add standard, non-
detergent 30-weight non detergent compres-
sor oil, (use lighter weight oil for cold
weather operation). Add a little at a time,
and check the level before each addition.
Do not overfill. If overfilled, you can re-
move the drain plug to allow oil to drain
out.
Proper
Oil Level
When the oil level is correct, replace the
dipstick.
Figure 1. Checking the Oil Level
Next, connect your air hoses, filter and regula-
tor to the compressor, as illustrated in Figure 2
below.
NOTE:
Use Pipe Thread Seal tape on all
threaded connections.
Warning: Fill with compressor oil before using;
running with NO or LOW OIL voids warranty.
Warning: Do not remove
factory sealed Air Flow Valve
(#9A); removal of valve voids
warranty.
Figure 2 — Connecting the Air Compressor
1.
The provided air outlet is 1/4” NPT. Connect the high pressure air hose to the air outlet.
Note: For easy connection or removal, a quick coupler (included) should be installed on the
end of the outlet (a female and a male coupler are also included to use with the quick coupler).
For best service, you should incorporate an oiler, a regulator, and a filter in line; as shown in the
above diagram.
Hoses, Couplings, Fittings, Oilers, Regulators, and Filters are all available from Harbor Freight
Tools.
2.
3.
Page 5 SKU # 38898
Rev 02/01
REV 03/04 REV 05/05
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OPERATION
Before each use, perform the following checks:
Check to be sure the drain valve at the bottom of
the tank is closed. Check to be sure the oil level
is between the marks on the dip stick. Be sure
1.
Note:Always use a 120Velectrical source
(±10% maximum variation).
the safety pressure release valve has not been
damaged, and is functional.
Pressure Gauge
Pressure Release Valve
Air Flow Valve
ON / OFF Switch
2.
3.
Turn the Air Flow Valve to the OFF position. In
the OFF position, the red handle is across (per-
pendicular to) the line of the air hose fitting.
In the ON position, the red handle is parallel with
the line of the air hose fitting.
Turn ON the compressor, by pulling the Red ON/
OFF Switch up. Turn OFF the compressor by
pushing the ON /OFF switch down.
4.
5.
6.
7.
Allow the compressor to build up at least 80 PSI
as indicated on the pressure gauge.
While the compressor is building up pressure,
Fig. 3. Controls
attach the hoses, fittings, and air tools you will use.
When the pressure has reached 80 PSI; open the air flow valve to allow the hoses and tools to
become pressurized. Check for any significant air leaks, and check the operation of your tool.
As long as the power switch is pulled ON, the operation of the compressor is automatic, con-
trolled by an internal pressure switch. The compressor will turn on automatically when the
pressure drops to 80 PSI, and will turn off when the pressure reaches 115 PSI. Warning: This
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.
NOTE: If it is necessary to quickly depressurize the air compressor,
First: Turn it off by pushing the ON / OFF switch down.
Then: Pull out on the ring on the pressure release valve to quickly release stored pressure.
Note: Compressor has a Thermal Overload Switch (#41). If Compressor shuts down from over-
heating or related problems, turn Compressor OFF and allow it to cool down for 10 minutes. Once
cooled, push in Thermal Overload Switch and restart Compressor.
WARNING
1.
To reduce the risk of fire or explosion, never spray flammable liquids in a confined area. Al-
ways operate the compressor in a well ventilated area. Do not smoke while spraying. Do not
spray where sparks or flame are present. Keep the compressor as far away from the spray area
as possible.
2.
3.
4.
Never directly inhale the compressed air produced by the compressor. It is not suitable for
breathing purposes.
Never weld on the 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.
5.
6.
7.
8.
Never point any nozzle or sprayer towards a person or animal.
Never work on or make adjustments to the tank when the tank is under pressure.
Never service or make adjustments to this product without first unplugging the electrical cord.
Never place flammable objects near the compressor. Never spray water or flammable liquids
toward or near the compressor.
9.
10.
11.
Always push the ON/OFF switch down into the OFF position when the unit is not in use.
Do not transport the pancake compressor when the tank is under pressure.
Only operate in a well-ventilated area which has proper air circulation.
Rev 03/00, REV 10/01, REV 11/04
Page 6 SKU # 38898
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Compressor Assembly
Part# Description
Part # Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Screw
Screw
Washer
Washer
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Connecting Rod
Crankshaft
Gasket, Front Cover
Front Cover
Washer
Washer
Bolt
Screw
Crankshaft Case
Nut
Seal Washer
Bearing
Electric Capacitor
Bolt
Screw
Motor
Air Filter
Cylinder Case
Gasket, Crankshaft Cover
Valve Seat
Gasket, Valve Seat
Valve Plate
Valve Seat
Gasket, Valve Seat
Cylinder
Cylinder Gasket
Compression Ring
Scraping Oil Ring
Piston
Washer
Piston Pin
Crankshaft Retainer
Oil Stick
Radiating Fan Wheel
Radiating Cover
Thermal Switch
Screw
MAINTENANCE
1.
2.
3.
4.
Check the oil before each use to be sure the level of oil is correct (see illustration on page 5). If
the oil level is too low, add oil. If it is too high, drain some oil out by removing the drain plug.
Drain and replace the oil once per year. Replace more often if the compressor is used heavily or
the oil appears dirty.
Check the air filter every six months, or more often if compressor is used in a dirty or dusty
environment. Replacement air filters are available from Harbor Freight Tools.
Drain the air tank after each use, by turning the drain petcock clockwise to open it. Turn the
petcock counterclockwise to close it. It is a good practice to leave the drain plug open between
uses to ensure that the tank remains dry.
5.
Never use flammable liquids or solvents to clean the compressor. For cleaning, unplug the unit,
and clean with a mild detergent and water. Be careful not to introduce water into any electrical
components.
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 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.
Page 7 SKU # 38898
Rev 03/00
REV 11/01
REV 03/04
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PARTS DIAGRAM
NOTE: Part # 7,8,9,10,11,12 are only available as a kit ( Rebuild Kit SKU 27349 )
Page 8 SKU # 38898
Rev 03/00 REV 11/01 REV 03/04 REV 11/05
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PARTS DIAGRAM (CONTINUED)
9A
4A
10A
11A
5A
12A
13A
6A
14A
Parts List A
4A Bolt
5A Hose
6A Rubber Foot
9A Air Flow Valve
10A Pressure-release Valve
11A Pressure Gauge
12A No-return Valve
13A Tank
14A Tank Drain Valve
Page 9 SKU # 38898
Rev 03/04 REV 11/05
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