Klutch 1230080 User manual

2 HP / 4 GALLON
AIR COMPRESSOR
OWNER'S MANUAL
Item # 1230080
WARNING:
Read carefully and understand all INSTRUCTIONS before
operating. Failure to follow the safety rules and other basic
safety precautions may result in serious personal injury.
0909

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Thank you very much for choosing a NORTHERN TOOL + EQUIPMENT CO., INC. Product!
For future reference, please complete the owner's record below:
Model: _______________ Purchase Date: _______________
Save the receipt, warranty and these instructions. It is important that you read the entire
manual to become familiar with this product before you begin using it.
This machine is designed for certain applications only. Northern Tool + Equipment cannot be
responsible for issues arising from modification. We strongly recommend this machine is not
modified and/or used for any application other than that for which it was designed. If you
have any questions relative to a particular application, DO NOT use the machine until you
have first contacted Northern Tool + Equipment to determine if it can or should be performed
on the product.
For technical questions please call 1-800-222-5381.
INTENDED USE
This Air Compressor is designed to power pneumatic (air-powered) tools.
TECHNICAL SPECIFICATIONS
Description Specifications
Motor: 120V ~ 60Hz
HP: 2
Weight: 59.5 lbs
Tank Capacity: 4 Gallon
Air Pressure: 115 psi
CFM: 5.5 CFM @ 40 psi, 3.5 CFM @ 90 psi
CSA Listed:
GENERAL SAFETY RULES
WARNING! Read and understand all instructions. Failure to follow all instructions listed below may result
in electric shock, fire and/or serious injury.
WARNING! The warnings, cautions, and instructions discussed in this instruction manual cannot
cover all possible conditions or situations that could 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
WORK AREA
• Keep work area clean, free of clutter and well lit. Cluttered and dark work areas can cause accidents.
• Do not use your tool where there is a risk of causing a fire or an explosion; e.g. in the presence of
flammable liquids, gasses, or dust. Power tools create sparks, which may ignite the dust or fumes.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose
control, so visitors should remain at a safe distance from the work area.

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• Be aware of all power lines, electrical circuits, water pipes and other mechanical hazards in your work
area, particularly those hazards below the work surface hidden from the operator's view that may be
unintentionally contacted and may cause personal harm or property damage.
• Be alert of your surroundings. Using power tools in confined work areas may put you dangerously close to
cutting tools and rotating parts.
ELECTRICAL SAFETY
WARNING! Always check to ensure the power supply corresponds to the voltage on the rating plate.
• Do not abuse the cord. Never carry a portable tool by its power cord, or yank tool or extension cords from
the receptacle. Keep power and extension cords away from heat, oil, sharp edges or moving parts. Replace
damaged cords immediately. Damaged cords may cause a fire and increase the risk of electric shock.
• Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes
and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter
plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.
• Double insulated tools are equipped with a polarized plug (one blade is wider than the other). This plug will
fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still doesn't
fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way.
• Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators. There is an
increase risk of electric shock if your body is grounded.
• When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W.” These cords
are rated for outdoor use and reduce the risk of electric shock.
• Extension Cord Use:
A. Use only 'Listed' extension cords. If used outdoors, they must be marked “For Outdoor Use.” Those
cords having 3-prong grounding type plugs and mating receptacles are to be used with grounded tools.
B. Replace damaged or worn cords immediately.
C. Check the name plate rating of your tool. Use of improper size or gauge of extension cord may cause
unsafe or inefficient operation of your tool. Be sure your extension cord is rated to allow sufficient current
flow to the motor. For the proper wire gauge for your tool, see chart.
CHART FOR MINIMUM WIRE SIZE OF EXTENSION CORD:
If in doubt, use larger cord. Be sure to check voltage requirements of the tool to your incoming power source.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of
electric shock.
• Do not let your fingers touch the terminals of plug when installing to or removing from the outlet.
• Ground fault circuit interrupters. If work area is not equipped with a permanently installed Ground Fault
Circuit Interrupter outlet (GFCI), use a plug-in GFCI between power tool or extension cord and power
receptacle.
PERSONAL SAFETY
• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a
power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention
while operating power tools may result in serious personal injury.
• Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair, clothing and gloves
away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. Air vents often
cover moving parts and should be avoided.

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• Use safety apparel and equipment. Use safety goggles or safety glasses with side shields which comply
with current national standards, or when needed, a face shield. Use as dust mask in dusty work conditions.
This applies to all persons in the work area. Also use non-skid safety shoes, hardhat, gloves, dust collection
systems, and hearing protection when appropriate.
• Avoid accidental starting. Do not carry the power tool with your finger on the switch. Ensure the switch is in
the off position before plugging tool into power outlet. In the event of a power failure, while a tool is being
used, turn the switch off to prevent surprise starting when power is restored.
• Do not overreach. Keep proper footing and balance at all times.
• Remove adjusting keys or wrenches before connecting to the power supply or turning on the tool. A
wrench or key that is left attached to a rotating part of the tool may result in personal injury.
TOOL USE AND CARE
• Do not force the tool. Tools do a better and safer job when used in the manner for which they are designed.
Plan your work, and use the correct tool for the job.
• Never use a tool with a malfunctioning switch. Any power tool that cannot be controlled with the switch is
dangerous and must be repaired by an authorized service representative before using.
• Disconnect power from tool and place the switch in the locked or off position before servicing, adjusting,
installing accessories or attachments, or storing. Such preventive safety measures reduce the risk of starting
the power tool accidentally.
• Secure work with clamps or a vise instead of your hand to hold work when practical. This safety precaution
allows for proper tool operation using both hands.
• Store idle tools. When tools are not is use, store them in a dry, secure place out of the reach of children.
Inspect tools for good working condition prior to storage and before re-use.
• Use only accessories that are recommended by the manufacturer for your model. Accessories that may be
suitable for one tool may create a risk of injury when used on another tool.
• Keep guards in place and in working order.
• Never leave tool running unattended.
• Never exceed the pressure rating of any component in system.
• Protect material and air lines from damage or puncture. Keep hose and power cable away from sharp
objects, moisture, chemicals, oil, etc.
• Check condition of hoses before each use. Do not use a damaged hose. If hose is damaged, replace immediately.
• Drain tank of moisture after each use. If Compressor is not to be used for extended periods of time, leave
tank drain valve open to allow moisture to completely drain from tank.
• Do not tamper with Safety Valve. The Safety Valve is factory set for your model air compressor. Any use
adjustments to Safety Valve will automatically void warranty.
• Air compressors get hot while in operation. NEVER touch the motor, discharge tubing or compressor pump
while in operation.
• The Compressor operates automatically while the motor is turned on.
• Compressed air from the unit may contain carbon monoxide. Air produced is not suitable for breathing purposes.
• Always use a respirator when spraying paint or chemicals.
• The air pressure switch is set at the factory for optimum performance of your equipment. Never attempt to
bypass or remove this switch as serious damage to equipment or personal injury could result from excessive
air pressure.

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ASSEMBLY
NOTE: Before performing any assembly or maintenance make sure compressor is turned off and unplugged
from the power supply.
Installing the Oil and Oil Breather Cap
Your air compressor is shipped without oil in the crankcase.
BEFORE STARTING THE AIR COMPRESSOR YOU MUST
ADD OIL TO THE CRANKCASE AS DESCRIBED BELOW:
1. Place compressor on level ground.
2. Remove the Oil Shipping Plug from the Oil Fill hole,
located on the top of the crankcase cover at the rear of
the air compressor.
3. Slowly pour the oil into the Oil Fill hole, until the oil level
rises to the center of the red dot on the Oil Sight Glass.
Note: This compressor uses only SAE 5W-30 motor oil.
4. Install the Oil Breather Cap into the Oil Fill hole.
5. Firmly hand tighten the Oil Breather Cap by turning
clockwise.
(See Figure 1)
Installing the Air Chuck
Note: The use of a sealant tape is recommended on the
threads of the Air Chuck to prevent air leakage.
1. Thread the Air Chuck into the Air Regulator by turning the
Air Chuck clockwise.
2. Securely tighten the Air Chuck in place with a wrench.
(See Figure 2)
Note: DO NOT over tighten Air Chuck.
WARNING: Do not over fill.
Installing the Air Filter
The metal Air Filter is installed into the threaded port of the
cylinder head.
1. Thread the Air Filter into the Cylinder Head by turning the Air
Filter clockwise.
2. Securely tighten the Air Filter in place with a wrench.
(See Figure 3)
Note: DO NOT over tighten Air Filter.
Oil
Fill
Crank-
case
Oil
Sight
Glass
Drain
Plug
Figure 1. Installing the Oil & Oil Breather Cap
Figure 2. Installing the Air Chuck
Figure 3. Installing the Air Filter

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OPERATION
BEFORE OPERATING YOUR NEW AIR COMPRESSOR please check the following points carefully:
1 Check that all nuts and bolts are secure.
2. Make sure oil has been properly added to compressor. (See Installing Oil and Oil Breather Cap section.)
Initial Start-Up Procedure
1. Open the Air Tank Drain Valve to permit air to escape, preventing air pressure buildup in the air tank.
2. Run the compressor for a minimum of 20 minutes in this “no-load” position to lubricate the piston and bearings.
3. Close Air Tank Drain Valve. Your compressor is ready for use.
Depending on the CFM draw of the tools being operated, your new Air Compressor can be used for operating
paint sprayers, air tools, grease guns, airbrushes, caulking guns, abrasive blasters, tire & plastic toy inflation,
spraying weed killer and insecticides, etc. Proper adjustment of the Air Pressure Regulator is necessary for all of
these operations. Refer to the air pressure specifications provided with the tool you are using.
General Overview
To compress air, the piston moves up and down in the cylinder. On the down stroke air is drawn in through the
valve inlet. The discharge valve remains closed. On the upstroke of the piston air is compressed. The inlet valve
closes and air is forced out through the discharge valve, through the check valve, and into the air tank. Working
air is not available until the compressor has raised the tank pressure above that required at the air service
connection. The air inlet filter openings must be kept clear of obstructions, which could reduce air delivery of
the compressor.
Installation and Location
Locate the compressor in a clean, dry and well ventilated area. The compressor should be located 12 to 18
inches from walls or any other obstruction which would interfere with airflow. Place the compressor on a firm,
level surface. The compressor is designed with heat dissipation fins which allow for proper cooling. Keep the fins
(and all other parts which collect dust or dirt) clean. A clean compressor runs cooler and provides longer service.
Do not place rags, containers or other material on top of the compressor.
Connecting to Power Source
This air compressor is designed to operate on a properly grounded 120 volt, 60Hz, single phase, alternating
current (ac) power source with a fused 20 amp time delayed fuse or circuit breaker. It is recommended that a
qualified electrician verify the ACTUAL VOLTAGE at the receptacle into which the unit will be plugged and
confirm that the receptacle is properly fused and grounded. The use of the proper circuit size can eliminate
nuisance circuit breaker tripping while operating your air compressor.
Extension Cords
For optimum Air Compressor performance an extension cord should not be used unless absolutely necessary. If
necessary, care must be taken in selecting an extension cord appropriate for use with your specific Air
Compressor. Select a properly grounded extension cord which will mate directly with the power source
receptacle and the Air Compressor power cord without the use of adapters. Make certain that the extension cord
is properly wired and in good electrical condition.
Maximum length of extension cord should be 50 feet. Minimum wire size of extension cord should be 12 gauge.
Attaching an Air Hose
Your Air Compressor is supplied with a 1/4" Quick Disconnect Air Chuck. Once you have correctly installed the
Air Chuck (See Installing the Air Chuck on p.4) your compressor will be ready to accept air hoses equipped with
1/4" male air couplers.
Note: Use only air hoses rated for use with 115psi air pressure or higher.
To install an air hose, equipped with a 1/4" male coupler:
1. Pull back on Air Chuck outer sleeve to allow coupler to be
fully inserted into Air Chuck.
2. Insert coupler into Air Chuck.
3. Release outer sleeve of Air Chuck.
4. Verify that air hose is securely connected to Air Chuck by
pulling lightly on air hose. (See Figure 4) Figure 4. Attaching an Air Hose

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Adjusting the Air Pressure
Your Air Compressor is supplied with an Air Pressure Regulator. This Regulator adjusts the air pressure.
• To increase air pressure, turn Air Regulator clockwise.
• To decrease air pressure, turn Air Regulator
counterclockwise.
(See Figure 5)
Cold Weather Starting
Temperatures below freezing (32°F) cause the
metal parts of your Air Compressor to contract and
that makes starting more difficult. To assist the Air
Compressor in starting in cold weather, follow
these tips:
1. Try to keep Air Compressor stored in temperatures above 32° fahrenheit.
2. Open the Air Tank Drain Valve and release all air pressure from the Air Tank before attempting to start in cold
weather. (After air is released)
3. Plug Air Compressor directly into a 120 volt electrical outlet. Do not use an extension cord when starting your
Air Compressor in cold weather.
MAINTENANCE
WARNING: Make sure this tool is disconnected from its power source before attempting any maintenance,
cleaning, or inspection.
• Maintain your tools. It is recommended that the general condition of any tool be examined before it is used.
Keep your tools in good repair by adopting a program of conscientious repair and maintenance in accordance
with the recommended procedures found in this manual. If any abnormal vibrations or noise occurs, turn the
tool off immediately and have the problem corrected before further use. Have necessary repairs made by
qualified service personnel.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less
likely to bind and are easier to control. Keep handles dry, clean, and free from oil and grease.
• Cleaning. Use only soap and a damp cloth to clean your tools. Many household cleaners are harmful to
plastics and other insulation. Never let liquid get inside a tool.
Daily (or before each use)
1. Check oil level
2. Drain condensation from the air tank.
3. Check for any unusual noise or vibration.
4. Be sure all nuts and bolts are tight.
Weekly
1. Clean breather hole on Oil Breather Cap.
Monthly
1. Inspect air system for leaks by applying soapy water to all joints. Tighten these joints if leaks are discovered.
6 Months (or after 250 hours of operation - whichever comes first)
1. Change Air Compressor Oil.
Note: Change oil more often if Air Compressor is used near paint spraying operations or in dusty environments.
Figure 5. Adjusting the Air Pressure

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TROUBLE SHOOTING
TROUBLE
Tank does not hold air or does not
reach operating pressure
POSSIBLE CAUSE
The air relief valve on the bottom
of the tank is not closed
CORRECTIVE ACTION
Close the air relief valve
Checking the Air Compressor Oil
1. Place Air Compressor on level surface. The oil level should be at the red dot on the Oil Sight Glass.
2. If oil level is low, remove Oil Breather Cap and add enough oil to bring the oil level to the red dot on the Oil
Sight Glass.
3. Replace Oil Breather Cap before starting compressor.
Changing the Air Compressor Oil
Note: This compressor uses only SAE 5W-30 motor oil.
1. Remove the Drain Plug under the Oil Sight Glass by turning the nut counter-clockwise with wrench. (See
Figure 1.)
Note: Oil will begin to drain as Drain Plug is loosened. Place a funnel and oil pan in place BEFORE loosening
Drain Plug.
2. Once Drain Plug is removed, tilt Air Compressor backwards to allow all of the oil to drain out of the crankcase.
3. Once oil is drained, replace Drain Plug and securely tighten in place with a wrench. Be careful not to
overtighten the Drain Plug, as this could damage the rubber seal.
4. Place Air Compressor on level surface.
5. Remove the Oil Breather Cap.
6. Slowly pour the oil into the Oil Fill hole, until the oil level rises to the center of the red dot on the Oil Sight Glass.
7. Install the Oil Breather Cap into the Oil Fill hole. Firmly hand tighten the Oil Breather Cap by turning clockwise.
Always inspect the tool before use, and make sure it is in good working condition. Make sure all air vents are
clear, (use compressed air to clean the machine where possible). Check the power cable to make sure it is
intact and free from cracks, bare wires etc. Avoid using solvents when cleaning plastic parts. Most plastics are
susceptible to damage from the various types of commercial solvents.
WARRANTY
One Year Warranty

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Part No. Description
01 Plastic Housing
02 Spring Washer
03 Washer
04 Screw M5x14
05 Fan
06 Screw M5x115
07 Rear Cap
08 Washer
09 Bearing 6202
10 Stator
11 Rotor
12 Starting Capacitor
13 Running Capacitor
14 Bearing 6204
15 Oil Seal
16 Nut M8
17 Crankcase
18 Crankshaft
19 Screw M8x16 (left
hand)
20 Gasket
21 Crankcase Cover
22 Oil Sight Glass
Part No. Description
23 Drain Plug
24 Pan Head Screw
25 Oil Breather Cap
26 Spring Washer 8
27 Washer 8
28 Screw M8x20
29 Connecting Rod
30 Piston
31 Spring Washer
32 Piston Pin
33 Cylinder Gasket
34 Cylinder
35 Spring Washer 6
36 Washer 6
37 Screw M6x40
38 Gasket
39 Sealer Ring
40 Valve Gasket
41 Valve Plate Assy
42 Air Intake Valve
43 Limit Pin
44 Cylinder Gasket
45 Metal Air Filter
Part No. Description
46 Cylinder Head
47 Elbow Exhaust
48 Exhuast Pipe
49 Check Valve
50 Unload Pipe
51 Air Tank
52 Tank Drain Valve
53 Rubber Feet
54
Screw M6x20/ Nut M6
55 Power Cord
56 Rubber Gasket
57 Centrifugal Switch
61 Rubber Grip
62 Safety Valve
63 Pressure Gauge
64 Pressure Switch
65 Connector
66 Pressure Gauge
67 Regulator
68 Air Chuck
79 Frame Assy

WARNING
Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities contains chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm. Some examples of
these chemicals are:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this
type of work. To reduce your exposure to these chemicals: work in a well
ventilated area, and work with approved safety equipment, such as those dust
masks that are specially designed to filter out microscopic particles.
Distributed by
Northern Tool & Equipment Co., Inc.
Burnsville, MN 55306
NorthernTool.com
Made in China