Harbor Freight 69784 Owner S Manual
2014-07-05
: Harbor-Freight Harbor-Freight-69784-Owner-S-Manual harbor-freight-69784-owner-s-manual harbor-freight pdf
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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. 30 GAL gas powered two-stage air compressor Using an engine indoors CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. Visit our website at: http://www.harborfreight.com Email our technical support at: tech@harborfreight.com ITEM 69784 When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken, please call 1-800-444-3353 as soon as possible. Copyright© 2012 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.......................................................... 2 Maintenance............................................... 13 Specifications.............................................. 5 Parts Lists and Diagrams........................... 16 Setup........................................................... 6 Warranty..................................................... 20 SAFETY Operation..................................................... 9 WARNING SYMBOLS AND DEFINITIONS 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. SETUP Addresses practices not related to personal injury. Symbol RPM HP Property or Statement Revolutions Per Minute Horsepower WARNING marking concerning Risk of Eye Injury. Wear ANSI-approved safety goggles with side shields. Symbol Property or Statement WARNING marking concerning Risk of Respiratory Injury. Operate engine OUTSIDE and far away from windows, doors, and vents. WARNING marking concerning Risk of Explosion. OPERATION IMPORTANT SAFETY INFORMATION General 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. 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. MAINTENANCE Set up Precautions 1. Gasoline fuel and fumes are flammable, and potentially explosive. Use proper fuel storage and handling procedures. Do not store fuel or other flammable materials nearby. 2. Have multiple ABC class fire extinguishers nearby. 3. Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements. Page 2 4. Set up and use only on a flat, level, well‑ventilated surface. 5. Use only lubricants and fuel recommended in the engine manual or in the Specifications chart of this manual. 6. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during set up. For technical questions, please call 1-800-444-3353. Item 69784 Engine Precautions Follow engine precautions and instructions in the included engine instruction manual. CARBON MONOXIDE HAZARD Using an engine indoors CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. 1. 11. People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure. Caution is necessary when near the engine’s magneto or recoil starter. SAFETY Operating Precautions 14. Stay alert, watch what you are doing and use common sense when operating this piece of equipment. Do not use this piece of equipment while tired or under the influence of drugs, alcohol or medication. 2. Keep children away from the equipment, especially while it is operating. 3. Fire Hazard! Do not fill gas tank while Compressor engine is running. Do not operate if gasoline has been spilled. Clean spilled gasoline before starting engine. Do not operate near pilot light or open flame. 4. Do not touch Compressor engine during use. Let engine cool down after use. 5. Never store fuel or other flammable materials near the Compressor engine. 6. Only use a suitable means of transport and lifting devices with sufficient weight bearing capacity when transporting the Compressor. 7. Secure the Compressor on transport vehicles to prevent the tool from rolling, slipping, and tilting. 8. Industrial applications must follow OSHA requirements. 9. Do not leave the equipment unattended when it is running. Turn off the equipment (and remove safety keys, if available) before leaving the work area. 10. Wear ANSI-approved safety glasses, hearing protection, and NIOSH-approved dust mask/ respirator under a full face shield along with steel-toed work boots during use. Item 69784 15. Do not overreach. Keep proper footing and balance at all times. This enables better control of the equipment in unexpected situations. 16. Dress properly. Do not wear loose clothing or jewelry. Keep hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. 17. Parts, especially exhaust system components, get very hot during use. Stay clear of hot parts. 18. Do not cover the engine or equipment during operation. OPERATION Only use OUTSIDE and far away from windows, doors, and vents. 19. Keep the equipment, engine, and surrounding area clean at all times. 20. Use the equipment, accessories, etc., in accordance with these instructions and in the manner intended for the particular type of equipment, taking into account the working conditions and the work to be performed. Use of the equipment for operations different from those intended could result in a hazardous situation. 21. Do not operate the equipment with known leaks in the engine’s fuel system. 22. This product contains or, when used, produces 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.) For technical questions, please call 1-800-444-3353. Page 3 MAINTENANCE NEVER use inside a home or garage, EVEN IF doors and windows are open. 13. Do not operate in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Gasoline-powered engines may ignite the dust or fumes. SETUP 12. Use only accessories that are recommended by Harbor Freight Tools for your model. Accessories that may be suitable for one piece of equipment may become hazardous when used on another piece of equipment. 23. When spills of fuel or oil occur, they must be cleaned up immediately. Dispose of fluids and cleaning materials as per any local, state, or federal codes and regulations. Store oil rags in a bottom-ventilated, covered, metal container. SAFETY 24. Keep hands and feet away from moving parts. Do not reach over or across equipment while operating. 25. Before use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the equipment’s operation. If damaged, have the equipment serviced before using. Many accidents are caused by poorly maintained equipment. 26. Use the correct equipment for the application. Do not modify the equipment and do not use the equipment for a purpose for which it is not intended. Service Precautions 1. Before service, maintenance, or cleaning: a. Turn the engine switch to its “OFF” position. b. Allow the engine to completely cool. c. Then, remove the spark plug cap from the spark plug. SETUP 2. Keep all safety guards in place and in proper working order. Safety guards include muffler, air cleaner, mechanical guards, and heat shields, among other guards. 3. Do not alter or adjust any part of the equipment or its engine that is sealed by the manufacturer or distributor. Only a qualified service technician may adjust parts that may increase or decrease governed engine speed. 4. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during service. 5. Maintain labels and nameplates on the equipment. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 6. Have the equipment serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the equipment is maintained. Do not attempt any service or maintenance procedures not explained in this manual or any procedures that you are uncertain about your ability to perform safely or correctly. 7. Store equipment out of the reach of children. 8. Follow scheduled engine and equipment maintenance. Air Compressor Safety Warnings OPERATION 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. Do not use to supply breathing air. 5. Do not use the air hose to move the compressor. MAINTENANCE 6. Drain Tank daily and after use. Internal rust causes tank failure and explosion. 7. Add correct amount of compressor oil before first use and every use. Operating with the incorrect amount of oil causes permanent damage and voids warranty. To prevent damage, do not use with overfilled or low oil. 8. Compressor head gets hot during operation. Do not touch it or allow children nearby during or immediately following operation. 9. Release the pressure in the storage tank before moving. 10. The use of accessories or attachments not recommended by the manufacturer may result in a risk of injury to persons. 11. All air line components, including hoses, pipe, connectors, filters, etc., must be rated for a minimum working pressure of 125 PSI, or 150% of the maximum system pressure, whichever is greater. SAVE THESE INSTRUCTIONS. Page 4 For technical questions, please call 1-800-444-3353. Item 69784 Pump Two stage Air Outlet Size 1/2″- NPT female Air Pressure Auto Shut-Off @ 180 PSI Restart @ 140 PSI Air Tank Capacity 30 Gallons Air Flow Capacity 18 CFM @ 90 PSI 19.5 CFM @ 40 PSI Oil Capacity 61 oz. (1.8L) Oil Type SAE 30W non-detergent Air Compressor Oil (SKU 95048, sold separately) Required Rotation viewed from PTO Counterclockwise Required Engine Idle Speed 2100 RPM ± 100 RPM (power takeoff - the output shaft) SAFETY Specifications Note: Engine specifications are found in the engine manual supplied with this equipment. Engine Controls Belt Guard Frame (122) & Belt Guard Cover (130) Pilot Valve Pump Safety Valve (91) Air Filter Assembly (84) SETUP ON/OFF Switch Oil Sight Glass (19) Tank Pressure Gauge (97) Tank Safety Valve (98) Air Outlet (106) Crankcase (16) 1. Belt Guard - The Belt Guard encloses the pulleys and drive belts. It protects the user from the moving parts and allows the large pulley to direct cooling air to the Air Pump. 2. Oil Sight Glass - The oil sight glass shows proper level of the oil. Oil level should be at center of Sight Glass. Oil Sight Glass (19) OIL LEVEL OVERFILL 4. Safety Valve - The Safety Valve automatically releases air if the Air Tank pressure exceeds the preset maximum. In an emergency, the ring can be pulled to relieve tank air pressure. There is one safety valve on the pump and one on the tank. FULL LOW 5. Air Outlet - An air hose attaches to this valve. Air pressure required by tools is set by an air pressure regulator. Opened Pilot Valve 6. Air Storage Tank - The Air Tank is where air pressurized by the Air Pump is stored for use. 7. Tank Pressure Gauge - The Air Tank Pressure Gauge displays the air pressure in the tank. 8. Pilot Valve - Open the Pilot Valve before starting the engine. It relieves resistance on the engine to make starting possible. Rotate the pin so it is vertical to open it. Once the engine is running, close the Pilot Valve so the Compressor can build up pressure. Item 69784 Closed Pilot Valve For technical questions, please call 1-800-444-3353. Page 5 MAINTENANCE 3. Tank Drain Valve - The Air Tank Drain Valve allows moisture to be removed from the tank to prevent corrosion. OPERATION Drain Valve (137) Setup The emission control system for this Compressor’s Engine is warranted for standards set by the U.S. Environmental Protection Agency and by the California Air Resources Board (also known as CARB). For warranty information, refer to the engine manual. SAFETY Mounting to a Truck bed 1. Before mounting, if needed, reinforce the area with plywood or steel plating. 2. With assistance, move the compressor to the truck bed location and mark the floor of the truck bed through the holes in the compressor’s feet. Check for any hidden wiring or cables and adjust the location for the holes as needed. Then, temporarily set the compressor aside. 3. Drill the four 1/2″ diameter holes through the truck bed and any reinforcing materials. 4. Set the compressor back in place, and align the foot holes with the pre-drilled holes. Use four 1/2″ diameter, bolts, washers and lock washers (all not included) to secure the compressor in place. SETUP Air Filter Assembly (84) Wing Nut Assembly Second Stage Cylinder Head First Stage (21) Connector Cylinder Head (61) To install the Air Filter Assembly (84), fit the Connector into the Air Filter Assembly and slide the assembly into the hole on the side of the First Stage Cylinder Head (61). Secure in place with the Wing Nut. OPERATION Break-In Compressor Break in the new Air Compressor as follows: a. Make sure the engine is off. Open the air outlet valve on the left side of the tank. b. Check all fluid levels in the engine and pump. c. Start the engine following the General Operating Instructions. d. Let the unit run for 30 minutes. Air will expel freely through the Coupler. e. Turn OFF the engine. f. Remove the male coupler. MAINTENANCE Connection 1. Connect a regulator valve, an in-line shut off valve and a 1/2″ NPT air hose (all sold separately) to the Quick Coupler. 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. 2. 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 Setup charts on the following pages. This is a truckbed compressor, so use the portable setup as a model. Page 6 For technical questions, please call 1-800-444-3353. Item 69784 Item 69784 For technical questions, please call 1-800-444-3353. Page 7 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 B B OPERATION Description Non-lubricated Tools A Lubricated Tools C C A SETUP Function A E E F H SAFETY Connects air to tool Prevents dirt and condensation from damaging tool or work piece Adjusts air pressure to tool For air tool lubrication Provides quick connection and release Increases coupler life Prevents water vapor from damaging work piece For fine tuning airflow at tool G D Figure A: Portable Air Supply Setup A B C D E F G H I J K L M N O F Description F G I I J N K Slope J H Function H L L M O 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 work piece Adjusts air pressure to tool For air tool lubrication Provides quick connection and release Increases coupler life Prevents water vapor from damaging work piece For fine tuning airflow at tool Non-lubricated Tools C C 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 Air Hose Filter Regulator Lubricator (optional) Coupler and Plug Leader Hose (optional) Air Cleaner / Dryer (optional) Air Adjusting Valve (optional) B A MAINTENANCE B A E OPERATION C D SETUP Figure B: Stationary Air Supply Setup SAFETY Page 8 For technical questions, please call 1-800-444-3353. Item 69784 F Operation 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. SAFETY Using the Compressor Inspect Compressor, engine, pump and equipment looking for damaged, loose, and missing parts before set up and starting. If any problems are found, do not use equipment until fixed properly. 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. Before starting the Compressor: SETUP a. Follow the Set Up Instructions in the equipment manual to prepare the equipment. b. Follow the Set Up Instructions in the Engine manual to prepare the engine. c. Inspect all components of the setup. Make sure all nuts and bolts are tight. d. Fill the Engine with the proper amount and type of both fuel and oil. e. Fill the Compressor Pump with compressor oil following the Maintenance Instructions in this manual. To Start and Use the Compressor 3. Open the Pilot Valve by rotating it to a vertical position. 4. Open the Fuel Valve. Item 69784 OPERATION 2. Close the in-line Shutoff Valve between the compressor and the air hose. 1 2 3 MAINTENANCE 1. Close the Drain Valve (137) by turning the lever up so that it is perpendicular to the valve. 4 For technical questions, please call 1-800-444-3353. Page 9 5 SAFETY 5. To start a cold engine, move the Choke to the CHOKE (start/closed) position. To restart a warm engine, leave the Choke in the RUN position. 6. For MANUAL START For ELECTRIC START a. Turn the Engine Switch to ON. Turn the Engine Switch to START. Note: To prolong starter life, use short starting cycles (5 seconds maximum). Then wait one minute before attempting to start again. ON ON SETUP OFF START ON b. Grip the Starter Handle of the Engine loosely and pull it slowly several times to allow the gasoline to flow into the Engine’s carburetor. Then pull the Starter Handle gently until resistance is felt. Allow Cable to retract fully and then pull it quickly. Repeat until the engine starts. Note: Do not let the Starter Handle snap back against the engine. Hold it as it recoils so it doesn't hit the engine. OFF START START OPERATION 7. Allow the Engine to run for several seconds. Then, if the Choke lever is in the CHOKE position, move the Choke Lever very slowly to its RUN position. MAINTENANCE Note: Moving the Choke Lever too fast could kill the engine. 7 8. Close the Pilot Valve by rotating it to a horizontal position. 8 Page 10 For technical questions, please call 1-800-444-3353. Item 69784 9. When the Gas Engine is started and running, the compressor Pump starts compressing air into the Air Tank. Open the in-line Shutoff Valve and adjust the Pressure Regulator (sold separately) 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 counterclockwise to decrease pressure. Adjust the pressure gradually, while checking the air output gauge to set the pressure. SAFETY 9 IMPORTANT: Allow the engine to run for five minutes with no load after each start‑up so that the engine can stabilize. Maintenance Break-in Period: Breaking-in the engine will help to ensure proper equipment and engine operation. The maintenance break‑in period will last about 20 hours of use. After this period, change the engine oil. Under normal operating conditions, subsequent maintenance follows the schedule explained in the MAINTENANCE AND SERVICING section. SETUP Note: When maximum tank pressure is reached, the compressor automatically disengages, and the engine RPM drops down to idle speed. The engine remains at idle until Air Tank pressure falls to a preset level. The Gas Engine will then accelerate and air pressure once again begins to build up in the Air Tank. Note: As long as the engine is running, the operation of the Air Compressor is automatic, controlled by an internal pressure switch. 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. OPERATION Note: Depressurization - If it is necessary to quickly depressurize the Compressor, turn OFF the engine. Then, pull on the ring on the tank Safety Valve to release stored air pressure. 10 10. Use the air tool as needed. ON OFF START OFF MAINTENANCE 11. After the job is complete, turn OFF the engine. To stop the engine in an emergency, turn the Engine Switch off. Under normal conditions, use the following procedure: a. Turn the Engine Switch off. b. Close the Fuel Valve. Item 69784 11 For technical questions, please call 1-800-444-3353. Page 11 12. Close the in-line Shutoff Valve. 12 SAFETY 13. Bleed air from the tool then disconnect the tool. 13 SETUP 14. Open the Drain Valve at the bottom of the Tank, to release any built-up moisture and the internal tank pressure. 14 OPERATION 15. Clean, then store the Air Compressor indoors. MAINTENANCE Page 12 For technical questions, please call 1-800-444-3353. Item 69784 Maintenance WARNING SAFETY TO PREVENT SERIOUS INJURY FROM ACCIDENTAL STARTING: Turn the Power Switch of the equipment to its “OFF” position, release tank air pressure, wait for the engine to cool, and disconnect the spark plug cap before performing any inspection, maintenance, or cleaning procedures. TO PREVENT SERIOUS INJURY FROM EQUIPMENT FAILURE: Do not use damaged equipment. If abnormal noise, vibration, or excess smoking occurs, have the problem corrected before further use. Follow all service instructions in this manual. The engine may fail critically if not serviced properly. Many maintenance procedures, including any not detailed in this manual, will need to be performed by a qualified technician for safety. If you have any doubts about your ability to safely service the equipment or engine, have a qualified technician service the equipment instead. SETUP Compressor Pump Oil Maintenance 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. Change the compressor oil after the first hour of use to remove any debris. Adding Oil OVERFILL FULL LOW 1. The oil level should be at the center of the “full” level on the Oil Sight Glass, as shown above. 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 Oil Sight Glass. 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. 3. If uncertain which oil to use for this compressor, please call Harbor Freight Tools customer service at 1-800‑444-3353 for assistance. 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. 2. To add oil: a. Remove the Oil Plug (17). b. Using a funnel to avoid spills, pour enough oil into the pump Crankcase to reach the “full” level in the Oil Sight Glass. c. Replace the Oil Plug. Item 69784 OPERATION OIL LEVEL Oil Sight Glass (19) Cold Weather Operation For technical questions, please call 1-800-444-3353. Page 13 MAINTENANCE Crankcase (16) Changing Oil 1. Place a container under the Drain Plug. 2. Remove the Oil Plug to allow air flow into the Pump. SAFETY 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 compressor oil to the FULL level on the Oil Sight Glass. 6. Replace and tighten the Oil Plug. 7. Discard the old oil according to local, state and federal regulations. Draining Moisture from the Tank The Drain Valve is located under the Tank. It must be accessed daily to release all trapped air and moisture from the Tank. This will eliminate condensation which can cause tank corrosion. To empty the air and condensation: 1. Make sure the compressor engine is off. SETUP 2. Place a collection pan under the Drain Valve. 3. Open the Drain Valve by pivoting the lever on the bottom of the Compressor so the lever is in line with the Drain Valve. 4. When all the pressure is released, close the Drain Valve by pivoting the lever on the bottom of the compressor so that the lever is perpendicular to 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: 2. Remove the Air Filter Assembly. 1. Unthread the Wing Nut holding the Air Filter Assembly in place. 4. Secure in place with the Wing Nut. 3. Replace with a new Air Filter. Adjusting Belt Tension 1. Remove the Belt Guard Cover (130) and set it aside. OPERATION Deflection Distance 2. Press on the center of the longest span on each belt with moderate finger pressure (4‑4.5 lb.). Then measure the deflection distance, the distance that the belt moved. The belt should deflect anywhere from 1/2″ to 1″. 3. If either belt deflects too much, tighten belts by loosening the four Bolts (111) on the Bottom Plate (115) and moving the engine away from the other pulley slightly by turning the Nut (116) holding the Threaded Rod (119). Secure engine mounting bolts and retest tension. If either belt is too long to be properly tensioned, both belts must be replaced. 4. If either belt deflects too little, loosen belts by loosening the Bolts on the Bottom Plate and moving the engine towards the other pulley slightly by turning the Nut (116) on the Threaded Rod (119). Secure engine mounting bolts and retest tension. 5. Before use, replace belt cover. Engine Base MAINTENANCE Threaded Rod (119) Engine Mounting Bolts Bolts (111) Nut (116) Page 14 Bottom Plate (115) For technical questions, please call 1-800-444-3353. Item 69784 Troubleshooting 1. Poor air outlet seal. 2. Loose cylinder/cylinder head. Severe air leakage 3. Damaged valve or housing. 4. Dirty, worn or damaged valve. 1. Low engine idle. 2. Severely clogged air filter. 3. Improper lubrication. 4. Defective pilot/unloader valve. 1. Loose drive pulley or flywheel. Unit stalls Excessive noise Oil in the discharge air 2. Misaligned pulleys. 3. Lack of oil in crankcase. 4. Worn connecting rod. 5. Worn wrist pin bushing. 6. Worn bearings. 7. Loose belts. 1. Wrong type of oil or low-quality oil. 2. Overheating. 3. Restricted intake air. 4. Worn piston rings. 5. Excessive moisture in the tank. 1. Air leaks. 2. Leaking valves. Low discharge pressure 3. Restricted air intake. 4. Blown gaskets. 5. Slipping belts. 1. Listen for escaping air. Apply soap solution to all fittings and connections. Bubbles will appear at points of leakage. Tighten or replace leaking fittings or connections. 2. Remove head and inspect for valve breakage, weak valves, scored valve plate, etc. Replace defective parts and reassemble. Replace head gasket each time the head is removed. 3. Clean or replace air filter element. 4. Replace and gaskets proven faulty on inspection. 5. Tighten Belts (See monthly maintenance.) Follow all safety precautions whenever diagnosing or servicing the equipment or engine. Item 69784 For technical questions, please call 1-800-444-3353. Page 15 SAFETY 1. Lubricate using recommended oil or grease according to directions. 2. Have qualified technician inspect internal mechanism and replace parts as needed. 1. Tighten or re-attach using thread seal tape. 2. Tighten cylinder/cylinder head assembly. If cylinder/cylinder head cannot tighten properly, internal parts may be misaligned. 3. Replace damaged components. 4. Clean or replace valve assembly. 1. Qualified technician should increase idle to 2,200±100 RPM by adjusting pressure switch. 2. Replace air filter. 3. Check for proper oil level. 4. Replace pilot valve. 1. Loose pulleys are a common cause of “knocking”. Tighten appropriate bolts. 2. Align pulleys with straightedge and secure in place. 3. Check for proper oil level. 4. Replace connecting rod. 5. Remove piston assembly and replace necessary parts. 6. Replace bearings and oil. 7. Check for proper belt tension. 1. Change oil. Check oil recommendations under EQUIPMENT SET UP, Equipment Oil Fill section of this manual. 2. See above Excessive Noise section. 3. Clean or replace air filter. 4. Replace piston rings. 5. Drain moisture from the tank daily. SETUP (Note: See engine 2. Tank already pressurized. manual for engine specific issues.) 1. Incorrect lubrication or not enough lubrication. Compressor overheats 2. Worn parts. Likely Solutions COMPRESSOR SPECIFIC: 1. Open pilot valve before start procedure, close after unit is running. 2. Turn engine on. Compressor will turn on as needed when pressure reaches preset level. OPERATION Possible Causes COMPRESSOR SPECIFIC: 1. Pilot Valve closed. MAINTENANCE Problem Engine will not start Parts Lists and Diagrams Pump Parts List SAFETY Part SETUP OPERATION MAINTENANCE 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 41 42 43 44 45 46 47 Description Bolt M12×55 Spring Washer 12 Flat Washer Drive Pulley Oil Seal Circle Flange Plate O-ring Ø85 Bearing Bolt M12×40 Oil Breather Crankcase End Cover Flat Key Crankshaft Bearing Gasket Crankcase Oil Plug Gasket Oil Sight Glass Drain Oil Bolt Second Stage Cylinder Bolt M12×40 Spring Washer 12 Gasket Connecting Rod A Connecting Rod B Bearing Shell Spring Washer 10 Bolt M10×55 Bushing Clip Pin Piston Wiper Ring Piston Ring Gasket Valve Aluminum Seal Bolt M6×25 Valve Stop Block Spring Valve Plate Nut M6 Lock Nut Elbow Taper Sleeve Nut Qty 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 2 4 2 1 2 1 1 2 2 1 1 1 4 4 8 4 4 1 1 1 1 Part 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 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 Description Brass Tube Cylinder Head Spring Washer Bolt M10×65 Bolt M8×60 Spring Washer 10 Nut Elbow Bolt M8×35 Spring Washer 8 Gasket Radiator Connector First Stage Cylinder Bolt M12×40 Spring Washer 12 Gasket Bushing Connecting Rod A Connecting Rod B Spring Washer 10 Bolt M10×55 Bushing Wiper Ring Piston Pin Clip Piston Ring Gasket Valve Aluminum Seal Bolt M8×30 Spring Restrictor Valve Plate Nut M8 Air Filter Asm. Cylinder Head Spring Washer 12 Bolt M12×70 Spring Washer 8 Bolt M8×70 Nut Safety Valve Elbow Taper Sleeve Nut Qty 1 1 4 4 1 1 1 1 2 2 1 1 1 1 4 4 1 2 1 1 2 2 1 2 1 1 2 2 1 1 1 4 8 4 4 4 1 1 4 4 4 4 1 1 1 1 1 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 16 For technical questions, please call 1-800-444-3353. Item 69784 MAINTENANCE OPERATION SETUP SAFETY Pump Assembly Diagram Item 69784 For technical questions, please call 1-800-444-3353. Page 17 Tank Parts List Part SAFETY SETUP 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 Description Tank Connector Pressure Gauge Safety Valve Unloader Valve Throttle Control Connector Taper Sleeve Pipe Nut Brass Tube Battery Terminal Air Outlet Engine Bolt M10×40 Nut M10 Bracket Bolt M10×50 Nut M10 Washer 8 Bolt M8×20 Bottom Plate Nut M14 Spring Washer 14 Qty 1 1 1 1 1 1 1 2 2 1 2 1 1 4 4 1 4 4 1 1 1 1 1 Part 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 Description Bracket Threaded Rod Bolt M6×20 Belt Guard Bracket A Belt Guard Frame Belt Driven Pulley Plate Ket Bushing Spring Washer 8 Bolt M8×30 Bolt M6×10 Belt Guard Cover Bolt M6×10 Belt Guard Bracket B Bolt M8×16 Washer 8 Bolt M12×45 Spring Washer 12 Bolt M12 Drain Valve Engine Oil Drain Bolt Wire Qty 1 1 1 1 1 2 1 1 1 2 2 11 1 1 1 4 4 4 4 2 1 1 1 OPERATION MAINTENANCE 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. Page 18 For technical questions, please call 1-800-444-3353. Item 69784 MAINTENANCE OPERATION SETUP SAFETY Tank Assembly Diagram Item 69784 For technical questions, please call 1-800-444-3353. 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 • (800) 444-3353 3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353 www.harborfreight.com
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2010:10:08 09:59:37-07:00, 2010:10:08 10:05:48-07:00, 2010:10:08 10:33:32-07:00, 2010:10:08 10:37:47-07:00, 2010:10:08 10:41:17-07:00, 2010:10:08 10:47:14-07:00, 2010:10:08 10:53:27-07:00, 2010:10:08 10:54:45-07:00, 2010:10:08 10:56:36-07:00, 2010:10:08 10:58:29-07:00, 2010:10:08 11:01:50-07:00, 2010:10:08 11:04:54-07:00, 2010:10:08 11:06:48-07:00, 2010:10:08 11:08:31-07:00, 2010:10:08 11:10:24-07:00, 2010:10:08 11:11:50-07:00, 2010:10:08 11:33:13-07:00, 2010:10:08 11:47:24-07:00, 2010:10:08 11:49:13-07:00, 2010:10:08 11:53:05-07:00, 2010:10:08 12:38:30-07:00, 2010:10:08 12:41-07:00, 2010:10:08 12:43:17-07:00, 2010:10:08 13:13:41-07:00, 2010:10:08 13:14:14-07:00, 2010:10:08 13:32:44-07:00, 2010:10:08 13:40:08-07:00, 2010:10:08 13:42:21-07:00, 2010:10:08 13:42:21-07:00, 2010:10:08 14:53:46-07:00, 2010:10:08 14:56:41-07:00, 2010:10:08 15:04:13-07:00, 2010:10:08 15:20:01-07:00, 2010:10:08 15:28:01-07:00, 2010:10:08 15:30:09-07:00, 2010:10:08 15:38:31-07:00, 2010:10:08 15:54:41-07:00, 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