Harbor Freight 93274 Owner S Manual US General Electric Compressor 2010
2014-07-05
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Stationary Air Compressor Manual For US General Models 3848 93274 90836 US660V US560V US7580V For questions concerning this air compressor, please call: 1-866-869-3114. Rev. 0110 Printed In USA TABLE OF CONTENTS PAGE 1 Safety Guidelines - Definitions Before Using the Air Compressor 2 When Installing or Moving the Compressor Before Each Use 3 Follow Safety Precautions for Electrical Connection Plan Ahead to Protect Your Eyes, Hands, Face & Ears When Operating 4 Spraying Precautions Perform These Maintenance Operations 5 Warning Labels Glossary 6 Wiring Starting the Compressor 7-8 Troubleshooting 9 Parts 10 Warranty Statement SAFETY GUIDELINES - DEFINITIONS Safety is a combination of common sense, staying alert and knowing how your compressor works. Read this manual to understand this compressor. DANGER means if safety information is not followed someone will be seriously injured or killed WARNING means if safety information is not followed someone could be seriously injured or killed CAUTION means if safety information is not followed someone may be seriously injured or killed IMPORTANT SAFETY INSTRUCTIONS Save these instructions Improper operation or maintenance of this product could result in serious injury and property damage. Read and understand all warnings and operation instructions before using this compressor. Before using the air compressor Things you should know Inspect your work area Air compressors are utilized in a variety of air 1. Keep work area clean. system applications. Because air compressors and other components (hoses, connectors, air 2. Cluttered areas and benches invite accidents. tools, spray guns, etc.) make up a high pressure Floors must not be slippery from wax or dust. pumping system, the following safety precautions should be observed at all times. Inspect your compressor Only persons familiar with these rules of safe operation should use the air compressor. 1. To reduce the risk of injury from accidental starting, turn switch off and disconnect the power before checking it. 1. Read the instruction manual carefully before attempting to assemble, disassemble or operate your system. Be thoroughly familiar with the controls and the proper use of the equipment. 2. If any part is missing, bent or broken in any way, or any electrical part does not work properly, keep the compressor off and disconnected. 3. Check hoses for weak or worn condition before each use, making certain all connections 2. Review and understand all safety instructions are secure. Do Not use if defect is found. and operating procedures in this manual. WARNING 3. Review the maintenance methods for this compressor (See “Maintaining Your Compressor” section). Do not operate compressor if damaged during shipping, handling or use. Damage may result in bursting and cause injury or property damage. DANGER This compressor is Not designed for and should not be used in breathing air applications. Page 1 When installing or moving the compressor WARNING This compressor is extremely top heavy. The compressor must be bolted to the floor with vibration pads before operating to prevent equipment damage, injury or death. Do Not tighten bolts completely as this may cause stress to the tank welds. To reduce the risk of a dangerous environment 6. A minimum clearance of 18 inches between the compressor and a wall is required because objects could obstruct airflow. 7. The compressor should be located where it can be directly wired to a circuit breaker. The compressor should be wired by a qualified electrician. 8. Never store flammable liquids or gases in the vicinity of an operating compressor. 1. Keep work area well lit. 2. Operate compressor in a well-ventilated area free from flammable liquids and vapors. 3. Operate compressor in a ventilated area so that compressor may be properly cooled and the surrounding air temperature will not be more than 100°F. 9. Do Not locate the compressor air inlet near steam, paint spray, sandblasting areas or any other source of contamination. The debris could damage the motor and pump. WARNING Never use plastic (PVC) pipe for compressed air. Serious injury or death could result. 4. Never use a compressor in a wet environment. CAUTION 5. Protect material lines and air lines from damage or puncture. Keep hose and wires away from sharp objects, chemical spills, oil, solvents and wet floors. Never use the shipping skid for mounting the compressor. WARNING This compressor is not intended for outdoor installation. NOTICE Do Not secure compressor with toggle bolts into drywall. Drywall sheeting or plaster will not support the weight of the compressor. WARNING Never install a shut off valve between the compressor pump and tank. Personal injury and/or equipment damage could occur. Note: Tank Outlet Size: 1/2” NPT for Stock# 3848 & 93274 3/4” NPT for Stock# 90836 Before each use Inspect your work area Inspect your compressor 1. Keep work area clean. Cluttered areas and benches invite accidents. 1. To reduce the risk of injury from accidental starting, turn the switch off and disconnect power. 2. The floor must not be slippery from wax or dust. 2. If any part is missing, bent or broken in any way, or any electrical part does not work properly, keep the compressor off and disconnect power. Do Not use if defect is found. 3. Check hoses for weak or worn condition before each use, making certain all connections are secure. Do Not use if a defect is found. Page 2 Follow the safety precautions for electrical connections 1. Follow all local electrical and safety codes, as well as the National Electric Code (NEC) and the Occupational Safety and Health Act (OSHA). 3. Protect wires from contact with sharp objects. CAUTION 2. Wiring and fuses should follow electrical codes, current capacity and be properly grounded. All electrical connections should be made by a qualified electrician. Plan ahead to protect your eyes, hands, face and ears Dress for safety 1. Wear safety glasses (meeting ANSI Z87.1 or in Canada CSA Z94.3-99) and use hearing protection when operating the unit. Everyday glasses are not safety glasses. WARNING Be careful when touching the exterior of compressor, pump, motor and air lines; they may become hot enough to cause injury. 2. Wear shoes to prevent shock hazards. WARNING 3. Tie back long hair. Pay attention to your hands WARNING Keep fingers away from running compressor. Fast moving and hot parts may cause injury and/or burns. Never operate the compressor without a beltguard. The compressor can start automatically without warning. Personal injury or property damage could occur from contact with moving parts. CAUTION The compressor may be hot even if the unit is stopped. WARNING Use of a mask or respirator per chemical manufacturers’ instructions may be necessary if there is a chance of inhaling toxic fumes. Read mask and respirator instructions carefully. Consult a safety expert if you are not sure about the use of certain masks or respirators. When operating WARNING 1. Do not exceed the pressure rating of any component of the system. 2. Release pressure within the system slowly to prevent flying dust and debris. 3. If the equipment starts to abnormally vibrate, STOP the compressor immediately and check for the cause. Page 3 Never change the safety valve or pressure switch settings. Keep safety valve free from paint and other accumulations. See compressor specification decal for maximum operating pressure. Do not operate with the pressure switch set higher than the maximum operating pressure. Spraying precautions WARNING Never point a spray gun at yourself or any other person or animal. Accidental discharge may result in serious injury. Reduce the risk of dangerous environment 1. Do Not spray in the vicinity of open flames or other places where a spark can cause ignition. Do Not smoke when spraying paint, insecticides, or other flammable substances. Be informed about the materials you use 1. When spraying with solvents or toxic chemicals, follow the instructions provided by the chemical manufacturer. Consult a safety expert if unsure about the use of masks or respirators. WARNING Extreme caution should be taken when spraying flammable liquids as the spark from a motor or pressure switch may cause a fire or explosion. Ample ventilation must be provided. WARNING Spray in a well ventilated area to keep fumes from collecting and causing serious injury and fire hazards. 2. If the material you intend to spray contains trichloreoethane and methylene chloride, do not use accessories that contain aluminum or galvanized materials, as these chemicals can react with galvanized components causing corrosion and weakening equipment. Use stainless steel accessories. Perform these maintenance operations 1. Do regular maintenance; keep all nuts, bolts, and screws tight, to be sure equipment is in safe working condition. 2. Inspect tank yearly for rust, pin holes or any other imperfections that could cause it to become unsafe. WARNING NEVER attempt to repair or modify a tank! Welding, drilling or any other modification will weaken the tank resulting in damage from rupture or explosion. Always replace worn, cracked or damaged tanks. 4. Drain tanks of moisture after each day’s use. If unit will not be used for awhile, it is best to leave the drain cock open until such time as it is to be used. This will allow moisture to completely drain out and help prevent corrosion of inside of tank. 5. Always disconnect from power source before working on or near a motor, or its connected load. If power disconnect point is out-ofsight, secure it in the “OFF” position and tag it to prevent unexpected application of power. WARNING 3. Clean electrical equipment with an approved cleaning agent, such as a dry, non-flammable cleaning solvent. Disconnect power and depressurize system before servicing air compressor. Slightly open drain cock after shutting off compressor. Daily Monthly (Make sure the main power is off.) Check the belts for tension. Belts should not move up and down when the compressor runs and when stopped, should not have more than ½ in of play when depressed. Be careful not to over tighten belts during adjustment. Check oil level at sight glass. Drain moisture from tank. Verify the pressure switch unloader is working by listening for a brief hissing sound when the compressor shuts off. Remove and check air filter, replace if necessary. Visually check the compressor for loose parts, excessive noise or vibration. Change oil every 3 months or 300 hours. A compressor grade non-detergent oil should be used. (40 wt for 3848 and 30wt for Models 93274 and 90836). Page 4 WARNING LABELS WIRING Find and read all warning labels found on the air compressor. GLOSSARY OF TERMS Air Filter Pressure Switch Porous element contained within a metal or plastic housing attached to the compressor cylinder head which removes impurity from the intake air of the compressor. Device which automatically controls the on/off cycling of the compressor. It stops the compressor when the cut-off pressure in the tank is reached and starts the compressor when the air pressure drops below the cut-in pressure. Air Tank PSI (Pounds per Square Inch) Cylindrical component which contains the compressed air. Check Valve Measurement of the pressure exerted by the force of air. The actual psi is measured by a pressure gauge on the compressor. Device which prevents compressed air from flowing back from the air tank to the compressor pump. Pump Electric Motor Device which produces the compressed air with a reciprocating piston contained within a cylinder. Device which provides the rotational force necessary to operate the compressor pump. Safety Valve Pressure Gauge Device which prevents air pressure in the air tank from rising over a predetermined limit. Device which shows the tank or regulated pressure of the compressed air. Thermal Overload Switch Device, integrated into the electric motor winding, which automatically “shuts off” the compressor if the temperature of the electric motor exceeds a predetermined limit. Page 5 WIRING WIRING For Models 3848 & 93274 WARNING Incoming power should be connected to the posts marked (line) ALL ELECTRICAL WIRING SHOULD BE DONE BY A QUALIFIED ELECTRICIAN General Information Adequate wiring and motor protection should be provided for all stationary compressors. Wiring used for other machinery should not be used. A qualified electrician familiar with local electrical codes in your area should be used. Size supply wiring per NEC (National Electric Code) requirements. Do Not Make Connections On Prewired Posts (Motor)! Grounding Screw 3848 Voltage WARNING 230V / 1 ph Full Load Amps To reduce the risk of electrical hazards, fire hazards or damage to the compressor, use proper circuit protection. Your compressor is wired at the factory for operation using the voltage shown. Connect the compressor to a power source with the correct breaker size. WARNING Electrical connections must be properly grounded. Ground connections should be connected at the grounding screw. Breaker Size 93274 90836 230V / 1 ph 230V / 1 ph 16 23 32 30 amp 40 amp 60 amp Incoming power should be connected to L1 and L2 at the Top of the Magnetic Starter. For 90836 CAUTION Overheating, short circuiting and fire damage will result from inadequate wiring. Ground STARTING THE COMPRESSOR STARTING THE COMPRESSOR Prior to actually running the compressor, check the following items: Operate the compressor for a few minutes unloaded (air system open) then allow the compressor to pump up. Make sure the electrical pressure switch properly switches off the compressor according to the setting desired. (130 psi for 3848, 165 for 93274, and 175 psi for 90836.) Crankcase oil - Make sure the sight glass shows ½ full or slightly above. Make sure all rags, tools, oil, etc. are away from the unit. CAUTION Open the air system to free it of any pressure. Switch the compressor on for a few revolutions to make sure the rotation is correct. Correct rotation is clockwise when facing the sight glass on the pump. Make sure the pressure in the tank does not exceed its rating. 3848 should operate at a maximum of 130 psi, 93274 should operate at a maximum of 165 psi, & 90836 at a maximum of 175 psi. If the pressure gauge indicates a pressure that is higher than these maximum pressures, shut off compressor immediately and call 1-866-869-3114. Page 6 TROUBLESHOOTING GUIDE Low discharge pressure 1. Compressor too small for application 2. Air leaks 3. Restricted intake air 4. Blown gasket(s) 5. Broken or misaligned valves 1. Reduce air demand or use a compressor with more air capacity. 2. Listen for air leaks. Apply a soap solution to all fittings and connections. Bubbles will form at points of leakage. Tighten or replace fittings or connections. 3. Clean or replace air filter. 4. Replace necessary gaskets. 5. Remove head and inspect for broken or misaligned valves. Replace valves, if necessary. ! Excessive noise “knocking” 1. Loose drive pulley or flywheel 2. Low on oil 3. Worn connecting rod or connecting rod bearing 4. Noisy check valve CAUTION Install a new head gasket each time head is removed 1. Tighten drive pulley or flywheel bolt. 2. Check for proper oil level. Low or dirty oil may cause bearing damage. 3. Replace connecting rod and/or connecting rod bearings. 4. Replace check valve. ! DANGER Do not remove check valve with air pressure in tank Excessive oil carryover 1. Worn piston rings 2. Restricted intake air 3. Too much oil in compressor 4. Incorrect oil viscosity 1. Replace with new piston rings. 2. Clean or replace air filter. 3. Drain oil to proper oil level. 4. Use a quality non-detergent 30 or 40wt oil specified for each model (Page 4). Water in tank and/or discharge line 1. Normal. Amount of water will increase as humidity in the air increases. 1. Drain tank at least once per day. 2. Add an inline filter to reduce moisture in in the air line. Will not run or motor hums 1. Low voltage 1. Check voltage with volt meter across both legs of incoming power. Check reset button on motor. 2. Malfunctioning pressure switch 2. Repair or replace pressure switch. 3. Malfunctioning check valve 3. Replace check valve or pressure switch. ! Breaker or reset repeatedly trips Do not remove check valve with air pressure in tank 1. Make sure the breaker is sized properly. See page 6 in this manual. 2. Check voltage with volt meter across both 2. Low voltage legs of incoming power. 3. Replace motor. 3. Malfunctioning motor 4. Check all electrical connections. 4. Loose electrical connections 5. Malfunctioning pressure switch 5. Adjust or replace pressure switch. 6. Replace check valve. 6. Malfunctioning check valve 1. Incorrect breaker size ! Tank does not hold pressure when not running and shut off valve is closed DANGER 1. Malfunctioning check valve Page 7 Do not remove check valve with air pressure in tank 1. Replace check valve. ! 2. Loose fittings or connections 3. Crack or pin hole in tank DANGER not remove check valve DANGER Do with air pressure in tank 2. Tighten or replace fittings or connections. 3. Replace tank. Do not attempt to repair tank. TROUBLESHOOTING GUIDE (Continued) Pressure switch unloader constantly leaking air 1. Malfunctioning check valve Pressure switch not unloading 1. Malfunctioning pressure switch 1. Replace check valve if unloader bleeds constantly. ! 1. Replace pressure switch if it does not release air pressure briefly when unit shuts off. ! Excessive vibration 1. Improper installation 2. Loose belts 3. Misaligned flywheel or drive pulley Overheating 1. Compressor too small for application 2. Cooling surfaces dirty 3. Improper cooling Page 8 not remove check valve DANGER Do with air pressure in tank DANGER Do not remove pressure switch with air pressure in tank 1. Make sure unit is mounted on a level surface with vibration pads. 2. Replace belts. Align and tighten properly. 3. Align flywheel and drive pulley. 1. Reduce air demand or use a compressor with more air capacity. 2. Clean all cooling surfaces of dirt and dust. 3. Install compressor in an area with adequate cool dry air. 01 02 10 03 09 08 11 05 06 04 07 Illustration Number 1 2 3 4 5 6 7 8 9 10 Part Description Compressor Air Filter Electric Motor Safety Valve Pressure Switch Tank Gauge Tank Drain Check Valve Discharge Tube Belt Guard (2 Part Numbers) Drive Belts Drive Pulley 3848 B3800 6229020500 1312100390 1312100005 1312100455 1312100006 1312100360 1312100168 1312100215 6222019500 6214343100 1312100134 1312100442 11 *Part Numbers Subject to Change Without Notice Compressor Support: 866-869-3114 Page 9 93274 T29S FS008 1312100387 1310251870 1312100459 1312100028 1312100360 1312100168 1312100214 1312100145 1312100146 1312100133 1312100442 90836 B6000 FS002 1312100400 9710533300 1312100510 1312100028 1312100360 1312100169 1312100208 1312100148 1312100150 1312100140 (2) 1312100420 DP75HP1 LIMITED 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 a period of one year (3848) or two years (3847, 93274, and 90836) from date of purchase (90 days if used by a professional contractor or if used as rental equipment). This warranty does not apply to damage due directly or indirectly to misuse, abuse, negligence or accidents; repairs or alterations outside our facilities; or 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. 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 the 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
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