Harbor Freight Tools 65204 Air Compressor User Manual
Contents
1. 9 OPERATING INSTRUCTIONS 10 WORK PIECE AND WORK AREA SET UP 2 10 GENERAL OPERATING INSTRUCTIONS 10 USER MAINTENANCE 12 CLEANING MAINTENANCE AND LUBRICATION 12 hy 12 WEEKLY 2 12 MONTHLY 12 14 PARTS LISTS 16 MAIN ASSEMBLY DIAGRAM 17 PUMP ASSEMBLY DIAGRAM 18 LIMITED 1 YEAR 90 DAY WARRANTY 19 SKU 65204 For technical questions please call 1 800 444 3353 Page 2 99918 SAVE THIS MANUAL Keep this manual for the safety warn ings and precautions assembly operat ing inspection maintenance and cleaning procedures Write 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 IMPORTANT SAFETY INFORMATION In this manual on the labeling and all other information provided with this product 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 DANGER indicates A DANGER a hazardous situation which if not avoided will result in death or seri2. Air Superiority x 13 HP 30 GALLON AIR COMPRESSOR Model 52206 SET UP AND OPERATING INSTRUCTIONS A DANGER 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 Only use OUTSIDE a home or garage and far away from EVEN IF doors and windows doors windows are open and vents Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Copyright 2008 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 For technical questions or replacement parts please call 1 800 444 3353 Manual revised 09c 09 091 CONTENTS IMPORTANT SAFETY INFORMATION 3 BASIC SPECIFICATIONS 8 COMPONENTS AND CONTROLS 8 EQUIPMENT SET 9 9 9 EQUIPMENT OIL
3. When unpacking make sure that the item is intact and undamaged If any parts are missing or broken please call Harbor Freight Tools at 1 800 444 3353 as soon as possible REV 09c SKU 65204 99918 For technical questions please call 1 800 444 3353 Mounting 1 compressor may vibrate strongly during use so mounting is needed to prevent movement 2 Before use mount the compressor securely using all four mounting holes to a solid level surface such as a concrete slab or truck bed 3 Rubber pads not included may be used at the mounting points to reduce vibration Equipment Oil Fill IMPORTANT TO PREVENT PROPERTY DAMAGE AND VOIDING OF THE WARRANTY Before first use fill the compres sor with compressor oil as follows 1 Remove the Breather Vent 22 and fill with 1 37 quarts of premium quality SAE 30 weight non detergent syn thetic air compressor oil Do not mix oils of different types 2 Check the oil level at the Oil Sight Glass The oil level should be at the middle of the Glass Add or drain oil as needed until it is at the proper level Thread the Breather Vent 22 back into place being careful not to cross thread it or strip its threads Page 9 OPERATING INSTRUCTIONS A 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 Inspect compressor before u
4. 36 Ah is fully charged and is correctly connected with proper cables Set up air system according to air tool s instructions sold separately All lubricated compressor pumps dis charge some condensed water and oil with the compressed air Compo nents such as air dryers moisture fil ters regulators and automatic oilers may be required Open the Fuel Valve Close the Choke Check the compressor oil level using the Oil Sight Glass and the engine oil level Add oil as needed Empty all air pressure from the tank Page 10 6 Before starting the engine open the Pilot Valve by standing the pin up Starter Control Panel 7 Run Charging System load Indi Start Overload Indicator Ignition Switch Charging System Ignition Switch Circuit Protector Close up To start the engine using the electric starter Insert the ignition key into the igni tion While turning the key to Start S position max 5 seconds very slowly move the choke lever from cold to run position Note To prolong starter life use short starting cycles 5 seconds maxi mum Then wait one minute before attempting to start again 5b To start the engine manually 11 To re start a warm engine move the Choke to halfway closed Insert the ignition key into the Ignition and turn 12 the Key to Run I position Grasp the starter handle and pull slowly until resistance is felt While holding the handle
5. Incorrect lubrication or not Lubricate using recommended oil or grease Compressor over enough lubrication according to directions heats Worn parts Have qualified technician inspect internal mechanism and replace parts as needed Poor air outlet seal Tighten or re attach using thread seal tape Loose cylinder cylinder head Tighten cylinder cylinder head assembly If Severe air cylinder cylinder head cannot tighten properly leakage internal parts may be misaligned Damaged valve or housing Replace damaged components Dirty worn or damaged valve Clean or replace valve assembly Low engine idle Qualified technician should increase idle to 1 800 100 RPM by adjusting pressure switch Unit stalls Severely clogged air filter Replace air filter Improper lubrication Check for proper oil level Defective pilot unloader valve 4 Replace Loose drive pulley or flywheel 1 Loose pulleys are a common cause of knocking Tighten appropriate bolts Misaligned pulleys Align pulleys with straightedge and secure place Lack of oil in crankcase Check for proper oil level 4 Worn connecting rod 4 Replace Worn wrist pin bushing Remove piston assembly and replace necessary parts Worn bearings Replace bearings and oil Loose belts Check for proper belt tension Wrong type of oil or low quality 1 Change oil Check oil recommendations oil under EQUIP
6. 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 SKU 65204 For technical questions please call 1 800 444 3353 Page 15 99918 PARTS LISTS Belt Guard Part 1 1 1 i 2 _Description Pump Qty 6 Hex Head Bolt 16 8 Bearing Sleeve 2 9 Bearing 2 1 1 1 2 2 1 Pilot Unloader Valve with Cable 1 set 1 1 1 2 1 1 Qty La eT CE 12 2 ate 1 set wm EA 2 i 1 EA SKU 65204 99918 For technical questions please call 1 800 444 3353 25 24 i 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 14 45 46 Shaft Jaw 2 PerRod 2set 47 ConnectingRos 48 4 49 i 50 i 51 Tel 52 1 53 i 54 Tel 55 5 56 Valve Plate 256 57 T 58 Exhaust Valve Plate 2 sel 59 3 1 62 63 64 65 67 70 71 16 MAIN ASSEMBLY DIAGRAM Spark Plug Wrench A24 SKU 65204 For technical questions please call 1 800 444 3353 Page 17 9
7. allow the starter rope to rewind slowly Then pull the starter handle with a rapid full arm stroke Once again while holding the handle allow the rope to rewind slowly Re peat as necessary until the engine starts 6 Allow the Engine to run for sev eral seconds Then if the Choke is closed open it move to the run posi tion SKU 65204 99918 For technical questions please call 1 800 444 3353 Note Moving the Choke too fast could kill the engine IMPORTANT Allow the engine to run at no load for five minutes after each start up so that the engine can stabi lize Close the pilot valve after the engine has started by laying the pin down This allows the compressor to build up pressure When the Gas Engine A4 is started and running the Air Pump A2 starts compressing air into the Air Tank A18 for storage When maximum tank pressure is reached the compressor automati cally 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 To turn off the engine turn the key off 0 position Close the fuel valve Drain the moisture from the tank daily Page 11 USER MAINTENANCE INSTRUCTIONS Procedures not specifically explained in this manual must be performed only by a qualified technician TO PREVENT AWARN
8. 9918 PUMP ASSEMBLY DIAGRAM 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 avail able individually as replacement parts SKU 65204 For technical questions please call 1 800 444 3353 Page 18 99918 LIMITED 1 YEAR 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 for a period of one year from date of purchase that the tank is free of defects in materials and work manship 90 days if used by a professional contractor or if used as rental equipment Harbor Freight Tools also warrants to the original purchaser for a period of ninety days from date of purchase that all other parts and components of the product are free from defects in materials and workmanship This warranty does not apply to damage due di rectly or indirectly to misuse abuse negligence or accidents repairs or alterations out side our facilities 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 limita tion of e
9. ING serious INJURY FROM ACCIDENTAL OPERATION Disconnect spark plug and release all air pressure before maintenance TO PREVENT SERIOUS INJURY FROM TOOL FAILURE Do not use damaged equipment If abnormal noise vibration or leaking air occurs have the problem corrected before further use TO PREVENT SERIOUS INJURY Do not adjust or tamper with any control or component way not specifically explained within this manual Improper adjustment can result in tool failure or other serious hazards Cleaning Maintenance and Lubrication Note These procedures are in addition to the regular checks and maintenance explained as part of the regular op eration of the air operated tool SKU 65204 99918 For technical questions please call 1 800 444 3353 Daily 1 Check compressor oil level at sight glass Add premium quality SAE 30 weight non detergent synthetic air compressor oil as needed Do not mix oils of different types Check engine oil level Add oil as needed according to engine manual s instructions 3 Drain moisture from tank Weekly 1 Inspect air pump s Air Filter 67 Re place if necessary To replace a Unscrew the wing nut holding the filter cover b Remove the filter cover c Remove the filter element and re place with a new one d Slide the filter cover back over the filter element and screw the wing nut back on and tighten securely 2 Check safety valve by p
10. MENT SET UP Equipment Oil Fill section of this manual Oil in the 2 Overheating See above section Restricted intake air Clean or replace air filter Worn piston rings Replace Excessive moisture the 5 Drain moisture from the tank daily Excessive noise Follow all safety precautions whenever diagnosing or servicing the tool SKU 65204 For technical questions please call 1 800 444 3353 Page 14 99918 Troubleshooting Possible Causes Likely Solutions 1 Air leaks 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 Leaking valves 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 Restricted air intake Clean or replace air filter element 4 Blown gaskets 4 Replace and gaskets proven faulty on inspection 5 Slipping belts _ Ti maintenance Low discharge pressure A Follow all safety precautions whenever diagnosing or servicing the tool 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
11. and in the manner intended for the T particular type of equipment taking 1 Before service maintenance or into account the working conditions cleaning and the work to be performed Use a Turn the engine switch to its of the equipment for operations differ OFF position ent from those intended could result a hazardous situation b the engine to completely 15 Do not operate the equipment with c Then remove the spark plug known leaks the engine s fuel sys wire s from the spark plug s tem 2 Keep all safety guards in place and in 16 This product contains or when used proper working order Safety guards produces a chemical known to the include the belt guard muffler air State of California to cause cancer cleaner mechanical guards and heat and birth defects or other reproduc shields among other guards tive harm California Health amp Safety Code 25249 5 et seq 3 not alter or adjust any part of the equipment or its engine that is 17 When spills of fuel or oil occur they sealed by the manufacturer or dis must be cleaned up immediately tributor Only a qualified service Dispose of fluids and cleaning materi technician may adjust parts that als as per any local state or federal may increase or decrease gov codes and regulations Store oil rags erned engine speed in a bottom ventilated covered metal container 4 Wear ANSI approved safety goggles heavy duty work gloves and dust 18 Keep
12. are recom mended 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 Do not operate in explosive atmo spheres such as in the presence of flammable liquids gases or dust Gasoline powered engines may ignite the dust or fumes Stay alert watch what you are doing and use common sense when operat ing this piece of equipment Do not use this piece of equipment while tired or under the influence of drugs alcohol or medication Do not overreach Keep proper foot ing and balance at all times This en ables better control of the equipment in unexpected situations Dress properly Do not wear loose clothing or jewelry Keep hair cloth ing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Page 4 Parts especially exhaust system components get very hot during use Stay clear of hot parts serviced before using Many ac cidents are caused by poorly main tained equipment 12 Do cover the engine or equipment 20 Use the correct equipment for the during operation application Do not modify the equip f ment and do not use the equipment 13 Keep the equipment engine and sur for a purpose for which it is not in rounding area clean at all times tended 14 Use the equipment accessories etc in accordance with these instructions SERVICE PRECAUTIONS
13. efuel in a well ventilated area only SAVE THESE INSTRUCTIONS SKU 65204 For technical questions please call 1 800 444 3353 Page 6 99918 THIS PAGE INTENTIONALLY LEFT BLANK SKU 65204 For technical questions please call 1 800 444 3353 Page 7 18 BASIC SPECIFICATIONS _ ing parts and allows the large pulley to direct cooling air to the Air Pump Compressor Oil A2 1 37 Quarts 2 Oil Sight Glass The oil sight glass 12 0P EFACARB shows proper level of the oil Oil level Engine Compliant should be at center of Sight Glass 99918 13 HP EPA Compliant Counterciockwise Tank Drain Valve The Air Tank A18 aa drain valve allows moisture to be Ty Long removed from the tank to reduce the Engine Shaft Keyway h f en h 3 24 UNF inner thread chance of corrosion inside the tank Air Pressure Range 145 175 PSI 4 Safety Valve This Safety Valve A15 Air Outlet 3 4 NPT automatically releases air if the Air Air Flow 19 5 CFM 40 PSI Tank A18 pressure exceeds the 18 7 CFM 100 PSI preset maximum l 1 800 100 RPM engine lde speed Pressure switch controlled In an emergency the ring could be pulled to reduce tank air pressure Note Engine specifications are found in the engine manual supplied with this 5 Ball Valve Air hose attaches to this equipment valve Air pressure required by tools is set by an air pressure regulator COMPONENTS AND Regulator and Gauge Not Incl
14. hands and feet away from mask respirator during service moving parts Do not reach over or across equipment while operating 5 Maintain labels and nameplates on the equipment These carry impor 19 Before use check for misalignment tant information If unreadable or or binding of moving parts breakage missing contact Harbor Freight Tools of parts and any other condition that for a replacement may affect the equipment s operation If damaged have the equipment SKU 65204 For technical questions please call 1 800 444 3353 Page 5 99918 10 11 Have the equipment serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the equip ment is maintained Do not attempt any service or maintenance proce dures not explained in this manual or any procedures that you are un certain about your ability to perform safely or correctly Store equipment out of the reach of children Follow scheduled engine and equip ment maintenance Tanks rust from moisture build up weakening the tank Drain tank daily and inspect periodically Do not remove or adjust safety valve Refueling a Do not smoke or allow sparks flames or other sources of ignition around the equipment especially when refuelling Do not refill the fuel tank while the engine is running or hot Do not fill fuel tank to the top Leave a little room for the fuel to expand as needed d R
15. lations relat ing to fire prevention requirements 4 Setup and use only a flat level well ventilated surface Page 3 SKU 65204 Wear ANSI approved safety goggles and heavy duty work gloves during set up Use only lubricants and fuel recom mended in the engine manual or in the Specifications chart of this man ual ENGINE PRECAUTIONS Follow engine precautions and in structions in the included engine instruction manual OPERATING PRECAUTIONS 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 NEVER use inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and away from windows doors and vents Keep children away from the equip ment especially while it is operating 99918 For technical questions please call 1 800 444 3353 Do not leave the equipment unat tended when it is running Turn off the equipment and remove safety keys if available before leaving the work area Wear ANSI approved safety glasses and hearing protection during use 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 neces sary when near the engine s magneto or recoil starter Use only accessories that
16. ous injury AWARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury ACAUTION CAUTION used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury SKU 65204 99918 For technical questions please call 1 800 444 3353 NOTICE is used to NOTICE address practices not related to personal injury CAUTION without CAUTION the safety alert symbol is used to address practices not related to personal injury WARNING Read all instructions Failure to follow all instructions listed below may result in fire serious injury and or DEATH The warnings and precautions discussed in this 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 SAVE THESE INSTRUCTIONS SET UP PRECAUTIONS 1 Gasoline fuel and fumes are flamma ble and potentially explosive Use proper fuel storage and handling pro cedures Do not store fuel or other flammable materials nearby 2 Have multiple ABC class fire extin guishers nearby 3 Operation of this equipment may cre ate sparks that can start fires around dry vegetation A spark arrestor may be required The operator should contact local fire agencies for laws or regu
17. se looking for damaged loose and missing parts If any problems are found do not use until repaired Work Piece and Work Area Set Up 1 The Compressor s engine runs on gasoline and must be set up in an area free from ignition sources Do not set up too close to a wall or in a confined area The Air Pump A2 and Gas Engine A4 must have adequate fresh air in order to operate properly and not overheat Designate a work area that is clean and well lit The work area must not allow access by children or pets to prevent injury and distraction Route the air hose along a safe route to reach the work area without creat ing a tripping hazard or exposing the air hose to possible damage The air hose must be long enough to reach the work area with enough extra length to allow free movement while working REV 09c 09i SKU 65204 99918 A 5 For technical questions please call 1 800 444 3353 General Operating Instructions Before starting the engine a Follow the Set Up Instructions to prepare the equipment Inspect the equipment and engine c Fill the engine with the proper amount and type of both fuel and oil Note The Oil Sensor if equipped will prevent the engine from operating if the oil is not up to the proper level NOTE THIS ENGINE INCLUDES AN AUTOMATIC LOW OIL SHUTDOWN SENSOR THAT DISABLES THE ENGINE IF THE OIL LEVEL IS TOO LOW d For electric start make sure battery is 12 V
18. uded CONTROLS Outlet air can be regulated by adjust ing the regulator knob Clockwise will Belt Guard raise outlet pressure and counter clockwise will lower outlet pressure et Outlet pressure will be displayed on iH the regulator s pressure gauge 6 Storage Tank The Air Tank 18 Hi is where air pressurized by the Air Pump A2 is stored for later use 7 Pressure Gauge The Air Tank Pressure Gauge A20 displays the Safety Pressure air pressure in the tank Ball Valve Gauge Valve Tank Drain Air Storage Tank Fig 1 1 Belt Guard The Belt Guard 1 encloses the pulleys and drive belts It protects the user from the mov SKU 65204 For technical questions please call 1 800 444 3353 Page 8 99918 8 Pilot Valve Open the Pilot Valve before starting the engine It relieves resistance on the engine to make starting easier It is shown in the open position above Push the pin over to one side to close it A EQUIPMENT SET UP 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 Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagrams near the end of this manual Unpacking Note Do not use the air cleaner to lift or move the compressor It is not de signed to withstand such force
19. ulling and re leasing ring Valve should seal once released 3 Clean excessive dirt dust from unit Monthly Check and adjust belt tension accord ing to the steps below 1 Remove the belt cover and set it aside Page 12 Deflection Distance 2 Press the center of the longest span on each belt with moderate finger pressure 4 4 5 Ib Then measure the deflection distance the distance that the belt moved The belt should deflect anywhere from 1 4 to 1 2 Engine Mounting Bolts 3 If the belts deflect too much tighten belts by loosening the en gine mounting bolts and moving the engine away from the other pulley slightly Secure engine mounting bolts and retest tension If either belt is too long to be properly tensioned both belts must be replaced 4 Ifthe belts deflect too little loosen belts by loosening the engine mount ing bolts and moving the engine towards the other pulley very slightly Secure engine mounting bolts and retest tension 5 Align pump and engine pulleys using a straight edge to reduce noise and vibration 6 Before use replace belt cover SKU 65204 For technical questions please call 1 800 444 3353 Page 13 99918 Troubleshooting Possible Causes Likely Solutions Start procedure not followed Empty all pressure from tank open pilot valve Engine will not f start completely and carefully follow starting instructions in engine manual
20. xclusion 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 com plaint must accompany the merchandise If our inspection verifies the defect we will ei ther 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 re paired 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 SKU 65204 For technical questions please call 1 800 444 3353 Page 19 99918
Download Pdf Manuals
Related Search