U.S. General 91824 Operator's Manual

STOCK# 91824

OPERATOR’S MANUAL

WARNING

To reduce the risk of injury, the user must read and understand the Operator’s Manual before using this product.

30 GALLON

AIR COMPRESSOR

REV0905

12.75 HP KOHLER GAS ENGINE

MODEL: US1230G

Warranty Statement

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 two years 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

Parts List US1230G

September 2005

Pump

B6000

Engine

ECS12ST

Safety Valve (200 psi)

SV25200

Beltguard

BG31184R

Pressure Gauge

GA300

Tan k

TK30GB

Drive Pulley S2AK74H

Belt(2) BA69

Idle Control IC34

Beltguard Fastener 5001369

Unloader/Pilot Valve

Tank Drain

U109

Ball Valve

BV75

FIB02DC16

Discharge Tube

DT027

Filter Assem.

FS002

2Page 1

Safety Instructions

This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

Safety Signal Words

Danger indicates

an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Warning indicates

a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

Caution indicates a

potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

Notice indicates

important information, that if not followed, may cause damage to equipment.

NOTICE

CAUTION

WARNING

DANGER

Since the air compressor and other components (pump, spray guns, filters, lubricators, hoses, etc.) used make up a high pressure pumping system, the following safety precautions must be observed at all times:

1. Read all manuals included with this product carefully. Be thoroughly familiar with the controls and the proper use of the equipment.

2. Follow all local safety codes as well as the United States Occupational Safety and Health Act (OSHA)

3. Only persons well acquainted with these rules of safe operation should be allowed to use the compressor.

4. Keep visitors away and NEVER allow children in the work area.

5. Wear safety glasses and use hearing protection when operating the pump or unit.

6. Do not stand on or use the pump or unit as a handhold.

7. Before each use, inspect compressed air system, fuel system and electrical components for signs of damage,

deterioration, weakness or leakage. Repair or replace defective items before using.

8. Check all fasteners at frequent intervals for proper tightness.

9. Do not wear loose clothing or jewelry that will get caught in the moving parts of the unit.

Before Using the Air Compressor

MANUAL

Never operate compressor without a beltguard. Compressors can start automatically without warning. Personal injury or property damage could occurfrom contact with moving parts.

WARNING

Compressor parts may be hot even if the unit is stopped.

CAUTION

Page 1

10. Keep fingers away from a running compressor; fast moving and hot parts will cause injury and/or burns.

11. If the equipment should start to vibrate abnormally, STOP the engine/motor and check immediately for the cause. Vibration is generally a warning of trouble.

WARNING

NEVER refuel a running or hot engine. Explosive fuel can cause fires and severe burns. Avoid overfilling fuel tank.

12. Check fuel level before starting the engine. Do not fill the gas tank indoors. Wipe off any spilled gas before starting the engine.

DANGER

Gasoline vapor is highly flammable. Refill outdoors or only in well ventilated areas. Do not store, spill or use gasoline near an open flame or heat devices such as a stove, furnace, or water heater, which utilize a pilot light, or any device that can create a spark. If gasoline is accidentally spilled, move unit away from the spill area and avoid creating any source of ignition until gasoline vapors have dissipated.

WARNING

Motors, electrical equipment and controls can cause electrical arcs that will ignite a flammable gas or vapor. Never operate or repair in or near

a flammable gas or vapor. Never store flammable liquids or gases in the vicinity of the compressor.

WARNING

Carbon monoxide can cause severe nausea, fainting or death. Do not operate unit inside a closed building or a poorly ventilated area.

13. To reduce fire hazard, keep engine/motor exterior free of oil, sol vent, or excessive grease.

WARNING

Never remove or attempt to adjust safety valve. Keep safety valve free from paint and other accumulations.

14. Do not tamper with governor setting on engine. Overspeeding the unit severely shortens engine life and may also be very hazardous.

DANGER

Never attempt to repair or modify tank! Welding, drilling or any other modifications will weaken the tank resulting in damage from rupture or explosion. Always replace worn or damaged tanks.

15. Tanks rust from moisture build-up, which weakens the tank. Make sure to drain tank daily and inspect periodical ly for unsafe conditions such as rust formation and corrosion.

Safety Instructions (continued)

Page 2

1. Crankcase 6061100

2. Cylinder 6030000

3. Head 6061401

4. Crankshaft 6061200

5. Crankcase Bottom 6061301

6. Crankcase Bottom Gasket 6050101

7. Valve Plate 6040051

8. Conrod Bearing (2 per Rod) 9013014

9. Connecting Rod 6011101

10. Conrod Nut 9128234

11. HP Piston 6021100

12. LP Piston 6022100

13. HP Wrist Pin 6021200

14. LP Wrist Pin 6022200

15. Circlip 9140060

16. HP Ring 9020011

17. HP Ring 9020041

18. HP Ring 9020073

19. LP Ring 9020016

20. LP Ring 9020046

21. LP Ring 9020076

22. Aftercooler 5070100

23. Bearing Housing (NDS) 5061690

24. Bearing Housing (DS) 6061590

25. Intercooler 5262010

26. Flywheel 5000100

27. Main Bearing 9170020

28. Main Bearing 9170090

29. Oil Sight Glass 9022003

30. Oil Fill Plug 9024006

31. Oil Seal 9163030

32. Flywheel Bolt 9110024 33 Flywheel Washer 9004009

34. Aftercooler Safety Valve Sv25225

35. Intercooler Safety Valve 9049064

36. Head Bolt 9101754

37. Cooler Bolt 9101254

38. Cylinder Bolt 9101324

39. Crankcase Btm. Bolt 9114262

40. Head Gasket 6050400

41. Cylinder Gasket 6050300

42. Aftercooler Gasket 5070200

43. Intercooler Gasket 5050600

44. Bearing Housing Gasket DS 6050500

45. Bearing Housing Gasket NDS 5050500

46. Frame Gasket 6050200

47. Oil Drain Tube 9053201

Gasket Kit 6050057 Filter Assembly FS002 Filter Element FE001

Page 11

Page 10

B6000

16. Fast moving air will stir up dust and debris which may be harmful. Release air slowly when draining moisture or depressurizing the com pressor system.

17. STOP the engine whenever leaving the work area, before cleaning, making repairs or inspections. When cleaning,

DANGER

This Compressor/pump is not equipped and should not be used “as is” to supply breathing quality air. For any application of air for human consumption, the air compressor/pump will need to be fitted with suitable in-line safety and alarm equipment. This additional equipment is necessary to properly filter and purify the air to meet minimal specifications for Grade D breathing as described in Compressed Gas Association Commodity Specification G 7.1 - 1966, OSHA 29 CFR 1910. 134, and/or Canadian Standards Associations (CSA). DISCLAIMER OF WARRANTIES In the event the compressor is used for the purpose of breathing air application and proper in-line safety and alarm equipment is not simultaneously used, existing warranties shall be voided, and The Manufacturer disclaims any liability whatsoever for any loss, personal injury or damage.

WARNING

Do not spray flammable materials in vicinity of open flame or near ignition sources including the compressor unit.

repairing or inspecting, make certain all moving parts have stopped. Disconnect the spark plug wire and keep the wire away from the plug to prevent acciden tal starting.

18. Allow engine to cool before storing.

Spraying Precautions

19. Do not smoke when spraying paint, insecticides, or other flammable sub stances.

20. Use a face mask/respirator when spraying and spray in a well ventilat-

ed area to prevent health and fire hazards.

21. Do not direct paint or other sprayed material at the compressor. Locate compressor as far away from the spraying area as possible to mini mize overspray accumulation on the compressor.

22. When spraying or cleaning with sol vents or toxic chemicals, follow the instructions provided by the chemi cal manufacturer.

Breathable Air Warning

Page 3

ASME Safety Valve A safety valve that automatically releases the air if the air receiver (tank) pressure exceeds the preset maximum.

PSI (Pounds per Square Inch) Measurement of the pressure exerted by the force of the air. The actual psi output is measured by a pressure gauge on the compressor.

ACFM (Actual Cubic Feet per Minute) Sometimes called CFM (Cubic Feet per Minute). Measurement of air volume delivered by the compressor at a given pressure..

Air Delivery A combination of psi and SCFM. The air delivery required by a tool is stated as (number) SCFM at (Number) psi. The combination of these figures determines what size compressor is needed.

WARNING

Glossary of Terms

Regulator (Not Included) A control that adjusts the line pressure to the proper amount needed to operate spray guns and air tools.

Tank Pressure Gauge Indicates tank pressure in psi.

Unpacking and Checking Contents

1. Remove the air compressor from the carton.

2. Place the compressor on a secure, stationary work surface and look it over carefully.

Do not operate unit if damaged during shipping, handling or use. Damage may result in bursting and cause injury or property damage.

WARNING

To reduce the risk of injury, if any parts are missing, do not attempt to assemble the air compressor until the missing parts are obtained and installed correctly.

WARNING

For your own safety, never operate unit until all assembly steps are complete and until you have read and understood the entire operator’s manual.

Page 4

Troubleshooting

TROUBLE REMEDYPROBABLE CAUSE

Overheating 1. Relocate the compressor

to an area where an ample supply of cool, clean, dry and well-circulated air is available

2. Clean the cooling surfaces of pump and engine.

3. Check air requirements of tools

1. Poor ventilation

2. Dirty cooling surfaces

3. Compressor undersized for application

1. Increase idle, refer to engine manual for details

2. Check for proper oil level

3. Replace

1. Low engine idle

2. Improper lubrication

3. Defective pilot/unloader valve

Unit stalls

Excessive noise

1. Loose pulleys are a com mon cause of “knocking”. Tighten appropriate bolts

2. Check for proper oil level

3. Replace

4. Remove piston assembly and replace necessary parts

5. Replace bearings and oil

6. Check for proper belt tension

1. Loose drive pulley or flywheel

2. Lack of oil in crankcase

3. Worn connecting rod

4. Worn wrist pin bushing

5. Worn bearings

6. Loose belts

Oil in the discharge air

1. Change oil. Check oil recommendations on page 7 of this manual

2. See above section

3. Clean or replace air filter

4. Replace

1. Wrong type or inferior grade of oil

2. Overheating

3. Restricted intake air

4. Worn piston rings

Page 9

Getting to Know Your Air Compressor

Belt Guard

Pilot/Unloader Vave

Air Filter

Safety Valve

Air Storage Tank

Tank Drain

Ball Valve

Oil Sight Glass

1. Belt Guard. The belt guard encloses the pulleys and drive belt. It protects the user from moving parts and directs cooling air to the compressor pump.

2. Air Filter. The air filter keeps dirt and debris from entering the compressor pump and reduces compressor noise.

3. Oil Sight Glass. The oil sight glass shows proper level and cleanliness of the oil. Oil level should show ½ full

4. Tank Drain Valve. The tank drain valve allows moisture to be removed from the tank.

5. Pilot/Unloader Valve. The pilot/unloader valve controls the engine rpm. When loaded, the engine will run at maximum operating speed and air will enter the tank. When compressor reaches maximum pressure, the engine will slow to an idle and air will vent to atmosphere.

6. ASME Safety Valve. This valve auto-

matically releases air if the tank pressure exceeds the preset maximum.

7. Ball Valve. The ball valve allows unregulated

outlet air with pressure up to 175 psi.

8. Air Storage Tank. The tank stores air for

later use.

9. Regulator and Gauge (Not Included).

Outlet air can be regulated by adjusting the regulator knob. Clockwise will raise outlet pressure and counterclockwise will lower outlet pressure. Outlet pressure will be displayed on gauge.

10. Tank Pressure Gauge. The tank pressure

gauge will display air pressure in tank.

Page 5

Troubleshooting

WARNING

For your own safety do not try and run the air compressor while troubleshooting.

TROUBLE REMEDYPROBABLE CAUSE

Low discharge pressure

1. Listen for escaping air. Ally 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

1. Air leaks

2. Leaking valves

CAUTION

Be sure that the old head gasket is replaced with a new one each time the head is removed

3. Clean or replace air filter element.

4. Replace and gaskets proven faulty on inspection

5. Loosen engine mounting bolts and move engine in a direction away from the compressor, being sure that the engine pulley is perfectly aligned with the flywheel. Tighten engine mounting bolts. Proper belt tension should not allow more than about ½ travel with less that 5 pounds of force

3. Restricted air intake

4. Blown gaskets

5. Slipping belts

Page 8

Operating Your Compressor

CAUTION

All lubricated compressor pumps discharge some condensed water and oil with the compressed air. Install appropriate water/oil removal equipment and controls as necessary for the intended application.

NOTICE

Before starting the compressor, thoroughly read all component instruction manuals, especially the engine manual.

NOTICE

Failure to install appropriate water/oil removal equipment may result in damage to machinery or workpiece.

NOTICE

Do not attach air tools to open end of the hose until start-up is completed and unit checks OK.

To ensure proper operation, unit must be on a level surface.

Moisture in compressed air will form into droplets as it comes from an air compressor pump. When humidity is high or when a compressor is in continuous use for an extended period of time, this moisture will collect in the tank. When using a paint spray gun, this water will be carried from the tank through the hose, and out of the gun as droplets mixed with the spray material.

Moisture in Compressed Air

IMPORTANT: This condensation will cause water spots in a paint job, especially when spraying other than water based paints. A filter in the air line, located as near to the gun as possible will eliminate most of this moisture..

Start-Up

3. Connect the negative (-) battery cable to a mounting bolt or an acceptable engine ground connection.

4. Connect the positive (+) battery cable to the positive (+) battery terminal.

5. Connect the negative (-) battery cable to the negative (-) battery terminal.

IMPORTANT: Number 2 wire or larger is recommended.

1. Locate the starter solenoid terminal. This is the top post farthest from the block with the small red wire..

2. Connect the positive (+) battery cable to the starter solenoid terminal.

Battery Connection

CAUTION

Make sure to follow instructions carefully to avoid a short and possible damage to the starter solenoid and/or battery. Always connect the positive (+) battery cable to the starter solenoid before connecting the negative (-) battery cable.

1. Turn the gas lever to the “On” position. Turn the choke lever to the left. Turn key to the “On” position, then to the “Start” position or pull start grip to start the engine. Once the engine is running, turn the choke lever to the original “right hand” position.

See Engine Manual for More Detailed Instructions

Page 6

2. This compressor is equipped with an auto matic start- relief valve. This valve allows the unit to run (unloaded) for a few seconds before air pressure starts to build in the tank.

3. When maximum tank pressure is reached, the compressor automatically unloads, slowing the engine to idle. The engine remains at idle until tank pressure falls to a preset level. The engine will then accelerate and air will once again build pressure in the tank.

4. To turn off compressor, turn key to the “Off” position.

Note: Turn Gas Off when not in use.

Remember to drain moisture from tank daily.

Operating Your Compressor (continued)

Adjusting A Regulator

(Regulator must be purchased Separately)

1. To adjust the regulator, pull out on the regulator knob. Turn regulator knob clockwise to raise outlet pressure and turn regulator knob counterclockwise to decrease outlet air pressure.

2. Once desired outlet pressure is obtained, push regulator knob in to lock setting.

Maintenance

WARNING

Disconnect spark plug and drain air system completely of all air pressure prior to performing maintenance on compressor..

NOTICE

Consult engine manual for scheduled maintenance instructions.

DAILY

1. Check oil level at sight glass. Check engine oil level.

2. Drain moisture from tank.

3. Visually check for loose parts or excessive noise or vibration.

WEEKLY

1. Inspect air filter. Replace if necessary.

2. Check safety valve by pulling ring and releasing. Valve should seal once released.

3. Clean excessive dirt/dust from unit..

MONTHLY

Check belt tension and alignment.

3 Months

Change Oil. A compressor grade nondetergent oil should be used.

Most automotive detergent oils cause excess carbon build-up and should not be used.

Cold climates (Below 30°F) use 20WT Moderate Climates (30°F-90°F) use 30WT Hot Climates (Above 90°F) use 40WT

Page 7

Table of Contents

Section Page

Safety Instructions

1 Safety Signal Words Before Using the Air Compressor Spraying Precautions Breathable Air Warning

Glossary of Terms 4

Unpacking and Checking Content 4

Getting to Know Your Air Compressor 5

Operating Your Air Compressor 6

Moisture in Compressed Air Lubricaton Start-up To Start Gasoline Engine

Section Page

Maintenance

Maintenance Schedule

Adjusting the Regulator

Filter Removal, Inspection, and Replacement Drive Belt

Troubleshooting 8-9

Replacement Parts

10-12

Notes

7 7

Warranty Statement

Notes

B6000

+ 21 hidden pages

U.S. General 91824 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual