Harbor Freight Tools Air Compressor 9592 User Manual

®
AIR COMPRESSOR PUMP  
3 HORSEPOWER  
Model 09592  
ASSEMBLY AND  
OPERATING INSTRUCTIONS  
®
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Copyright 2003 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.  
For technical questions, please call 1-800-444-3353.  
 
5.  
6.  
7.  
USE EYE AND HAND PROTECTION. Wear ANSI approved safety impact eye  
goggles and heavy-duty work gloves when using this product. ANSI  
approved safety impact eye goggles and heavy-duty work gloves are available  
from Harbor Freight Tools.  
DRESS SAFELY. Do not wear loose clothing or jewelry, as they can become  
caught in moving parts. Wear a protective hair covering to prevent long hair from  
becoming caught in moving parts. If wearing a long-sleeve shirt, roll sleeves up  
above elbows.  
DO NOT OVERREACH. Keep proper footing and balance at all times to prevent  
tripping, falling, back injury, etcetera.  
8.  
9.  
INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.  
STAY ALERT. Watch what you are doing at all times. Use common sense. Do  
not use this product when you are tired or distracted from the job at hand.  
10.  
11.  
CHECK FOR DAMAGED PARTS. Before using this product, carefully check that  
it will operate properly and perform its intended function. Check for damaged  
parts and any other conditions that may affect the operation of this product. Re-  
place or repair damaged or worn parts immediately.  
REPLACEMENT PARTS AND ACCESSORIES: When servicing, use only  
identical replacement parts. Only use accessories intended for use with this  
product. Approved accessories are available from Harbor Freight Tools.  
12.  
13.  
14.  
MAINTAIN THIS PRODUCT WITH CARE. Keep this product clean and dry for  
better and safer performance.  
MAINTENANCE: For your safety, service and maintenance should be performed  
regularly by a qualified technician.  
USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force a small tool or  
attachment to do the work of a larger industrial tool. There are certain  
applications for which this tool was designed. It will do the job better and more  
safely at the rate for which it was intended. Do not modify this tool, and do not  
use this tool for a purpose for which it was not intended.  
15.  
WARNING: The warnings, precautions, and instructions discussed in this manual  
cannot cover all possible conditions and situations that may occur. The operator  
must understand that common sense and caution are factors, which cannot be  
built into this product, but must be supplied by the operator.  
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PAGE 3  
 
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS  
1.  
2.  
THIS AIR COMPRESSOR PUMP IS DESIGNED FOR USE ONLY WITH A  
3 HORSEPOWER MOTOR 3,400 RPM (not included).  
WARNING! Make sure to fill the Air Compressor Pump with a premium quality,  
30-weight, non-detergent oil before each use. Running the Air Compressor  
Pump with no oil or low oil will cause damage to the equipment.  
3.  
4.  
WHEN FILLING WITH OIL: Make sure to unscrew (do not pull) the Oil Fill Plug  
(part #20) out. (See Figure D.)  
MAKE SURE ALL TOOLS AND EQUIPMENT USED WITH THE AIR  
COMPRESSOR PUMP ARE RATED TO THE APPROPRIATE CAPACITY. Do  
not use any tool or equipment that does not operate from 0 to 140 PSI.  
5.  
MAINTAIN A SAFE WORKING ENVIRONMENT. Keep the work area well lit.  
Make sure there is adequate surrounding workspace. Always keep the work  
area free of obstructions, grease, oil, trash, and other debris. Do not use the Air  
Compressor Pump in areas near flammable chemicals, dusts, and vapors.  
6.  
7.  
AVOID INJURY: Never direct the Exhaust Elbow (part #3) at people or animals.  
(See Figure D.)  
AVOID BURNS: The Air Compressor Pump becomes very hot during use and for  
a while after its use. Do not touch the Air Compressor Pump until it has com-  
pletely cooled.  
8.  
9.  
WARNING! DO NOT USE THE AIR COMPRESSOR PUMP UNTIL A PROP-  
ERLY FUNCTIONING PULLEY/BELT GUARD (not included) HAS BEEN  
INSTALLED. (See Figure C.)  
BEFORE PERFORMING ANY INSPECTION, MAINTENANCE, OR CLEANING  
PROCEDURES, MAKE SURE ALL AIR PRESSURE HAS BEEN RELEASED  
FROM THE AIR COMPRESSOR’S TANK (not included) AND THAT THE  
EQUIPMENT IS UNPLUGGED FROM ITS ELECTRICAL OUTLET, and ALL  
COMPONENTS HVAE COLLED.  
10.  
WARNING! This product contains or 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.)  
SKU 09592  
PAGE 4  
 
UNPACKING  
When unpacking, check to make sure all the parts shown on the Parts List on page 9 are  
included. If any parts are missing or broken, please call Harbor Freight Tools at the num-  
ber shown on the cover of this manual as soon as possible.  
ASSEMBLY INSTRUCTIONS  
NOTE: For additional references to the parts mentioned in the following pages, refer to  
the Assembly Diagram on page 10.  
To Attach The Air Compressor Pump To A Mounting Surface:  
1.  
2.  
NOTE: Depending on your level of assembly expertise, you may wish to have a  
qualified technician perform the assembly procedures.  
CAUTION: Make sure the mounting surface (air compressor stand, work-  
bench, etc.) to which the Air Compressor Pump will be attached is flat, level, and  
sturdy enough to withstand the weight of the Air Compressor Pump and all other  
necessary equipment and accessories.  
3.  
4.  
At the base of the Air Compressor Pump are four 3/8” mounting holes with a hole  
pattern of 5-1/2” long by 7-1/2” wide. If four 3/8” mounting holes with a hole  
pattern of 5-1/2” long by 7-1/2” wide do not already exist in the mounting surface,  
it will be necessary to drill the four 3/8” mounting holes through the mounting  
surface. IMPORTANT: Prior to drilling, make sure there are no electrical cables,  
wires or other obstructions in the drilling path. (See Figure A.)  
To do so, temporarily position the Air Compressor Pump in the desired location  
on the mounting surface. Use the base of the Air Compressor Pump, with its four  
3/8” mounting holes, as a template by which to mark the four 3/8” mounting holes  
that are to be drilled through the mounting surface. Then, remove the Air Com-  
pressor Pump from the mounting surface. NOTE: You may also follow the illus-  
tration below by which to measure where each of the four 3/8” mounting holes  
should be drilled. (See Figure A.)  
5-1/2”  
BOTTOM VIEW  
PULLEY  
(#38)  
BASE OF AIR COMPRESSOR PUMP  
FIGURE A  
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PAGE 5  
 
5.  
6.  
Once the four 3/8” mounting holes are drilled through the mounting surface,  
place the Air Compressor Pump on the mounting surface and align its four  
mounting holes with the four drilled mounting holes on the mounting surface.  
Then, secure the Air Compressor Pump to the mounting surface, using four 3/8”  
Bolts of appropriate length, four Lockwashers, and four Nuts (all not included).  
The Air Compressor Pump requires the use of a “V” Pulley Belt (not included).  
The “V” Pulley Belt should be no wider than 1-5/16” wide at its widest point and  
of appropriate length depending on the distance between the Air Compressor  
Pump’s Pulley (part #38) and the 3 HP Motor’s Pulley (not included). Once the  
V” Belt Pulley is installed, its proper length is indicated by pushing down with  
your finger midway on the “V” Belt Pulley. The “V” Belt Pulley should not de-  
press more than 1/2”. (See Figure B.)  
“V” BELT PULLEY  
(NOT INCLUDED)  
3 HP MOTOR PULLEY  
(NOT INCLUDED)  
PULLEY  
(#38)  
FIGURE B  
7.  
WARNING! To avoid personal injury and/or property damage, it is recommended  
that a properly functioning Pulley/Belt Guard (not included) be installed. The  
Pulley/Belt Guard should fully enclose (front, back, top, bottom) the Air Compres-  
sor Pump’s Pulley (part #38), the “V” Belt, and the Motor’s Pulley. NOTE: Make  
sure to allow for about 1” clearance, on all sides, between the Pulley/Belt Guard  
and the Air Compressor Pump’s Pulley, the “V” Belt, and the Motor’s Pulley.  
(See Figure C.)  
CONVENTIONAL PULLEY/BELT GUARD  
(NOT INCLUDED)  
FIGURE C  
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PAGE 6  
 
8.  
Attach the Air Compressor Tank’s Inlet Hose (not included) to the 1/2” by 14-TPI  
Exhaust Elbow (part #3). NOTE: Make sure to wrap the male threads of Tank’s  
Inlet Hose Connector with pipe seal tape (not included). Then, screw the Con-  
nector firmly into the Exhaust Elbow. (See Figure D.)  
EXHAUST ELBOW  
(#3)  
ATTACH  
AIR TANK INLET HOSE  
AIR FILTER  
(#4)  
(NOT INCLUDED)  
HERE.  
OIL FILL PLUG  
(#20)  
OIL WINDOW  
(#25)  
FIGURE D  
OPERATING INSTRUCTIONS  
NOTE: For additional references to the parts mentioned in the following pages, refer to  
the Assembly Diagram on page 10.  
To Check The Oil Level:  
1.  
2.  
The Oil Window (part #25) is used to determine if oil is needed. To check the oil,  
observe the Oil Window. The oil should appear at the midway point (horizon-  
tally) in the circle of the Oil Window. (See Figure D.)  
Note: The optimal capacity of the oil tank is 28.73 ounces.  
If the oil level is below the midway point in the Oil Window (part #25) then it is  
necessary to add a premium quality, 30-weight, non-detergent oil until the level of  
oil reaches the midway point in the Oil Window. Do not overfill. NOTE: Make  
sure to unscrew the Oil Fill Plug and remove it from its Oil Fill Hole. Add the  
new oil. Then screw the Oil Fill Plug back into the Oil Fill Hole, being careful not  
to strip the threads. (See Figure D.)  
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PAGE 7  
REV 02/04  
 
3.  
4.  
Start the Air Compressor, and visually check the “V” Belt for proper tension. Also  
check for air leaks in the system, abnormal noise or vibration. If a problem oc-  
curs immediately disconnect the Air Compressor from its electrical supply source,  
release all air pressure from the system, and have the problem corrected before  
further use.  
IMPORTANT: After starting the Air Compressor Pump, it should run for about 30  
minutes without a load in order for it to build up sufficient air pressure.  
INSPECTION, MAINTENANCE, AND CLEANING  
1.  
2.  
WARNING! Before performing any inspection, maintenance, and cleaning proce-  
dures, make sure all air pressure has been released from the Air Compressor’s  
Tank and that the Air Compressor is unplugged from its electrical outlet.  
BEFORE EACH USE, inspect the general condition of the Air Compressor  
Pump. Check all air fittings for leaks. Check for loose screws, misalignment or  
binding of moving parts, cracked or broken parts, and any other condition that  
may affect the safe operation of this equipment. If abnormal noise or vibration  
occurs, immediately disconnect the Air Compressor from its electrical supply  
source and have the problem corrected before further use.  
Do not use damaged equipment.  
3.  
DAILY: Check the Air Compressor Pump’s oil level. If necessary, fill with a pre-  
mium quality, 30-weight, non-detergent oil. NOTE: When checking the oil level,  
make sure to unscrew (do not pull) the Oil Fill Plug (part #20).  
(See Figure D.)  
4.  
5.  
EVERY 100 HOURS OF USE: Clean the Air Filter Element (part #4) with a mild  
solvent. Then, dry and re-attach the Air Filter Element. NOTE: Replace the Air  
Filter Element if it is too dirty to properly clean. (See Assy. Diagram.)  
EVERY 500 HOURS OR 12 MONTHS: Replace the old oil with new, premium  
quality, 30-weight, non-detergent oil.  
6.  
7.  
TO CLEAN: wipe with a damp cloth, using a mild detergent or mild solvent.  
WHEN STORING: Keep the Air Compressor Pump in a clean, dry location.  
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PAGE 8  
 
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 KINDTO THE BUYERTHAT  
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 MANUFACTUER AND/OR  
DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE  
UNDERTAKEN BY CERTIFIED AND LICENSEDTECHNICIANS, AND NOT BYTHE 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 PARTSTHERETO.  
PARTS LIST  
Part #  
1
2
3
4
5
6
7
Description  
Screw  
Cylinder Head  
Exhaust Elbow  
Air Filter  
Spring Washer  
Screw  
Cylinder Head Washer  
Valve Plate Seat  
Valve Plate  
Qty.  
6
1
1
1
2
2
1
2
4
1
2
2
2
2
4
2
Part #  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
Description  
Qty.  
3
1
1
1
1
1
1
1
1
8
1
2
1
1
1
1
Bolt  
Crankcase Front Cover  
Crankcase Front Washer  
O-Ring  
Oil Window  
Oil Drain Plug  
O-Ring  
Crankcase Seal  
Crankcase Down Cover  
Bolt  
Crankcase  
Bearing  
Crankshaft  
Crankcase Back Washer  
Oil Seal  
Crankcase Back Cover  
Bolt  
Pulley  
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
Aluminum Washer  
Cylinder Up Washer  
Piston Ring Assembly  
Piston  
Piston Pin  
Retaining Ring In Hole  
Connect Rod Assembly  
Bolt  
Cylinder  
Cylinder Down Washer  
Oil Fill Plug  
6
1
1
1
3
1
1
1
Large Washer  
Bolt  
NOTE: Some parts are listed and shown for illustration purposes only, and are not  
available individually as replacement parts.  
SKU 09592  
PAGE 9  
 
ASSEMBLY DIAGRAM  
1
6
5
4
2
3
7
8
9
10  
8
11  
12  
13  
14  
16  
15  
37  
40  
20  
39  
17  
18  
19  
36  
38  
35  
32  
34  
32  
20  
33  
31  
23  
22  
21  
24  
25  
28  
27  
26  
29  
30  
NOTE: Some parts are listed and shown for illustration purposes only, and are not  
available individually as replacement parts.  
SKU 09592  
PAGE 10  
 

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