Harbor Freight Tools Air Compressor 90168 User Manual

Oilless COMPRessOR  
90168  
set uP and OPeRating instRuCtiOns  
®
distributed exclusively by Harbor Freight tools .  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
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 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. 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 08h  
 
ranges and refrigerators. There is  
an increased risk of electric shock if  
your body is grounded.  
doubt, use the next heavier gage.  
The smaller the gage number, the  
heavier the cord.  
c.do not expose compressors to  
rain or wet conditions. Water enter-  
ing a compressor will increase the  
risk of electric shock.  
3. Personal safety  
a.stay alert, watch what you are do-  
ing and use common sense when  
operating this compressor. do  
not use this compressor while you  
are tired or under the influence of  
drugs, alcohol or medication. A  
moment of inattention while operating  
compressors may result in serious  
personal injury.  
d.do not abuse the cord. never use  
the cord for carrying, pulling or  
unplugging the compressor. Keep  
cord away from heat, oil, sharp  
edges or moving parts. Damaged  
or entangled cords increase the risk  
of electric shock.  
b.use personal protective equip-  
ment. always wear eye protection.  
Safety equipment such as dust mask,  
non-skid safety shoes, hard hat, or  
hearing protection used for appropri-  
ate conditions will reduce personal  
injuries.  
e.if operating a compressor in a  
damp location is unavoidable, use  
a ground Fault Circuit interrupter  
(gFCi) protected supply. Use of  
a GFCI reduces the risk of electric  
shock.  
ReCOMMended MiniMuM WiRe  
c.Prevent unintentional starting.  
ensure the switch is in the off-po-  
sition before connecting to power  
source or moving the compressor.  
gauge FOR eXtensiOn CORds  
(120 VOlt)  
eXtensiOn CORd  
naMePlate  
lengtH  
aMPeRes  
d.do not overreach. Keep proper  
footing and balance at all times.  
This enables better control of the  
compressor in unexpected situations.  
(at full load)  
25’  
18  
18  
16  
14  
50’ 100’ 150’  
0 – 6  
16  
16  
16  
12  
16  
14  
14  
14  
12  
12  
6.1 – 10  
10.1 – 12  
12.1 – 16  
taBle a  
e.dress properly. do not wear loose  
clothing or jewelry. Keep your  
hair, clothing and gloves away  
from moving parts. Loose clothes,  
jewelry or long hair can be caught in  
moving parts.  
do not use.  
f. use PROPeR eXtensiOn CORd.  
Make sure your extension cord is  
in good condition. When using an  
extension cord, be sure to use one  
heavy enough to carry the current  
your product will draw. An undersized  
cord will cause a drop in line voltage  
resulting in loss of power and over-  
heating. Table A shows the correct  
size to use depending on cord length  
and nameplate ampere rating. If in  
f. Only use safety equipment that  
has been approved by an appropri-  
ate standards agency. Unapproved  
safety equipment may not provide  
adequate protection. Eye protection  
must be ANSI-approved and breath-  
ing protection must be NIOSH-ap-  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 3  
 
proved for the specific hazards in the 5. service  
work area.  
a.Have your compressor serviced  
by a qualified repair person using  
only identical replacement parts.  
This will ensure that the safety of the  
compressor is maintained.  
4. Compressor use and care  
a.do not force the compressor. use  
the correct compressor for your  
application. The correct compressor  
will do the job better and safer at the  
rate for which it was designed.  
air Compressor safety Warnings  
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.  
b.do not use the compressor if the  
switch does not turn it on and off.  
Any compressor that cannot be con-  
trolled with the switch is dangerous  
and must be repaired.  
c.disconnect the plug from the  
power source of the compressor  
before making any adjustments,  
changing accessories, or stor-  
ing compressors. Such preventive  
safety measures reduce the risk of  
starting the compressor accidentally.  
2. Risk of bursting - do not adjust  
regulator to result in output pressure  
greater than marked maximum pres-  
sure of attachment.  
d.store idle compressors out of the  
reach of children and do not allow  
persons unfamiliar with the com-  
pressor or these instructions to  
operate it. Compressors are danger-  
ous in the hands of untrained users.  
3. Risk of injury - do not direct air  
stream at body. To reduce the risk of  
electric shock, do not expose to rain.  
Store indoors.  
e.Maintain compressors. Check for  
misalignment or binding of moving  
parts, breakage of parts and any  
other condition that may affect the  
compressor’s operation. if dam-  
aged, have the compressor re-  
paired before use. Many accidents  
are caused by poorly maintained  
compressors.  
4. Do not use to supply breathing air.  
5. Do not direct air flow from the Com-  
pressor at people or animals.  
6. Industrial applications must follow  
OSHA requirements.  
7. Maintain labels and nameplates on  
the compressor. These carry impor-  
tant safety information. If unreadable  
or missing, contact Harbor Freight  
Compressors for a replacement.  
f. use the compressor in accordance  
with these instructions, taking into  
account the working conditions  
and the work to be performed. Use  
of the compressor for operations  
different from those intended could  
result in a hazardous situation.  
8. Avoid unintentional starting. Prepare  
to begin work before turning on the  
compressor.  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 4  
 
9. This product is not a toy. Keep it out  
of reach of children.  
those dust masks that are specially  
designed to filter out microscopic  
particles. (California Health & Safety  
Code § 25249.5, et seq.)  
10. WARNING: The brass components  
of this product contain lead, a chemi-  
cal known to the State of California  
to cause birth defects (or other repro-  
ductive harm). (California Health &  
Safety code § 25249.5, et seq.)  
13. WARNING: Handling the cord on  
this product will expose you to lead,  
a chemical known to the State of  
California to cause cancer, and birth  
defects or other reproductive harm.  
Wash hands after handling. (Califor-  
nia Health & Safety Code § 25249.5,  
et seq.)  
11. People with pacemakers should  
consult their physician(s) before use.  
Electromagnetic fields in close prox-  
imity to heart pacemaker could cause  
pacemaker interference or pacemak- 14. The warnings, precautions, and in-  
er failure. In addition, people with  
pacemakers should:  
• Avoid operating alone.  
• Do not use with power switch locked  
on.  
• Properly maintain and inspect to  
avoid electrical shock.  
• Any power cord must be properly  
grounded. Ground Fault Circuit Inter-  
rupter (GFCI) should also be imple-  
mented – it prevents sustained elec-  
trical shock.  
structions discussed in this instruction  
manual cannot cover all possible con-  
ditions 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.  
12. Some dust created by power sand-  
ing, sawing, grinding, drilling, and  
other construction activities, contains  
chemicals known [to the State of Cali-  
fornia] to cause cancer, birth defects  
or other reproductive harm. Some  
examples of these chemicals are:  
• Lead from lead-based paints  
• Crystalline silica from bricks and ce-  
ment or other masonry products  
• Arsenic and chromium from chemi-  
cally treated lumber  
Your risk from these exposures var-  
ies, depending on how often you do  
this type of work. To reduce your  
exposure to these chemicals: work in  
a well ventilated area, and work with  
approved safety equipment, such as  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
instructions are not completely under-  
stood, or if in doubt as to whether the  
compressor is properly grounded.  
gROunding instRuCtiOns  
tO PReVent  
eleCtRiC sHOCK  
and deatH FROM  
inCORReCt gROunding  
WiRe COnneCtiOn  
Read and FOllOW tHese  
instRuCtiOns:  
5. Use only 3-wire extension cords that  
have 3-prong grounding plugs and  
3-pole receptacles that accept the  
compressor’s plug.  
6. Repair or replace damaged or worn  
cord immediately.  
grounded Compressors:  
Compressors with three Prong  
Plugs  
1. In the event of a malfunction or  
breakdown, grounding provides a  
path of least resistance for electric  
current to reduce the risk of electric  
shock. This compressor is equipped  
with an electric cord having an  
equipment-grounding conductor and  
a grounding plug. The plug must be  
plugged into a matching outlet that  
is properly installed and grounded in  
accordance with all local codes and  
ordinances.  
7. This compressor is intended for use  
on a circuit that has an outlet that  
looks like the one illustrated above  
in 125 V~ 3-Prong Plug and Outlet.  
The compressor has a grounding  
plug that looks like the plug illustrated  
above in 125 V~ 3-Prong Plug and  
Outlet.  
2. Do not modify the plug provided – if it  
will not fit the outlet, have the proper  
outlet installed by a qualified electri-  
cian.  
8. The outlet must be properly installed  
and grounded in accordance with all  
codes and ordinances.  
3. Improper connection of the equip-  
ment-grounding conductor can re-  
sult in a risk of electric shock. The  
conductor with insulation having an  
outer surface that is green with or  
without yellow stripes is the equip-  
ment-grounding conductor. If repair  
or replacement of the electric cord or  
plug is necessary, do not connect the  
equipment-grounding conductor to a  
live terminal.  
9. Do not use an adapter to connect this  
compressor to a different outlet.  
4. Check with a qualified electrician or  
service personnel if the grounding  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 6  
 
double insulated Compressors:  
Compressors with two Prong  
Plugs  
sPeCiFiCatiOns  
Electrical  
Requirements  
120 V~ / 60 Hz / 210 W  
(Load) / 4.5 A (Start Up) /  
6.25 A (Peak)  
Three Prong Plug  
Air Tank Capacity 3 Gallons  
Pressure Range 70-100 PSI  
Air Flow Capacity .5 CFM @ 90 PSI / .7 CFM  
@ 40 PSI  
Accessories  
25’ Coil Air Hose / Air Chuck  
unPaCKing  
When unpacking, make sure that the  
item is intact and undamaged. If any parts  
are missing or broken, please call Harbor  
Freight Tools at the number shown on the  
cover of this manual as soon as possible.  
1. To reduce the risk of electric shock,  
double insulated equipment has a po-  
larized plug (one blade is wider than  
the other). This plug will fit in a polar-  
ized outlet only one way. If the plug  
does not fit fully in the outlet, reverse  
the plug. If it still does not fit, contact  
a qualified electrician to install the  
proper outlet. Do not change the plug  
in any way.  
2. Double insulated compressors may  
be used in either of the 120 volt  
outlets shown in the preceding illus-  
tration. (see Outlets for 2-Prong  
Plug.)  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
tOOl  
PRessuRe  
gauge  
(2a)  
air line  
Connection  
Point  
tOOl  
tanK  
(14)  
POWeR  
sWitCH  
(19)  
PRessuRe  
RegulatOR  
(6)  
tanK  
PRessuRe  
gauge  
(2)  
saFetY  
ValVe  
(3)  
dRain  
(9)  
note: For additional information regarding  
the parts listed in the following pages,  
refer to the Assembly Diagram near  
the end of this manual.  
PROduCt OVeRVieW  
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.  
Prior to using the Air Compressor,  
make sure to familiarize yourself with its  
basic features and methods of operation  
as described in this section:  
tO PReVent  
seRiOus injuRY  
FROM aCCidental  
1. Power switch (19): The Power  
Switch turns the Air Compressor ON  
and OFF. When the Power Switch  
is in its ON position it allows the Air  
Compressor to automatically start up  
or shut down depending on the level  
of compressed air in the Air Com-  
pressor’s Tank (14).  
OPeRatiOn:  
turn the Power switch of the  
compressor to its “OFF”  
position and unplug the  
compressor from its electrical  
outlet before assembling or  
making any adjustments to  
the compressor.  
2. safety Valve (3): If the Air Compres-  
sor does not automatically shut down  
when the air pressure reaches the  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 8  
 
factory preset level, the Safety Valve  
will automatically pop open to prevent  
over pressurization in the Tank (14).  
To operate the Safety Valve manually,  
pull the ring on the Safety Valve to  
relieve air pressure in the Tank.  
3. tank Pressure gauge (2): The Tank  
Pressure Gauge measures the air  
pressure stored in the Tank (14), and  
is not adjustable by the operator.  
4. tool Pressure gauge (2a): The Tool  
Pressure Gauge measures the air  
pressure being supplied to the tool  
being used.  
5. tool Pressure Regulator (6): The  
Tool Pressure Regulator allows you to  
adjust the air pressure (0 to 120 PSI)  
being supplied to the tool being used.  
Turn the Tool Pressure Regulator  
clockwise to increase the air pressure  
to the tool, and counterclockwise to  
decrease the air pressure.  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
9. the air Compressor is now ready  
to use. When finished using the Air  
Compressor, turn the Power Switch  
(19) to its OFF or O position. Then,  
unplug the Air Compressor from its  
electrical outlet.  
OPeRating instRuCtiOns  
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.  
10. Turn the Tool Pressure Regulator  
(6) counterclockwise until it is fully  
closed.  
1. Close the Drain (9) completely.  
2. Turn the Tool Pressure Regulator  
(6) counterclockwise until it is fully  
closed.  
11. Pull the ring on the Safety Valve (3)  
to relieve all remaining air pressure in  
the Tank.  
3. Pull the ring on the Safety Valve (3)  
to check that it operates properly.  
12. Activate the tool in a safe manner  
to release air pressure from the air  
hose. Then, disconnect the air hose  
from the tool, and store the compres-  
sor in a safe, dry location.  
4. Attach the Air Hose (20) to the air  
outlet on the Regulator (6). Connect  
the other end of the air hose to the air  
inlet of the tool. Other components,  
such as a connector and quick cou-  
pler, will make operation more effi-  
cient, but are not required.  
note: If inflating tires or other objects,  
connect the Air Hose (20) to the Infla-  
tion Chuck (21). Do not overinflate  
any object.  
5. Plug the Power Cord/Plug (7) into the  
nearest 120 volt, grounded, electrical  
outlet.  
6. Turn the Power Switch (19) to its  
|
autO or position.  
7. Observe the Tank Pressure Gauge  
(2), and allow the air pressure in the  
Tank (14) to build up to 70 Psi.  
8. Observe the Tool Pressure Gauge  
(2A), while turning the Tool Pressure  
Regulator clockwise to increase pres-  
sure up to the desired level.  
WaRning! do not exceed the tools  
maximum air pressure.  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 10  
 
Open the Drain (9) on the bottom of  
the Tank, and tilt the Tank to allow the  
moisture to drain. Then, make sure  
to fully close the Drain.  
MaintenanCe and  
seRViCing  
Procedures not specifically  
explained in this manual  
must be performed only by a  
qualified technician.  
3. tO Clean: Use a clean cloth and  
mild detergent to clean the body  
of the Air Compressor. Do not use  
solvents. Do not immerse any part of  
the Air Compressor in liquid.  
tO PReVent  
seRiOus injuRY  
FROM aCCidental  
OPeRatiOn:  
4.  
WaRning! if the supply cord of  
this power tool is damaged, it must  
be replaced only by a qualified  
service technician.  
turn the Power switch of the  
compressor to its “OFF”  
position and unplug the  
compressor from its electrical  
outlet before performing any  
inspection, maintenance, or  
cleaning procedures.  
tO PReVent seRiOus  
injuRY FROM COMPRessOR  
FailuRe:  
do not use damaged  
equipment. if abnormal noise  
or vibration occurs, have the  
problem corrected before  
further use.  
1. BeFORe eaCH use, inspect the  
general condition of the Air Compres-  
sor. Check for loose screws, mis-  
alignment or binding of moving parts,  
damaged electrical wiring, Tank, air  
hoses/accessories (not included),  
and any other condition that may af-  
fect its safe operation.  
2. at end OF eaCH WORKdaY:  
Condensation will accumulate inside  
the Tank (14). To prevent corrosion  
inside the Tank, the moisture should  
be drained at the end of each work-  
day. To drain the moisture, Pull the  
ring on the Safety Valve (3) to relieve  
all remaining air pressure in the Tank.  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 11  
 
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.  
PaRts list  
PaRts list  
Part  
description  
Qty.  
Part  
11  
description  
Qty.  
1
2
Shroud w/Handle  
1
1
1
1
1
2
1
1
1
1
4
Circuit Board  
1
1
1
1
2
2
1
8
1
1
1
Tank Pressure Gauge  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
Pressure Switch  
Pump Assembly  
Tank  
Connector (1/8”-27 NPT)  
Connection Nut  
Copper Vent Tube  
Screw  
Power Switch  
25’ Air Hose (Not Shown)  
Inflation Chuck (Not Shown)  
2A Tool Pressure Gauge  
3
4
5
6
7
8
9
10  
Safety Valve  
Air Line Outlet  
Connector  
Tool Pressure Regulator  
Power Cord/Plug  
Fan  
Drain  
Rubber Foot  
SKU 90168  
For technical questions, please call 1-800-444-3353.  
Page 12  
 
asseMBlY diagRaM  
2
1
3
2a  
6
19  
18  
4
5
5
15  
13  
8
air line  
Connection  
Point  
17  
16  
15  
7
11  
12  
14  
9
10  
10  
Parts 20 and 21 - Air Hose and Inflation Chuck - not shown.  
Record Products 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 90168  
For technical questions, please call 1-800-444-3353.  
Page 13  
 
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 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 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 90168  
For technical questions, please call 1-800-444-3353.  
Page 14  
 

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