Merlin 58547 Assembly instructions

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Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the 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. 21e
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright©2021 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 ma y n o t b e i n c l u d e d .
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the 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.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright©2021 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.
Too l s r e q u i r e d f o r a s s e m b l y a n d s ervice ma y n o t b e i n c l u d e d .
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

Page 2 For technical questions, please call 1-888-866-5797. Item 58547
SAFETY OPERATION MAINTENANCESETUP
Table of Contents
Safety ......................................................... 2
Specifications ............................................. 4
Setup .......................................................... 5
Operation.................................................... 8
Maintenance............................................... 8
Parts List and Diagram.............................. 10
Warranty .................................................... 12
WARNING SYMBOLS AND DEFINITIONS
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.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INSTRUCTIONS
General Safety Warnings
WARNING Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The warnings, precautions, and instructions discussed in this instruction 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.
1. Work area safety
a. Keep work area clean and well lit.
Cluttered or dark areas invite accidents.
b. Keep children and bystanders away
from an operating Filter/Regulator.
2. Personal safety
a. Stay alert, watch what you are doing and use
common sense when operating this
Filter/Regulator. Do not use this
Filter/Regulator while you are tired or under
the influence of drugs, alcohol or medication.
A moment of inattention while operating a
Filter/Regulator may result in
serious personal injury.
b. Use personal protective equipment.
Always wear ANSI-approved eye
protection during setup and use.

Page 3For technical questions, please call 1-888-866-5797.Item 58547
SAFETYOPERATIONMAINTENANCE SETUP
3. Filter/Regulator use and care
a. Store an idle Filter/Regulator out of the
reach of children and do not allow persons
unfamiliar with the Filter/Regulator or
these instructions to operate it.
b. Maintain the Filter/Regulator. Keep the
Filter/Regulator clean for better and safer
performance. Follow instructions for
lubricating and changing accessories.
Keep dry, clean and free from oil and grease.
Check for misalignment or binding of moving
parts, breakage of parts and any other
condition that may affect the
Filter/Regulator’s operation. If damaged,
have the Filter/Regulator repaired before use.
c. Use the Filter/Regulator in accordance with
these instructions, taking into account
the working conditions and the work to
be performed. Use of the Filter/Regulator
for operations different from those intended
could result in a hazardous situation.
4. Service
a. Have your Filter/Regulator serviced by a
qualified repair person using only identical
replacement parts. This will ensure that the
safety of the Filter/Regulator is maintained.
Air Filter/Regulator Safety Warnings
1. Risk of bursting - do not adjust Filter/Regulator
higher than marked maximum
pressure of attachment.
2. Risk of injury - do not direct air
stream at people or animals.
3. Do not use to supply breathing air.
4. Keep Filter/Regulator well-ventilated.
Do not cover Filter/Regulator during use.
5. Drain Air Filter daily and after use.
Internal rust causes tank failure and explosion.
6. Do not remove the valve cover or
adjust internal components.
7. Do not use the air hose to move the Filter/Regulator.
8. The use of accessories or attachments not
recommended by the manufacturer may
result in a risk of injury to persons.
9. All air line components, including hoses, pipe,
connectors, filters, etc., must be rated for a minimum
working pressure of 200 PSI, or 150% of the
maximum system pressure, whichever is greater.
10. Industrial applications must follow OSHA guidelines.
11. Maintain labels and nameplates on the
Filter/Regulator. These carry important safety
information. If unreadable or missing, contact
Harbor Freight Tools for a replacement.
12. This product is not a toy.
Keep it out of reach of children.
13. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields in
close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
SAVE THESE INSTRUCTIONS.

Page 4 For technical questions, please call 1-888-866-5797. Item 58547
SAFETY OPERATION MAINTENANCESETUP
Specifications
Operating Pressure 0 -200 PSI
Max Temperature 150° F (regulator)
Air Inlet and Outlet Size
Inlet: 1/2" -14 NPT (female thread)
Outlet: 1/4"-18 NPT (male thread)
Features Replaceable air filter element
Filter 5 micron, for particles and water
Installation
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 Diagram near the end of this manual.
Note: This air tool may be shipped with protective plugs covering the air ports. Remove these plugs before set up.
TO PREVENT SERIOUS INJURY FROM EXPLOSION:
Use only clean, dry, regulated, compressed air to power this tool.
Do not use oxygen, carbon dioxide, combustible gases,
or any other bottled gas as a power source for this tool.
Functions
Regulator
Handle
Regulator
Air Outlet
Tank
Gauge
Filter/Regulator Valve
Air Inlet
Shut Off Valve

Page 5For technical questions, please call 1-888-866-5797.Item 58547
SAFETYOPERATIONMAINTENANCE SETUP
Installation
Regulator
Handle
Regulator
1. Thread the Regulator Handle into the
Filter/Regulator only a couple of turns.
Do not tighten it. Tightening it will set
the Filter/Regulator to high pressure,
possibly causing property damage when
first connecting the air supply.
2. Incorporate an in-line shutoff valve, and quick
coupler for best service, as shown on Figure A on
page 6 and Figure B on page 7. An in-line
shutoff ball valve is an important safety device
because it controls the air supply even if the air
hose is ruptured. The shutoff valve should be
a ball valve because it can be closed quickly.
Note: Wrap all threaded connectors before
connecting them with pipe thread seal
tape (PTFE) to prevent leaking.
3. Attach an air hose to the compressor’s air outlet.
Connect the air hose to the Air Inlet of the unit.
Note: Air flow, and therefore tool performance,
can be hindered by undersized air supply components.
4. Close the in-line shutoff valve between
the compressor and the tool.
5. Turn on the air compressor according to
the manufacturer’s directions and allow it
to build up pressure until it cycles off.
6. Inspect the air connections for leaks.
Repair any leaks found.
Air Connection Setup
1. Connect the Filter/Regulator, an in line shut
off valve and a 1/4″NPT air hose to the
Compressor’s Quick Coupler as outlined in
Step #3 of Installation. Next, add an air hose
from the outlet of the Filter/Regulator to the air
tool in the work area. The air hose must be long
enough to reach the work area with enough extra
length to allow free movement while working.
Note: An in-line shutoff ball valve is an important
safety device because it controls the air supply even
if the air hose is ruptured. The shutoff valve should
be a ball valve because it can be closed quickly.
2. Depending on the tool that will be used with this
Filter/Regulator, incorporate additional components,
such as an in-line oiler, a filter, or a dryer
(all sold separately), as shown on
Figure A on page 6 and Figure B on page 7.
Consult air tool’s manual for needed accessories.

Page 6 For technical questions, please call 1-888-866-5797. Item 58547
SAFETY OPERATION MAINTENANCESETUP
Figure A: Portable Air Supply Setup
G
A
E
E
H
F
B
Non-lubricated Tools Lubricated Tools
A
B
C
C
DA
Description Function
A Air Hose Connects air to tool B Filter Prevents dirt and condensation from damaging tool or workpiece
C Regulator Adjusts air pressure to tool D Lubricator (optional) For air tool lubrication
E Coupler and Plug Provides quick connection and release
F Leader Hose (optional) Increases coupler life
G Air Cleaner / Dryer (optional) Prevents water vapor from damaging workpiece
H Air Adjusting Valve (optional) For fine tuning airflow at tool

Page 7For technical questions, please call 1-888-866-5797.Item 58547
SAFETYOPERATIONMAINTENANCE SETUP
Figure B: Stationary Air Supply Setup
N
L
L O
M
C C
Non-lubricated Tools
Lubricated Tools
H
I
I
J
JKH
F
G
E
Slope
F
F
B
B
A
A
CD
Description Function
A Vibration Pads For noise and vibration reduction B Anchor Bolts Secures air compressor in place
C Ball Valve Isolates sections of system for maintenance D Isolation Hose For vibration reduction
E Main Air Line - 3/4″minimum recommended Distributes air to branch lines
F Ball Valve To drain moisture from system
G Branch Air Line -1/2″minimum recommended Brings air to point of use
H Air Hose Connects air to tool
I Filter Prevents dirt and condensation from damaging tool or workpiece
J Regulator Adjusts air pressure to tool
K Lubricator (optional) For air tool lubrication
L Coupler and Plug Provides quick connection and release
M Leader Hose (optional) Increases coupler life
N Air Cleaner / Dryer (optional) Prevents water vapor from damaging workpiece
O Air Adjusting Valve (optional) For fine tuning airflow at tool

Page 8 For technical questions, please call 1-888-866-5797. Item 58547
SAFETY OPERATION MAINTENANCESETUP
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.
Filter/Regulator Area Set Up
Designate a work area that is clean and well-lit.
The work area must not allow access by
children or pets to prevent injury.
General Operation
Note: At the beginning of the day’s first use of the
Filter/Regulator, check for air leaks by applying soapy
water to connections while the Filter/Regulator
is pumping and after pressure cut-out.
Look for air bubbles. If air bubbles are present at
connections, tighten connections. Do not use the
Filter/Regulator unless all connections are air tight,
the extra air leaking out will cause the regulator to
operate too often, increasing wear on the regulator.
WARNING! TO PREVENT SERIOUS
INJURY AND DEATH FROM
EXPLOSION:
Do not exceed 200 PSI
1. Adjust the Regulator Handle so that the air output
is enough to properly power the tool, but the output
will not exceed the tool’s maximum air pressure
at any time. Turn the knob clockwise to increase
the pressure and counter-clockwise to decrease
pressure. Adjust the pressure gradually, while
checking the air output gauge to set the pressure.
2. Connector air hose to tool’s Air Outlet.
3. Make sure the air tool’s throttle or switch is in the
off position. Connect the air tool to the air hose.
4. Open the in-line Shutoff Valve.
5. Use the air tool as needed.
6. After the job is complete, turn the
compressor’s Power Switch OFF.
7. Disconnect the Filter/Regulator.
8. Close the in-line Shutoff Valve.
9. Bleed air from the tool then disconnect the tool.
10. Drain the Filter/Regulator of water daily. With the
unit under pressure, open the Drain Plug to expel
any accumulated moisture from the Air Filter.
11. Clean, then store the Filter/Regulator indoors.
Maintenance and Servicing
Procedures not specifically explained in this manual must
be performed only by a qualified technician.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch “OFF” and unplug the Filter/Regulator from its electrical outlet
before performing any inspection, maintenance, or cleaning procedures.
TO PREVENT SERIOUS INJURY FROM FILTER/REGULATOR FAILURE:
Do not use damaged equipment. If abnormal noise or vibration occurs,
have the problem corrected before further use.

Page 9For technical questions, please call 1-888-866-5797.Item 58547
SAFETYOPERATIONMAINTENANCE SETUP
Cleaning, Maintenance, and Lubrication
1. BEFORE EACH USE, inspect the general
condition of the Filter/Regulator. Check for:
• loose hardware,
• misalignment or binding of moving parts,
• cracked or broken parts,
• damaged electrical wiring, and
• any other condition that may
affect its safe operation.
2. AFTER USE, wipe external surfaces of
the Filter/Regulator with a clean cloth.
3. WARNING! TO PREVENT SERIOUS INJURY:
If the supply cord of this Filter/Regulator
is damaged, it must be replaced only
by a qualified service technician.
Maintenance Schedule
Following are general guidelines for maintenance checks of the Filter/Regulator.
Note: The environment in which the Filter/Regulator is used, and the frequency of use will affect how
often you will need to check the Filter/Regulator components and perform maintenance procedures.
Daily:
a. Make sure all nuts and bolts are tight.
b. Drain moisture from air tank.
c. Check for abnormal noise or vibration.
d. Check for air leaks.
• To check for air leaks, apply soapy water
to joints while the Filter/Regulator is
pressurized. Look for air bubbles.
e. Wipe off any oil or dirt from the Filter/Regulator.
• To clean the Filter/Regulator surface,
wipe with a damp cloth, using a
mild detergent or mild solvent.
Weekly:
Inspect Air Filter.
Quarterly (every 3 months):
Tool Disassembly, Cleaning, and Inspection:
Have the internal mechanism cleaned, inspected,
and lubricated by a qualified technician.
Air Filter Maintenance
Check the Air Filter weekly to see if it needs replacement. Replace the filter
more often if Filter/Regulator is used in dirty environments.
Periodically remove the Filter, rinse it out with water and put it back in.
1. To access the Air Filter:
a. Loosen the bottom Filter/Regulator Valve
until pressure is at zero.
b. Remove all four screws from the Bottle Lid.
c. Pull off the Tank, exposing the Filter Assembly.
d. Disassemble the Filter Assembly
using figure to the right as reference.
Keep track of assembly order.
2. Remove the Filter.
3. Check that the Washer and Shield are in
place, and replace with a new Filter.
4. Reassemble Filter Assembly according
to assembly order shown.
5. Place Retainer back on Rod Assembly and
Filter. Thread on bottom Nut and tighten.
Note: Retainer must be tight against the Filter.
If it is loose, the Filter will not function.
6. Use the four screws to reconnect the
Bottle Lid. Tighten screws.
Note: Rubber Seals on Nuts and Tank must
be in good condition before reassembly.
7. Reconnect Filter/Regulator Valve.
Tighten to repressurize.
Filter/Regulator
Valve
Nut
Filter
Washer
Gasket
Bottle Lid
Screws
Retainer
Shield
Rod Assembly

Page 10 For technical questions, please call 1-888-866-5797. Item 58547
SAFETY OPERATION MAINTENANCESETUP
Parts List and Diagram
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
Part Description Qty
1 Tank 1
2 Bottle Lid 1
3 Washer 1
4 Shield 1
5 Filter 1
6 Retainer 1
7 Rod Assembly 1
8 Nut 1
9 Air Body 1
10 Valve Spring 1
11 Valve 1
12 Valve Seat 1
13 Valve Body 1
14 Gasket 1
15 Screw 1
16 Gasket 1
Part Description Qty
17 Nut 1
18 Pressure Spring 1
19 Washer 1
20 Regulator 1
21 Pressure Gauge 1
22 Regulator Handle 1
23 Shut Off Valve/Air Outlet 1
24 Plug 1
25 Plug 1
26 Elbow 1
27 Screw 4
28 Screw 4
29 Male Connector 1
30 Filter/Regulator Valve 1
31 Gasket 1
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 available
individually as replacement parts. Specify UPC 193175441348 when ordering parts.

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SAFETYOPERATIONMAINTENANCE SETUP
Diagram
22 27
20 19
18
17
16
15
14
13
12
11
10
21
24
23
9
26
29
28
2
25
31
7
3
4
5
6
8
1
30

Limited 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 this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, 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 limitation 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 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 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.
26541 Agoura Road • Calabasas, CA 91302 • 1-888-866-5797