U.S. General 93039 User manual

®
DIESEL ENGINE COMPRESSION
TESTER SET
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit ourWeb site at http://www.harborfreight.com
Copyright©2005 by Harbor FreightTools®. 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 consentofHarborFreightTools.
For technical questions and replacement parts, please call 1-800-444-3353.
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.
OPERATING INSTRUCTIONS
93039

Page 2SKU 93039 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS TABLE
SAVE THIS MANUAL
You will needthis manual for thesafety warnings andprecautions,applications
instructions,inspection,maintenance,and cleaning procedures. Keep your invoice
with this manual. Write the invoice number on the inside of the front cover. Keep this
manual and invoice in a safe and dry place for future reference.
GENERAL SAFETY WARNINGS AND PRECAUTIONS
1. KEEPWORK AREA CLEAN AND DRY. Cluttered, damp or wet work areas invite
injuries.
2. KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handle
thisproduct.
3. STORE IDLE EQUIPMENT. Whennotin use,toolsand equipmentshouldbe stored
in a dry location to inhibit rust. Always lock up tools and equipment and keep out of
reach of children.
4. DO NOT USE THIS PRODUCT IF UNDER THE INFLUENCE OF ALCOHOL OR
DRUGS. Read warning labels on prescriptions to determine if your judgment or
reflexesare impaired while taking drugs. Ifthere is any doubt,donot attempt to use
thisproduct.
5. USE EYE PROTECTION. Wear ANSI approved safety impact goggles when using
thisproduct.
6. DRESS SAFELY. Nonskid footwear or safety shoes should be used when working
with this product. Do not wear loose clothing or jewelry as they can become caught
inmovingparts. Wear aprotectivehair covering to prevent long hair from becoming
caught in moving parts.
7. INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.
8. DO NOT OVERREACH. Keep proper footing and balance at all times to prevent
tripping, falling, back injury, etcetera.
9. 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. 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. Replace or
repair damaged or worn parts immediately.
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Page 3SKU 93039 For technical questions, please call 1-800-444-3353.
UNPACKING
Whenunpacking,checktomake surethe partslisted onthe next pageof thismanual
are included. 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.
11. REPLACEMENT PARTS AND ACCESSORIES. Whenservicing,use onlyidentical
replacement parts. Only use accessories intended for use with this product.
Approved accessories are available from Harbor Freight Tools.
12. MAINTAIN THIS PRODUCT WITH CARE. Keep this tool clean and dry for better
andsaferperformance.
13. MAINTENANCE: For your safety, service and maintenance should be performed
regularly by a qualified technician.
14. USETHE RIGHT PRODUCT FORTHE RIGHT JOB. There arecertain applications
forwhichthisproductwasdesigned. Donot usesmallequipment,toolsorattachment
to do the work of larger industrial equipment, tools or attachments. Do not use this
product for a purpose for which it was not intended.NOT FOR OXYGEN SERVICE
USE.
15. PRIOR TO USING THIS PRODUCT, READ AND ADHERE TO ALL
INSTRUCTIONS AND SAFETY PRECAUTIONS AS OUTLINED INTHEVEHICLE
MANUFACTURER’S MANUAL AND ENGINE DIAGNOSTIC/REPAIR MANUALS.
16. ALWAYS RELEASE THE PRESSURE PROPERLY USING THE PRESSURE
RELEASE VALVE (see page 4) BEFORE DISCONNECTING THE ADAPTER.
17. USE EXTREME CARE AROUND HOT OR MOVING ENGINE PARTS.
18. DO NOT EXCEEDTHE MAXIMUM PRESSURE CAPACITY OFTHISTOOL (1,000
PSI /70 BAR). Exceeding the maximum pressure capacity could cause serious
personal injury and/or property damage.
19. USE THE COMPRESSION TESTER ONLY IN WELL VENTILATED AREAS. A
running engine produces carbon monoxide. Carbon monoxide is a colorless,
odorless, gas that, if inhaled, can cause serious injury or death.
20. WHEN WARMING UP AN ENGINE IN PREPARATION FOR COMPRESSION
TESTING, MAKE SURE THE VEHICLE’S TRANSMISSION IS PLACED IN
“PARK”, (OR NEUTRAL FOR A MANUAL TRANSMISSION) AND THE
EMERGENCY BRAKE IS APPLIED.
21. WARNING: The brass components of this product contain lead, 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. )

Page 4SKU 93039 For technical questions, please call 1-800-444-3353.
PARTS LIST / ASSEMBLY DIAGRAM
NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts.
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Pressure
Release
Valve

Page 5SKU 93039 For technical questions, please call 1-800-444-3353.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A
REFERENCETOOL ONLY. NEITHERTHEMANUFACTURERNORDISTRIBUTOR MAKESANYREPRESENTATION
ORWARRANTYOFANYKINDTOTHEBUYERTHAT HE OR SHE IS QUALIFIEDTOMAKE ANY REPAIRSTOTHE
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 TOTHE
ORIGINALPRODUCTOR REPLACEMENT PARTSTHERETO,OR ARISING OUT OF HIS OR HER INSTALLATION
OF REPLACEMENT PARTS THERETO.
PRODUCT OVERVIEW
The Engine CompressionTest Set measures cylinder pressure on diesel-equipped
cars and trucks. The Gauge (1) features a release valve, 16” of high pressure hose, a dial
reading from 0-1,000 PSI, a 0-70 bar, and a quick coupler for convenient connection to the
Adapters(2-5).
ADAPTER CONNECTION/REMOVAL
1. Pull the collar at the end of the Coupler (1) away from the opening of the
hose and insert the end of the correct Adapter (2-5) for your application.
2. Let go of the collar and press the Adapter into the Coupler until the collar
movesforward.
3. Pullonthe Adapter(2-5) to ensurethat itisproperly connectedto theCoupler.
The Adapter is ready for use.
4. After use, release all pressure in the tool using the pressure release valve
(see page 4) and remove the Adapter (2-5) from the engine. Carefully clean
the Adapter and Gauge Assembly (1). Pull the collar back and remove the
Adapter. Store all parts in the provided case.
Adapter(3) Hose
and
Coupler
(1)
collar

Page 6SKU 93039 For technical questions, please call 1-800-444-3353.
INSPECTION, MAINTENANCE, AND CLEANING
1. Before each use, inspect the general condition of the CompressionTester. Check
for broken, cracked, or bent parts, loose or missing parts, and any condition that
mayaffecttheproperoperation ofthe product. Ifaproblemoccurs,have theproblem
corrected before further use.
Do not use damaged equipment.
2. When cleaning, use a clean cloth with a mild detergent. Do not use solvents, as
damage to the Compression Tester may result. Do not immerse the Gauge (1) in
any liquid. Then,storethe CompressionTesterinside thecase in asafe,drylocation
out of reach of children.
3. WARNING! All maintenance, service, or repairs not listed in this manual are
only to be attempted by a qualified service technician.
TESTING PROCEDURES
Due to the variations in engine design and testing
procedure, it is beyond the scope of this manual to cover
all possible testing procedures.
ALWAYS REFER TO AND CAREFULLY ADHERE TO THE
APPROPRIATE ENGINE MANUFACTURER’S
INSTRUCTIONS FOR USING THIS KIT.