Harbor Freight Tools Diesel Engine Compression Tester 20 Pc Product manual

Diesel Engine Compression Tester
Item 93644
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
When unpacking, make sure that the product is intact and undamaged.
If any parts are missing or broken, please call 1-800-444-3353 as soon as possible.
Visit our website at: http://www.harborfreight.com
Copyright© 2011 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.
Manual Revised 11g
Save This Manual
Specifications
Pressure
Scale
Gauge
Accuracy
Air Release
Type
0-1000 PSI / 0-7000 kPa
± 2%
Push Button
Hose Size
15/64 IN. I.D. x 35/64 IN. O.D. x 16 IN. L.
Accessories
Carrying Case, 9 adapter configurations
Page 2
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.
For technical questions, please call 1-800-444-3353.
SKU 93644
IMPORTANT SAFETY
INFORMATION
WARNING Read all safety warnings
and instructions. Failure to follow the warnings
and instructions may result in fire and/or
serious injury.
Save all warnings and instructions
for future reference.
1. Stay alert, watch what you are doing and use
common sense when using the tester.
Do not use while you are tired or under the
influence of drugs, alcohol or medication.
A moment of inattention while testing may
result in serious personal injury.
2. Wear ANSI-approved safety goggles and
heavy‑duty work gloves during setup and use.
3. Do not overreach. Keep proper
footing and balance at all times.
4. Dress properly. Do not wear loose clothing or
jewelry. Keep your hair, clothing and gloves
away from hot or moving parts. Loose clothes,
jewelry or long hair can be caught in moving parts.
5. Use as intended only.
6. Store idle testers out of the reach of children
and do not allow persons unfamiliar with the
tester or these instructions to operate it.
7. Maintain the Tester. Check for breakage
of parts and any other condition that may
affect the tester’s operation. If damaged,
have the tester repaired before use.
8. Have your tester serviced by a qualified
repair person using only identical
replacement parts. This will ensure that
the safety of the tester is maintained.
9. Maintain labels and nameplates on the tester.
These carry important safety information.
If unreadable or missing, contact Harbor
Freight Tools for a replacement.
10. Do not exceed 1000 PSI maximum pressure.
11. Use the Tester only in well-ventilated areas.
A running engine produces carbon monoxide.
Carbon monoxide is a colorless, orderless, gas
that, if inhaled, can cause serious injury or death.
12. Before testing, place the transmission in park
(or neutral for a manual transmission)
and set the emergency brake.
13. Keep hands and fingers away from moving
parts and hot parts of vehicle’s engine.
14. This product is not a toy.
Keep it out of reach of children.
15. WARNING: The brass components of this product
contain lead, a chemical known to the State of
California to cause birth defects
(or other reproductive harm).
(California Health & Safety code § 25249.5, et seq.)
16. 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.
SAVE THESE
INSTRUCTIONS.
SKU 93644
For technical questions, please call 1-800-444-3353.
Page 3
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.
TO PREVENT SERIOUS INJURY AND/OR DEATH:
Avoid carbon monoxide poisoning. Do not run an
engine in an enclosed garage or other contained area.
TO PREVENT SERIOUS INJURY:
• Wear appropriate work clothes, heavy-duty
work gloves and ANSI-approved safety goggles
when working on a hot engine. Keep hands
away from the fan and other moving parts
and protect yourself from electrical shock or
burns. Be aware that working on an automotive
or truck engine is inherently dangerous,
and suitable precautions must be taken.
• If you are not experienced in doing this
type of diagnostic test, the work should
be done by a qualified technician.
• Install/remove the Tester only while
the engine is stopped.
Note: Good engine cylinder compression will be
indicated with a high initial reading, and a progressive
buildup to the final maximum reading. Poor engine
cylinder compression will be indicated with a low initial
reading and a much slower buildup to the final maximum
reading. The compression readings for all of the
engine cylinders should not vary by more than 10%.
1. Check that the vehicle’s battery is fully charged.
Securely block the vehicle’s tires, set the parking
brake and the transmission to neutral or park.
Page 4
2. Refer to the Diesel Adapters chart to select
the proper Adapter to be used for the specific
vehicle you will test. After identifying the correct
adapter, assemble it securely as shown on the
Parts List and Assembly Diagram on page 7.
3. Prepare the engine for compression
testing by starting the engine and allowing
it to warm up to its normal operating
temperature. Then, switch off the engine.
4. Once the engine has been turned off, disconnect
the fuel shutdown solenoid (refer to the
engine maintenance manual for location).
5. Remove all of the injectors or all of the glow plugs
(depending on the connector used). They can be
labeled to aid during reassembly. Unless instructed
to do so by the engine manual, do not inject oil
into the cylinders (a “wet” test); the oil may not
compress properly and damage the engine.
6. Connect the Compression Tester to an engine
cylinder. With the fuel pedal depressed completely,
crank the engine for eight revolutions.
Do not continue to crank the engine; the
engine’s starter may overheat, damaging itself.
7. After cranking the engine, record the
reading on the Pressure Gauge (1).
8. Once the maximum reading has been
recorded, release the Gauge (1) pressure by
depressing the Air Release Button (2).
9. Use caution, the engine will be hot! Remove
the Compression Tester from the first cylinder.
10. Repeat steps 6-9 for the remaining cylinders.
11. Reconnect the fuel injection solenoid and
reinstall all glow plugs/injectors.
12. When finished, clean, then store the Tester in
its case, indoors, out of children’s reach.
For technical questions, please call 1-800-444-3353.
SKU 93644
Diesel Adapters
Manufacturer
Audi
Engine
®
Type
Thread
Adapter #
Early models, see VW for TDI
Injector
24 x 2.00
C
®
Mercedes-Benz
Early models
Injector
24 x 2.00
C
VW®
1970’s Rabbit®
Injector
24 x 2.00
C
Volvo®
Early models except 30’s & 40’s
Injector
24 x 2.00
C
2.4L
Glow Plug
12 x 1.25
HU
Chevette /Isuzu ; Luv /
Isuzu®
1.8L, 2.2L
Glow Plug
10 x 1.25
E
Deutz®
Many models
Glow Plug
12 x 1.25
HU
Ford®/Mazda®
(1984-87) 2.0L
(1983-84) 2.2L Escort®, Lynx®,
Ranger®, Tempo®, Topaz®
Glow Plug
10 x 1.25
F
Ford®/Mitsubishi®
(1985-87) Ranger® 2.3L
Glow Plug
10 x 1.25
F
Ford®/Navistar®
6.9L and 7.3L (up to 1994)
Glow Plug
10 x 1.00
A
General Motors®
4.3L V6, 4.3L V8, 5.7L V8
Glow Plug
10 x 1.00
A
Duramax® 6.6L Turbo Diesel
Glow Plug
10 x 1.25
E
Optimizer 6500® V8 Turbo
Glow Plug
10 x 1.25
E
(1992-98) 4HE1-TC
(1998-2005) 6HK1-TC
Glow Plug
10 x 1.25
E
(1998-2005) 4HE1-TC
(Up to 1998) 6HK1-TC
Glow Plug
12 x 1.25
HUIU
Some models
Glow Plug
10 x 1.25
F
Lincoln , Mark VII/
Continental®
2.4L used in 1984-85 autos
Glow Plug
12 x 1.25
H
with Volvo® engines
Glow Plug
10 x 1.25
F
Mercedes-Benz®
(1988-89) 190E 2.5L
Glow Plug
12 x 1.25
IU
(1991-99) E300
Glow Plug
12 x 1.25
HU
2005 E320 CDI
Glow Plug
10 x 1.00
A
2 and 3 cylinder engines
Glow Plug
10 x 1.25
F
Medium
Glow Plug
10 x 1.25
F
6.9L and 7.3L
Glow Plug
10 x 1.00
A
2.2L
Glow Plug
10 x 1.25
F
Medium
Glow Plug
10 x 1.25
F
Most
Glow Plug
12 x 1.25
HU
Certain Models
Glow Plug
18 x 1.50
H
1.8L
Glow Plug
10 x 1.25
E
2.2L
Glow Plug
10 x 1.25
F
(1979-84) Rabbit
(1979-99) Jetta®
(1981-84) Pick-Up
(1987-99) Golf®
(1992-97) Passat®
(1992-98) Eurovan®
Glow Plug
12 x 1.25
HUIU
(1995-97) Passat®
(1997-05) Golf®
(1997-05) Jetta® & Jetta® Wagon
(1998-05) New Beetle®
2004 Touareg®
Glow Plug
10 x 1.00
A
®
BMW®
®
®
®
Hummer®
Isuzu /Isuzu Truck
®
®
Kubota®
®
®
Mitsubishi
®
Mitsubishi-Fuso®
Navistar / International
®
Nissan®/ UD Truck®
Peugeot
Toyota
VW
®
U
®
®
®
®
- Indicates that part 7 must be removed for these applications.
SKU 93644
For technical questions, please call 1-800-444-3353.
Page 5
Maintenance
Procedures not specifically explained
in this manual must be performed
only by a qualified technician.
TO PREVENT SERIOUS INJURY
FROM TOOL FAILURE:
Do not use damaged equipment.
If abnormal noise, vibration, or leaking air occurs,
have the problem corrected before further use.
1. Before each use, inspect the general condition of
the Tester. Check for cracked, worn or damaged
Adapters, damaged Pressure Gauge and Hose, and
any other condition that may affect the tester’s safe
operation. If a problem occurs, have the problem
corrected before further use.
Do not use damaged equipment.
2. To clean, use a damp cloth and a mild detergent.
3. When storing, keep the Tester and components in
a clean, dry, safe location out of reach of children.
Page 6
For technical questions, please call 1-800-444-3353.
SKU 93644
Parts List and Assembly Diagram
Part
Qty
Part
1
Pressure Gauge
Description
1
10
ZG 1/8" (M) Male Quick Coupler
Description
Qty
1
2
Air Release Button
1
11
ZG 1/8" (F)-M24 x 2 (M) Adapter
1
3
Rubber Hose
1
12
Adapter Sleeve
1
4
1/8" NPT Quick Coupler
1
13
Quick Connect with Ball Tip
1
5
7/16"-20 (F) Quick Coupler
3
14
1/2"-19 Lock Nut
1
6
M12 x 1.25 (M)-7/16"-20 (M) Adapter
3
15
7/16"-20 (M)-7/16" x 20 (F) 90° Connector
1
7
M12 x 1.25 (F)-M18 x 1.5 (M) Adapter
2
16
ZG 1/8" (M)-M24 x 1.5 (M) Adapter
1
8
M10 x 1.25 Short Adapter
1
17
M10 x 1 (M) Adapter
1
9
M10 x 1.25 Long Adapter
1
18
Copper Washer
2
Letters designate adapter assemblies.
SKU 93644
For technical questions, please call 1-800-444-3353.
Page 7
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 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 RISKS 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.
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.
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.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353