Campbell Hausfeld HU500000, HU502000, IN633701AV User Manual

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See Warranty on page 10 for important information about commercial use of this product.
Operating Instructions HU500000, HU502000
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.
Oilless Compressors
Description
This residential oilless compressor is designed for do-it-yourselfers with a variety of home and automotive jobs. These compressors power spray guns, impact wrenches and other tools. Compressed air from this unit will contain moisture. Install a water filter or air dryer if application requires dry air.
Unpacking
After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Make sure to tighten fittings, bolts, etc., before putting unit into service. In case of questions, damaged or missing parts, please call 1-800-543-6400 for customer assistance. Have the serial number, model number, and parts list (with missing parts circled) before calling.
DO NOT RETURN
STOP!
Do not operate unit
shipping, handling or use. Damage may result in bursting and cause injury or property damage.
READ & FOLLOW ALL INSTRUCTIONS
THE PRODUCT TO THE RETAILER!
if damaged during
SAVE THESE INSTRUCTIONS
DO NOT DISCARD
Record the Model No., Serial No. and date of purchase in the space below.
Model No. ____________________ Serial No. ____________________ Date of purchase ____________________
Retain these numbers for future reference.
Breathable Air Warning
This compressor / pump is not equipped and should not be used “as is” to supply breathing quality air. For any application of air for human consumption, the air compressor / pump will need to be fitted with suitable in-line safety and alarm equipment. This additional equipment is necessary to properly filter and purify the air to meet minimal specifications for Grade D breathing as described in Compressed Gas Association Commodity Specification G 7.1 - 1966, OSHA 29 CFR 1910.
134, and / or Canadian Standards Associations (CSA).
DISCLAIMER OF WARRANTIES In the event the compressor is used for the purpose of breathing air application and proper in-line safety and alarm equipment is not simultaneously used, existing warranties shall be voided, and the manufacturer disclaims any liability whatsoever for any loss, personal injury or damage.
REMINDER: Keep your dated proof of purchase for warranty purposes!
Attach it to this manual or file it for safekeeping.
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IN633701AV 6/10
Operating Instructions
Safety Guidelines
This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.
Danger indicates
an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
Warning indicates
a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
Caution indicates
a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.
Notice indicates
important information, that if not followed, may cause damage to equipment.
NOTE: Information that requires special attention.
General Safety Information
CALIFORNIA PROPOSITION 65
This product or its
power cord may contain chemicals, including lead, known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
You can
create dust when you cut, sand, drill or grind materials such as wood, paint, metal, concrete, cement, or other masonry. This dust often contains chemicals known to cause cancer, birth defects, or other reproductive harm. Wear protective gear.
GENERAL SAFETY
Since the air compressor and other components (material pump, spray guns, filters, lubricators, hoses, etc.) used, make up a high pressure pumping system, the following safety precautions must be observed at all times:
Do not run
unattended. Leaving compressor in AUTO position may allow it to turn on inadvertently. To prevent this and possible damage from power surge, turn to OFF position after each use.
1. Read all manuals included
with this product carefully.
MANUAL
Be thoroughly familiar with the controls and the proper use of the equipment.
2. Follow all local electrical and safety
codes as well as in the United States, the National Electrical Codes (NEC) and Occupational Safety and Health Act (OSHA).
3. Only persons well acquainted with
these rules of safe operation should be allowed to use the compressor.
4. Keep visitors away and NEVER allow
children in the work area.
5. Wear safety glasses and
use hearing protection when operating the unit.
6. Do not stand on or use the unit as a
handhold.
7. Before each use, inspect compressed
air system and electrical components for signs of damage, deterioration, weakness or leakage. Repair or replace defective items before using.
8. Check all fasteners at frequent
intervals for proper tightness.
Motors,
electrical equipment and controls can cause electrical arcs that will ignite a flammable gas or vapor. Never operate or repair in or near a flammable gas or vapor. Never store flammable liquids or gases in the vicinity of the compressor.
Compressor parts may be hot even if the unit is stopped.
9. Keep fingers away from a running compressor; fast moving and hot parts will cause injury and/ or burns.
10. If the equipment should start to vibrate abnormally, STOP the engine/ motor and check immediately for the cause. Vibration is generally a warning of trouble.
11. To reduce fire hazard, keep engine/motor exterior free of oil, solvent, or excessive grease.
Never remove or
attempt to adjust safety valve. Keep safety valve free from paint and other accumulations.
Never use plastic
(PVC) pipe for compressed air. Serious injury or death could result.
Never
attempt to repair or modify a tank! Welding, drilling or any other modification will weaken the tank resulting in damage from rupture or explosion. Always replace worn, cracked or damaged tanks.
Drain liquid from
tank daily.
12. Tanks rust from moisture build-up,
which weakens the tank. Make sure to drain tank regularly and inspect periodically for unsafe conditions such as rust formation and corrosion.
13. Fast moving air will stir up dust
and debris which may be harmful. Release air slowly when draining moisture or depressurizing the compressor system.
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HU500000, HU502000
General Safety Information (Continued)
SPRAYING PRECAUTIONS
Do not
spray flammable materials in vicinity of open flame or near ignition sources including the compressor unit.
14. Do not smoke when spraying paint,
insecticides, or other flammable substances.
15. Use a face mask /
respirator when spraying and spray in a well ventilated area to prevent health and fire hazards.
16. Do not direct paint or other sprayed
material at the compressor. Locate compressor as far away from the spraying area as possible to minimize overspray accumulation on the compressor.
17. When spraying or cleaning with
solvents or toxic chemicals, follow the instructions provided by the chemical manufacturer.
Assembly
HANDLE ASSEMBLY (Figures 1 and 2)
1. Place ends of handle around tank and into the mounting pipe. Align holes in handle to holes in mounting pipe.
2. Assemble four (4) screws (from parts package) through holes in mounting pipe and handle. Tighten screws.
Never use the
handle to lift the unit completely off the ground. Only use the handle to lift one end so the wheels may be used to move the unit.
Screws
Figure 1 - Handle Assembly (horizontal unit)
WHEEL ASSEMBLY (Figures 3 and 4)
Wheel assembly kit includes:
- 2 wheels *
- 2 axle bolts *
- 2 washers *
- 2 nuts *
- 2 wheel inserts *
The items marked with an asterisk (*) were shipped loose with the unit.
1. Wheel has an offset hub. Place wheel insert into center of hub. With offset hub facing axle iron, assemble axle bolt through washer and then holes in wheel and axle iron.
2. Place lock washer on axle bolt. Then tighten nut securely to threaded part of axle bolt.
3. Repeat procedure with other side.
Axle Iron
Wheel Washer
Nut
Wheel Insert
Axle Bolt
Figure 3 - Wheel Assembly (horizontal unit)
Screws
Figure 2 - Handle Assembly (vertical unit)
3
Axle Iron
Wheel Washer
Nut
Wheel Insert
Axle Bolt
Figure 4 - Wheel Assembly (vertical unit)
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Operating Instructions
Introduction
Refer to Figure 5 to locate the following items.
Pressure Switch - Auto/Off Switch - In the "AUTO" position, the compressor shuts off automatically when tank pressure reaches the maximum preset pressure. In the "OFF" position, the compressor will not operate. This switch should be in the "OFF" position when connecting or disconnecting the power cord from the electrical outlet.
Regulator - The regulator controls the amount of air pressure at the hose outlet.
ASME Safety Valve - This valve automatically releases air if the tank pressure exceeds the preset maximum.
Exhaust Tube - This tube carries compressed air from the pump to the check valve. This tube becomes very hot during use. To avoid the risk of severe burns, never touch the discharge tube.
Check Valve - One-way valve that allows air to enter the tank, but prevents air in the tank from flowing back into the compressor pump.
Handle - Designed to move the compressor.
Never use the
handle on wheeled units to lift the unit completely off the ground.
Drain Valve - This valve is located on the bottom of the tank. Use this valve to drain moisture from the tank daily to reduce the risk of corrosion.
Pressure Gauges - These gauges will show air pressure in the compressor tank and at the compressor outlet.
Outlet Pressure Gauge - Will show air pressure at the outlet in pounds per square inch (psi). Make sure this gauge reads ZERO (by adjusting regulator knob fully counterclockwise) before changing air tools or disconnecting air hose from outlet.
Tank Pressure Gauge - Will show air pressure in tank while the compressor is running, indicating compressor is building pressure properly. This gauge will show maximum pressure of compressor when it shuts off automatically at the pressure switch.
Motor Reset - (not shown, located inside motor). Designed to keep the motor from overheating. The motor has an auto reset protector. To reset once the motor has cooled, turn the pressure switch to the OFF position, then to the AUTO position.
This compressor is
equipped with an overload protector which will shut off motor if it becomes overloaded.
If the overload
protector is actuated, the motor must be allowed to cool down for approximately 30 minutes before it will reset.
Pressure Switch (AUTO / OFF)
Tank Gauge
Check Valve
Handle
Drain Valve
Figure 5 - Unit Identification
Regulator
Safety Valve
Check Valve
Outlet Gauge
Gauge
Pressure Switch
(AUTO / OFF)
Outlet
Tank
Gauge
Regulator
Safety Valve
Handle
Drain Valve
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HU500000, HU502000
Installation
LOCATION
It is extremely important to install the compressor in a clean, dry, and well ventilated area. The compressor must be placed on a firm, level surface where the surrounding air temperature will not be more than 100°F.
A minimum clearance of 18 inches between the compressor and a wall is required because objects could obstruct air flow.
Do not locate the
compressor air inlet near steam, paint spray, sandblast areas or any other source of contamination. This debris will damage the motor.
ELECTRICAL INSTALLATION
All wiring
and electrical connections should be performed by a qualified electrician. Installation must be in accordance with local codes and national electrical codes.
WIRING
1. Local electrical wiring codes
differ from area to area. Source wiring, plug and protector must be rated for at least the amperage and voltage indicated on motor nameplate, and meet all electrical codes for this minimum.
2. Use a slow blow fuse or a circuit
breaker.
3. This product is for use on a
nominal 120 volt circuit and has a grounding plug that looks like the plug illustrated in Figure 6.
Grounded Outlet
RESET
TEST
Grounding Pin
Figure 6 - Grounding Method
Make sure the product is connected to an outlet having the same configuration as the plug. This product must be grounded. In the event of an electrical short circuit, grounding reduces risk of electrical shock by providing an escape wire for electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. Plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.
Overheating, short
circuiting and fire damage will result from inadequate wiring.
Minimum Gauge of Extension Cord
25 ft. 50 ft. 100 ft.
14 12 10
Use of an extension cord may cause excess heat to motor. This could lead to tripped breaker (at electrical panel) or tripped thermal overload (on compressor motor). If this occurs, eliminate extension cord and plug compressor directly into electrical outlet. Avoid using extension cords; use longer air hose(s) instead.
Operation
BEFORE FIRST START-UP BREAK-IN PROCEDURE
(Complete this procedure before using compressor for the first time. Once completed, it is not necessary to repeat.)
1. Open drain valve located on bottom of tank.
2. Turn ON / OFF switch to OFF position.
3. Plug in power cord.
4. Turn ON / OFF switch to ON position and run compressor for 30 minutes.
5. Turn ON / OFF switch to OFF position.
6. Unplug power cord.
7. Close drain valve.
The compressor is now ready for use.
OPERATING PROCEDURE
1. Turn switch to OFF position and plug in power cord.
2. Turn regulator knob counterclockwise to close air flow.
3. Turn switch to AUTO position.
4. Compressor will build to maximum pressure and shut off.
5. With hose attached to outlet of compressor, attach tire chuck or other tool to open end of hose.
6. Adjust regulator to proper pressure for tool or tire. Operate tool per instructions.
As air is depleted from the tank by use of a tire chuck, tool, etc., the compressor will restart automatically at its preset “cut-in” pressure. When a tool is being used continuously, the compressor will cycle on and off automatically.
7. Turn switch to OFF position, unplug power cord and drain tank of air when finished using compressor.
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Operating Instructions
Maintenance
Disconnect, tag and lock out power source, then release all pressure from the system before attempting to install, service, relocate or perform any maintenance.
Check compressor often for any visible problems and follow maintenance procedures each time compressor is used.
ASME SAFETY VALVE
Do not remove or
attempt to adjust
the safety valve!
Check the safety valve by performing the following steps:
1. Plug the compressor in and run until shut off pressure is reached.
2. Wearing safety glasses, pull the ring on the safety valve to release pressure from compressor tank. Use your other hand to deflect fast­moving air from being directed toward your face.
DRAIN TANK
1. Turn compressor off and release pressure from system. (To release pressure from system, pull ring on ASME safety valve. Deflect escaping air by shielding valve with one hand as you pull ring with other hand.) Pull ring until tank is empty.
A large amount of
fast moving air will be released when the safety valve is opened with pressure in the tank. Wear ANSI approved Z87.1 safety glasses.
2. Drain moisture from tank by
opening drain valve underneath tank. Tilt tank to remove all moisture.
3. Clean dust and dirt from tank,
air lines and pump cover while compressor is still OFF.
INTAKE AIR FILTER MAINTENANCE
Removal, Inspection and Replacement (Figure 8).
Filter Element
4. Reinstall filter, cover, and bolt. IMPORTANT: Locate unit as far from
spraying area as hose will allow to prevent overspray from clogging filter.
END OF OPERATION/STORAGE
1. Turn AUTO/OFF switch to the OFF position.
2. Unplug power cord from wall outlet and wrap around handle to prevent damage when not in use.
3. Wearing safety glasses drain tank of air by pulling the ring on the safety valve. Use other hand to deflect fast moving air from being directed toward your face.
4. Drain tank of condensation by opening drain valve on bottom of tank. Tank pressure should be below 10 psi when draining tank.
5. Air hose should be disconnected from compressor and hung open ends down to allow any moisture to drain.
6. Compressor and hose should be stored in a cool, dry place.
Figure 7
3. The safety valve should automatically close at approximately 40 psi - 50 psi. If the safety valve does not allow air to be released when you pull on the ring, or if it does not close automatically, it MUST be replaced.
Safety valve must be
replaced if it cannot be actuated or it leaks air after ring is released.
Filter Cover
Bolt
Figure 8 - Intake Filter Maintenance
The intake filter element should be removed and checked periodically. A clogged intake filter can decrease compressor performance and cause the compressor to overheat.
1. Remove bolt.
2. Remove the filter cover and filter element. Inspect each piece.
3. If the filter element is dirty or clogged, replace it.
TECHNICAL SERVICE
For information regarding the operation or repair of this product, please call 1-800-543-6400.
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HU500000, HU502000
Maintenance (Continued)
MAINTENANCE SCHEDULE
OPERATION DAILY WEEKLY MONTHLY
DRAIN TANK CHECK AIR FILTER CHECK SAFETY VALVE CLEAN UNIT
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Notes
MOISTURE IN COMPRESSED AIR
Moisture in compressed air will form into droplets as it comes from an air compressor pump. When humidity is high or when a compressor is in continuous use for an extended period of time, this moisture will collect in the tank. When using a
l
paint spray or sandblast gun, this water will be carried from the tank through the hose, and out of the gun as droplets mixed with the spray material.
IMPORTANT: This condensation will cause water spots in a paint job, especially when spraying other than water based paints. If sandblasting, it will cause the sand to cake and clog the gun, rendering it ineffective.
A filter in the air line, located as near to the gun as possible, will help eliminate this moisture.
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Operating Instructions
Troubleshooting Chart
Symptom Possible Cause(s) Corrective Action
Compressor will not run
Fuses blow / circuit breaker trips repeatedly
Tank pressure drops
when compressor shuts off
Compressor runs continuously and / or air output is lower than normal / low discharge pressure
1. Switch in OFF position 1. Make sure compressor is plugged in and switch is ON.
2. No electrical power at wall
2. Check circuit breaker or fuse at electrical panel.
outlet
3. Compressor has reached automatic shut-off pressure
3. Release air from tank until compressor restarts automatically.
4. Motor overheated 4. Allow compressor to cool for approximately 30 minutes so thermal overload switch will reset. Make sure compressor is run in a clean, well-ventilated area where temperature will not exceed 100°F.
5. Loose electrical connection 5. Check all electrical connections.
6. ON / OFF switch bad 6. Replace ON / OFF switch.
7. Pressure switch bad 7. Replace pressure switch.
8. Defective motor 8. Replace pump / motor assembly.
1. Incorrect size fuse, circuit
overloaded
1. Check for proper fuse, use time-delay fuse. Disconnect other electrical appliances from circuit or operate compressor on its own branch circuit.
2. Extension cord usage - wrong gauge wire and/or too long
2. Remove extension cord or refer to Extension Cord Chart on page 5.
3. Worn check valve 3. Replace check valve.
Do not disassemble check valve with
4. Defective unloader valve (on
4. Replace unloader valve.
pressure switch)
5. Defective motor capacitor(s) 5. Replace capacitor(s).
6. Defective motor 6. Replace motor.
1. Loose connections (fittings, tubing, etc.)
1. Check all connections with soap and water solution. Tighten; or remove and apply pipe dope or pipe tape to the threads, then reassemble.
2. Open tank drain valve 2. Close tank drain valve.
3. Tank leaks 3. Check tank for leaks with soap and water solution. If leak is detected, tank must be replaced with genuine replacement part.
1. Excessive air usage 1. Decrease air usage; compressor not large enough for air requirement.
2. Clogged intake filter 2. Clean or replace filter.
3. Open tank drain valve 3. Close tank drain valve.
4. Air leaks in piping (on machine
or in outside system)
4. Check all connections with soap and water solution. Tighten; or remove and apply pipe dope or pipe tape to the threads, then reassemble.
5. Piston ring worn 5. Replace piston and cylinder.
6. Broken valve (in pump) 6. Replace valve.
7. Tank leaks 7. Check tank for leaks with soap and water solution. If leak is detected, tank must be replaced with genuine replacement part.
8. Defective pressure switch 8. Replace switch.
air pressure in tank; bleed tank.
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Troubleshooting Chart (Continued)
Symptom Possible Cause(s) Corrective Action
Excessive moisture in discharge air
Knocks, rattles, and/or excessive vibration
Compressor runs continuously and safety valve opens as pressure rises
Air leaking from unloader valve on pressure switch
1. Excessive water in tank 1. Drain tank.
2. High humidity 2. Move to area of less humidity; use air line filter.
1. Loose mounting bolts 1. Tighten bolts.
2. Tank not level 2. Use sturdy wedge / object to bring tank to level position.
3. Cylinder or piston is worn/
3. Replace or repair as necessary.
scored
1. Defective pressure switch 1. Replace switch.
2. Defective safety valve 2. Replace safety valve with genuine replacement part.
1. Check valve stuck in an open
1. Replace check valve.
position
2. Unloader valve stuck in open position
2. Replace unloader valve.
Do not disassemble check valve with
HU500000, HU502000
air pressure in tank; bleed tank.
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Operating Instructions
Limited Warranty
1. DURATION: From the date of purchase by the original purchaser as follows: One Year.
2. WHO GIVES THIS WARRANTY (WARRANTOR): Campbell Hausfeld / Scott Fetzer Company, 100 Production Drive, Harrison, Ohio, 45030, Telephone: (800) 543-6400.
3. WHO RECEIVES THIS WARRANTY (PURCHASER): The original purchaser (other than for purposes of resale) of the Campbell Hausfeld compressor.
4. WHAT PRODUCT IS COVERED BY THIS WARRANTY: This Campbell Hausfeld air compressor.
5. WHAT IS COVERED UNDER THIS WARRANTY: Substantial defects due to material and workmanship with the exceptions noted below.
6. WHAT IS NOT COVERED UNDER THIS WARRANTY: A. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED FROM THE DATE OF
ORIGINAL PURCHASE AS STATED IN THE DURATION. If this compressor is used for commercial, industrial or rental purposes, the warranty will apply for ninety (90) days from the date of purchase. Some States do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.
B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECT, FAILURE,
OR MALFUNCTION OF THE CAMPBELL HAUSFELD PRODUCT. Some States do not allow the exclusion or limitations of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
C. Any failure that results from an accident, purchaser’s abuse, neglect or failure to operate products in accordance with instructions
provided in the owner’s manual(s) supplied with compressor. D. Pre-delivery service, e.g. assembly, oil or lubricants, and adjustment. E. Items or service that are normally required to maintain the product, e.g. lubricants, filters and gaskets, etc. F. Gasoline engines and components are expressly excluded from coverage under this limited warranty. The Purchaser must comply with
the warranty given by the engine manufacturer which is supplied with the product. G. Additional items not covered under this warranty:
1. All Compressors a. Any component damaged in shipment or any failure caused by installing or operating unit under conditions not in accordance
with installation and operation guidelines or damaged by contact with tools or surroundings. b. Pump or valve failure caused by rain, excessive humidity, corrosive environments or other contaminants. c. Cosmetic defects that do not interfere with compressor functionality. d. Electric motors, check valves and pressure switches. e. Drain cocks. f. Damage due to incorrect voltage or improper wiring. g. Other items not listed but considered general wear parts. h. Pressure switches, air governors and safety valves modified from factory settings.
2. Lubricated Compressors a. Pump wear or valve damage caused by using oil not specified. b. Pump wear or valve damage caused by any oil contamination or by failure to follow proper oil maintenance guidelines.
3. Belt Drive / Direct Drive / Gas Driven Compressors a. Belts. b. Ring wear or valve damage from inadequate filter maintenance. c. Manually adjusted load/unload and throttle control devices.
7. ADDITIONAL WARRANTY LIMITATIONS FOR UNITS WITH THE 10 YEAR "TOUGH TANK" GUARANTEE. A. WHAT IS COVERED BY THE 10 YEAR "TOUGH TANK" GUARANTEE:
1. At the warrantor’s option, replace any tank or product which is found to have a manufacturer’s defect in the tank for ten (10) years from the date of purchase by the original purchaser and subject to the exclusions below.
B. WHAT IS NOT COVERED BY THE 10 YEAR "TOUGH TANK" GUARANTEE:
1. The compressor and all parts other than the tank, consult the written warranty issued for your specific compressor model.
2. Defects in the tank not related to a manufacture's defect including but not limited to: a. Failures due to rust. b. Failures due to corrosive environments. c. Failures due to neglect or abuse.
3. Any tank that has been altered in any way.
4. Any tank used for anything other than its original intended purpose.
5. Any unit that has been fitted with any non-OEM parts.
6. Labor to replace a defective tank.
8 RESPONSIBILITIES OF WARRANTOR UNDER THIS WARRANTY: Repair or replace, at Warrantor’s option, compressor or component which is
defective, has malfunctioned and/or failed to conform within the duration of the specific warranty period.
9. RESPONSIBILITIES OF PURCHASER UNDER THIS WARRANTY: A. Provide dated proof of purchase and maintenance records. B. Portable compressors or components must be delivered or shipped to the nearest Campbell Hausfeld Authorized Service Center. Freight
costs, if any, must be borne by the purchaser.
C. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).
10. WHEN WARRANTOR WILL PERFORM REPAIR OR REPLACEMENT UNDER THIS WARRANTY: Repair or replacement will be scheduled and serviced according to the normal work flow at the servicing location, and depending on the availability of replacement parts.
This Limited Warranty applies in the U.S., Canada and Mexico only and gives you specific legal rights. You may also have other rights which vary from State to State or country to country.
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