Campbell Hausfeld DC200100 Operating Instructions And Parts Manual

Oilless Compressors

Operating Instructions and Parts Manual

Model: DC200100

IN641601 3/17

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.

REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

For parts, product & service information

Model #: __________________________ Serial #: ___________________________ Purchase Date: _____________________

READ AND FOLLOW ALL INSTRUCTIONS • SAVE THESE INSTRUCTIONS • DO NOT DISCARD

visit www.campbellhausfeld.com

Campbell Hausfeld 100 Production Drive Harrison, Ohio 45030

BEFORE YOU BEGIN

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

STOP!

Do not lift or move unit without appropriately rated equipment. Be sure the unit is securely

to lift other attached equipment.

After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Check for loose, missing or damaged parts. Check to be sure all supplied accessories are enclosed with the unit. In case of questions, damaged or missing parts, please visit www.campbellhausfeld.com for customer assistance.

DO NOT RETURN THE PRODUCT TO THE RETAILER!

Do not operate unit if damaged during shipping, handling or use. Damage may result in

attached to lifting device used. Do not lift unit by holding onto tubes or coolers. Do not use unit

bursting and cause injury or property damage.

GENERAL SAFETY 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

Warning indicates a potentially hazardous situation which, if not avoided, COULD result in

Caution indicates a potentially hazardous situation which, if not avoided, MAY result in minor or

or serious injury.

death or serious injury.

moderate injury.

SPECIFICATIONS

SAFETY /

INSTALLATION

ASSEMBLY /

Notice indicates important information, that if not followed, may cause damage to equipment.

IMPORTANT or NOTE: Information that requires special attention.

Safety Symbols

The following Safety Symbols appear throughout this manual to alert you to important safety hazards and precautions.

MANUAL

Wear Eye and Mask Protection

Risk of Shock

Read Manual First

Risk of Pressure

Wear eye and hearing protection

Risk of Fire

Risk of Hot Parts

Risk of Explosion

TROUBLESHOOTINGOPERATION

MAINTENANCE /

REPAIR

SAFETY /

ASSEMBLY /

GENERAL SAFETY INSTRUCTIONS (CONTINUED)

California Proposition 65

GETTING STARTED

SPECIFICATIONS

INSTALLATION

This product or its power cord may contain chemicals known to the State of California to cause

You can create dust when you cut, sand, drill or grind materials such as wood, paint,

cancer, birth defects, or other reproductive harm. Wear protective gear.

Important Safety Information

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.

This manual contains important safety, operational and maintenance information. If you have any questions, lease visit www.campbellhausfeld.com for customer assistance.

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, 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 Campbell Hausfeld disclaims any liability whatsoever for any loss, personal injury or damage.

cancer and birth defects or other reproductive harm. Wash hands after handling.

metal, concrete, cement, or other masonry. This dust often contains chemicals known to cause

BREATHABLE AIR WARNING

MANUAL

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

each use.

1. Read all manuals included with this product carefully. 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

store flammable liquids or gases in the vicinity of the compressor.

9. Keep fingers away from a running compressor; fast moving and hot parts will cause injury and/or burns.

inadvertently. To prevent this and possible damage from power surge, turn to OFF position after

flammable gas or vapor. Never operate or repair in or near a flammable gas or vapor. Never

Compressor parts may be hot even if the unit is stopped.

GENERAL SAFETY INFORMATION (CONTINUED)

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

Never attempt to repair or modify a tank! Welding, drilling or any other modification will

or damaged tanks.

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.

Spraying Precautions

Do not spray flammable materials in vicinity of open flame or near ignition sources

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.

and other accumulations.

Never use plastic (PVC) pipe for compressed air. Serious injury or death could result.

weaken the tank resulting in damage from rupture or explosion. Always replace worn, cracked

Drain liquid from tank daily.

including the compressor unit.

SPECIFICATIONS

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INSTALLATION

ASSEMBLY /

TROUBLESHOOTINGOPERATION

MAINTENANCE /

REPAIR

SAFETY /

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SPECIFICATIONS

Motor HP 1.3 Tank Capacity 20 gallon

GETTING STARTED

SPECIFICATIONS

Phase Single Number of Cylinders 1 Air Delivery @ 90 psi 4.0 SCFM Voltage 120 Amperes 14A Hertz (Cycle) 60 Maximum Pressure 150 Tank Outlet 1/4 in. IM Unit Weight 88.4 pounds

DIMENSIONS

Length 19.9 in. Width 18.7 in.

INSTALLATION

Height 42.1 in.

DC200100

ASSEMBLY INSTRUCTIONS

Handle Assembly (Figure 1)

1. Place ends of handle around tank and into the mounting pipe. Align holes in handle to holes in mounting pipe.

2. Assemble two (2) 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.

Wheel Assembly (Figure 2)

Wheel assembly kit includes:

- 2 wheels *

- 2 axle bolts *

- 2 washers *

- 2 nuts *

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.

Handle

Bolt

Figure 1 - Handle Assembly

Wheel

Axle

Figure 2 - Wheel Assembly

Nut

Spring Washer

SPECIFICATIONS

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INSTALLATION

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GETTING TO KNOW YOUR UNIT

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.

GETTING STARTED

SPECIFICATIONS

INSTALLATION

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.

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.

Never use the handle on wheeled units to lift the unit completely off the ground.

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

If the overload protector is actuated, the motor must be allowed to cool down for

overloaded.

approximately 30 minutes before it will reset.

Outlet

Check Valve

Pressure Switch

(AUTO / OFF)

Tank

Gauge

Safety Valve

Gauge

Regulator

Handle

Figure 3

Drain Valve

INSTALLATION INSTRUCTIONS

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 4. 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.

SPECIFICATIONS

SAFETY /

INSTALLATION

ASSEMBLY /

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.

Grounded Outlet

Grounding

Figure 4 - Grounding Method

TROUBLESHOOTINGOPERATION

MAINTENANCE /

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SAFETY /

ASSEMBLY /

OPERATING INSTRUCTIONS

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.)

GETTING STARTED

SPECIFICATIONS

INSTALLATION

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.

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 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.

TROUBLESHOOTING GUIDE

SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION

Compressor will not run 1. Switch in OFF position 1. Make sure compressor is plugged in and switch is

ON.

2. No electrical power at wall outlet 2. Check circuit breaker or fuse at electrical panel.

Fuses blow / circuit breaker trips repeatedly

3. Compressor has reached automatic shut-off pressure

4. Motor overheated 4. Allow compressor to cool for approximately 30

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.

2. Extension cord usage - wrong gauge wire and/or too long

3. Worn check valve 3. Replace check valve.

3. Release air from tank until compressor restarts automatically.

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.

Disconnect other electrical appliances from circuit or operate compressor on its own branch circuit.

2. Remove extension cord or refer to Extension Cord Chart on page 5.

SPECIFICATIONS

SAFETY /

INSTALLATION

ASSEMBLY /

Tank pressure drops when compressor shuts off

Compressor runs continuously and / or air output is lower than normal / low discharge pressure

Do not disassemble check valve

tank.

4. Defective unloader valve (on pressure switch)

5. Defective motor capacitor(s) 5. Replace capacitor(s).

6. Defective motor 6. Replace motor.

1. Loose connections (fittings, tubing, etc.)

2. Open tank drain valve 2. Close tank drain valve.

3. Tank leaks 3. Check tank for leaks with soap and water solution.

1. Excessive air usage 1. Decrease air usage; compressor not large enough

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)

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.

8. Defective pressure switch 8. Replace switch.

4. Replace unloader valve.

1. Check all connections with soap and water solution. Tighten; or remove and apply pipe dope or pipe tape to the threads, then reassemble.

If leak is detected, tank must be replaced with genuine replacement part.

for air requirement.

4. Check all connections with soap and water solution. Tighten; or remove and apply pipe dope or pipe tape to the threads, then reassemble.

If leak is detected, tank must be replaced with genuine replacement part.

with air pressure in tank; bleed

TROUBLESHOOTINGOPERATION

MAINTENANCE /

REPAIR

SAFETY /

ASSEMBLY /

TROUBLESHOOTING GUIDE (CONTINUED)

SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION

GETTING STARTED

SPECIFICATIONS

INSTALLATION

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

3. Cylinder or piston is worn/scored 3. Replace or repair as necessary.

1. Defective pressure switch 1. Replace switch.

2. Defective safety valve 2. Replace safety valve with genuine replacement

1. Check valve stuck in an open position 1. Replace check valve.

2. Unloader valve stuck in open position

position.

part.

2. Replace unloader valve.

Do not disassemble check valve

with air pressure in tank; bleed

tank.

MAINTENANCE AND INSPECTION INSTRUCTIONS

Disconnect, tag and lock out power source, then release all pressure from the system

Check compressor often for any visible problems and follow maintenance procedures each time compressor is used.

ASME 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 fast-moving air from being directed toward your face.

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.

before attempting to install, service, relocate or perform any maintenance.

Do not remove or attempt to adjust the safety valve!

Safety valve must be replaced if it cannot be actuated or it leaks air after ring is released.

Figure 5

SPECIFICATIONS

SAFETY /

INSTALLATION

ASSEMBLY /

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 6). 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.

4. Reinstall filter, cover, and bolt. Thread the intake air filter into the threaded opening in the side of the compressor head as illustrated in Figure 6 before use.

IMPORTANT: Locate unit as far from spraying area as hose will allow to prevent overspray from clogging filter.

Figure 6 - Intake Filter Maintenance

TROUBLESHOOTINGOPERATION

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.

REPAIR

MAINTENANCE /

MAINTENANCE AND INSPECTION INSTRUCTIONS (CONTINUED)

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.

SAFETY /

ASSEMBLY /

GETTING STARTED

SPECIFICATIONS

INSTALLATION

Technical Service

For information regarding the operation or repair of this product, please visit www.campbellhausfeld.com.

MAINTENANCE SCHEDULE

OPERATION DAILY WEEKLY MONTHLY

DRAIN TANK

CHECK AIR FILTER

CHECK SAFETY VALVE

CLEAN UNIT

NOTES

SPECIFICATIONS

SAFETY /

INSTALLATION

ASSEMBLY /

TROUBLESHOOTINGOPERATION

MAINTENANCE /

REPAIR

REPAIR PARTS ILLUSTRATION FOR DC200100

SAFETY /

ASSEMBLY /

GETTING STARTED

SPECIFICATIONS

INSTALLATION

For Repair Parts, visit www.campbellhausfeld.com

24 hours a day – 365 days a year

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

REPAIR PARTS LIST FOR DC200100

Ref. No. Description Part Number Qty.

1 PUMP/MOTOR ASSEMBLY DC200102AV 1 2 FILTER DC200150AV 1 3 CONNECT -- 1 4 PRESSURE SWITCH 5 TANK GAUGE 6 SAFETY VALVE 7 CONNECT 8 OUTLET GAUGE 9 REGULATOR 10 COUPLER 11 CHECK VALVE ASSEMBLY DC200151AV 1 12 UNLOAD TUBE DC200152AV 1 13 EXHAUST TUBE 14 O-RING 15 HANDLE 16 BOLT 17 TANK -- 1 18 RUBBER PAD -- 4 19 M8X35 BOLT -- 4 20 M8 WASHER -- 4 21 M8 SPRING WASHER 22 M8 NUT 23 FRONT SHROUD -- 1 24 REAR SHROUD -- 1 25 SCREW -- 5 26 M5X12 BOLT -- 2 27 POWER CORD -- 1 28 CABLE CONNECT U -- 2 29 CABLE CONNECT O -- 1 30 AXLE 31 WHEEL 32 DRAIN VALVE DC200153AV 1 33 RUBBER FOOT -- 2 34 M8X20 BOLT -- 2

REPLACEMENT PARTS KITS

EXHAUST TUBE KIT DC200154AV PRESSURE SWITCH AND REGULATOR KIT DC200155AV WHEEL KIT DC200163AV HANDLE KIT DC200164AV

1 1 1

SPECIFICATIONS

SAFETY /

1 1 1 1

1 2

INSTALLATION

ASSEMBLY /

1 2

4 4

2 2

TROUBLESHOOTINGOPERATION

MAINTENANCE /

REPAIR

REPAIR PARTS ILLUSTRATION FOR DC200102AV

GETTING STARTED

SAFETY /

ASSEMBLY /

SPECIFICATIONS

INSTALLATION

For Repair Parts, visit www.campbellhausfeld.com

24 hours a day – 365 days a year

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

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Campbell Hausfeld DC200100 Operating Instructions And Parts Manual

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Frequently Asked Questions

User Manual