Campbell Hausfeld EX8000Series, WL5000 Series Operating Instructions Manual
Portable Air Compressors
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.
Description
Portable oilless air compressors are for
home and workshop use. All models
are equipped with regulators, needle
and ball bearings and 1725 or 3450
RPM, 60 Hz motors with automatic
overload protection. Cleaning or
replacement of the inlet filter on all
models and draining moisture from the
air receivers are required maintenance.
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.
Unpacking
When unpacking unit, inspect carefully
for any damage that may have occurred
during transit. Make sure any loose
fittings, bolts, etc., are tightened before
putting unit into service.
Operating Instructions EX8000, WL5000 Series Contractor Models
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 Campbell Hausfeld
disclaims any liability
whatsoever for any loss,
personal injury or damage.
General Safety
Air compressors are utilized in a variety
of air system applications. Because air
compressors and other components
(material pump, spray gun, filters,
lubrications, hoses, etc.) used make up a
high pressure pumping system, the
following safety precautions should be
observed at all times. Only persons well
acquainted with these rules of safe
operation should be allowed to use the
air compressor.
All electrical work
should be done by a
qualified (licensed or certified)
electrician. On a properly wired circuit,
the black wires supply a voltage
potential even when the unit is off.
1. Read instruction manuals for each
component carefully, before
attempting to assemble,
disassemble or operate your
particular system.
2. Do not exceed pressure rating of
any component in system.
3. Protect material lines and air lines
from damage or puncture. Keep
hose and power cable away from
sharp objects, chemical spills, oil,
solvents, and wet floors.
4. Never point a spray gun at oneself
or any other person. Accidental
discharge may result in serious
injury.
5. Check hoses for weak or worn
condition, before each use, making
certain all connections are secure;
do not use if deficiency is found.
Notify an authorized service facility
for examination or repair.
6. Release all pressures within system
IN602302AV 12/02
slowly; dust and debris may be
harmful.
Disconnect power
and depressurize
system before servicing air compressor!
(Turn pressure regulator knob fully
clockwise after shutting off
compressor.)
7. Follow all local electrical and safety
© 2002 Campbell Hausfeld/Scott Fetzer
For parts, product & service information
visit www.chpower.com
REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.
See Warranty on page 6 for important information about commercial use of this product.
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DANGER
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DANGER
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WARNING
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CAUTION
NOTICE
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WARNING
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WARNING
Portable Air Compressors
2
General Safety (Cont.)
codes, as well as the National Electrical
Code (NEC) and the Occupational
Safety and Health Act (OSHA).
8. Wiring and fuses should follow
electrical codes, current capacity, and
be properly grounded.
9. Electric motors must be securely and
adequately grounded. See grounding
instructions and extension cord
information, in this manual.
10. Always disconnect power source
before working on or near a motor, or
its connected load. If power
disconnect point is out-of-sight, lock it
in the open position and tag to
prevent unexpected application of
power.
11. Guard all moving parts; keep visitors
away. Never allow children in work
area.
12. Use only a properly grounded outlet
that will accept a three pronged plug,
and wear shoes to prevent shock
hazards.
13. Be careful when touching exterior of
operating motor; it may be hot
enough to cause injury.
14. Protect power cable from coming in
contact with sharp objects.
15. Clean electrical or electronic
equipment with an approved cleaning
agent, such as dry, nonflammable
cleaning solvent.
16. To avoid spontaneous combustion,
discard waste rags into approved
metal waste cans.
17. Never store flammable liquids or gases
in vicinity of compressor.
18. When spraying with solvent of toxic
chemicals, follow instructions provided
by the chemical manufacturer.
19. Spray in a well ventilated area, to
keep fumes from collecting and
causing health and fire hazards.
20. Do not spray in vicinity of open flames
or other places where a spark can
cause ignition. Do not smoke when
spraying paint, insecticides, or other
flammable substances.
21. Use a respirator when spraying.
22. NEVER reset safety valve or pressure
switch. Keep safety valve free from
paint and other accumulations. This
provides safety against over pressure.
23. Do regular maintenance; keep all
nuts, bolts, and screws tight, to be
sure equipment is in safe working
condition .
24. Keep cleaning rags and other
flammable waste materials in a tightly
closed metal container and dispose of
later in the proper fashion.
25. Drain tanks of moisture after each
day’s use. If unit will not be used for a
while, it is best to leave drain cock
open until such time as it is to be used.
This will allow moisture to completely
drain out and help prevent corrosion
of inside of tank.
26. Inspect tank yearly for rust, pin holes
or any other imperfections that could
cause it to become unsafe. NEVER
weld or drill holes in air tank.
Assembly
FEET (3 GALLON MODELS ONLY)
Insert threaded post of rubber foot into
hole in ground iron. Tighten securely
with locknut.
Installation
1. Check and tighten all bolts, fittings,
etc., before operating compressor.
2. Operate compressor in a ventilated
area so that compressor may be
properly cooled.
3. Compressor should be located where
it can be directly plugged into an
outlet, but if this is not possible, an
extension cord may be used. It should
be selected using the extension cord
chart on page 3 as a guide.
4. To avoid loss of power and
overheating, it is better to use
additional air hose instead of
extension cords to reach work area.
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 type T or a
circuit breaker.
Overheating, short
circuiting and fire
damage will result from inadequate
wiring, etc.
NOTE: 120 volt, 10 and 13 amp units can
be operated on a 115 volt, 15 amp circuit
under the following conditions:
a. No other electrical appliances or lights
are connected to the same branch
circuit.
b. Voltage supply is normal.
c. Extension cords are of the minimum
gauge specified in this instruction
manual.
d. Circuit is equipped with a 15 amp
circuit breaker or a 15 amp slow blow
fuse type T.
3. If above conditions cannot be met or
if nuisance tripping of current
protection device occurs, it may be
necessary to operate compressor from
a 115 volt, 20 amp circuit.
GROUNDING INSTRUCTIONS
1. This product should 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
Figure 1
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Nut
Foot
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CAUTION
Gauge of Cord 14 10 10 866442
Extension cords for 120V/15 Amp Unit
Length of Cord (ft) 25 50 100 150 200 250 300 400 500
EX8000, WL5000 Series Contractor Models
3
Installation (Cont.)
appropriate grounding plug. Plug
must be plugged into an outlet that
is properly installed and grounded
in accordance with all local codes
and ordinances.
Improper use of
grounding plug can
result in a possible risk of electrical shock!
NOTE: Do not use grounding adapter.
2. If repair or replacement of cord or
plug is necessary, do not connect
grounding wire to either flat blade
terminal. The wire with insulation
having an outlet surface that is green
with or without yellow stripes is the
grounding wire.
3. Check with a qualified electrician or
serviceman if grounding instructions
are not completely understood, or if in
doubt as to whether product is
properly grounded. Do not modify
plug provided; if it will not fit outlet,
have proper outlet installed by a
qualified electrician.
Never connect
green (or green and
yellow) wire to a live terminal.
EXTENSION CORDS
1. Use only a 3-wire extension cord that
has a 3-blade grounding plug, and a
3-slot receptacle that will accept plug
on product.
2. Make sure extension cord is in good
condition, and heavy enough to carry
current product will draw. An
undersized cord will cause a drop in
line voltage resulting in loss of power
and overheating.
3. To avoid loss of power and
overheating, it is better to use
additional air hose instead of
extension cords to reach work area.
4. Table below shows correct size to use
depending on cord length and
nameplate ampere rating. If in doubt,
use next heavier gauge.
NOTE: The smaller the gauge number,
the heavier the cord.
5. This product is for use on a nominal
120 volt circuit and has a grounding
plug that looks like plug illustrated in
Figure 2. Make sure that product is
connected to an outlet having same
configuration as plug.
Do not use adapter
with this product!
Operation
FOR TROUBLE-FREE OPERATION
1. Read instructions: Carefully read
through this owner’s manual BEFORE
OPERATING the new air compressor.
It contains information about
operation and maintenance of unit.
2. Drain tank daily: Depressurize system
prior to draining tank. Open drain
cock and drain moisture from tank.
Be sure to close cock tightly before
operating compressor. This helps
prevent tank corrosion and keeps oil
and moisture out of air used.
3. Change air filter: Never run
compressor without an air filter nor
with a clogged air filter. Rotate filter
cover when element is dirty, or
replace with a new filter.
ASME SAFETY VALVE
1. This valve automatically releases air if
air receiver pressure exceeds preset
maximum.
Do not attempt to
tamper with this
valve!
2. This valve should be checked
occasionally by pulling the ring by hand.
If air leaks after ring has been released,
or valve is stuck and cannot be actuated
by ring, it MUST be replaced.
Figure 2 - Grounding Method
Grounding
Pin
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 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.
Power cord White Line No
Motor cord White Load No
Power cord Black Line Yes
Motor cord Black Load Yes
✽ Wire and Terminal Guide
Wire Color Terminal Hot
(✽) When the unit is not in operation
Grounded
Outlet
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Figure 3
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DANGER
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WARNING
RESET
TEST
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DANGER
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DANGER
4
Portable Air Compressors
Operation (Cont.)
REGULATOR KNOB
1. This knob controls air pressure to an air
operated tool, or paint spray gun.
2. Turning knob clockwise increases air
pressure at outlet.
3. Turning counterclockwise will lower air
pressure at outlet.
4. Fully counterclockwise will shut off flow
of air completely.
REGULATED OUTLET GAUGE
1. This gauge shows at-a-glance, air
pressure at outlet. Air pressure is
measured in pounds per square inch
(PSI).
2. Be sure this gauge reads ZERO before
changing air tools or disconnecting hose
from outlet.
TANK PRESSURE GAUGE
Gauge shows pressure in air receiver
indicating compressor is building pressure
properly.
Maintenance
Release all
pressure and
disconnect power before making any
repair.
1. Check compressor for any visible
problems, especially check air filter to be
sure it is clean.
2. Pull ring on safety valve and allow it to
snap back to normal position.
Safety valve must
be replaced if it
cannot be actuated or it leaks air after ring
is released.
3. Daily with compressor shut off:
Depressurize system prior to draining
tank. Drain moisture from tanks by
opening drain cocks underneath end of
tanks.
4. Turn power OFF and clean dust and dirt
from motor, tank, air lines and pump
cooling fins.
NOTE: The air filter in the filter housing on
the side of the head must be checked and
cleaned periodically, more often if used
under very dusty conditions or when a
great deal of fog from spraying is allowed
to circulate near unit.
IMPORTANT: Unit should be located as
far from spraying area as hose will allow
to prevent over-spray from clogging filter.
FILTER REMOVAL, INSPECTION AND
REPLACEMENT
To change a filter, pull off the filter
housing cover. If filter element is dirty,
rotate filter cover so the holes line up with
clean element material and snap cover
onto housing. If filter element has no
clean areas, replace element or entire
filter.
LUBRICATION
This is an oilless type compressor requiring
no lubrication.
THERMAL OVERLOAD PROTECTOR
This compressor is
equipped with an
automatic reset thermal overload
protector which will shut off motor if it
becomes overheated.
If thermal overload protector shuts motor
OFF frequently look for the following
causes.
1. Low voltage.
2. Wrong gauge wire or length of
extension cord.
3. Clogged air filter.
4. Lack of proper ventilation.
The motor must be
allowed to cool
down before start-up is possible. The
motor will automatically restart without
warning if left plugged into electrical
outlet, if the motor is turned on.
STORAGE
1. When not in use, hose and compressor
should be stored in a cool dry place.
2. Tank should be drained of moisture.
3. Hose should be disconnected and hung
open ends down to allow any moisture
to drain.
Figure 5
Figure 4
Close
Open
Attach
Hose
Drain
Cock
Figure 6
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WARNING
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WARNING
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CAUTION
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CAUTION
Troubleshooting Chart
Symptom Possible Cause(s) Corrective Action
1. Loss of power or overheating
2. No electrical power
3. Blown fuse
4. Breaker open
5. Thermal overload open
6. Pressure switch bad
1. Low voltage
2. Wrong gauge wire or length of
extension cord
3. Shorted or open motor winding
4. Defective check valve or unloader
1. Incorrect size fuse, circuit overloaded
2. Wrong gauge wire or length of
extension cord
3. Defective check valve or under loader
1. Low voltage
2. Clogged air filter
3. Lack of proper ventilation/room
temperature too high
4. Wrong gauge wire or length of
extension cord
1. Loose connections (fittings, tubing,
etc.)
2. Loose drain lock
3. Check valve leaking
1. Excessive water in air receiver
2. High humidity
1. Defective pressure switch
2. Excessive air usage
Loose mounting bolts
1. Broken inlet valves
2. Intake filter dirty
3. Connections leaking
1. Check for proper use of extension cord (see
EXTENSION CORDS, page 3)
2. Plugged in? Check fuse/breaker or motor overload
3. Replace blown fuse
4. Reset, determining why problem happened
5. Motor will restart when cool
6. Replace
1. Check with voltmeter
2. Check gauge chart, under Operation for proper
gauge wire and cord length
3. Replace motor
4. Replace or repair
1. Check for proper fuse, use time-delay fuse.
Disconnect other electrical appliances from circuit or
operate compressor on its own branch circuit
2. Check gauge chart, under Operation
3. Replace or repair
1. Check with voltmeter
2. Clean filter (see Maintenance section)
3. Move compressor to well ventilated area
4. Check gauge chart, under Operation
1. Check all connections with soap and water solution
and tighten
2. Tighten
3. Disassemble check valve assembly, clean or replace
Do not disassemble check valve
with air in tank; bleed tank
1. Drain receiver
2. Move to area of less humidity; use air line filter
1. Replace switch
2. Decrease air usage; compressor not large enough for
a requirement
Tighten
1. Have authorized service representative repair unit
2. Clean or replace intake filter
3. Tighten connections
Compressor will not run
Motor hums but cannot
run or runs slowly
Fuses blow/circuit
breaker trips repeatedly
Thermal overload
protector cuts out
repeatedly
Air receiver pressure
drops when compressor
shuts off
Excessive moisture in
discharge air
Compressor runs
continuously
Compressor vibrates
Air output lower than
normal
EX8000, WL5000 Series Contractor Models
5
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DANGER
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Portable Air Compressors
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Limited Warranty
1. DURATION: From the date of purchase by the original purchaser as follows: Standard Duty - One Year; Serious Duty - Two
Years; Extreme Duty - Three Years; Maxus Model Series - Five Years.
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 PRODUCTS ARE COVERED BY THIS WARRANTY: Any 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. Extreme Duty Contractor
Compressors are not limited to a ninety (90) day warranty when used in contractor applications. Four cylinder singlestage and two-stage compressors are not limited to a ninety (90) day warranty when used in commercial or industrial
applications. 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, i.e. assembly, oil or lubricants, and adjustment.
E. Items or service that are normally required to maintain the product, i.e. 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. Rusted tanks, including but not limited to rust due to improper drainage or corrosive environments.
e. Electric motors, check valves and pressure switches after the first year of ownership.
f. Drain cocks.
g. Damage due to incorrect voltage or improper wiring.
h. Other items not listed but considered general wear parts.
i. 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. 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 duration of the warranty period.
8. 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).
9. 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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