Campbell Hausfeld FP202899TT, FP202901, FP202801, FP202897, FP202999DB, FP202999DQ User Manual

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Operating Instructions and Parts Manual

FP202801, FP202901, FP202897,

FP202999DB, FP202999DQ, and FP202899TT

 

 

 

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

Oilless compressors are designed for do-it-yourselfers with a variety of home and automotive jobs. These units operate without oil. Compressed air from this unit will contain moisture. Install a water filter or air dryer if application requires dry air.

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

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 date code, model number, and parts list (with missing parts circled before calling.)

DO NOT RETURN THE PRODUCT TO THE RETAILER! CALL

1 - 800 - 543 - 6400

Record the Model No., Serial No. and date of purchase located on the base below the pump in the space below.

Model No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Date Code _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Date of purchase _________________

Retain these numbers for future r e f e r e n c e.

Do not operate unit if damaged during

shipping, handling or use. Damage may result in bursting and cause injury or property damage.

General Safety

Inf orm a t ion

Since the air compressor and other components used (filters, lubricators, hoses, etc.), make up a high pressure pumping system, the following safety precautions must be observed at all times:

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 US, 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 pump or unit.

© 2008

IN614205AV 11/08

Oilless Compressors

General Safety

Information (Continued)

6 . Do not stand on or use the pump or 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 abnormally vibrate, STOP the engine/motor and check immediately for the cause. Vibration is generally a warning of trouble.

1 1 . 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 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 or damaged tanks.

Drain liquid from tank daily.

13 . Tanks rust from moisture build-up, which weakens the tank. Make sure to drain tank daily and inspect periodically for unsafe conditions such as rust formation and corrosion.

14 . Fast moving air will stir up dust and debris which may be harmful. Release air slowly when draining moisture or depressurizing the compressor system.

15. Indoor use only.

16 . To reduce the risk of electrical shock, do not expose to rain. Store indoors.

CALIFORNIA PROPOSITION 65

This product

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

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

SPRAYING PRECAUTIONS

Do not spray flammable materials in vicinity of open flame or near ignition sources including the compressor unit.

1 6 . Do not smoke when spraying paint, insecticides, or other flammable

s u b s t a n c e s .

1 7 . Use a face mask/ respirator when spraying and spray in a well ventilated area to

prevent health and fire hazards.

1 8 . 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.

1 9 . When spraying or cleaning with solvents or toxic chemicals, follow the instructions provided by the chemical manufacturer.

Installation

LOCATION

It is extremely important to use the compressor in a clean, well ventilated area 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.

For Household use only.

GROUNDING INSTRUCTIONS

1 . This product is for use on a nominal 120 volt circuit and has a grounding plug that looks like the plug illustrated in Fig. 1. 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.

Grounding

Pin

Grounded Outlet

Figure 1 - Grounding Method

Improper use of

grounding plug can result in a possible risk of electrical shock!

Do not use a grounding adapter

with this product!

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 external surface that is green (with or without yellow stripes) is the grounding wire.

Never connect green (or green and

yellow) wire to a live terminal.

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.

Overheating, short circuiting and fire

damage will result from inadequate wiring, etc.

2

FP202801, FP202901, FP202897,

FP202999DB, FP202999DQ, and FP202899TT

Handle

ON/OFF Switch

Pressure Gauge

Air Outlet

Drain Valve

Safety Valve

Figure 2 - Unit Identification

 

Op eration

DEFINITION OF TERMS

ON / OFF Switch ( I / O ) - Push switch to the ON ( I ) position to turn compressor on. Push switch to the OFF ( O ) position to turn compressor off. This switch should be in the OFF ( O ) position when connecting / disconnecting power cord from electrical outlet or when changing tools.

changing air tools or disconnecting hose from outlet.

ASME Safety Valve - This valve automatically releases air if the tank pressure exceeds the preset maximum.

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.

ON Position

OFF Position

Figure 3

Pressure Switch (located internally)- When the compressor is turned ON, this switch will shut compressor off automatically when tank pressure reaches maximum shut-off / cut-out pressure. If compressor remains on and air is depleted from tank, this switch will allow compressor to automatically restart at the restart / cut-in pressure.

Pressure Gauge - This gauge reads air pressure in pounds per square inch (psi) in the compressor tank. Make sure this gauge reads ZERO BEFORE

Figure 4

LU B RICATION

This is an oilless product and DOES NOT require lubrication to operate.

BEFORE FIRST STARTUP

BREAK-IN PROCEDURE

(Complete this procedure before using compressor for the first time. Once completed, it is not necessary to

r e p e a t . )

1.Do not attach a hose or any other fitting to the compressor air outlet.

2.Turn on/off switch to OFF position.

3.Plug in power cord.

4.Turn on/off switch to ON position. Allow compressor to run for 5 minutes.

5.Turn on/off switch to OFF position.

6.Unplug power cord.

BEFORE EACH STARTUP

OPERATING PROCEDURE

1.Connect air hose to open port located below pressure gauge.

2.Attach the necessary fitting or tool to open end of air hose.

3.Turn on/off switch to OFF ( O ) position.

4.Plug in power cord.

5a. If using inflation needles/nozzles:

Attach air hose with inflation fitting to the object you are going to inflate. While holding inflation fitting firmly in place, turn on/off switch to ON position. Allow compressor to inflate the object. Turn off compressor and remove inflation fitting.

5b. If using tire chuck or tool: Once chuck or tool is attached to air hose, turn on/off switch to ON position and allow compressor to run until it automatically shuts off. When using tire chuck to inflate tires, observe gauge reading on compressor and periodically check tire pressure with a separate tire gauge to prevent overinflation.

6 . 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 ( O ) position, unplug power cord and drain tank of air when finished using compressor.

M a i ntenance

Disconnect power source then release all pressure from the system before attempting to install,

service, relocate or perform any maintenance. Service should be performed by an authorized service representative.

3

Oilless Compressors

M a intenance (Continued)

The compressor should be checked often for any visible problems and the following maintenance procedures should be performed each time the compressor is used.

ASME SAFETY VALVE

Do not remove or attempt to adjust

the safety valve!

Figure 5

Check the safety valve by performing the following steps:

1 . Plug the compressor in and run until shut off pressure is reached (see Operating Procedure).

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.

3 . The safety valve should close automatically 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.

DRAIN TANK

With compressor shut off and pressure released, drain moisture from tank by opening drain valve underneath tank.

Figure 6

CLE ANING

Turn power OFF and clean dust and dirt from pump cover, tank, and air lines.

IMP ORTANT: Unit should be located as far from spraying area as hose will allow to prevent over-spray from clogging air filter.

LUB RICATION

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 . Lack of proper ventilation

If the thermal overload protector

is actuated, 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 and unit is turned on.

END OF OPERATION/STORAGE

1 . Turn ON / OFF switch to the OFF p o s i t i o n .

2 . Unplug power cord from wall outlet and wrap around handle area 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 d r a i n .

6 . Compressor and hose should be stored in a cool, dry place.

4

 

 

 

 

FP202801, FP202901, FP202897,

 

 

 

 

FP202999DB, FP202999DQ, and FP202899TT

 

 

 

Troubleshooting Chart

 

 

 

 

 

Symptom

Possible Cause(s)

Corrective Action

 

 

 

 

Compressor will not run

1 . Switch in OFF p o s i t i o n

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.

 

3

. Compressor has reached automatic

3

. Release air from tank until compressor restarts

 

 

shut-off pressure

 

a u t o m a t i c a l l y

 

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

 

 

 

 

Thermal overload

1 . Lack of proper ventilation/room

1

. Move compressor to a clean,well ventilated area

protector cuts out

 

temperature too high

 

where temperature will not exceed 100°F.

r e p e a t e d l y

2 . Excessive air usage, compressor too

2

. Decrease usage or purchase unit with higher air

 

 

s m a l l

 

delivery (SCFM)

 

 

 

 

Tank pressure drops

1 . Open tank drain valve

1

. Close tank drain valve

when compressor shuts

2 . Loose connections (fittings, tubing,

2

. Check all connections with soap and water solution.

o f f

 

air hose, any connections, etc.)

 

If a leak is detected, tighten. Or remove fitting and

 

 

 

 

apply pipe tape to threads and reassemble.

 

 

 

 

Do not disassemble check valve.

 

 

 

 

With air in tank, bleed tank first.

 

3. Tank leaks

3

. Check entire tank for leaks with soap and water

 

 

 

 

s o l u t i o n .

Compressor runs continuously / air output lower than normal

1 . Excessive air usage, compressor too s m a l l

2.Open tank drain valve

3.Loose connections (fittings, tubing, air hose, any connections, etc.)

4.Pump wore out

1 . Decrease usage or purchase unit with higher air delivery (SCFM)

2. Close tank drain valve

3 . Check all connections with soap and water solution. If a leak is detected, tighten. Or remove fitting and apply pipe tape to threads and reassemble.

4. Replace pump / motor assembly

Excessive moisture in

1

. Excessive water in tank

1

. Drain tank, tilt tank to remove moisture

discharge air

2

. High humidity

2

. Move to area of less humidity; use air line filter

 

 

 

 

 

Safety valve pops open

1

. Defective pressure switch

1

. Replace pressure switch

 

2

. Defective safety valve

2

. Replace safety valve with genuine replacement part

5

Oilless Compressors

1

3

23

12

2

4

25

20 17

18

21

19

11

 

16

28

22

 

27

8

24

6

 

 

 

7

10

 

30

29

 

5

9

15

26

31

14 13

32

Figure 7

6

FP202801, FP202901, FP202897,

FP202999DB, FP202999DQ, and FP202899TT

For replacement parts or technical assistance, call 1-800-543-6400

Please provide following information:

Address parts correspondence to:

- Model number

Attn: Customer Service

- Serial number (if any)

100 Production Drive

- Part description and number as shown in parts list

Harrison, OH 45030 U.S.A.

Replacement Parts List

Ref.

 

 

 

No.

Description

Part Number

Qty.

1

Shroud

1

2

Shroud insert

1

3

On/off switch

FP204824AV

1

4

M3x15 screw

6

5

Manifold

FP202832AV

1

6

Gauge

FP204012AV

1

7

Safety valve

V-215102AV

1

8

Plastic base

1

9

Pressure switch

FP209530AV

1

10

Check valve (includes part #29 & #30)

FP209532AV

1

11

M4 x 0.7 x 6 screw

 

1

12

M6 x 1.0 x 10 screw

 

4

13

Drain valve

D-1403

1

14

Rubber feet (tank)

FP202828AV

3

15

Wire (pressure switch to power switch)

FP209523AV

1

16

Power cord / Strain relief

FP209534AV

1

17

M3 x 10 screw

 

1

18

Pump/motor assembly (includes part #21)

FP209039AV

1

19

Motor cover

1

20

Wire clip

FP202823AV

1

21

Exhaust tube kit

FP202839AV

1

22

Motor isolator bushing kit

FP209037AV

1

23

Accessories

FP204008AV

1

24

Nut

 

4

25

Screw

 

4

26

Screw

 

4

27

Washer

 

2

28

Screw

 

2

29

Spring

(see part #10)

1

30

Cap

(see part #10)

1

31

Tank

--

1

32

25-foot Recoil Hose

MP268100AV

1

 

 

 

 

REPAIR KITS

 

 

 

 

 

 

 

Shroud kit

FP209034AV

 

Motor cover and base kit

FP209038AV

 

 

Fastener kit

FP209040AV

 

 

Decal kit

FP202837AV

 

 

 

 

 

Standard hardware item

--Not available

7

Oilless Compressors

FP202801, FP202901, FP202897,

FP202999DB, FP202999DQ, and FP202899TT

Limited Wa rr a n t y

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.

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 g u i d e l i n e s .

3 . Belt Drive / Direct Drive / Gas Driven Compressors a . B e l t s .

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: 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 . Call Campbell Hausfeld (800-543-6400) to obtain your warranty service options. Freight costs must be borne by the p u r c h a s e r .

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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