Campbell Hausfeld FP2040 User Manual

precautions must be observed at all times:

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).

assistance or call the nearest Campbell Hausfeld Authorized Service Center.

A listing of service center locations is enclosed. Have the serial number, model number, and parts list (with missing parts circled before calling.)

Do not operate

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

General Safety Information

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

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

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.

aution 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

Operating Instructions and Parts Manual FP2040

IN606800AV 11/02

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.

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

Model No. ____________________

Serial No. ____________________

Date of purchase _________________

Retain these numbers for future reference.

Oilless Compressors

DO NOT RETURN THE PRODUCT TO THE RETAILER!

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

See Warranty on page 8 for important information about commercial use of this product.

For parts, product & service information

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BUILT TO LAST

STOP!

DANGER

Need

Assistance?

Call Us First!

1-800-543-8622

DANGER

WARNING

CAUTION

NOTICE

WARNING

MANUAL

Oilless Compressors

General Safety Information (Continued)

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.

6. Do not stand on or use the pump or unit as a handhold.

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.

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 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.

SPRAYING PRECAUTIONS

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

15. Do not smoke when spraying paint, insecticides, or other flammable substances.

16. Use a face mask/ respirator when spraying and spray in a well ventilated area to prevent health and fire hazards.

17. 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.

18. 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.

Never use an extension cord with this product. Use additional air hose instead of an extension cord to avoid power loss and permanent motor damage. Use of an extension cord voids the warranty.

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.

Figure 1 - Grounding Method

Grounding

Grounded Outlet

100

1 2 5

100

1 2 5

bar

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DANGER

WARNING

CAUTION

WARNING

CAUTION

STOP!

RESET

TEST

FP2040

Installation

(Continued)

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.

WIRING

Overheating, short

circuiting and fire damage will result from inadequate wiring, etc.

NOTE: 120 volt, 15 amp units can be operated on a 120 volt 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. Circuit is equipped with a 15 amp

circuit breaker or a 15 amp slow blow

fuse. If these conditions cannot be met or if nuisance tripping of current protection

device occurs, it may be necessary to operate compressor from a 120 volt, 20 amp circuit.

Operation

Regulator - The regulator controls the

amount of air pressure released at the hose outlet.

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

Handle - Designed to move the compressor.

Drain Petcock - 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.

Reduce tank pressure below 10 psi, then drain moisture from tank daily to avoid tank corrosion. Drain moisture from tank(s) by opening the drain petcock located underneath the tank.

LUBRICATION This is an oilless product and DOES

NOT require lubrication to operate.

BREAK-IN PROCEDURE

Do not attach air

chuck or other tool to open end of hose until start-up has been completed and unit checks OK.

IMPORTANT: Do not operate compressor before reading instructions or damage may result.

1. Turn regulator fully clockwise to

open air flow.

2. Turn switch to OFF position and plug

in power cord.

3. Turn switch to ON position and run

unit for 5 minutes to break in the pump parts.

4. Turn regulator knob fully

counterclockwise. Compressor will build to maximum preset pressure and shut off.

5. Turn regulator knob clockwise to

cause air to bleed off. Compressor will restart at a preset pressure.

6. Turn regulator knob

counterclockwise to shut off the air and turn switch to Off position.

Handle

Regulator

ON/OFF Switch

Drain Petcock

Figure 2 - Unit Identification

Safety Valve

Gauge of Cord 18 14 12 10 88664

Extension cords for 120V/8 Amp Unit

Length of Cord (ft) 25 50 100 150 200 250 300 400 500

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DANGER

WARNING

CAUTION

Operation (Continued)

7. Attach chuck or other tool to open end of hose. Turn the regulator on.

In the ON position, the compressor pumps air into the tank. It shuts off automatically when unit reaches its maximum preset pressure. In the OFF position, the pressure switch cannot function and the compressor will not operate. Make sure switch is in OFF position when connecting or disconnecting power cord from electrical outlet.

ASME SAFETY VALVE

Do not remove or attempt to adjust

the safety valve!

This valve should be checked occasionally by pulling the ring by hand. Air may leak even after ring has been released. However, if the leaking continues for an extended period of time, or if the safety valve is stuck and cannot be activated by the ring, the safety valve MUST be replaced. (Note: Valve will reset when tank pressure reaches 40-50 PSI.)

REGULATOR KNOB

1. This knob controls air pressure to an air operated tool or paint spray gun.

2. Turn knob clockwise to increase air pressure.

3. To lower air pressure turn knob counterclockwise.

4. Turn fully counterclockwise to shut off flow of air completely.

Maintenance

Disconnect 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.

1. 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.

2. Turn compressor off and release

pressure from system. Drain moisture from tank by opening drain cock underneath tank. Tilt tank to remove all moisture.

3. Clean dust and dirt from motor, tank,

air lines and pump cooling fins while compressor is still OFF.

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. Clogged air filter.

3. 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.

STORAGE

1. When not in use, store hose and

compressor in a cool dry place.

2. Drain tank of moisture.

3. Disconnect hose and hang open ends

down to allow any moisture to drain.

Figure 3

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 (MP3105), located as near to the gun as possible, will help eliminate this moisture.

Oilless Compressors

Figure 4

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WARNING

CAUTION

FP2040

Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

1. No power or switch in OFF position

2. Blown fuse

3. Motor overheated

4. Tank pressure at maximum

5. Breaker open

6. Pressure switch bad

1. Incorrect size fuse, circuit overloaded

2. Defective check valve

1. Low voltage

2. Lack of proper ventilation/room temperature too high

3. Check valve malfunction

4. Compressor valves failed

1. Loose bolts, tank not level

2. Defective bearing on eccentric or motor shaft

3. Cylinder or piston ring is worn or scored

1. Loose drain cock

2. Check valve leaking

3. Loose connections at pressure switch, hose or regulator

1. Make sure compressor is plugged in and switch is ON

2. Disconnect compressor from power source then remove pump shroud. Replace fuse (Part. No. FP200352AV)

3. Allow compressor to cool for approximately 30 minutes so thermal overload switch will reset. If unit still does not start, empty air from tank and refer to actions 1 and 2.

4. Release air from tank

5. Reset, determine cause of problem

6. Replace pressure switch

1. Check for proper fuse in supply circuit. Disconnect other electrical appliances from circuit or operate compressor on its own branch circuit

2. Replace check valve assembly

Do not disassemble check valve. With air in tank, bleed tank

first.

1. Eliminate extension cord, check with voltmeter

2. Move compressor to well ventilated area

3. Replace check valve assembly

4. Replace pump assembly

Do not disassemble check valve. With air in tank, bleed tank

first.

1. Tighten bolts, shim tank to level position

2. Replace pump assembly

3. Replace pump assembly

1. Tighten

2. Replace pump assembly

3. Check all connections with soap and water solution and tighten

Do not disassemble check valve. With air in tank, bleed tank

first.

Compressor will not run

Fuses blow/circuit breaker trips repeatedly

Never use an extension cord with this product

Thermal overload protector cuts out repeatedly

Knocks, rattles, excessive vibration

Tank pressure drops when compressor shuts off

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CAUTION

DANGER

Oilless Compressors

Troubleshooting Chart (Continued)

Symptom Possible Cause(s) Corrective Action

1. Excessive air usage, compressor too small

2. Air leaks in piping (on machine or in outside system)

3. Broken inlet valves

4. Piston ring worn

1. Excessive water in tank

2. High humidity

1. Defective pressure switch

2. Defective safety valve

Excessive condensation in tank

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

2. Replace leaking components or tighten as necessary

3. Replace pump assembly

4. Replace piston assembly

1. Drain tank, tilt tank to remove moisture

2. Move to area of less humidity; use air line filter NOTE: Water condensation is not caused by compressor malfunction

1. Replace pressure switch

2. Replace safety valve with genuine replacement part

Drain more often

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

Excessive moisture in discharge air

Compressor runs continuously and safety valve opens as pressure rises

Excessive starting and stopping (auto start)

Notes

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FP2040

For Replacement Parts, Call 1-800-543-6400

Please provide following information:

-Model number

-Serial number (if any)

-Part description and number as shown in parts list

Ref. No. Description Part Number Qty.

1 Shroud with handle FP204001AV 1 2 Handle assembly FP204002AV 1 3 Tank gauge FP200347AV 1 4 Regulator gauge FP200345AV 1 5 Manifold assembly FP204003AV 1 6 Safety valve V-215102AV 1 7 On/Off switch FP200343AV 1 8 Drain cock D-1401 1

9 Pump/Motor assembly FP204004AV 1 10 Circuit board FP204005AV 1 11 Pressure switch FP200354AV 1 12 Exhaust tube

▲ 1

13 Fan FP204006AV 1 14 Compression nut

▲ 2

15 Compression ferrule

▲ 2

16 Shroud screws (M6-10 x 20) Standard hardware item 4 17 25’ hose MP285100AV 1 18 Tool kit (5 pieces) FP204008AV 1 19 Check valve kit FP204010AV 1 20 Storage cover FP204007AV 1 21 Piston assembly FP204009AV 1 ▲ Exhaust tube kit (includes

12, 14 & 15) FP200339AV 1 Decal kit (not shown) FP204011AV 1

Replacement Parts List

100

psi

1 2 5

100

1 2 5

bar

psi

bar

Address parts correspondence to:

The Campbell Group Attn: Parts Department 100 Production Drive Harrison, OH 45030 U.S.A.

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0 0 1

1 2 5

5 7

5 1

0 5

r a b

i s p

0 0 1

1 2 5

5 7

5 1

0 5

r a b

5 2

i s p

FP2040

Oilless 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.

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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