Campbell Hausfeld FP209601, FP209599, FP209699DQL, FP209501, FP209598 User Manual

...

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.

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

CALIFORNIA PROPOSITION 65

This product or its

power cord may contain chemicals, including lead, known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

GENERAL SAFETY INFORMATION

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:

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.

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.

Operating Instructions and Parts Manual

FP209501, FP209598, FP209599, FP209601

FP209699DB, and FP209699DQL

IN619402AV 1/09

Breathable Air Warning

This compressor/pump is not equipped and should not be used “as is” to supply breathing quality air. For any application of air for human consumption, the air compressor/pump will need to be fitted with suitable in-line safety and alarm equipment. This additional equipment is necessary to properly filter and purify the air to meet minimal specifications for Grade D breathing as described in Compressed Gas Association Commodity Specification G 7.1 - 1966, OSHA 29 CFR 1910. 134, and/or Canadian Standards Associations (CSA).

DISCLAIMER OF WARRANTIES In the event the compressor is used for the purpose of breathing air application and proper in-line safety and alarm equipment is not simultaneously used, existing warranties shall be voided, and the manufacturer disclaims any liability whatsoever for any loss, personal injury or damage.

STOP!

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 reference.

Oilless Compressors

DO NOT RETURN THE PRODUCT TO THE RETAILER! CALL 1-800-543-6400

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.

MANUAL

Oilless Compressors

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.

12.

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.

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.

14. Indoor use only.

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

SPRAYING PRECAUTIONS

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

16. Do not smoke when spraying paint,

insecticides, or other flammable substances.

17. Use a face mask/

respirator when spraying and spray in a well ventilated area to prevent health and fire hazards.

18. 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.

19. 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.

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.

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.

TEST

RESET

Figure 1 - Grounding Method

Grounding

Grounded

Outlet

General Safety Information

FP209501, FP209598, FP209599,

FP209601, FP209699DB, and FP209699DQ

Operation

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.

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.

Regulator - The regulator controls the amount of air pressure released at the hose outlet. Turning the regulator knob clockwise (to the right) will increase air pressure at the outlet. Turning the knob counter-clockwise (to the left) will lower air pressure to the outlet. Turning knob fully counter-clockwise will shut off flow of air completely.

Pressure Gauges - There are two gauges located next to the regulator. These gauges read air pressure in pounds per square inch (psi) The larger gauge shows pressure at the outlet. Make sure this gauge reads ZERO (by adjusting the regulator) BEFORE changing air tools or disconnecting hose from outlet. The small gauge shows pressure in the tank indicating compressor is building pressure properly.

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.

LUBRICATION

This is an oilless product and

DDOOEESS

NNOOTT

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 repeat.)

1. Turn regulator knob fully clockwise (to the right) to open air flow.

2. Do not

attach a hose or any other

fitting to the compressor.

3. Turn on/off switch to OFF position.

4. Plug in power cord.

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

6. Turn on/off switch to OFF position.

7. Unplug power cord.

BEFORE EACH STARTUP OPERATING PROCEDURE

1. Turn switch to OFF ( O ) position and

plug in power cord.

2. Turn regulator knob counterclockwise to close air flow.

3. Turn switch to ON ( I ) 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 ( O ) position, unplug power cord and drain tank of air when finished using compressor.

Maintenance

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.

Figure 4

ON/OFF Switch

Drain Valve

Safety Valve

Pressure Gauge

Handle

Figure 2 - Unit Identification

Drain Valve

Regulator Knob

Air outlet

OFF Position

Figure 3

ON Position

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!

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 40-50 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.

CLEANING

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

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

LUBRICATION

This is an oilless type compressor requiring no lubrication.

THERMAL OVERLOAD PROTECTOR

This com-pressor 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 position.

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 drain.

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

Figure 5

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 6

Maintenance

(continued)

Notes

FP209501, FP209598, FP209599,

FP209601, FP209699DB, and FP209699DQ

Oilless Compressors

Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

1. Switch in OFF position

2. No electrical power at wall outlet

3. Compressor has reached automatic shut-off pressure

4. Motor overheated

5. Loose electrical connection

6. ON / OFF switch bad

7. Pressure switch bad

8. Defective motor

1. Lack of proper ventilation/room temperature too high

2. Excessive air usage, compressor too small

1. Open tank drain valve

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

3. Tank leaks

1. Excessive air usage, compressor too small

2. Open tank drain valve

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

4. Pump wore out

1. Excessive water in tank

2. High humidity

1. Defective pressure switch

2. Defective safety valve

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

2. Check circuit breaker or fuse at electrical panel.

3. Release air from tank until compressor restarts automatically

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. Check all electrical connections

6. Replace ON / OFF switch

7. Replace pressure switch

8. Replace pump / motor assembly

1. Move compressor to a clean,well ventilated area where temperature will not exceed 100°F.

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

1. Close tank drain valve

2. 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.

Do not disassemble check valve.

With air in tank, bleed tank first.

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

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

1. Drain tank, tilt tank to remove moisture

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

1. Replace pressure switch

2. Replace safety valve with genuine replacement part

Compressor will not run

Thermal overload protector cuts out repeatedly

Tank pressure drops when compressor shuts off

Compressor runs continuously / air output lower than normal

Excessive moisture in discharge air

Safety valve pops open

1 Shroud G 1 2 Shroud insert G 1 3 On/off switch FP204824AV 1 4 M3x15 screw F 4 5 Manifold assembly FP209527AV 1

6 2 in. Diameter gauge FP209529AV 1

6A 1.5 in. Diameter gauge FP209528AV 1

7 Safety valve V-215102AV 1 8 Motor isolator bushing kit FP209037AV 1 9 Pressure switch FP209530AV 1

10 Check valve (includes 26 and 27) FP209532AV 1 11 M4x0.7x6 screw F 1 12 M6x1.0x10 screw M 4 13 Drain valve D-1403 1

14 Rubber feet (tank) FP209522AV 4 15 Wire (pressure switch to

power switch) FP209523AV 1 16 Power cord/ strain relief FP209534AV 1 17 M3x10 screw G 6

18 Pump/motor assembly FP209039AV 1

(Includes part #20) 19 Motor cover L 1 20 Exhaust tube kit FP202839AV 1 21 Nailer hook FP209521AV 1

22 Accessories FP204008AV 1 23 25' Recoil Hose MP268100AV 1 24 Plastic base L 1 25 Pressure switch tube kit FP209535AV 1 26 Cap (see part #10) 1

27 Spring (see part #10) 1 28 Tank — 1 29 Screw M 2 30 Washer M 2 31 Screw M 4

32 Nut M 4 33 Screw M 4 34 Wire Clip FP202823AV 1 35 Screw F 1

36 Decal kit (not shown)

Model FP209501 FP209537AV Model FP209601 FP209620AV

REPAIR PART KITS

M Fastener Kit FP209040AV G Shroud kit FP209536AV L Plastic base & Motor cover FP209038AV F Standard hardware item

— Not Available

For Replacement Parts or Technical Assistance, Call 1-800-543-6400

Address parts correspondence to:

Attn: Customer Service 100 Production Drive Harrison, OH 45030 U.S.A.

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

Ref. Ref. No. Description Part Number Qty. No. Description Part Number Qty.

Replacement Parts List

FP209501, FP209598, FP209599,

FP209601, FP209699DB, and FP209699DQ

Oilless Compressors

Limited Warranty

1. DURATION: From the date of purchase by the original purchaser as follows: One Year.

2. WHO GIVES THIS WARRANTY (WARRANTOR): Campbell Hausfeld / Scott Fetzer Company, 100 Production Drive, Harrison, Ohio, 45030, Telephone: (800) 543-6400

3. WHO RECEIVES THIS WARRANTY (PURCHASER): The original purchaser (other than for purposes of resale) of the Campbell

Hausfeld compressor.

4. WHAT 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: 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

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 PROVIDE REPLACEMENT UNDER THIS WARRANTY: Replacement will be scheduled according to the availability of replacement compressor or 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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