Campbell Hausfeld FP209699DQL, FP209699DB, FP209598, FP209501, FP209599, FP209601 User Manual

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

Operating Instructions and Parts Manual

FP209501, FP209598, FP209599, FP209601

FP209699DB, and FP209699DQL

 

 

 

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 STOP! 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 reference.

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:

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.

1. Read all manuals included

with this product carefully.

MANUAL

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.

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

© 2009 Campbell Hausfeld/Scott Fetzer

IN619402AV 1/09

Oilless Compressors

General Safety

Information

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.

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.

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.

Grounding

Pin

TEST

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

 

 

 

FP209501, FP209598, FP209599,

 

 

 

FP209601, FP209699DB, and FP209699DQ

Operation

 

Regulator Knob

Handle

 

Definition of Terms

Pressure Gauge

 

 

ON / OFF Switch ( I / O ) - Push switch

 

Air outlet

 

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 )

 

ON/OFF Switch

 

position when connecting /

 

 

 

 

 

disconnecting power cord from

 

 

 

electrical outlet or when changing tools.

 

 

 

ON Position

OFF Position

Drain Valve

 

 

 

Safety Valve

Drain Valve

Figure 3

 

Figure 2 - Unit Identification

 

 

 

Pressure Switch (located internally)-

ASME Safety Valve - This valve

2. Turn regulator knob

When the compressor is turned ON,

this switch will shut compressor off

automatically releases air if the tank

counterclockwise to close air flow.

automatically when tank pressure

pressure exceeds the preset maximum.

3. Turn switch to ON ( I ) position.

reaches maximum shut-off / cut-out

Handle - Designed to move the

4. Compressor will build to maximum

pressure. If compressor remains on and

compressor.

pressure and shut off.

air is depleted from tank, this switch

Drain Valve - This valve is located on

5. With hose attached to outlet of

will allow compressor to automatically

the bottom of the tank. Use this valve

compressor, attach tire chuck or

restart at the restart / cut-in pressure.

to drain moisture from the tank daily

other tool to open end of hose.

 

 

 

 

 

 

 

 

 

to reduce the risk of corrosion.

6. Adjust regulator to proper pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LUBRICATION

for tool or tire. Operate tool per

 

 

 

 

 

 

 

 

 

This is an oilless product and DOES

instructions.

 

 

 

 

 

 

 

 

 

NOT require lubrication to operate.

As air is depleted from the tank by use

 

 

 

 

 

 

 

 

 

Figure 4

 

 

 

BEFORE FIRST STARTUP

of a tire chuck, tool, etc., the

 

 

 

 

 

 

 

 

 

 

compressor will restart automatically at

 

 

 

 

 

 

 

 

 

Regulator - The regulator controls the

BREAK-IN PROCEDURE

its preset “cut-in” pressure. When a

amount of air pressure released at the

 

 

(Complete this procedure before using

tool is being used continuously, the

hose outlet. Turning the regulator knob

compressor for the first time. Once

compressor will cycle on and off

clockwise (to the right) will increase air

completed, it is not necessary to repeat.)

automatically.

pressure at the outlet. Turning the knob

1.

Turn regulator knob fully clockwise

7. Turn switch to OFF ( O ) position,

counter-clockwise (to the left) will lower

 

(to the right) to open air flow.

 

unplug power cord and drain tank of

air pressure to the outlet. Turning knob

 

 

2.

Do not attach a hose or any other

air when finished using compressor.

fully counter-clockwise will shut off flow

 

fitting to the compressor.

 

 

 

 

of air completely.

 

 

 

 

 

3. Turn on/off switch to OFF position.

Maintenance

Pressure Gauges - There are two

 

 

 

 

 

 

 

 

 

 

 

 

 

gauges located next to the regulator.

4. Plug in power cord.

 

 

 

 

 

 

 

 

5. Turn on/off switch to ON position.

 

 

 

 

These gauges read air pressure in

 

 

 

 

 

Allow compressor to run for 5 min.

 

 

 

 

 

Disconnect power source

 

pounds per square inch (psi) The larger

 

 

 

 

 

gauge shows pressure at the outlet.

6.

Turn on/off switch to OFF position.

then release all pressure

 

Make sure this gauge reads ZERO (by

7.

Unplug power cord.

from the system before

 

 

attempting to install, service, relocate

adjusting the regulator) BEFORE

BEFORE EACH STARTUP

or perform any maintenance. Service

changing air tools or disconnecting hose

OPERATING PROCEDURE

should be performed by an authorized

from outlet. The small gauge shows

1. Turn switch to OFF ( O ) position and

service representative.

 

 

 

 

 

 

 

 

 

 

 

 

 

pressure in the tank indicating

plug in power cord.

compressor is building pressure properly.

 

 

 

3

Oilless Compressors

Maintenance

(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!

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.

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 40-50 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 6

4

FP209501, FP209598, FP209599,

FP209601, FP209699DB, and FP209699DQ

Notes

5

Oilless Compressors

Troubleshooting Chart

Symptom

Possible Cause(s)

Corrective Action

 

 

 

 

Compressor will not run

1. Switch in OFF position

1.

Make sure compressor is plugged in and switch is ON

 

2.

No electrical power at wall outlet

2.

Check circuit breaker or fuse at electrical panel.

 

3.

Compressor has reached automatic

3.

Release air from tank until compressor restarts

 

 

shut-off pressure

 

automatically

 

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

protector cuts out

 

temperature too high

repeatedly

2.

Excessive air usage, compressor too

 

 

small

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)

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.

off

 

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.

 

 

 

 

 

 

 

3.

Tank leaks

 

 

 

With air in tank, bleed tank first.

 

3.

Check entire tank for leaks with soap and water

 

 

 

 

 

solution.

 

 

 

 

 

 

 

Compressor runs

1.

Excessive air usage, compressor too

continuously / air

 

small

output lower than

2.

Open tank drain valve

normal

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

6

FP209501, FP209598, FP209599,

FP209601, FP209699DB, and FP209699DQ

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

Please provide following information:

-Model number

-Serial number (if any)

-Part description and number as shown in parts list

Address parts correspondence to:

Attn: Customer Service

100 Production Drive Harrison, OH 45030 U.S.A.

 

12

 

1

2

 

17

34

31

35

 

 

31

 

19

29

30

30

24

33

32

Replacement Parts List

11

3

25

16

15

9

10

4

5

 

 

6

6A

 

22

21

20

23

18

26

27

8

28

13

7

14

Ref.

 

 

Ref.

 

 

No. Description

Part Number

Qty.

No. Description

Part Number

Qty.

 

 

 

 

 

 

1

Shroud

1

2

Shroud insert

1

3

On/off switch

FP204824AV

1

4

M3x15 screw

 

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

 

1

12

M6x1.0x10 screw

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

6

18

Pump/motor assembly

FP209039AV

1

 

(Includes part #20)

 

 

19

Motor cover

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

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

2

30

Washer

2

31

Screw

4

32

Nut

4

33

Screw

4

34

Wire Clip

FP202823AV

1

35

Screw

 

1

36

Decal kit (not shown)

 

 

 

Model FP209501

FP209537AV

 

 

Model FP209601

FP209620AV

 

REPAIR PART KITS

 

 

Fastener Kit

FP209040AV

 

Shroud kit

FP209536AV

 

Plastic base & Motor cover

FP209038AV

 

 

Standard hardware item

 

 

Not Available

7

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.

8

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