Campbell Hausfeld IN633000AV, FP2603, FP2604 User Manual

See Warranty on page 10 for important information about commercial use of this product.

Operating Instructions and Parts Manual FP2603, FP2604

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

Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . .1

Unpacking . . . . . . . . . . . . . . . . . . . . . . .1

Safety Guidelines . . . . . . . . . . . . . . . . .2

General Safety Information . . . . . . . . .2

Installation. . . . . . . . . . . . . . . . . . . . . . .3

Operation . . . . . . . . . . . . . . . . . . . . . . .4

Maintenance . . . . . . . . . . . . . . . . . . . . .5

Troubleshooting Chart . . . . . . . . . . . . .6

Replacement Parts List . . . . . . . . . . . . .8

Warranty . . . . . . . . . . . . . . . . . . . . . . .10

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.

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 operate

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

Figure 1 - FP2603 and FP2604

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.

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.

REMINDER: Keep your dated proof of purchase for warranty purposes!

Attach it to this manual or file it for safekeeping.

For parts, product & service information

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IN633000AV 12/09

Operating Instructions and Parts Manual

READ & FOLLOW ALL INSTRUCTIONS

SAVE THESE INSTRUCTIONS

DO NOT DISCARD

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.

NOTE: Information that requires special attention.

General Safety Information

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.

You can create dust when you cut, sand, drill or grind materials such as wood, paint, metal, concrete, cement, or other masonry. This dust often contains chemicals known to cause cancer, birth defects, or other reproductive harm. Wear protective gear.

GENERAL SAFETY

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.

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

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FP2603, FP2604

General Safety Information (Continued)

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.

HOSE PRECAUTIONS

20. Inspect hose before use.

Do not exceed working pressure marked on hose.

Do not twist, bend knot, or abrade hose.

21. Do not wrap hose around body.

Keep away from hot surfaces and chemicals.

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 Figure 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

Grounded outlet

TEST

RESET

plug provided; if it will not fit outlet, have proper outlet installed by a qualified electrician.

Overheating, short

circuiting and ﬁre

Grounding pin

Figure 1 - Grounding method

damage will result from inadequate wiring, etc.

MOISTURE IN COMPRESSED AIR

Moisture in compressed air will form into droplets as it comes from an air compressor pump. When humidity is high or when a compressor is in continuous use for an extended period of time, this moisture will collect in the tank. When using a paint spray or sandblast gun, this water will be carried from the tank through the hose, and out of the gun as droplets mixed with the spray material.

IMPORTANT: This condensation will cause water spots in a paint job, especially when spraying other than water based paints. If sandblasting, it will cause the sand to cake and clog the gun, rendering it ineffective. A filter in the air line, located as near to the gun as possible, will help eliminate this moisture.

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Operating Instructions and Parts Manual

Power Cord with Plug

Tank Gauge

Handle

Shroud

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.

ASME Safety Valve

Outlet Gauge

Regulator

Air Outlet

Figure 2 - Unit identification

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.

Position

Figure 3 - ON/OFF switch

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.

OFF

Position

ON/OFF Switch

Tank

Tank Drain Valve

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 gauge on the right 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 gauge on the left 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.

Figure 4 - Drain valve

Motor Protection - If the unit is over

worked, a thermal limiter will shut unit off. If this happens, switch unit to OFF, wait 30 minutes to cool, turn ON again to resume work.

LUBRICATION

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 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 minutes.

6. Turn ON/OFF switch to OFF position.

7. Unplug power cord.

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.

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FP2603, FP2604

Operation (Continued)

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.

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).

Figure 5 - Safety valve

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 automatically close 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.

Figure 6 - Drain 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.

END OF OPERATION/STORAGE

1. Turn ON / OFF ( I / O ) switch to the OFF ( O ) 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.

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Operating Instructions and Parts Manual

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 shut-

off pressure

4. Motor overheated/overworked 4. Switch unit to OFF, wait 30 minutes to cool,

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 protector cuts out repeatedly

1. Lack of proper ventilation/room

temperature too high

2. Excessive air usage, compressor too small 2. Decrease usage or purchase unit with higher

Tank pressure drops when compressor shuts off

1. Open tank drain valve 1. Close tank drain valve

2. Loose connections (fittings, tubing, air

hose, any connections, etc.)

3. Tank leaks 3. Check entire tank for leaks with soap and

Compressor runs

1. Excessive air usage, compressor too small 1. Decrease usage or purchase unit with higher

continuously / air output lower than normal

2. Open tank drain valve 2. Close tank drain valve

3. Loose connections (fittings, tubing, air

hose, any connections, etc.)

4. Pump wore out 4. Replace pump / motor assembly

Excessive moisture in discharge air

1. Excessive water in tank 1. Drain tank, tilt tank to remove moisture

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

Safety valve pops open 1. Defective pressure switch 1. Replace pressure switch

2. Defective safety valve 2. Replace safety valve with genuine

3. Release air from tank until compressor restarts automatically

turn ON again to resume work. Make sure compressor is run in a clean, well-ventilated area where temperature will not exceed 100°F.

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

air delivery (SCFM)

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.

water solution.

air delivery (SCFM)

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.

filter

replacement part

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Notes

FP2603, FP2604

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Operating Instructions and Parts Manual

For Replacement Parts or Technical Assistance,

Call 1-800-543-6400

Please provide following information: Address any correspondence to:

- Model number Campbell Hausfeld

- Serial number (if any) Attn: Customer Service

- Part description and number as shown in parts list 100 Production Drive

Harrison, OH 45030 U.S.A.

25 26 27

7 16

Figure 7 – Replacement parts illustration for models FP2603 and FP2064

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Replacement Parts List

FP2603, FP2604

Ref. No. Description

1 Accessory Tray

Part No. Qty.

2 On/Off Switch FP205129AV 1 3 Shroud 4 Screw 5 Shroud Insert 6 Screw 7 Screw

8 Pump/Motor Assembly -- 1 9 Motor Cover

10 Motor Cover Isolator

11 Screw -- 1 12 Wire Clip FP202823AV 1 13 Exhaust Tube Assembly FP202839AV 1 14 Wire (Pressure Switch to

FP209523AV 1

Power Switch) 15 Power Cord 16 Wire Clip/Strain Relief

17 Screw -- 1 18 Washer with Teeth -- 1 19 Terminal -- 1 20 Outlet Gauge FP204013AV 1

Ref. No. Description

21 Tank Gauge FP204012AV 1

22 Regulator and Manifold 1 4 1 4 2

Assembly 23 Safety Valve V-215100AV 1 24 Check Valve Assembly FP209532AV 1 25 Check Valve 26 Poppet -- 1

Part No. Qty.

FP018300AV 1

27 Spring -- 1

1 1

28 Pressure Switch FP018400AV 1 29 Tank -- 1 30 Drain Valve D-1403 1 31 Rubber Foot 32 Screw

3 2

REPLACEMENT PARTS KITS

Shroud Kit FP018500AV 1 1

Fastener Kit FP018600AV

Motor Cover Kit FP018700AV

Powercord with Strain Relief FP209534AV

Rubber Foot Kit FP202836AV

-- Not available

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Operating Instructions and Parts Manual

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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+ 22 hidden pages

Campbell Hausfeld IN633000AV, FP2603, FP2604 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual