Campbell Hausfeld HJ3001, HG3000, HJ3002, IN634100AV User Manual

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

Operating Instructions HG3000 Series, HJ3001 Series, HJ3002 Series

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.

200 PSI Portable ASME

Air Compressors

Description

Portable oilless air compressors are for home and workshop use. Cleaning or replacement of the inlet filter on all models and draining moisture from the air receivers are required maintenance.

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.

Record the Model No., Serial No. and date of purchase in the space below.

Model No. ______________________ Serial No. ______________________ 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 Campbell Hausfeld disclaims any liability whatsoever for any loss, personal injury or damage.

Unpacking

When unpacking unit, inspect carefully for any damage that may have occurred during transit. Make sure any loose fittings, bolts, etc., are tightened before putting unit into service. In case of questions, damaged or missing parts, please call 1-800-543-6400 for customer assistance. Have the serial number, model number, and parts list (with missing parts circled) before calling.

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

DO NOT RETURN

STOP!

Do not operate unit

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

Attach it to this manual or file it for safekeeping.

THE PRODUCT TO THE RETAILER!

if damaged during

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READ & FOLLOW ALL INSTRUCTIONS

SAVE THESE INSTRUCTIONS

DO NOT DISCARD

Operating Instructions

General Safety

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.

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 INFORMATION

Air compressors are utilized in a variety of air system applications. Because air compressors and other components (material pump, spray gun, filters, lubrications, hoses, etc.) used make up a high pressure pumping system, the following safety precautions should be observed at all times. Only persons well acquainted with these rules of safe operation should be allowed to use the air compressor.

Risk of Bursting! This compressor is designed to provide air pressure up to 200 psi. Most attachments are designed to operate at a maximum pressure of less than 125 psi. DO NOT adjust the regulator to result in output pressure greater than the marked maximum pressure of the attachment.

Risk of Injury! Do not

direct air stream at body.

All electrical work

should be done by a qualified (licensed or certified) electrician. On a properly wired circuit, the black wires supply a voltage potential even when the unit is off.

1. Read instruction

manuals for each component carefully, before attempting to assemble, disassemble or operate your particular system.

2. Wear safety glasses and

use hearing protection when operating the pump or unit.

MANUAL

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

4. Do not exceed pressure rating of any component in system.

5. Protect material lines and air lines from damage or puncture. Keep hose and power cable away from sharp objects, chemical spills, oil, solvents, and wet floors.

6. Never point a spray gun at oneself or any other person. Accidental discharge may result in serious injury.

7. Check hoses for weak or worn condition, before each use, making certain all connections are secure; do not use if deficiency is found. Notify an authorized service facility for examination or repair.

Do not run

unattended. Leaving compressor in ON position may allow it to turn on inadvertently. To prevent this and possible damage from power surge, turn to OFF position after each use.

8. Release all pressures within system

slowly; dust and debris may be harmful.

Keep

fingers away from a running compressor; fast moving and hot parts will cause injury and/or burns.

Disconnect power

and depressurize system before servicing air compressor!

9. Follow all local electrical and safety

codes, as well as the National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA).

10. Wiring and fuses should follow

electrical codes, current capacity, and be properly grounded.

11. Electric motors must be securely

and adequately grounded. See grounding instructions and extension cord information, in this manual.

12. Always disconnect power source

before working on or near a motor, or its connected load. If power disconnect point is out-of-sight, lock it in the open position and tag to prevent unexpected application of power.

13. Guard all moving parts; keep visitors away. Never allow children in work area.

14. Use only a properly grounded outlet that will accept a three pronged plug, and wear shoes to prevent shock hazards.

careful when touching exterior of operating motor; it may be hot enough to cause injury. Compressor parts may be hot even if the unit is stopped.

15. Protect power cable from coming in

contact with sharp objects.

16. Clean electrical or electronic

equipment with an approved cleaning agent, such as dry, nonflammable cleaning solvent.

Motors,

electrical equipment and controls can cause electrical arcs that will ignite a flammable gas or vapor. Never operate or repair the unit near a flammable gas or vapor. Never store flammable liquids or gases in the vicinity of the compressor.

17. To reduce fire hazard,

keep engine/motor exterior free of oil, solvent, or grease.

18. To avoid spontaneous combustion,

discard waste rags into approved metal waste cans.

19. NEVER reset safety valve or pressure

switch. Keep safety valve free from paint and other accumulations. This provides safety against over pressure.

Never remove or

attempt to adjust safety valve. Keep safety valve free from paint and other accumulations.

20. Do regular maintenance; keep all

nuts, bolts, and screws tight, to be sure equipment is in safe working condition .

21. Keep cleaning rags and other

flammable waste materials in a tightly closed metal container and dispose of later in the proper fashion.

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HG3000 Series, HJ3001 Series, HJ3002 Series

General Safety

(Continued)

22. Drain tanks of moisture after each day’s use. If unit will not be used for a while, it is best to leave drain cock open until such time as it is to be used. This will allow moisture to completely drain out and help prevent corrosion of inside of tank.

23. Inspect tank yearly for rust, pin holes or any other imperfections that could cause it to become unsafe. NEVER weld or drill holes in air tank.

24. Household use only.

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

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.

SPRAYING PRECAUTIONS

Do not spray

flammable materials in vicinity of open flame or near ignition sources including the compressor unit.

1. Spray in a well ventilated area, to

keep fumes from collecting and causing health and fire hazards.

2. Do not spray in vicinity of open

flames or other places where a spark can cause ignition. Do not smoke when spraying paint, insecticides, or other flammable substances.

3. Use a respirator when spraying.

4. 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.

5. When spraying or cleaning with

solvents or toxic chemicals, follow the instructions provided by the chemical manufacturer.

6. Do not smoke when spraying paint,

insecticides, or other flammable substances.

7. Use a face mask/

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

8. Do not direct airstream at body.

Assembly

ASSEMBLY TOOLS REQUIRED

Tools (not provided) for assembly:

- (1) #2 Phillips screwdriver

- (2) adjustable wrenches

WHEEL ASSEMBLY (FIGURE 1)

Wheel assembly kit includes:

- (2) wheels

- (2) axle bolts

- (2) wheel inserts

- (2) washers

- (2) nuts

1. Wheel has an offset hub. With offset hub facing axle iron, assemble axle bolt through wheel insert, holes in wheel and axle iron.

2. Place adjustable wrench on axle bolt. Using a second adjustable wrench, tighten nut securely to threaded part of axle bolt.

3. Repeat procedure with other side.

HANDLE ASSEMBLY (FIGURE 2)

Never use the

handle to lift the unit completely off the ground. Only use the handle to lift one end so the wheels may be used to move the unit.

Handle assembly kit includes:

- (1) handle

- (4) bolts

1. Insert ends of handle into tube

shaped brackets on tank.

2. Align screw holes.

3. Thread screw into hole until tight.

4. Tighten securely with #2 Phillips

screwdriver.

Wheel

Washer

Nut

Figure 1 - Wheel assembly

Wheel insert

Handle

Bolt

Figure 2 - Handle assembly

Bolt

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Operating Instructions

Introduction

Pressure Switch - ON/OFF Switch - In

the ON position, the compressor shuts off automatically when tank pressure reaches the maximum preset pressure. In the OFF position, the compressor will not operate. This switch should be in the OFF position when connecting or disconnecting the power cord from the electrical outlet or when changing air tools.

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.

Exhaust Tube - This tube carries compressed air from the pump to the check valve. This tube becomes very hot during use. To avoid the risk of severe burns, never touch the exhaust tube.

Check Valve - A one-way valve that allows air to enter the tank, but prevents air in the tank from flowing back into the compressor pump.

Handle - Designed to move the compressor.

Air Outlet - A quick connect coupler designed to work in combination with a quick connect plug to quickly and easily join a pneumatic tool to an air hose.

Pressure Gauges - These gauges will show air pressure in the compressor tank and at the compressor outlet.

Outlet Pressure Gauge - Will show air pressure at the outlet in pounds per square inch (psi). Make sure this gauge reads ZERO (by adjusting regulator knob fully counterclockwise) before changing air tools or disconnecting air hose from outlet.

Tank Pressure Gauge - Will show air pressure in tank while the compressor is running, indicating compressor is building pressure properly. This gauge will show maximum pressure of compressor when it shuts off automatically at the pressure switch.

Drain Valve - This valve is located underneath the tank. Use this valve to drain moisture from the tank daily to reduce the risk of corrosion.

Drain liquid from

tank daily.

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

Installation

LOCATION

It is extremely important to install 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

Household use only. Store indoors.

ELECTRICAL INSTALLATION

1. Check and tighten all bolts, fittings,

etc., before operating compressor.

2. Operate compressor in a ventilated

area so that compressor may be properly cooled.

3. Compressor should be located

where it can be directly plugged into an outlet, but if this is not possible, an extension cord may be used. It should be selected using the extension cord chart on page 5 as a guide.

4. To avoid loss of power and

overheating, it is better to use additional air hose instead of extension cords to reach work area.

Outlet Pressure Gauge

Air Outlet

Figure 3

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Regulator

Pressure Switch

Tank Pressure Gauge

ASME Safety Valve

HG3000 Series, HJ3001 Series, HJ3002 Series

Installation (Continued)

WIRING

1. Local electrical wiring codes differ from area to area. Source wiring, plug and protector must be rated for at least the amperage and voltage indicated on motor nameplate, and meet all electrical codes for this minimum.

2. Use a slow blow fuse type T or a circuit breaker.

Overheating, short

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

All wiring and

electrical connections should be performed by a qualified electrician. Installation must be in accordance with local codes and national electrical codes.

NOTE: 120 volt, compressor can be operated on a 120 volt, 15 amp 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. Extension cords are of the

minimum gauge specified in this

instruction manual. d. Circuit is equipped with a 15 amp

circuit breaker or a 15 amp slow

blow fuse type T.

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.

3. If above 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.

GROUNDING INSTRUCTIONS

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Grounding

TEST

RESET

Grounded

Outlet

Check with a qualified electrician or serviceman when the grounding instructions are not completely understood, or when in doubt as to whether the product is properly grounded. Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a qualified technician.

This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illustrated in Figure 4. Only connect the product to an outlet having the same configuration as the plug. Do not use an adapter with this product.

EXTENSION CORDS

To avoid loss

of power and overheating, it is better to use additional air hose instead of extension cords to reach work area.

Use only a 3-wire extension cord that

Figure 4 - Grounding Method

Improper installation

of the grounding plug is able to result in a risk of electric shock. When repair or replacement of the cord or plug is required, do not connect the grounding wire to either flat blade terminal. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.

Do not use a

grounding adapter with this product!

Never connect green

(or green and yellow) wire to a live terminal.

has a 3-blade grounding plug, and a 3-slot receptacle that accepts the plug on the product. Make sure your extension cord is not damaged. When using an extension cord, be sure to use one heavy enough to carry the current your product draws. An undersized cord results in a drop in line voltage and loss of power and overheating. [The table on page 5 shows the correct size to use depending on cord length and nameplate ampere rating. When in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.]

✽ Wire and Terminal Guide

Wire Color Terminal Hot

Power cord White Line No Motor cord White Load No Power cord Black Line Yes Motor cord Black Load Yes

(✽) When the unit is not in operation

Minimum Gauge of Extension Cords for 120V Unit

Motor Amp Rating Range

25 feet 50 feet 100 feet

Length of Cord

10-12 amp 16 14 10 12-14 amp 16 12 10 14-16 amp 16 12 10

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Operating Instructions

Operation

BEFORE FIRST START-UP 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 and open drain valve.

2. Turn ON/OFF switch to OFF position.

3. Plug in power cord.

4. Turn ON/OFF switch to ON position and run compressor for 30 minutes.

5. Turn ON/OFF switch to OFF position.

6. Unplug power cord.

7. Close drain valve.

The compressor is now ready for use.

BEFORE EACH START-UP OPERATING PROCEDURE

1. Turn regulator knob fully counter clockwise (to the left) to close air flow.

2. Connect air hose to outlet of regulator.

3. Turn On/Off Switch to OFF position.

4. Plug in power cord.

5. Turn On/Off Switch to ON position and let compressor run until it reaches automatic shutoff pressure.

6. Attach tire chuck or tool to end of hose.

7. Turn regulator knob clockwise (to the right) to desired pressure of tool being used.

Risk of

Bursting! This compressor is designed to provide air pressure up to 200 psi. Most attachments are designed to operate at a maximum pressure of less than 125 psi. DO NOT adjust the regulator to result in output pressure greater than the marked

maximum pressure of the attachment.

ON/OFF CYCLING OF COMPRESSOR

In the ON position, the compressor pumps air into the tank. When a shut-off (preset “cut-out”) pressure is reached, the compressor automatically shuts off.

If the compressor is left in the ON position and 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.

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.

PRESSURE GAUGES

The gauge attached to control panel is the Outlet Gauge, and it indicates air pressure going to hose (and tool attached to end of hose).

The gauge toward the front of the shroud is the Tank Gauge, and it indicates air pressure in tank.

Maintenance

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 (see Figure 5) to release pressure from compressor tank. Use your other hand to deflect fast-moving air from being directed toward your face.

Figure 5

3. The safety valve should automatically close when pressure in the tank has been released. 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.

Safety valve must be

replaced if it cannot be actuated or it leaks air after ring is released.

GENERAL

Release all pressure

and disconnect power before making any repair.

1. Check compressor for any visible

problems, especially check air filter to be sure it is clean.

2. Pull ring on safety valve and allow it to snap back to normal position (Figure 5).

Safety valve must be

replaced if it cannot be actuated or it leaks air after ring is released.

3. Daily with compressor shut off:

Depressurize system prior to draining tank. Drain moisture from tank by opening drain valve underneath the tank.

NOTE: Tank should be emptied regularly.

Figure 6

Do not remove drain

plug with tank under pressure.

4. Turn power OFF and clean dust and

dirt from motor, tank, air lines and pump cooling fins.

NOTE: The air filter in the filter housing on the side of the head must be checked and cleaned periodically, more often if used under very dusty conditions or when a great deal of fog from spraying is allowed to circulate near unit.

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

FILTER REMOVAL, INSPECTION AND REPLACEMENT

To change a filter, remove the screw in the filter housing cover. If filter element is dirty, rotate filter element so the holes line up with clean element material and snap cover onto housing. If filter element has no clean areas, replace element.

LUBRICATION

This is an oilless type compressor requiring no lubrication.

THERMAL OVERLOAD PROTECTOR

Turn off the pressure switch or unplug compressor for 20 minutes and allow it to cool. Reset the unit. Switch unit to OFF and turn ON again to resume work.

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