See Warranty on page 12 for important information about commercial use of this product.
Operating Instructions & Parts Manual HL5403, HL5404
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.
Oil Lubricated Compressors
Description
This oil-lubricated compressor is
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.
designed for do-it-yourselfers with a
variety of home and automotive jobs.
These compressors power spray guns,
impact wrenches and other tools.
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 serial number,
model number, and parts list (with
missing parts circled before calling.)
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.
REMINDER: Keep your dated proof of purchase for warranty purposes!
Attach it to this manual or file it for safekeeping.
IN626401AV 5/10
Operating Instructions and Parts Manual
Safety Guidelines
(Continued)
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
• Onlypersonswellacquaintedwith
these rules of safe operation should
be allowed to use the unit.
Do not operate unit
if damaged during
shipping, handling or use. Damage may
result in bursting and cause injury or
property damage.
Do not run
unattended. Leaving
compressor in AUTO position may allow
it to turn on inadvertently. To prevent
this and possible damage from power
surge, turn to OFF position after each
use.
Since the air compressor and other
components (filters, lubricators, hoses,
etc.) used, 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
MANUAL
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 Code (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.
13. Tanks rust from moisture build-up,
which weakens the tank. Make sure
to drain tank regularly and inspect
periodically for unsafe conditions
such as rust formation and corrosion.
14. Fast moving air will stir up dust
and debris which may be harmful.
Release air slowly when draining
moisture or depressurizing the
compressor system.
SPRAYING PRECAUTIONS
Do not
spray
flammable materials in
vicinity of open flame or near
ignition sources including the
compressor unit.
15. Do not smoke when spraying paint,
insecticides, or other flammable
substances.
16. Use a face mask/
respirator when spraying
and spray in a well
ventilated area to prevent
health and fire hazards.
17. Do not direct paint or other sprayed
material at the compressor. Locate
compressor as far away from
the spraying area as possible to
minimize overspray accumulation on
the compressor.
18. When spraying or cleaning with
solvents or toxic chemicals, follow
the instructions provided by the
chemical manufacturer.
2
Glossary of Terms
HL5403, HL5404
Pressure Switch - Auto/Off Switch - In
the AUTO 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 at the
hose outlet. Turning regulator knob
clockwise (to the right) will increase air
pressure at the outlet. Turning knob
counterclockwise (to the left) will lower
air pressure to the outlet. Turning knob
fully counterclockwise will shut off flow
of air completely.
ASME Safety Valve - This valve is
attached to the pressure switch. It will
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 - This valve is located at
the end of the exhaust tube where it
meets the tank. It is 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.
Never use the
handle on wheeled
units to lift the unit completely off the
ground.
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.
Pressure Gauges - These gauges will
show air pressure in the compressor
tank and at the compressor outlet.
Handle
Outlet
Pressure
Gauge
Exhaust
Tube
Oil Sight
Gauge
Oil Drain PlugAir Filter
Figure 1 - Unit Identification
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.
Motor Reset - (not shown, located
inside motor). Designed to keep the
motor from overheating. The motor has
an auto reset protector. To reset once
the motor has cooled, turn the pressuer
switch to the OFF position, then to the
AUTO position.
This compressor is
equipped with an
overload protector which will shut off
motor if it becomes overloaded.
If the overload
protector is
actuated, the motor must be allowed
to cool down for approximately 30
minutes before it will reset.
Pressure Switch
Tank Pressure
Gauge
Regulator
Installation
LOCATION
It is extremely important to install the
compressor in a clean, dry, and well
ventilated area. The compressor must
be placed on a firm, level surface 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.
ELECTRICAL INSTALLATION
All wiring and
electrical
connections should be performed by a
qualified electrician. Installation must
be in accordance with local codes and
national electrical codes.
3
Operating Instructions and Parts Manual
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 or a circuit
breaker.
3. This product is for use on a nominal
120 volt circuit and has a grounding
plug that looks like the plug
illustrated in Figure 2. 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.
Overheating, short
circuiting and fire
damage will result from inadequate
wiring.
Grounded
Outlet
RESET
TEST
Grounding Pin
Figure 2 - Grounding Method
Minimum Gauge of Extension Cord
25 ft.50 ft.100 ft.
141210
Use of an extension cord may cause excess
heat to motor. This could lead to tripped
breaker (at electrical panel) or tripped
thermal overload (on compressor motor).
If this occurs, eliminate extension cord and
plug compressor directly into electrical
outlet. Avoid using extension cords; use
longer air hose(s) instead.
LUBRICATION
This unit is shipped
without oil!
Follow lubrication instructions before
operating compressor.
Use oil shipped with the compressor. Do
not use regular automotive oil such
as 10W-30. Additives in regular motor
oil can cause valve deposits and reduce
pump life. For maximum pump life,
drain and replace oil after the first hour
of run time.
The compressor pump takes
approximately 175mL (6 oz) of oil. The
sight glass, located on the crankcase
portion of the pump, is used to
determine proper oil level. Fill the
crankcase with oil until the level is in
the middle of the sight glass. Avoid
overfilling by adding oil gradually and
checking the oil level with the sight
glass several times. Add enough oil to
reach the “max” level on the sight glass.
Proper oil level is illustrated in Figure 3.
Max.
Min.
Figure 3 - Proper Oil Level
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. Open drain valve located on bottom
of tank.
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.
OPERATING PROCEDURE
1. Turn switch to OFF position and plug
in power cord.
2. Turn regulator knob
counterclockwise to close air flow.
3. Turn switch to AUTO 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 position, unplug
power cord and drain tank of air
when finished using compressor.
4
HL5403, HL5404
Maintenance
Disconnect power source and
then release all pressure from
the system before attempting
to install, service, relocate or perform
any maintenance.
Check compressor often for any visible
problems and follow maintenance
procedures each time compressor is
used.
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
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.
Safety valve must
be replaced if it
cannot be actuated or it leaks air after
ring is released.
A large amount of
fast moving air will
be released when the safety valve is
opened with pressure in the tank. Wear
ANSI approved Z87.1 safety glasses.
Figure 4
DRAIN TANK
With compressor shut off and pressure
released, drain moisture from tank by
opening drain valve underneath tank
(See Figure 5).
Figure 5
CLEANING
Turn power OFF and clean dust and dirt
from motor, tank, air lines and pump
cooling fins.
IMPORTANT: Unit should be located as
far from spraying area as hose will allow
to prevent over-spray from clogging air
filter.
OIL CHANGE
1. Allow compressor to run and warm
up oil. Unplug unit.
2. Position a pan under pump end of
unit.
3. Remove drain plug (see Figure 1).
Allow oil to collect in pan. Tilt unit
to completely drain.
4. Replace drain plug, fill pump to
center of sight glass. Use Chevron
synthetic 5W-30, Mobil 1 5W-30 or
10W-30 synthetic motor oil. Using
other types of oil will cause starting
problems.
5. Change oil after every 50 hours of
use.
AIR FILTER MAINTENANCE
Removal, Inspection and Replacement
(Figure 6)
The intake filter element should be
removed and checked periodically.
A clogged intake filter can decrease
compressor performance and cause the
compressor to overheat.
1. Gently pry filter cover from housing.
2. Remove the filter element and
inspect.
Filter
Cover
Filter
Element
Figure 6
3. If the filter element is dirty or
clogged, clean with hot, soapy water
or replace if necessary.
4. Reinstall filter and cover.
IMPORTANT: Locate unit as far from
spraying area as hose will allow to
prevent overspray from clogging filter.
END OF OPERATION/STORAGE
1. Turn AUTO/OFF switch to the OFF
position.
2. Unplug power cord from wall outlet
and wrap around handle 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.
TECHNICAL SERVICE
For information regarding the
operation or repair of this product,
please call 1-800-543-6400.
5
Operating Instructions and Parts Manual
Troubleshooting Chart
SymptomPossible Cause(s)Corrective Action
Compressor will not run1. No electrical power1. Plugged in? Switch on? Check fuse/breaker
2. Breaker open2. Reset, determine cause of problem
3. Pressure switch bad3. Replace
4. Motor over worked4. Turn off, let cool, turn on.
5. Tank pressure above cut-in5. Bleed tank pressure down to cut-in.
Fuses blow/circuit breaker
trips repeatedly
Tank pressure drops
when compressor shuts
off
Compressor runs
continuously and/or air
output is lower than
normal/low discharge
pressure
Excessive moisture in
discharge air
1. Incorrect size fuse, circuit overloaded 1. Check for proper fuse, use time-delay fuse.
25 Ferrule u2
26 Nut u 2
27 Exhaust tube u1
28 M6 x 12 Bolt — 3
29 M6 Washer l7
30 Drain valve D-1403 1
31 Rubber foot l4
32 M6 x 16 Bolt l4
33 Tank assembly — 1
34 Pump motor cord strain relief CW212800AV 1
35 Powercord strain relief CW212300AJ 1
36 Nut, to check valve s1
37 Ferrule, to check valve s1
38 Lock washer — 4
39 Mounting screws t10
40 Washers t10
41 Right side pressure gauge tank HL036100AV 1
42 Nut — 3
REPLACEMENT PARTS KITS
s Unloader tube kit HL039100AV n Manifold tube kit HL036000AV
lFoot kit HL032400AV
uExhaust tube kit HL032300AV
t Shroud kit HL031100AV
— Not available
HL5403, HL5404
9
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.
2
15
16
17
13
14
20
12
24
18
19
30
23
21
47
48
5
42
7
5
8
10
22
36
35
41
38
37
40
39
33
34
46
43
45
44
1
3
4
6
9
11
22
25
26
27
18
28
Figure 8 – Replacement Parts Illustration for pump/motor
www.chpower.com
29
1
31
32
33
34
10
Replacement Parts List for Pump/Motor
Ref. Part
No. Description No. Qty.
1 M6 Lock washer n l 8
2 M6 X 50 Head bolt l 4
3 Cylinder head l 1
4 Head gasket 6 1
5 Valve plate o 2
6 Metal gasket o 1
7 Valve o 2
8 Valve plate gasket 6 1
9 Cylinder s 1
10 M8 X 25 Cylinder bolt s 2
11 Cylinder gasket 6 1
12 Wrist pin t 1
13 Compression ring t 2
14 Oil ring t 1
15 Wrist pin retainer t 2
16 Piston t 1
17 Connecting rod HL030300AV t 1
18 M6 X 20 Bolt n 5
19 M6 Nut — 1
20 Eccentric — 1
21 Capacitor : 1
22 M8 Lock washer s : 3
23 M8 Nut : 1
24 Crankcase cover n 1
25 O-ring w 1
26 Sight glass w 1
27 O-ring v 1
28 M5 x 10 Drain plug v 1
29 O-ring m 1
30 Breather m 1
31 Crankcase cover gasket 6 1
32 Crankcase — 1
33 M5 Washer — 4
34 M5 X 16 Shroud screw — 4
35 Oil seal — 1