Campbell Hausfeld IN610502AV User Manual
See Warranty on page 8 for important information about commercial use of this product.
Operating Instructions and Parts Manual FP204100
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.
DO NOT RETURN THE
STOP!
Record the Model No., Serial No. and date
of purchase located on the base below the
pump in the space below.
Model No. _______________________
Date Code _______________________
Date of purchase _________________
Retain these numbers for future reference.
Have the date code, model number,
and parts list (with missing parts circled
before calling.)
Do not operate
during shipping, handling or use.
Damage may result in bursting and
cause injury or property damage.
PRODUCT TO THE
RETAILER! CALL
1-800-543-6400
unit if damaged
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:
1. Read all manuals included
with this product
carefully. Be thoroughly
familiar with the controls
and the proper use of the
equipment.
MANUAL
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 Campbell Hausfeld disclaims any liability whatsoever for any loss, personal injury or
damage.
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).
REMINDER: Keep your dated proof of purchase for warranty purposes!
© 2010 Campbell Hausfeld/Scott Fetzer
Attach it to this manual or file it for safekeeping.
For parts, product & service information
visit www.chpower.com
IN610502AV 4/10
Oilless Compressors
General Safety Information
(Continued)
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 daily 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.
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.
RESET
TEST
Grounding Pin
Figure 1 - Grounding Method
Improper
use of
grounding plug can result in
a possible risk of electrical
shock!
Grounded
Outlet
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FP204100
Installation (Continued)
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.
Operation
DEFINITION OF TERMS
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.
Handle - Designed to move the
compressor.
Drain Valve - This valve is located on
the bottom of the tank. Use this valve
to drain moisture from the tank daily to
reduce the risk of corrosion.
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.
Handle
Safety Valve
Drain Valve
Figure 2 - Unit Identification
LUBRICATION
This is an oilless product and DOES NOT
require lubrication to operate.
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.
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 5 minutes.
5. Turn on/off switch to OFF position.
6. Unplug power cord.
The compressor is now ready for use.
ON/OFF Switch
Regulator
BEFORE EACH START-UP
OPERATING PROCEDURE
1. Turn regulator knob fully
counterclockwise (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.
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.
Extension cords for 120V/2.5 Amp Unit
Length of Cord (ft) 25 50 100 150
Gauge of Cord 18 18 16 14
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Oilless Compressors
Operation (Continued)
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.
ASME SAFETY VALVE
Do not remove or
attempt to adjust
the safety valve!
Figure 3
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 fast-moving 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.
REGULATOR KNOB
1. This knob controls air pressure to an
air operated tool or tire chuck.
2. Turn knob clockwise to increase air
pressure.
3. To lower air pressure turn knob
counterclockwise.
4. Turn fully counterclockwise to shut
off flow of air completely.
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.
LUBRICATION
This is an oilless type compressor
requiring no lubrication.
Figure 4
Maintenance
Disconnect power source
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.
Safety valve must
be replaced if it
cannot be actuated or it leaks air after
ring is released.
1. Turn compressor off and release
pressure from system. (To release
pressure from system, pull ring on
ASME safety valve. Deflect escaping
air by shielding valve with one hand
as you pull ring with other hand.) Pull
THERMAL OVERLOAD PROTECTOR
This compressor
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, make sure that
the compressor is used in a clean, wellventilated area where temperature will
not exceed 100° F.
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.
STORAGE
1. Drain tank of moisture.
2. When not in use, store compressor in
a cool dry place.
3. Disconnect hose and hang open ends
down to allow any moisture to drain.
ring until tank is empty.
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.
2. Drain moisture from tank by opening
drain valve underneath tank. Tilt tank
to remove all moisture.
3. Clean dust and dirt from tank,
air lines and pump cover while
compressor is still OFF.
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Troubleshooting Chart
Symptom Possible Cause(s) Corrective Action
Compressor will not run 1. Switch in OFF position
2. No electrical power at wall outlet
3. Compressor has reached automatic shutoff pressure
4. Motor overheated
5. Blown fuse (inside pump cover)
6. Pressure switch bad
Knocks, rattles, excessive vibration 1. Tank not level
2. Defective bearing on eccentric or motor
shaft
3. Cylinder or piston ring is worn or scored
Tank pressure drops when compressor
shuts off
Compressor runs continuously and air
output is lower than normal/low
discharge pressure
Excessive moisture in discharge air 1. Excessive water in tank
1. Loose drain valve
2. Check valve leaking
3. Loose connections (fittings, tubing, etc.)
1. Excessive air usage, compressor too small
2. Loose connections (fittings, tubing, etc.)
3. Broken inlet valves
4. Piston ring worn
2. High humidity
1. Make sure compressor is plugged in and
switch is ON
2. Check circuit breaker or fuse at electrical
panel.
3. Release air from tank until compressor
restarts automatically
4. Allow compressor to cool for approximately
30 minutes so thermal overload switch
will reset. Make sure compressor is run
in a clean, well-ventilated area where
temperature will not exceed 100°F.
5. Disconnect compressor from power source
then remove pump cover. Replace fuse –
Part. No. FP200352AV. If replacement fuse
blows, call 1-800-543-6400.
6. Replace pressure switch
1. Shim tank to level position
2. Replace pump assembly
3. Replace pump assembly
1. Tighten drain valve
2. Replace check 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.
Do not disassemble
in tank, bleed tank first.
1. Decrease usage or purchase unit with
higher 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.
3. Replace pump assembly
4. Replace piston assembly
1. Drain tank, tilt tank to remove moisture
2. Move to area of less humidity; use air line
filter
NOTE: Water condensation is not caused by
compressor malfunction
FP204100
check valve. With air
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Oilless Compressors
Troubleshooting Chart (Continued)
Symptom Possible Cause(s) Corrective Action
Compressor runs continuously and safety
valve opens as pressure rises
Excessive starting and stopping 1. Excessive condensation in tank
1. Defective pressure switch
2. Defective safety valve
2. Loose connections (fittings, tubing, etc.)
1. Replace pressure switch
2. Replace safety valve with genuine
replacement part
1. Drain more often
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.
Notes
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6
For Replacement Parts, 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.
12
18
16
15
13
FP204100
14
1
7
3
4
6
5
Replacement Parts List
Ref.
No. Description
1 Shroud with handle FP204001AV 1
2 Handle assembly FP204002AV 1
3 Tank gauge FP204012AV 1
4 Regulator gauge FP204013AV 1
5 Manifold assembly FP204835AV 1
6 Safety valve V-215102AV 1
7 On/Off switch FP204824AV 1
8 Drain valve D-1403 1
9 Pump/Motor assembly
(includes line cord) –– 1
10 Circuit board –– 1
11 Pressure switch FP200354AV 1
12 Exhaust tube
Part
No. Qty.
▲
17
13
20
2
8
Ref.
No. Description
13 Compression fitting
14 Shroud screws (M6-10 x 20) Standard
15 25 foot hose MP268100AV 1
16 Tool kit (5 pieces) FP204008AV 1
17 Check valve kit FP204010AV 1
18 Storage cover FP204007AV 1
19 Fuse –– 1
20 Fan FP204006AV 1
REPLACEMENT PARTS KITS
▲
Exhaust tube kit (includes 12 & 13) FP200355AV 1
1
Decal kit (not shown) –– 1
19
11
10
9
Part
No. Qty.
▲
hardware item 4
2
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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. 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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