Campbell Hausfeld WL6500 Series, IronForce WL6500 Series Operating Instructions Manual
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).
assistance or call the nearest Campbell
Hausfeld Authorized Service Center.
A listing of service center locations is
enclosed. Have the serial number,
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.
General Safety
Information
Since the air compressor and other
components (material pump, spray
guns, filters, lubricators, hoses, etc.)
used, make up a high pressure
pumping system, the following safety
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.
Description
Oilless compressors are designed for
do-it-yourselfers with a variety of home
and automotive jobs. These
compressors power spray guns, impact
wrenches and other tools. These units
operate without oil.
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.
C
aution 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
Operating Instructions WL6500 Series
IN610200AV 9/03
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.
Record the Model No., Serial No. and
date of purchase located on the base
below the pump in the space below.
Model No. ____________________
Serial No. ____________________
Date of purchase _________________
Retain these numbers for future
reference.
A
Oilless Air
Compressors
DO NOT RETURN THE
PRODUCT TO THE
RETAILER!
For parts, product & service information
visit www.chpower.com
© 2003 Campbell Hausfeld/Scott Fetzer
Model
Information
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Need
A
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Q
Assistance?
Call Us First!
1-800-543-8622
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A
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DANGER
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WARNING
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CAUTION
NOTICE
STOP!
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MANUAL
2
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 or spray 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 regularly 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.
SPRAYING PRECAUTIONS
Do not spray flammable
materials in vicinity of
open flame or near
ignition sources including the
compressor unit.
14. Do not smoke when spraying paint,
insecticides, or other flammable
substances.
15. Use a face mask/
respirator when
spraying and spray in
a well ventilated area
to prevent health and
fire hazards.
16. 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.
17. When spraying or cleaning with
solvents or toxic chemicals, follow
the instructions provided by the
chemical manufacturer.
Assembly
HANDLE ASSEMBLY
Compressor handle has a notch (or
detent) at top of handle. This notch
provides a handy place to hang a spray
gun, sandblast gun, or other tool
equipped with a hook.
1. If a handle grip was included with
the unit, coat the inside of grip with
a thin film of soapy water. Push grip
onto handle.
2. Insert handle through shroud and
into baseplate as shown in Figure 1.
Handle must fit into special openings
in baseplate.
3. Place a short piece of wood against
end of handle and tap it with a
mallet or hammer to drive handle
into baseplate until hole in handle
and baseplate line up.
4. Assemble and tighten 2 screws (from
parts package) through hole in baseplate ensuring it goes through handle.
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.
5. Insert threaded post of rubber foot
into hole in ground iron. Tighten
securely with locknut.
WHEEL ASSEMBLY
The items marked with an asterisk (*)
are included in parts package.
1. Insert shoulder bolt through wheel
hub. The bolt hex head should be
on the opposite side of protruding
hub center.
2. For 6 - 8 inch diameter wheels, feed
the shoulder bolt through the
bottom hole on the tank axle iron
and tightly secure with the locknut.
Figure 1 – Handle screws
Shoulder
bolt
*
*
Figure 2 - Wheel Assembly
Lock nut
Wheel
*
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WL6500 Series
3
Assembly (Con't)
For 10 inch diameter wheels, feed
the shoulder bolt through the top
hole on the tank axle iron and
tightly secure with the locknut.
Repeat on the opposite side.
OPTIONAL VERTICAL STORAGE
GROUND IRON
1. Push plastic plug into end of one inch
tube.
2. Assemble the grip onto the tube as
described in the handle assembly.
3. Assemble the tube to the tank as
shown in figure 8. Fasten the tube
with 5/16 inch locking bolts. Tighten
securely with 5/16 inch locking nuts.
4. Assemble rubber foot with 5/16 inch
washer. Insert threaded post of
rubber feet into holes at top of tube.
Tighten securely with 5/16 inch
locking nuts.
NOTE: See Parts List for exploded
assembly.
Installation
LOCATION
When assembled, the tank must sit
level or slope slightly towards the drain
cock to allow the tank to drain
properly.
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.
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.
Never use an extension
cord with this product. Use
additional air hose instead
of an extension cord to
avoid power loss and
permanent motor damage. Use of an
extension cord voids the warranty.
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. 4. 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
plug provided; if it will not fit outlet,
have proper outlet installed by a
qualified electrician.
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.
Overheating, short
circuiting and fire
damage will result from inadequate
wiring, etc.
NOTE: 120 volt, 15 amp units can be
operated on a 120 volt 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. Circuit is equipped with a 15 amp
circuit breaker or a 15 amp slow blow
fuse.
3. If these 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.
Figure 4 - Grounding Method
Grounding
Pin
Grounded Outlet
Figure 5
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Tool Storage
Pressure Switch
Safety Valve
Regulator
Grip
Washer
Plastic Plug
Rubber
Foot
Figure 3- Optional Assembly
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DANGER
RESET
TEST
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CAUTION
4
Operation
Pressure Switch - Auto/Off Switch - In
the ON position, the compressor shuts
off automatically when tank pressure
reaches the maximum preset pressure.
The compressor will automatically
restart when it reaches the minimum
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.
Handle - Designed to move the
compressor.
Tool Storage - 1/4 inch quick connect
couplers fit in holes to support air
chuck and other inflation fittings.
Never use the
handle on wheeled
units to lift the unit completely off the
ground.
Drain Petcock - 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(s) by opening the drain
petcock located underneath the tank.
LUBRICATION
This is an oilless product and DOES
NOT require lubrication to operate.
IMPORTANT: Do not operate compres-
sor before reading instructions or
damage may result.
1. Turn switch to OFF position and plug
in power cord.
2. Attach chuck or other tool to open
end of hose.
3. Turn regulator clockwise to open air
flow.
4. Turn switch to ON position.
5. Compressor will build to maximum
preset pressure and shut off.
6. Adjust regulator to proper pressure
for tool or tire. Operate tool per
instructions. Compressor will
automatically restart when pressure
in tank drops below cut-in pressure.
7. Turn regulator knob counterclockwise to shut off the air and turn
switch to Off position.
In the ON position, the compressor
pumps air into the tank. It shuts off
automatically when unit reaches its
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.
ASME SAFETY VALVE
Do not remove or
attempt to adjust
the safety valve!
This valve should be checked under
pressure occasionally by pulling the ring
by hand. If air leaks after ring has been
released, or valve is stuck and cannot be
actuated by ring, it MUST be replaced.
REGULATOR KNOB
1. This knob controls air pressure to an
air operated tool, or paint spray gun.
2. Turning knob clockwise increases air
pressure at outlet.
3. Turning counterclockwise will lower
air pressure at outlet.
4. Fully counterclockwise will shut off
flow of air completely.
OUTLET (TOOL) PRESSURE GAUGE
1. This gauge shows at-aglance, air pressure at
outlet. Air pressure is
measured in pounds
per square inch (psi).
2. Be sure this gauge reads ZERO before
changing air tools or disconnecting
hose from outlet.
TANK PRESSURE GAUGE
Gauge shows pressure in
tank indicating
compressor is building
pressure properly.
Disconnect power source
then release all pressure
from the system before
attempting to install,
service, relocate or perform any
maintenance.
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.
Oilless Compressors
Figure 7
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Figure 6
Tank
Pressure
gauge
Regulator
Tool
Pressure
gauge
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Maintenance
The compressor should be checked
often for any visible problems and the
following maintenance procedures
should be performed each time the
compressor is used.
1. Pull ring on safety valve and allow it
to snap back to normal position.
Safety valve must
be replaced if it
cannot be actuated or it leaks air after
ring is released.
2. Place unit in the horizontal position
as shown in Figure 8. With
compressor shut off and pressure
released: Drain moisture from tank
by opening drain cock underneath
tank.
3. 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 filter.
LUBRICATION
This is an oilless type compressor
requiring no lubrication.
STORAGE
1. When not in use, hose and compressor should be stored in a cool dry
place.
2. Tank should be drained of moisture.
3. Hose should be disconnected and
hung open ends down, to allow any
moisture to drain.
Figure 8
WL6500 Series
Notes
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WARNING
6
Troubleshooting Chart
Symptom Possible Cause(s) Corrective Action
1. No electrical power
2. Breaker open
3. Pressure switch bad
4. Check valve defective
1. Poor contacts, line voltage incorrect
2. Shorted or open motor winding
3. Defective check valve or unloader
1. Incorrect size fuse, circuit overloaded
2. Defective check valve or unloader
1. Loose connections (fittings, tubing,
etc.)
2. Loose drain cock
3. Check valve leaking
1. Air leaks in piping (on machine or in
outside system)
2. Piston ring broken
1. Plugged in? Check fuse/breaker or motor overload
2. Reset, determine cause of problem
3. Replace
4. Remove and replace check valve
Do not disassemble check valve
with air in tank; bleed tank
1. Check connections, check with voltmeter
2. Replace motor
3. Replace or repair
Do not disassemble check valve
with air in tank; bleed tank
1. Check for proper fuse, use time-delay fuse.
Disconnect other electrical appliances from circuit or
operate compressor on its own branch circuit
2. Replace or repair
Do not disassemble check valve
with air in tank; bleed tank
1. Check all connections with soap and water solution
and tighten
2. Tighten
3. Disassemble check valve assembly, clean or replace
Do not disassemble check valve
with air in tank; bleed tank
1. Replace leaking components or tighten as necessary
2. Replace
Compressor will not run
Motor hums but cannot
run or runs slowly
Fuses blow/circuit
breaker trips repeatedly
Never use an extension
cord with this product
Tank pressure drops
when compressor shuts
off
Air output lower than
normal/low discharge
pressure
Oilless Compressors
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CAUTION
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DANGER
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7
Troubleshooting Chart (Continued)
Symptom Possible Cause(s) Corrective Action
1. Excessive water in tank
2. High humidity
1. Defective pressure switch
2. Excessive air usage
1. Excessive condensation in tank
2. Air leaks in piping (on machine or in
outside system)
3. Tank check valve leaking
Check valve stuck in an open position
Belt broken
1. Drain tank
2. Move to area of less humidity; use air line filter
1. Replace switch
2. Decrease air usage; compressor not large enough for
air requirement
1. Drain more often
2. Replace leaking components or tighten as necessary
3. Replace or repair as necessary
Do not disassemble check valve
with air in tank; bleed tank
Remove and replace check valve
Do not disassemble check valve
with air in tank; bleed tank
Replace belt
Excessive moisture in
discharge air
Compressor runs
continuously
Excessive starting and
stopping (auto start)
Air leaking from
unloader on pressure
switch
Motor runs but no air
output
WL6500 Series
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Tool Recommendations for this Air Compressor
RECOMMENDED TOOLS FOR
CONTINUOUS USE
Butterfly impact wrench
Ratchets
Spray guns
Reciprocating saws
Screwdrivers
Brad nailers
Framing nailers
Grease guns
Caulk guns
Engine cleaners
RECOMMENDED TOOLS FOR
INTERMITTENT USE
(Short powerful bursts)
Impact wrenches
Die grinders
Drills
Chisels
Cut-off tools
TOOLS NOT RECOMMENDED
Straight line sanders
Highspeed sanders
Dual action sanders
Jitterbug sanders
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8
WL6500 Series
Oilless Compressors
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Limited Warranty
1. DURATION: From the date of purchase by the original purchaser as follows: Standard Duty - One Year; Serious Duty - Two
Years; Extreme Duty - Three Years; Maxus Model Series - Five Years.
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 and Maxus branded compressors are not limited to a ninety (90) day warranty when used in contractor
applications. Four cylinder single-stage 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: Repair or 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. Portable compressors or components must be delivered or shipped to the nearest Campbell Hausfeld Authorized Service
Center. Freight costs, if any, 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 PERFORM REPAIR OR REPLACEMENT UNDER THIS WARRANTY: Repair or replacement will be
scheduled and serviced according to the normal work flow at the servicing location, and depending on the availability of
replacement 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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