Campbell Hausfeld MW2500, IN634000AV User Manual

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

Operating Instructions and Parts List MW2500 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.

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.

Unpacking

After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Make sure to tighten fittings, bolts, etc., before putting unit into service. In case of questions, damaged or missing parts, please call 1-800-543-6400 for customer assistance.

Have the date code, model number, and parts list (with missing parts circled) before calling.

DO NOT RETURN

STOP!

Do not operate

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

THE PRODUCT TO THE RETAILER!

unit if damaged

Record the Model No., Serial No. and date of purchase located on the back of the unit.

Model No.: ______________________

Serial No.: _______________________

Date of purchase: ________________

Retain these numbers for

future reference.

MW250000

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.

READ & FOLLOW ALL

INSTRUCTIONS

SAVE THESE INSTRUCTIONS

DO NOT DISCARD

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

Safety Guidelines

This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

Danger indicates an imminently hazardous situation which, if

not avoided, WILL result in death or serious injury.

Warning indicates a potentially hazardous situation which, if

not avoided, COULD result in death or serious injury.

Caution indicates a potentially hazardous situation which, if

not avoided, MAY result in minor or moderate injury.

Notice indicates important information, that if not followed,

may cause damage to equipment.

NOTE: Information that requires special attention.

Attach it to this manual or file it for safekeeping.

visit www.chpower.com

Operating Instructions and Parts List

General Safety Information

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

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 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 United States, the National Electrical Codes (NEC) and Occupational Safety and Health Act (OSHA).

3. Only persons well acquainted

with these rules of safe operation should be allowed to use the compressor.

4. Keep visitors away and NEVER

allow children in the work area.

5. Wear safety glasses and

use hearing protection when operating the unit.

6. Do not stand on or use the 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.

MANUAL

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 vibrate abnormally, 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.

An ASME code

safety relief valve with a setting no higher than 170 psi MUST be installed in the tank for this compressor. The ASME safety valve must have sufﬁcient ﬂow and pressure ratings to protect the pressurized components from bursting.

See compressor

speciﬁcation decal for maximum operating pressure. Do not operate with pressure switch or pilot valves set higher than the maximum operating pressure.

12. Never attempt to adjust ASME

safety valve. Keep safety valve free from paint and other accumulations.

Never use plastic

(PVC) pipe for compressed air. Serious injury or death could result.

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, cracked 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.

MW2500 Series

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.

Introduction

Refer to Figure 2 to locate the following items.

On/Off Switch — This unit is equipped with an illuminated On / Off switch. In the “ON” position the button will be depressed and the switch will light up. The switch will remain lit as long as the button is depressed and there is power to the unit. The pressure switch will automatically turn the pump / motor on or off based on the pressure inside the tank. If the unit is unplugged the light will not be on. In the “OFF” position the switch will not be depressed and the light will not be on.

www.chpower.com

Operating Instructions and Parts List

Introduction (Continued)

Pressure Switch (located internally) - When the compressor

is turned ON, this switch will shut compressor off automatically when tank pressure reaches maximum shutoff / cut-out pressure. If compressor remains on and air is depleted from tank, this switch will allow compressor to automatically restart at the restart / cut-in pressure.

Regulator - The regulator controls the amount of air pressure released at the hose outlet. Turning the regulator knob clockwise (to the right) will increase air pressure at the outlet. Turning the knob counter-clockwise (to the left) will lower air pressure to the outlet. Turning knob fully counterclockwise will shut off flow of air completely.

Pressure Gauges - There are two gauges on this compressor. These gauges read air pressure in pounds per square inch (psi). The larger gauge shows pressure at the outlet. Make sure this gauge reads ZERO (by adjusting the regulator) BEFORE changing air tools or disconnecting hose from outlet. The small gauge shows pressure in the tank indicating compressor is building pressure properly.

ASME Safety Valve - This valve automatically releases air if the tank pressure exceeds the preset maximum.

Handle - Designed to move the compressor.

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.

Figure 1

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 switch to the OFF position, then to the ON 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.

MW2500 Series

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 104°F.

A minimum clearance of 18 inches between the compressor and a wall is required because objects could obstruct air flow.

Do not locate the

compressor air inlet near steam, paint spray, sandblast areas or any other source of contamination. This debris will damage the motor.

GROUNDING INSTRUCTIONS

1. This product is for use on a

nominal 120 volt circuit and has a grounding plug that looks like the plug illustrated in Figure 3. 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.

Figure 2

Outlet Gauge

ON / OFF Switch

Shroud

Tank

Regulator

Handle

Tank Gauge

ASME Safety Valve

www.chpower.com

Operating Instructions and Parts List

Installation (Continued)

Grounded

Outlet

RESET

TEST

Grounding

Figure 3 - Grounding Method

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.

Overheating, short

circuiting and ﬁre damage will result from inadequate wiring.

LUBRICATION This is an oilless product and DOES

NOT require lubrication to operate.

MW2500 Series

Pre-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.

2. Do not attach a hose or any other ﬁtting to the compressor.

3. Turn ON / OFF switch to OFF position.

4. Plug in power cord.

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

6. Turn ON / OFF switch to OFF position.

7. Unplug power cord.

The compressor is now ready for use.

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.

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.

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

Operation

START-UP

Do not attach air

tools to open end of the hose until start-up is completed and the unit checks OK.

ON / OFF CYCLING OF COMPRESSOR

In the ON / AUTO 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 / AUTO 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 large gauge next to the regulator knob indicates air pressure going to hose (and any tool attached to end of hose).

The small gauge next to the safety valve indicates air pressure in tank.

EXTENSION CORDS FOR 120V / 15 AMP UNIT

Length of Cord (Feet)

Gauge of Cord 16 12 10 8 6 6 4 4 2

www.chpower.com

25 50 100 150 200 250 300 400 500

Operating Instructions and Parts List

Maintenance

Disconnect, tag and lock out 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 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.

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.

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 psi - 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.

Figure 4

MW2500 Series

DRAIN TANK

With compressor shut off and pressure released, drain moisture from tank by opening drain valve underneath tank. Tilt tank to completely drain moisture.

CLEANING

Turn power OFF and clean dust and dirt from pump cover, tank, and air lines.

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

LUBRICATION.

This is an oilless type compressor requiring no lubrication.

END OF OPERATION/STORAGE

1. Turn ON / OFF switch to the OFF position.

2. Unplug power cord from wall outlet and wrap around handle area to prevent damage when not in use.

3. Wearing safety glasses drain tank of air by pulling the ring on the safety valve. Use other hand to deﬂect fast moving air from being directed toward your face.

4. Drain tank of condensation by opening drain valve on bottom of tank. Tank pressure should be below 10 psi when draining tank.

5. Air hose should be disconnected from compressor and hung open ends down to allow any moisture to drain.

6. Compressor and hose should be stored in a cool, dry place.

MAINTENANCE SCHEDULE

OPERATION DAILY WEEKLY MONTHLY

DRAIN TANK CHECK SAFETY VALVE CLEAN UNIT

TECHNICAL SERVICE

For information regarding the operation or repair of this product, please call 1-800-543-6400.

www.chpower.com

Operating Instructions and Parts List

MW2500 Series

Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

Compressor will not run 1. Switch in OFF position 1. Make sure compressor is plugged in and switch is ON.

2. No electrical power at wall outlet 2. Check circuit breaker or fuse at electrical panel.

3. Compressor has reached automatic shutoff pressure

4. Motor overheated 4. Allow compressor to cool for approximately 30 minutes so

5. Pressure switch bad 5. Replace pressure switch.

Thermal overload protector cuts out repeatedly

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

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

1. Low voltage 1. Check voltage at wall outlet with voltmeter.

2. Wrong gauge wire or length of extension cord

3. Lack of proper ventilation/room temperature too high

4. Defective check valve 4. Repair or replace.

5. Defective unloader valve (on pressure switch)

6. Compressor valves failed 6. Replace valve assembly.

1. Loose connections at fittings, tubing, air line, or tool

2. Loose drain valve 2. Tighten.

3. Check valve leaking 3. Remove check valve. Clean or replace.

4. Tank leaks 4. Check tank for leaks with soap and water solution. If leak is

1. Excessive air usage, compressor too small

2. Loose connections at fittings, tubing, air line, or tool

3. Tank leaks 3. Check tank for leaks with soap and water solution. If leak is

4. Broken valves 4. Replace compressor valves as necessary.

5. Piston ring worn 5. Replace piston ring.

1. Excessive water in tank 1. Drain tank.

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

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

3. Release air from tank until compressor restarts automatically.

thermal overload switch will reset. Make sure compressor is run in a clean, well-ventilated area.

2. Check extension cord chart for proper extension cord usage.

3. Move compressor to well-ventilated area. Ambient temperature must be below 104°F for proper operation.

5. Repair or replace.

Do not disassemble check valve with

air pressure in tank; bleed tank.

1. Check all connections with soap and water solution. If a leak is detected, (1) tighten or (2) remove fitting and apply pipe tape to threads and reassemble.

detected, tank must be replaced with genuine replacement part.

Do not disassemble check valve with

air pressure in tank; bleed tank.

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, (1) tighten or (2) remove fitting and apply pipe tape to threads and reassemble.

detected, tank must be replaced with genuine replacement part.

NOTE: Water condensation is not caused by compressor

malfunction.

www.chpower.com

Notes

MW2500 Series

Operating Instructions and Parts List

For replacement parts or technical assistance, call 1-800-543-6400

MW2500 Series

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

Address any correspondence to:

Campbell Hausfeld Attn: Customer Service 100 Production Drive Harrison, OH 45030

www.chpower.com

Operating Instructions and Parts List

Replacement Parts List for MW2500

MW2500 Series

Ref. Part No. Description Number Qty.

1 Handle 2 Screw 3 Top grip 4 Bottom grip 5 Screw 6 On/off switch WL052500AV 1 7 Screw 8 Top shroud 9 Bottom shroud 10 Pump/motor assembly WL052600AV 1 11 Bolt 12 Motor isolator bushing 13 Power cord 14 Strain relief 15 Tank WL052700AV 1 16 Drain valve WL052800AV 1 17 Rubber feet 18 Screw 19 Pressure switch WL052900AV 1 20 Manifold tube (includes nut

and fitting)

21 Regulator (includes knob,

cap and screw) 22 Outlet gauge WL053200AV 1 23 1/4 inch male industrial

coupler 24 Tank gauge WL053400AV 1 25 Safety valve WL053500AV 1

WL053000AV 1

WL053100AV 1

WL053300AV 2

1 4 1 1 2

8 1 1

3 3 1 1

3 3

Ref. Part No. Description Number Qty.

26 Screw 27 Discharge tube (includes

nuts and ferrules) 28 Check valve WL053700AV 1 29 Washers 30 Rubber insert 31 Intake tube

REPLACEMENT PARTS KITS

l =

n =

s =

Motor isolator bushing kit WL051900AV

Rubber feet kit WL052100AV

Handle grip kit WL051800AV

Power cord and strain relief

kit

Shroud kit WL051600AV

Handle kit WL051700AV

Valve and gasket kit

includes valves, valve plate

and all gaskets

Belt kit WL052400AV

Piston ring kit WL052200AV

Not available

Not shown

WL053600AV 1

WL052000AV

WL052300AV

3 1 1

www.chpower.com

Operating Instructions and Parts List

MW2500 Series

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: This 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. 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, e.g. assembly, oil or lubricants, and adjustment. E. Items or service that are normally required to maintain the product, e.g. lubricants, filters and gaskets, etc. F. Additional items not covered under this warranty:

1. 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.

2. Pump or valve failure caused by rain, excessive humidity, corrosive environments or other contaminants.

3. Cosmetic defects that do not interfere with compressor functionality.

4. Rusted tanks, including but not limited to rust due to improper drainage or corrosive environments.

5. Drain cocks.

6. Damage due to incorrect voltage or improper wiring.

7. Other items not listed but considered general wear parts.

8. Pressure switches, air governors and safety valves modified from factory settings.

9. Belts.

10. Ring wear or valve damage from inadequate filter maintenance.

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 the duration of the specific warranty period.

8. RESPONSIBILITIES OF PURCHASER UNDER THIS WARRANTY: A. Provide dated proof of purchase and maintenance records. B. Call Campbell Hausfeld (800-543-6400) to obtain your warranty service options. Freight costs must be borne by the

purchaser.

C. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).

9. WHEN WARRANTOR WILL PROVIDE REPLACEMENT UNDER THIS WARRANTY: Replacement will be scheduled according to the availability of replacement compressor or parts.

This Limited Warranty applies in the U.S., Canada and Mexico only and gives you specific legal rights. You may also have other rights which vary from State to State or country to country.

www.chpower.com

+ 22 hidden pages

Campbell Hausfeld MW2500, IN634000AV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual