Campbell Hausfeld CE5002 Service manual

Electric Air Compressor
Operating Instructions and Parts Manual
Models: CE5002 and XC602100
IN573900 10/18
© 2018 Campbell Hausfeld
A Marmon/Berkshire Hathaway Company
EN

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.
REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to
this manual or file it for safekeeping.
REGISTER YOUR PRODUCT ONLINE NOW! www.campbellhausfeld.com/reg
READ AND FOLLOW ALL INSTRUCTIONS • SAVE THESE INSTRUCTIONS • DO NOT DISCARD
Model #: __________________________
Serial #: ___________________________
Purchase Date: _____________________
For parts, product & service information
visit www.campbellhausfeld.com
Campbell Hausfeld
100 Production Drive
Harrison, Ohio 45030

MAINTENANCE / REPAIR
TROUBLESHOOTINGOPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS
GETTING STARTED
1
BEFORE YOU BEGIN
Description
Air compressor units are intended to provide compressed air to power pneumatic tools, operate spray guns
and supply air for pneumatic valves and actuators. The pumps supplied with these units have oil lubricated
bearings. A small amount of oil carryover is present in the compressed air stream. Applications requiring air
free of oil vapor should have the appropriate filters installed. The air compressor units are to be mounted
per the instructions provided on a solid floor. Any other use of these units will void the warranty and the
manufacturer will not be responsible for problems or damages resulting from such misuse.
QUICK REFERENCE
Recommended Oil (2 Options)
Single viscosity SAE 30 ISO100 nondetergent compressor oil. Part number ST125303AV (0.5
qt) or ST126701AV (4 qt).
10W30 synthetic oil such as Mobil 1®or CE0032 (1 qt).
Oil Capacity
Approximately 47.4 oz.
UNPACKING
Do not lift or move unit without appropriately rated equipment. Be sure the unit is securely
attached to lifting device used. Do not lift unit by holding onto tubes or coolers. Do not use unit
to lift other attached equipment.
After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Check for
loose, missing or damaged parts. Check to be sure all supplied accessories are enclosed with the unit. In case
of questions, damaged or missing parts, please visit www.campbellhausfeld.com for customer assistance.
Do not operate unit if damaged during shipping, handling or use. Damage may result in
bursting and cause injury or property damage.
Required Items - Not Included
• Oil
• Concrete anchors
• Isolation pads
• Isolation valve
• Power cord/electrical disconnect

MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
2
GENERAL SAFETY INSTRUCTIONS
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.
IMPORTANT or NOTE: Information that requires special attention.
Safety Symbols
The following Safety Symbols appear throughout this manual to alert you to important safety hazards and
precautions.
California Proposition 65
This product can expose you to chemicals including lead, which are known to the State of
California to cause cancer and birth defects or other reproductive harm. For more information
go to www.P65Warnings.ca.gov.
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.
Illinois Lead Poisoning Prevention Act
CONTAINS LEAD. MAY BE HARMFUL IF EATEN OR CHEWED. COMPLIES WITH FEDERAL
STANDARDS.
Risk of
Fumes
Risk of
Pressure
Risk of Shock
MANUAL
Read
Manual
First
Top Heavy Risk of
Moving Parts
Risk of
Hot Parts
Risk of
Explosion
Risk of
Fire
Wear Eye
and Mask
Protection

MAINTENANCE / REPAIR
TROUBLESHOOTINGOPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS
GETTING STARTED
3
Important Safety Information
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.
This manual contains important safety, operational and maintenance information. If you have any
questions, please visit www.campbellhausfeld.com for customer assistance.
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, 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.
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:
• Read all manuals included with this product carefully. Be thoroughly familiar with the controls and
the proper use of the equipment.
• Follow all local electrical and safety codes as well as the United States National Electrical Codes (NEC)
and Occupational Safety and Health Act (OSHA).
• Only persons well acquainted with these rules of safe operation should be allowed to use the
compressor.
• Keep visitors away and NEVER allow children in the work area.
• Wear safety glasses and use hearing protection when operating the unit.
• Do not stand on or use the unit as a handhold.
• 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.
• Check all fasteners at frequent intervals for proper tightness.
This compressor is extremely top heavy. The unit must be bolted to the floor with isolation pads
before operating to prevent equipment damage, injury or death.
Never install a shut-off valve between the compressor pump and the tank.
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.
Never operate compressor without a beltguard. This unit can start automatically without
warning. Personal injury or property damage could occur from contact with moving parts.
• Do not wear loose clothing or jewelry that will get caught in the moving parts of the unit.
Compressor parts may be hot even if the unit is stopped.
• Keep fingers away from a running compressor; fast moving and hot parts will cause injury and/or
burns.
MANUAL

MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
4
GENERAL SAFETY INSTRUCTIONS (CONTINUED)
• If the equipment should start to vibrate abnormally, STOP the engine/motor and check immediately
for the cause. Vibration is generally an indication of trouble.
• 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 200 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 specifications for maximum operating pressure. Do not operate with pressure
switch or pilot valves set higher than the maximum operating pressure.
Maximum operating pressure is 175 PSI for single stage compressors. Do not operate with
pressure switch or pilot valves set higher than 175 PSI (2-stage).
• 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.
• 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.
• 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.
• Do not smoke when spraying paint, insecticides, or other flammable substances.
• Use a face mask/respirator when spraying and spray in a well ventilated area to prevent health and fire
hazards.
• 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.
• When spraying or cleaning with solvents or toxic chemicals, follow the instructions provided by the
chemical manufacturer.
The DANGER, WARNING, CAUTION, and NOTICE notifications and instructions in this manual cannot
cover all possible conditions and situations that may occur. It must be understood by the operator that
caution is a factor which cannot be built into this product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS
DO NOT DISCARD

SPECIFICATIONS
CE5002 XC602100
HP 3.5 3.5
Number of Cylinders 2 2
Number of Stages 2 2
Air Delivery @ 90 PSI 11 CFM 11 CFM
Voltage 230 Volts /
16.2 Amps
230 Volts /
16.2 Amps
Max Pressure 175 PSI 175 PSI
Oil Capacity 47.4 ounces 47.4 ounces
Tank Outlet Size 3/4 NPT 3/4 NPT
Weight 270 lbs. 270 lbs.
DIMENSIONS
CE5002 XC602100
Length 21.9 inches 21.9 inches
Width 27.5 inches 27.5 inches
Height 69.6 inches 69.6 inches
MAINTENANCE / REPAIR
TROUBLESHOOTINGOPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS
GETTING STARTED
5

MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
6
GETTING TO KNOW YOUR UNIT
Pressure Switch
Tank Pressure Gauge
Check Valve
Discharge Tube
Pump
Air Filter
ASME Safety Valve
Oil Fill Port
Breather
Belt Guard
Motor
Tank Outlet
Tank Drain Valve
Figure 1 - Unit Identification

MAINTENANCE / REPAIR
TROUBLESHOOTINGOPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS
GETTING STARTED
7
GETTING TO KNOW YOUR UNIT
Pressure Switch - Auto/Off Switch - In the auto position, the compressor shuts off automatically when tank
pressure reaches the maximum preset pressure. After air is used from the tank and drops to a preset low
level, the pressure switch automatically turns the motor back on. In the off position, the compressor will not
operate. This switch should be in the off position when connecting or disconnecting the power from the
unit.
When the pressure switch turns the motor off you will hear air leaking out of the pressure switch unloader
valve for a short time. This releases the air pressure from the discharge tube and allows the compressor to
restart easier.
ASME Safety Valve - This valve automatically releases air if the tank pressure exceeds the preset maximum.
Discharge 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 discharge tube.
Check Valve - One-way valve that allows air to enter the tank, but prevents air in the tank from flowing
back into the compressor pump.
Belt Guard - Covers the belt, motor pulley and flywheel.
Tank 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.
Tank Pressure Gauge - Indicates amount of air pressure stored in tank.
Air Filter - Keeps large particulates out of the air flowing into the compressor.
Breather - Vent for crankcase.
Oil Fill Port - Port used to refill the oil in the pump after oil changes or when oil is low.
Pump - Cast Iron 2-Stage air compressor pump that generates compressed air.
Motor - Power source that drives the pump to create compressed air.
Tank Outlet - This is where you plumb into to get compressed air from the pressure vessel. An isolation
valve should be installed here to be able to shut off the air supply from the tank.
INSTALLATION INSTRUCTIONS
Disconnect, tag and lock out power source then release all pressure from the system before
attempting to install, service, relocate or perform any maintenance.
Do not lift or move unit without appropriately rated equipment. Be sure the unit is securely
attached to lifting device used. Do not lift unit by holding onto tubes or coolers. Do not use unit
to lift other attached equipment.
Never use the wood shipping skids for mounting the compressor.
This compressor is not intended for outdoor installation.
Preparation
Before beginning installation and/or assembly of product, make sure all parts are present. Compare parts
with package contents list. If any part is missing or damaged, do not attempt to assemble or use the
product.
Do not operate unit if damaged during shipping, handling or use. Damage may result in
bursting and cause injury or property damage.
Estimated Installation and Assembly Time: 120 minutes
Tools Required for Installation and Assembly (not included): Safety Glasses; Work Gloves; 9/16 in. Socket and
Ratchet; Tape measure; Hammer Drill and Masonry Bit; Hammer; Phillips Screwdriver; Flathead Screwdriver;
Pipe Wrench; Two Adjustable Wrenches; 1/4 in. Nut Driver, Socket or Wrench; 240 Volt, 30 Amp Double Pole
Circuit Breaker; Voltage Meter; Vibration Pads; 3/8 in. x 5 in. Wedge Anchors (for concrete installation).

MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
8
INSTALLATION INSTRUCTIONS (CONTINUED)
Picking the Location
Install and operate unit at least 18 inches from any
obstructions in a clean, well ventilated area. The
surrounding air temperature should not exceed
100°F. This will ensure an unobstructed flow of air
to cool compressor and allow adequate space for
maintenance.
Do not locate the compressor air
inlet near steam, paint spray,
sandblast areas or any other source of contamination.
NOTE: If compressor operates in a hot, moist
environment, supply compressor pump with clean, dry
outside air. Supply air should be piped in from external
sources.
Tank Mounting
The tank should be bolted into a flat, even, concrete
floor or on a separate concrete foundation. Vibration
isolators should be used between the tank leg and
the floor. Model MP345700AJ isolator pads are
recommended for installation.
When using isolator pads, do not draw bolts tight.
Allow the pads to absorb vibrations. When isolators
are used, a flexible hose or coupling should be
installed between the tank and service piping.
Failure to properly install the
tank can lead to cracks at the
welded joints and possible bursting.
1. Unbolt the unit from the shipping skid. Use a
ratchet with a 9/16 in. socket. Remove the unit
from the skid. This requires at least two people -
one person to walk the unit off the skid and one
to help maintain balance so the unit does not
topple. Place the unit where you plan to install it
(at least 18 in. from any wall or surface).
2. Place pre-drilled vibration pads (sold separately)
under each foot to avoid unnecessary vibration
which could damage the unit.
Using the mounting holes and the holes of the
vibration pads as a guide, drill holes into concrete
using a 3/8 in. masonry bit. Holes drilled must be
at least 5 in. into the concrete.
3. Insert mounting bolts. Use 3/8 in. x 5 in. wedge
anchors (not included) to secure the unit. Place
nut and washer on bolt. Thread nut onto bolt
until tops are flush. Strike bolt with hammer
until nut and washer are setting on top of the
compressor foot.
Tighten nut using ratchet with a 9/16 in. socket
until anchor is set (using installation torque
specifications of bolt being used). Loosen nut
to leave a 1/16 in. (1.6 mm) gap for stress relief
during unit operation.
18 inches
18 inches
Figure 2
Figure 3
Concrete Anchor
1/16 inch
(1.6 mm)
Metal Plate
Rubber
Pad
Figure 4

MAINTENANCE / REPAIR
TROUBLESHOOTINGOPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS
GETTING STARTED
9
Piping
Never use plastic (PVC) pipe for compressed air. Serious injury or death could result.
Any tube, pipe or hose connected to the unit must be able to withstand the temperature generated and
retain the pressure. All pressurized components of the air system must have a pressure rating of 200 PSI or
higher. Minimum recommended pipe size is 3/4 in. Larger diameter pipe is always better. Incorrect selection
and installation of any tube, pipe or hose could result in bursting and injury. Connect piping system to tank
using the same size fitting as the discharge port.
Minimum Pipe Size For Compressed Air Line
CFM
LENGTH OF PIPING SYSTEM
25 FEET 50 FEET 100 FEET 250 FEET
10 1/2 inch 1/2 inch 3/4 inch 3/4 inch
20 3/4 inch 3/4 inch 3/4 inch 1 inch
40 3/4 inch 1 inch 1 inch 1 inch
60 3/4 inch 1 inch 1 inch 1 inch
100 1 inch 1 inch 1 inch 1-1/4 inch
Chart 1
Installing A Shut-Off Valve
A shut-off valve should be installed on the discharge port of the
tank to control the air flow out of the tank. The valve should be
located between the tank and the piping system.
Never install a shut-off valve between the compressor pump and the tank. Personal injury and/or
equipment damage may occur. Never use reducers in discharge piping.
When creating a permanently installed system to distribute compressed air, find the total length of the
system and select pipe size from Chart 1.Bury underground lines below the frost line and avoid pockets
where condensation can gather and freeze.
Apply air pressure to the piping installation and make sure all joints are free from leaks BEFORE
underground lines are covered. Before putting the compressor into service, find and repair all leaks in the
piping, fittings and connections.
Figure 5

MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
10
INSTALLATION INSTRUCTIONS (CONTINUED)
Wiring
Improperly grounded motors are shock hazards. Make sure all the equipment is properly
grounded.
All wiring and electrical connections must be performed by a qualified electrician
familiar with induction motor controls. Installations must be in accordance with local and
national codes.
Overheating, short circuiting and fire damage will result from inadequate wiring.
Disconnect, tag and lock out power source, then release all pressure from the system before
attempting to install, service, relocate or perform any maintenance.
Damage to the motor from improper electrical voltage or connection will void the warranty.
Wiring must be installed in accordance with National Electrical Code and local codes and standards that
have been set up covering electrical apparatus and wiring. These should be consulted and local ordinances
observed. Be certain that adequate wire sizes are used, and that:
• Service is of adequate ampere rating.
• The supply line has the same electrical
characteristics (voltage, cycles and phase) as
the motor. Refer to motor name plate for
electrical ratings and specifications.
• The line wire is the proper size and that no
other equipment is operated from the same
line. The chart gives minimum recommended
wire sizes for compressor installations.
• Use a slow blow fuse type T or a 240 Volt
double pole circuit breaker.
Minimum Wire Size (Use 75°C Copper Wire)
Make sure voltage is correct with the motor wiring.
NOTE: If using 208 volts single phase, make sure the motor name plate states it is rated for 208 volts single
phase. 230 volt single phase motors do not work on 208 volts unless they have the 208 volt rating.
Single Phase
HP Amps 230V
1-4 HP up to 22.0 10 AWG
5.0 8 AWG
Recommended wire sizes may be larger than the minimum set up by local ordinances. If so, the larger size
wire should be used to prevent excessive line voltage drop. The additional wire cost is very small compared
with the cost of repairing or replacing a motor electrically “starved” by the use of supply wires which are too
small.
WIRING INSTRUCTIONS
1. Inspect the source wiring before continuing with installation. Confirm voltage with volt meter line-to-
ground (see Figure 7).
Figure 6
Volt Meter -
120 Volts
Volt Meter -
230/240 Volts
Line Wire
Line Wire
Ground Wire
Line Wire
Line Wire
Ground Wire
Figure 7 Figure 8

MAINTENANCE / REPAIR
TROUBLESHOOTINGOPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS
GETTING STARTED
11
Volt meter should read 120 Volts.
Confirm voltage with volt meter line-to-line Volt
meter should read 230 / 240 Volts (see Figure 8).
2. Remove the pressure switch cover by loosening
the screw (see Figure 9). Use a Phillips
screwdriver (not included). Pressure switch styles
may vary.
3. Familiarize yourself with the pressure switch
once cover is removed.
4. Remove ground screw. Install strain relief on
pressure switch. DO NOT tighten strain relief on
power cord until wiring is complete. Insert the
bare wires (black, white, bare/green) through
the strain relief.
Attach bare/green ground wire first to ground
screw on pressure switch body.
Look for the “Line” markings on pressure
switch. Install Line wires and tighten terminal
screws.
5. Tighten strain relief nut. Place a flathead
screwdriver (not included) into raised notch and
tap screwdriver with hammer (not included)
until tight.
Tighten strain relief screws to hold power cord
securely. Replace the pressure switch cover
(knob must be in the same position as when
removed to sit correctly in place). Tighten the
pressure switch screw with Phillips screwdriver.
Check that switch is in the OFF position. Follow
break-in procedure starting on page 13.
Figure 10
Tank Pressure
Gauge
ASME Safety
Valve
Line Terminal
Ground
Screw
Motor Cord
Strain Relief
Motor Terminal
Motor Power
Cord
Figure 9
Screw
Figure 11
Terminal Screw White Line Wire
Black Line Wire
Power Cord
Strain Relief
Bare/Green
Ground
Wire
Figure 12
Strain Relief
Nut
Strain Relief Screw

MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
12
INSTALLATION INSTRUCTIONS (CONTINUED)
Grounding
Improperly grounded electrical components are shock hazards. Make sure all the
components are properly grounded to prevent death or serious injury.
This product must be grounded. Grounding reduces the risk of electrical shock by providing an escape wire
for the electric current if short circuit occurs. This product must be installed and operated with a power cord
or cable that has a grounding wire.
Install permanent wiring from the electrical source
to the pressure switch with a ground conductor
connected to the grounding screw on the pressure
switch. A properly sized cord with a ground conductor
and plug may also be installed by the user.
Installing Air Filter
Install air filter on pump (see Figure 13). Filter styles
may vary.
Lubrication
This unit contains no oil.
Before operating compressor, fill to
the center of the sight gauge (see Figure 15).
Using any other type of oil may
shorten pump life and damage
valves.
Recommended Oil (2 Options)
Single viscosity SAE 30 ISO100 nondetergent compressor
oil. Part number ST125303AV (0.5 qt) or ST126701AV (4
qt).
10W30 synthetic oil such as Mobil 1®or CE0032 (1 qt).
Oil Capacity
Approximately 47.4 oz.
Remove oil fill plug on pump. Check oil level; some
models are shipped with oil in the pump. Add oil if
needed. Fill the pump with oil to the center of the
sight gauge using oil fill opening (see Figure 15).
Place oil fill plug back on pump. Do NOT fill the pump
through the breather cap opening as this may cause oil to
leak and spray out during operation.
Do not use regular automotive oil. Additives in
regular motor oil can cause valve deposits and
reduce pump life.
For maximum pump life, drain and replace oil after
the first 50 hours of run time and then follow the
regular maintenance schedule outlined later in the
manual.
This pump has an oil sight glass as shown in Figure
14. Oil level can be monitored and maintained as
shown in Figure 15.
NOTE: Some residual oil may still be in the pump
from factory testing leaving a thin coat on the sight
gauge; however, there is not enough oil to operate
the unit.
Figure 13
Air Filter
Figure 14
Oil FIll
Plug
Sight
Glass
Oil Drain Plug
Figure 15
Full
Low
Sight Glass

MAINTENANCE / REPAIR
TROUBLESHOOTINGOPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS
GETTING STARTED
13
OPERATING INSTRUCTIONS
Start-up/Break-in Procedure
Do not attach air tools to open end of the hose until start-up is completed and the unit checks
okay.
Never disconnect threaded joints with pressure in tank!
1. Return power to unit from main.
2. Check oil level per the Lubrication Section of this manual.
3. Open the tank drain valve (see Figure 16). Turn outlet valve to open air flow.
4. Move pressure switch to the AUTO position to run the unit (see Figure 17).
5. Run the unit for thirty (30) minutes at zero (0) PSI (under no load) to break in pump parts.
6. Move the pressure switch lever or knob to OFF and turn tank drain valve to shut off air flow. The
compressor is now ready for use.
7. Change oil after first fifty (50) hours of operation. Perform oil changes every three (3) months or two
hundred (200) hours of run time, whichever comes first.
On/Off Cycling of Compressor
Drain tank every day to prevent corrosion and possible injury due to tank damage. For optimal
performance of tank drain, tank pressure should be between 10 PSI - 40 PSI. Do not operate
drain with more than 40 PSI in tank or drain valve may be damaged. Drain tank of moisture daily using the drain valve
in the bottom of the tank.
Drain liquid from tank daily.
In the 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 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 compressor will not operate.
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.
Figure 16 Figure 17
Tank Drain
Valve

TROUBLESHOOTING GUIDE
MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
14
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Low discharge pressure 1. Air demand exceeds pump capacity 1. Reduce air demand or use a compressor with more
capacity.
2. Air leaks (fittings, tubing on
compressor, or plumbing outside of
system).
2. Listen for escaping air. Apply soap solution to
all fittings and connections. Bubbles will appear
at points of leakage. Tighten or replace leaking
fittings or connections. Use pipe thread sealant.
3. Restricted air intake 3. Clean or replace the air filter element.
4. Blown gaskets 4. Replace any gaskets proven faulty on inspection.
5. Leaking or damaged valves 5. Remove head and inspect for valve breakage,
misaligned valves, damaged valve seats, etc. Replace
defective parts and reassemble.
Install a new head gasket
each time the head is removed.
Excessive noise (knocking) 1. Loose motor pulley or flywheel. 1. Tighten pulley / flywheel clamp bolts and set-
screws.
2. Loose fasteners on pump or motor. 2. Tighten fasteners.
3. Lack of oil in crankcase 3. Check for proper oil level; if low, check for possible
damage to bearings. Dirty oil can cause excessive
wear.
4. Worn connecting rod 4. Replace connecting rod. Maintain oil level and
change oil more frequently.
5. Worn piston pin bores 5. Remove piston assemblies from the compressor and
inspect for excess wear. Replace excessively worn
piston pin or pistons, as required. Maintain oil level
and change oil more frequently.
6. Piston hitting the valve plate 6. Remove the compressor head and valve plate
and inspect for carbon deposits or other foreign
matter on top of piston. Replace head and valve
plate using new gasket. See Lubrication section for
recommended oil.
7. Noisy check valve in compressor
system
7. Replace check valve.
Do not disassemble check valve
with air pressure in tank.
Large quantity of oil in the
discharge air
NOTE: In an oil lubricated
compressor there will always
be a small amount of oil in the
air stream.
1. Worn piston rings 1. Replace with new rings. Maintain oil level and
change oil more frequently.
2. Compressor air intake restricted 2. Clean or replace filter. Check for other restrictions
in the intake system.
3. Excessive oil in compressor 3. Drain down to full level.
4. Wrong oil viscosity 4. Use Mobil 1®10W-30 or full synthetic.
Water in discharge air/tank Normal operation. The amount of water
increases with humid weather
1. Drain tank more often. At least daily.
2. Add a filter to reduce the amount of water in the
air line.

TROUBLESHOOTING GUIDE
MAINTENANCE / REPAIR
TROUBLESHOOTINGOPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS
GETTING STARTED
15
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Motor hums and runs slowly or
not at all.
1. Low voltage. 1. Check incoming voltage. It should be approximately
230 volts. Motor will not run properly on 208 volts.
Low voltage could be due to wires (from electrical
source to compressor) being too small in diameter
and / or too long. Have a qualified electrician check
these conditions and make repairs as needed.
2. Too many devices on same circuit. 2. Limit the circuit to the use of compressor only.
3. Loose electrical connections. 3. Check all electrical connections.
4. Malfunctioning pressure switch -
contacts will not close.
4. Replace pressure switch.
5. Malfunctioning check valve. 5. Replace check valve.
Do not disassemble check valve
with air pressure in tank.
6. Defective unloader valve on pressure
switch.
6. Replace unloader valve.
7. Defective motor capacitor(s). 7. Replace capacitor(s).
8. Defective motor. 8. Replace motor.
Reset mechanism cuts out
repeatedly or circuit breaker
trips repeatedly.
1. Lack of proper
ventilation / room temperature too
high.
1. Move compressor to well-ventilated area.
2. Too many devices on same circuit. 2. Limit the circuit to the use of only the air
compressor.
3. Restricted air intake. 3. Clean or replace filter element.
4. Loose electrical connection. 4. Check all electrical connections.
5. Pressure switch shut-off pressure set
too high.
5. Replace pressure switch.
6. Malfunctioning check valve. 6. Replace check valve.
Do not disassemble check valve
with air pressure in tank.
7. Defective unloader valve on pressure
switch.
7. Replace unloader valve.
8. Defective motor capacitor(s). 8. Replace capacitor(s).
9. Malfunctioning motor. 9. Replace motor.
Tank does not hold pressure
when compressor is off and
the shut off valve is closed.
1. Air leaks (fittings, tubing on
compressor, or plumbing outside
system).
1. Check all connections with soap and water solution.
Tighten; or remove and apply sealant to threads,
then reassemble.
2. Worn check valve. 2. Replace check valve.
Do not disassemble check valve
with air pressure in tank.
3. Check tank for cracks or pin holes. 3. Replace tank. Never repair a damaged tank.
Pressure switch continuously
blows air out the unloader
valve
Malfunctioning check valve Replace the check valve if the unloader valve on the
pressure switch bleeds off constantly when unit shuts
off.
Do not disassemble check valve
with air pressure in tank.
Pressure switch does not
release air when the unit shuts
off
Malfunctioning unloader valve on
pressure switch
Replace the pressure switch if it does not release the
pressure for a short period of time when the unit shuts
off.
Do not disassemble pressure
switch with air pressure in tank
Excessive vibration 1. Loose fasteners on pump or motor 1. Tighten fasteners.
2. Belt needs replaced 2. Replace with correct size.
3. Belt alignment 3. Align flywheel and pulley.

MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
16
MAINTENANCE AND INSPECTION INSTRUCTIONS
Disconnect, tag and lock out power source then release all pressure from the system before
attempting to install, service, relocate or perform any maintenance.
All repairs should be performed by an authorized service representative.
In order to maintain efficient operation of the compressor system,
check the air filter and oil level before each use. The ASME safety
valve should also be checked daily (see Figure 18). Pull ring on
safety valve and allow the ring to snap back to normal position.
This valve automatically releases air if the tank pressure exceeds
the preset maximum. If air leaks after the ring has been released,
or the valve is stuck and cannot be actuated by the ring, the ASME
safety valve must be replaced.
Do not tamper with the ASME safety valve.
Tank
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.
Drain Tank: Disconnect, tag and lock out power source; release pressure. Drain moisture from tank by
opening drain valve underneath tank once tank pressure is less than 40 PSI (See Figure 16 on page 13).
The tank should be carefully inspected at a minimum of once a year. Look for cracks forming near the
welds. If a crack is detected, remove pressure from tank immediately and replace.
Compressor Lubrication
See Installation. Add oil as required. The oil should be changed every three months or after every 200 hours
of operation; whichever comes first.
If the compressor is run under humid conditions for short periods of time, the humidity will condense in
the crankcase and cause the oil to look creamy. Oil contaminated by condensed water will not provide
adequate lubrication and must be changed immediately. Using contaminated oil will damage bearings,
pistons, cylinders and rings and is not covered under warranty. To avoid water condensation in the oil,
periodically run the compressor with tank pressure near 120 PSI for 2-stage compressors by opening the
drain cock or an air valve connected to the tank or hose. Run the pump for an hour at a time at least once a
week or more often if the condensation reoccurs.
IMPORTANT: Change oil after first 50 hours of operation.
Air Filter
Never run the compressor pump without an intake air filter or
with a clogged intake air filter. The air filter element should be
checked monthly (see Figure 19). Operating compressor with
a dirty filter can cause high oil consumption and increase oil
contamination in the discharge air. If the air filter is dirty it must
be replaced.
Figure 18 - ASME Safety Valve
Figure 19

MAINTENANCE / REPAIR
TROUBLESHOOTINGOPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS
GETTING STARTED
17
Belts
Lock out and tag the power then release all pressure from the tank to prevent unexpected
movement of the unit.
Check belt tension every 3 months. Adjust belt tension to allow 3/8 inch to 1/2 inch deflection with normal
thumb pressure. Also, align belts using a straight edge against the face of the flywheel and touching the
rim on both sides of the face. The belts should be parallel to this straight edge (see Figure 20). Dimension A
should be the same as B and C to ensure proper alignment of the belts.
Slots in the bed-plate allow for sliding the motor back and forth to adjust belt tension.
Removing Belt Guard
When removing belt guard front to
inspect or replace belts, inspect plastic retaining
clips and replace if damaged or if clip can be removed without a tool.
Removing Retaining Clips
1. Using crescent wrench on pliers, rotate clip 90°.
2. Pull clip out and away from beltguard.
3. Reverse process to reinstall after inspecting the clip.
Storage
If compressor is to be stored for a short period of time, make sure that it is stored in a normal position and
in a cool protected area.
MAINTENANCE SCHEDULE
OPERATION DAILY WEEKLY MONTHLY 3 MONTHS
Check Oil Level l
Drain Tank l
Check Air Filter l
Check Safety Valve l
Clean Unit l
Check Belt Tightness l
Change Oil* l
* Change oil after first fifty (50) hours of operation then perform oil changes every three (3) months or two hundred
(200) hours of run time, whichever comes first.
A B
C
Figure 20 - Top View
Air Compressor
Motor
Flywheel
Straight Edge
Motor
Drive
Pulley
Setscrew
Figure 21
1
2

For Repair Parts, visit www.campbellhausfeld.com
24 hours a day – 365 days a year
Please provide following information:
- Model number
- Serial number (if any)
- Part description and number as shown in parts list
REPAIR PARTS ILLUSTRATION FOR CE5002 AND XC602100
MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION
ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
18
1
2
3
4