DeWalt D55153 TYPE 2 Owner’s Manual
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INSTRUCTION MANUAL
GUIDE D'UTILISATION
INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIO Y POLIZA
DE GARANTIA. ADVERTENCIA: LI_ASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.
MANUAL DE INSTRUCCIONES
D55150, D55151, D55152, D55153, D55155
Contractor's Electric 4 Gallon Hand Carry Air Compressor
Compresseurs d'air portatifs _lectriques de 4 gallons de classe entrepreneur
Compresor de aire port_itil el_ctrico de 4 galones para contratistas
®
TANK PRESSURE GUAGE
REGULATOR
f DIPSTICK
REGULATED
PRESSURE
GUAGE
PUMP OIL
QUICK
DISCONNECT
COUPLERS
-SAFETY
RELIEF
VALVE
ON/OFF
LEVER
A. TANK PRESSURE GUAGE
B. ON/OFF LEVER
C. PRESSURE SWITCH
D. REGULATED PRESSURE GUAGE
E. REGULATOR
F COUPLERS
G. PUMP OIL FILL DIPSTICK
H. PUMP OIL DRAIN
I. MOTOR RESET SWITCH
J. DRAIN VALVE
K. SAFETY RELIEF VALVE
G
PUMP OIL DRAIN
,
MOTOR RESETSWITCH
K
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MODEL D55150 D55151 D55152 D55153 D55155
SPECIFICATIONS
WEIGHT 57 Ibs, 56 Ibs, 65 Ibs, 58 Ibs, 61 Ibs,
HEIGHT 16,75 in, 16,75 in, 16,0 in, 16,75 in, 12,5 in,
WIDTH 18,0 in, 18,0 in, 18,0 in, 18,0 in, 21,75 in,
LENGTH 15,0 in, 15,0 in, 18,0 in, 15,0 in, 21,75 in,
MOTOR 1 HP (max),120 V, 2,5 HP (max), 120 V, 2,75 HP (max), 120 V, 2,75 HP (max), 120 V, 2,75 HP (max), 120 V,
12A, 60 Hz, 15A, 60 Hz, 14A, 60 Hz, 14A, 60 Hz, 15A, 60 Hz,
1725 RPM 3450 RPM 3450 RPM 3450 RPM 3450 RPM
PUMP OIL 4 oz, 6 oz, 12 oz, 12 oz, 4 oz,
CFM/PSl 4,0@40 4,3@40 5,1 @40 5,1 @40 5,4@40
3,9@60 3,9@60 4,6@60 4,6@60 5,1 @60
3,3@90 3,3@90 4,0@90 4,0@90 4,6@90
3,1 @100 3,2@100 3,8@100 3,8@100 4,5@100
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IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR
ANY DEWALTTOOL, CALL US TOLL FREE AT 1-800-4-DEWALT
(1-800-433-9258).
WARNING! Read and understand all instructions before
operating this compressor. Failure to follow all instructions listed
below may result in electric shock, fire and/or serious personal injury
SAVE THESE INSTRUCTIONS
Safety Instructions
WARNING: Some dust created by thisproduct contains chemicals
known to State of California to cause cancer, birth defects or other
reproductive harm. Some examples of these chemicals are:
• compounds in fertilizers
• compounds in insecticides, herbicides and pesticides
• arsenic and chromium from chemically treated lumber
Toreduce your exposure to these chemicals, wear approved safety
equipment such as dust masks that are specially designed to filter
out microscopic particles.
d_ WARNING: Use of this product will expose you to chemicals
known to the State of California to cause cancer, birth defects and
other reproductive harm. Avoid inhaling vapors and dust, and
wash hands after using.
d_ WARNING: This product contains chemicals, including lead,
known to the State of California to cause cancer, and birth defects
or other reproductive harm. Wash hands after handling.
The user of the air compressor must understand these instructions.
Each person operating the air compressor must be of sound mind
and body and must not be under the influence of any substance
which might impair vision, dexterity, or judgement.
AIR TANK
The tank on yourAir Compressor is designed and may be UM coded
(for units with tanks greater than 6 inch diameter) \
according to ASME Section VIII, Div. 1 rules. All\ _ _ J
pressure vessels must be inspected once every two
years. Tofind your state pressure vessel inspector,
look under the Division of Labor and Industries in
the government section of a phone book or call 1-
800-4DEWAL T for assistance.
The following conditions could lead to a weakening of the tank, and
result in a violent tank explosion:
1. Failure to properly drain condensed water from the tank,
causing rust and thinning of the steel tank. Drain tank daily or
after each use. If tank develops a leak, replace it immediately witha
new tank or new compressor outfit.
2. Modifications or attempted repairs to the compressor tank.
Never drill into, weld, or make any modifications to the tank or its
attachments.
3. Modifications of the pressure switch, safety valve, or any other
components that control tank pressure. The tank is designed to
withstandspecific operating pressures. Never make adjustments or
substitute parts to alter the factory set operating pressures.
ATTACHMENTS & ACCESSORIES
Exceeding the pressure rating of air tools, spray guns, air operated
accessories, tires and other inflatables can cause them to explode or
fly apart, resulting in serious injury. Follow the
equipment manufacturers recommendation and
never exceed the maximum allowable pressure
rating of attachments. Never use the compressor
to inflate small, low-pressure objects such as
children's toys, footballs, basketballs, etc..
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RISK OF EXPLOSION OR FIRE
or explosion. When spraying flammable materials, locate com-
pressor at least 20 feet upwind from spray area. An additional length
of hose may be required.
Store flammable materials in a secure location away from the
compressor.
Restricting any of the compressor ventilation openings will cause
serious overheating and could cause fire. Never place objects
against or on top of compressor. Operate the compressor in an open
area at least 3 feet away from any wall or obstruction that would
restrict the flow of fresh air to the ventilation openings.
RISK OF ELECTRICAL SHOCK
Your air compressor is powered by electricity. If it is
not used properly itcould cause electric shock. Never
operate the compressor outdoors when it is g or
in wet conditions.
Never operate compressor with guards or I:
covers that are damaged or removed. Repairs by anyone other than
qualified personnel can result in serous injury or death by
electrocution. Any electrical wiring or repairs required on this product
should be performed by authorized service center personnel in
accordance with national and local electrical codes.
GROUNDING INSTRUCTIONS
In the event of a malfunction or breakdown, grounding provides a
path of least resistance for electric current to reduce the risk of
electric shock. This tool is equipped with an electric cord having an
equipment-grounding conductor and grounding plug. The plug must
be plugged into a matching outlet that is properly installed and
grounded in accordance with all local codes and ordinances. Do not
modify plug provided: if it will not fit the outlet, have the proper outlet
installed by a qualified electrician.
Improper connection of the equipment-grounding conductor can
result in a risk of electric shock. The conductor with insulation having
an outer surface that is green with or without yellow stripes is the
equipment-grounding conductor. If repair or replacement of the
electric cord or plug is necessary do not connect the equipment-
grounding conductor to a live terminal.
If the grounding Instructions are not completely understood or if in
doubt as to whether the tool is properly grounded, check with a
qualified electrician or service personnel.
Use only 3-wire extension cords that have 3-prong grounding plugs
and 3-pole receptacles to avoid overheating.
REPAIR OR REPLACE DAMAGED OR WORN CORDS IMME-
DIATELY.
THE USE OF A GFCI OUTLET IS RECOMMENDED AND MAY BE
REQUIRED IN CERTAIN AREAS.
Grounded tools intended for use on a supply circuit having a nominal
rating less than 150 volts: This tool is intended for use on a circuit
that has an outlet that looks like the one illustrated in Figure A. The
tool has a grounding plug that looks like the plug illustrated in Figure
A. A temporary adapter, which looks like the adapter illustrated in
Figures B and C, may be used to connect this plug to a 2-pole
receptacle as shown in Figure B if a properly grounded outlet is not
available. The temporary adapter should be used only until a
properly grounded outlet can be installed by a qualified electrician,
The green-colored rigid ear, lug, and the like, extending from the
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A GROUNDED B C
OUTLET GROUNDING
BOX MEANS
_GROUNDIN_
- - ADAPTER
adapter must be connected to a permanent ground such as a
properly grounded outlet box.
The adapter (C) is not for use in Canada.
DEWALT does not recommend the use of extension cords. This
can create power loss and overheating of the motor. Use an
additional air hose rather than an extension cord. If use of an
extension cord is unavoidable, it should be plugged into a GFCI
found in circuit boxes or protected receptacles. When using an
extension cord, observe the following.
Extension Cord Chart
1 Hp Motor
Rating Length of Cord in Feet
12 amp, 115V 14Ga. 12Ga. 10Ga.
2 Hp Motor
Rating Length of Cord in Feet
15 amp, 115V 14Ga. 12Ga. 8Ga.
25' 50' 100'
25' 50' 100'
RISK FROM FLYING OBJECTS
The compressed air stream can cause soft tissue damage to
exposed skin and can propel dirt, chips, loose particles and small
objects at high speed, resulting in serious injury. Always wearANSI
Z28.1 approved safety glasses with side shields when using the
compressor. Never direct air stream at people or animals. Use only
OSHA approved air blow guns.
RISK TO BREATHING
The compressed air from your compressor is not safe for breathing!
The air stream may contain carbon monoxide, toxic
vapors or solid particles. Never inhale air from the
compressor either directly or from a breathing device
connected to the compressor.
Sprayed materials such as paint, paint solvents, paint
remover, insecticides, weed killers, etc. contain
harmful vapors and poisons. NOTE: Operate air compressor only in
a well ventilated area. Read and follow the safety instructions
provided on the label or safety data sheets for the material you are
spraying. Use a NIOSH/MSHA approved respirator designed for
use with specific application.
RISK FROM MOVING PARTS
The compressor cycles automatically when the pressure switch is in
the ON/AUTO position. Always turn off the com- _Y'_-qc;_-_
pressor, bleed pressure from the air hose and tank, yL_<dL2d_'_3
and disconnect from power source before_)_7_'qy('C___q
performing maintenance or attaching tools and
accessories.
Keep your hair, clothing, and gloves away from _ b-_'_
moving parts. Loose clothes, jewelry, or long hair
can be caught in moving parts. Air vents may cover moving parts
and should be avoided as well. Do not remove the protective covers
from this product. Never operate compressor with guards or
protective covers that are damaged or removed. Never stand on
the compressor.
RISK OF BURNS
Touching exposed metal such as the compressor head or aftercooler
can result in serious burns. Never touch any exposed metal parts
on compressor during or immediately after operation. Compressor
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[HOT SURFACES
PUMP
PUMP CYLINDER
PUMP
HEAD
AFTERCOOLER
will remain hot for several minutes after operation. Do
not move the compressor while it is running. Hot motor
parts could cause burns contributing to the dropping of
the compressor, damaging the compressor and/or
injuring the operator.
RISK FROM NOISE
_,CAUTION: Wear appropriate personal hearing _
protection during use. Under some conditions and
duration of use, noise from this product may contribute to
hearing loss.
Introduction
Congratulations on the purchase of your new DEWALT Air
Compressor! You can be assured that this tool has been constructed
with the highest level of precision and accuracy. Each component
has been rigorously tested by technicians to ensure the quality,
endurance and performance of this air compressor.
By reading the following simple safety, installation, operation,
maintenance and troubleshooting steps described in this manual,
you will receive years of trouble-free operation.The manufacturer
reserves the right to make changes in price, color, materials,
equipment specifications, or models at any time without notice.
Inspection of Compressor
Inspect for signs of obvious or concealed freight damage. Report any
damage to the delivering freight carrier immediately. Be sure that all
damaged parts are replaced and any mechanical problems are
corrected prior to the operation of the air compressor. The air
compressor serial number is located on the shroud of the
compressor. Please write the serial number in the space provided in
the service section for future reference.
_, WARNING: When using electric tools, basic safety precautions
should always be followed to reduce risk of fire, electric shock, and
personal injury.
DEWALT Air Compressor Features
PRESSURE SWITCH
This switch (A) is used to start or stop the air compressor. Moving the
switch to the ON position will provide automatic power to the
pressure switch which will allow the motor to start when the air tank
pressure is below the factory set cut-in pressure. When in the ON
(AUTO) position, the pressure switch stops the compressor from
charging air when the air tank pressure reaches the factory set cut-
out pressure limit. For ease of starting, this
switch also has a pressure release valve
located on the side of the switch designed to
automatically release compressed air from the
air compressor pump head and its discharge
line when the air compressor reaches the cut-
out pressure limit or is shut off. Moving the
switch to the OFF position will open the
pressure switch contacts and stop the air
compressor.
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SAFETY RELIEF VALVE
This valve (B) is designed to prevent system failures by relieving
pressure from the system when the compressed air reaches a
predetermined level. The valve is preset by the manufacturer and
must not be modified in any way.
AIR TANK DRAIN VALVE
The drain valve is used to remove moisture from the air tank after the
air compressor is shut off.
MOTOR THERMAL OVERLOAD
The electric motor has a manual thermal
overload protector (C). If the motor overheats
for any reason, the thermal overload will cut
off power, thus preventing the motor from
being damaged. Turn the pressure switch to
the OFF position and wait until the motor
cools before pressing the thermal overload
button.
AIR INTAKE FILTER
This filter (D) is designed to clean air entering the pump. To ensure
the pump continually receives a clean, cool, and dry air supply this
filter must always be clean and the filter intake must be free from
obstructions.
TANK PRESSURE GAGE
The tank pressure gage indicates air pressure in the air tank.
REGULATED PRESSURE GAGE
The regulated pressure gage indicates the air pressure available at the
outlet sideof the regulator.Thispressure is controlled by the regulatorand
is always less than or equal to the air tank pressure.
PRESSURE REGULATOR
The regulator knob controls the air pressurecoming from the air tank.
OIL DIPSTICK
The dipstick (H) will indicate the amount of oil in the pump. Oil levelshould
be checkedon a daily basisto ensure that itdoes notexceed the maximum
notch or fall belowthe minimum notchon the dipstick.
Common Procedures
CHECKING COMPRESSOR PUMP OIL LEVEL
_, WARNING: Aftercooler, pump head, and
surrounding parts are very hot. Do not touch. (see
Hot Surfaces on page 4).
1. Ensure that the unit is off.
2. Locate unit on a flat horizontal surface.
3. Remove dipstick (H) from oil fill port.
4. Look for visual signs of contaminants (water, dirt,
etc.) in oil on dipstick.
5. Wipe oil off of the dipstick.
6. Reinsert the dipstick fully into the oil fill port for a few
seconds to allow oil to collect on dipstick.
7. Remove the oil dipstick to read oil level. Oil should
not exceed top raised line (MAX) on dipstick. If oil is
below lower mark (MIN), add DEWALT synthetic oil
and follow steps 5 through 7.
CHECKING SAFETY RELIEF VALVE OPERATION MIa
_, WARNING: Aftercooler, pump head, and surrounding
parts are very hot. Do not touch (see Hot Surfaces on page 4).
1. Ensure that the unit is off.
2. Ensure that the tank is empty by looking at tank pressure gage.
Drain the tanks if necessary.
3. Grasp the wire ring on the safety valve.
4. Pull and release the ring a few times to ensure that the plunger
moves in and out. Replace the safety valve if plunger does not
move or is difficult to move.
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CHECKING AIR FILTER ELEMENT
WARNING: Aftercooler, pump head, and surrounding parts are
very hot. Do not touch (see Hot Surfaces on page 4).
1. Ensure that the unit is off.
2. Allow the unit to cool.
3. Unscrew the filter from pump head by turning counter clockwise.
4. Separate the filter body into two halves.
5. If the element needs cleaning blow out with air. Replace air filter
assembly if unsure whether element can be cleaned sufficiently.
6. Reconnect the filter body.
7. Screw the filter into pump head by turning clockwise until the
filter is hand tight.
TURNING THE UNIT ON
Follow the pre-start and start-up procedures in the operating
procedure section.
TURNING THE UNIT OFF
Follow the shut-down procedures in the operating procedures
section.
ADJUSTING THE REGULATOR
1. Pull the regulator knob out. (For D55155 compressor)
2. Turn the knob clockwise to increase regulated pressure and
counter clockwise to decrease regulated pressure.
3. When desired pressure is shown on the regulated pressure gage,
push the knob in to lock it. (For D55155 compressor)
INSTALLING HOSES
_ WARNING: Firmly grasp the hose when installing or disconnect-
ing toprevent hose whip.
1. Ensure that the regulated pressure gage reads 0 PSI.
2. Grasp the hose at the coupler.
3. Pull back the collar on the female quick-connect coupler located
on the compressor.
4. Push the male connector into the female connector.
5. Release the female connector.
6. Grasp hose and pull to ensure couplers are seated.
7. Adjust regulator to desired pressure.
DISCONNECTING HOSES
_ WARNING: Firmly grasp the hose when installing or disconnect-
ing toprevent hose whip.
1. Ensure that the regulated pressure gage reads 0 PSI.
2. Grasp the hose at the coupler.
3. Pull back the collar on female quick-connect coupler located on
the compressor.
4. Pull the male connector out of the female connector.
5. Release the female connector.
DRAINING THE TANK
WARNING: The tank contains high pressure air. Keep the outlet
of drain away from face and other body parts. Use safety glasses
when draining because debris can be kicked up into face. Use ear
protection because air flow noise is loud when draining.
NOTE: All compressed air systems generate condensate that
accumulates in any drain point (e.g. tanks, filter, aftercoolers, dryers).
This condensate contains lubricating oil and/or substances which
may be regulated and must be disposed of in accordance with local,
state, and federal laws and regulations.
1. Ensure that the ON/OFF switch is in the OFF position.
2. Move the compressor into an inclined position so that the drain
valve(s) are at the lowest point This will assist in removing
moisture, dirt, etc. from the tanks.
3. Place a suitable container under the drain to catch discharge.
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4. Open the valve from below, keeping hands away from hot
components.
5. Slowly rotate the lever or turn knob counter clockwise to gradually
bleed air from tank.
6. When tank is at 10 PSI, rotate the lever or knob to the fully open
position.
7. Close the drain valve when finished.
Preparation For Use
INITIAL SET-UP
Read all safety instructions before setting-up air compressor.
1. Remove oil plug.
2. Pour DEWALTsynthetic oil into crankcase (See Specifications).
_, WARNING: THE COMPRESSORIS SHIPPED WITHOUT OILIN THE
CRANKCASE. ADD OIL.
3. Insert dipstick.
4. Close air tank drain valve.
_, CAUTION: Do not operate without lubricant or with inadequate
lubricant. DEWALT is not responsible for compressor failure caused
by inadequate lubrication.
Compatibility
Air tools and accessories that are operated with the compressor
must be compatible with petroleum based products. If you suspect
that a material is not compatible with petroleum products, use an air
line filter for removal of moisture and oil vapor in compressed air.
NOTE: Always use an air line filter to remove moisture and oil vapor
when spraying paint.
Location
_, CAUTION: In order to avoid damaging the air compressor, do not
allow the unit to be tilted more than 10 °from the normal horizontal
position when operating.
All hand carry compressors should be run with the rubber feet resting
on a horizontal, flat surface.
Place the air compressor at least 3 feet away from obstacles that
may prevent proper ventilation. Keep the compressor away from
areas that have dirt and/or volatile fumes in the atmosphere. These
impurities may clog the intake filter and valves, causing inefficient
operation.
NOTE: The D55155 single tank air compressor is designed to be
carried in the vertical orientation but will right itself in the proper
horizontal position when placed on a flat surface.
HUMID AREAS
In frequently humid areas, moisture may form in the bare pump and
produce sludge in the lubricant, causing running parts to wear out
prematurely. Excessive moisture is especially likely to occur if the
unit is located in an unheated area that is subject to large
temperature changes. Two signs of excessive humidity are external
condensation on the bare pump when it cools down and a "milky"
appearance in compressor lubricant. You may be able to prevent
moisture from forming in the bare pump by increasing ventilation or
operating for longer intervals.
ELECTRICAL
Refer to the safety instructions before using unit. Observe extension
cord safety instructions if necessary. Always shut off the air com-
pressor switch before removing the plug from the outlet.
NOISE CONSIDERATIONS
Consult local officials for information regarding acceptable noise
levels in your area. To reduce excessive noise, use vibration mounts
or silencers, relocate the unit or construct total enclosures or baffle
walls. Contact a DEWALT service center or call 1-800-4DEWALT for
assistance.
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TRANSPORTING
When transporting the compressor in a vehicle, trailer, etc., ensure
that the tanks are drained and the unit is secured. Use care when
driving to avoid tipping the unit over inthe vehicle. Damage can occur
to the compressor or surrounding items if the compressor is tipped.
MOVING
When moving the compressor, grasp the handle grip and carry the
compressor as close to your body as possible.
WARNING: Ensure proper footing and use caution when carrying
compressor to avoid a loss of balance.
Air Inlet Filter
A CAUTION: Do not operate without the air inlet filter.
General Requirements
The piping, fittings, receiver tank, etc. must be certified safe for at
least the maximum working pressure of the unit. Use hard welded
or threaded steel or copper pipes, cast iron fittings and hoses that
are certified safe for the unit's discharge pressure and temperature.
Use pipe thread sealant on all threads and tighten joints thoroughly
to prevent air leaks. DO NOT USE PVC PLASTIC.
CONDENSATE DISCHARGE PIPING
To install a condensate discharge line, use piping at least one size
larger than the connection. Connect the piping so that it is secured
tightly and is routed to a suitable drain point. Use as short and direct
a pipe as possible. Condensate must be disposed of in accordance
with local, state, and federal laws and regulations.
NOTE: All compressed air systems generate condensate that
accumulates in any drain point (e.g. tanks, filter, aftercoolers and
dryers). This condensate contains lubricating oil and/or substances
which may be regulated and must be disposed of in accordance with
local, state, and federal laws and regulations.
Operating Procedures
PRE-START CHECKLIST
1. Ensure that the ON/OFF lever switch is in the OFF position.
2. Ensure that the tank is drained so that moisture, dirt, etc. can be
eliminated.
3. Ensure that the tank pressure gage reads 0 PSI.
4. Ensure that the safety and drain valves are functioning properly.
5. Ensure that the drain valve is closed.
6. Check the oil level in the pump.
NOTE: The air compressor is shipped without oil in crankcase. Add
oil before using.
7. Ensure that all guards and covers are in place and securely
mounted. Ensure that all labels are legible. Do not use the
compressor until all these items have been verified.
START-UP
1. Ensure that the ON/OFF lever on the pressure switch is in the
OFF position.
2. Pull out and turn the regulator knob counterclockwise until it is ful-
ly closed. Push in to lock. The regulated pressure gage should
read 0 PSI.
3. Plug the power cord into a grounded outlet.
4. Move the ON/OFF lever to the ON position. Allow the compressor
to reach cut-out pressure limit. This pressure will cause the
compressor to shut down automatically.
NOTE: When the compressor is started and the tank is empty, an
air noise will be heard. This noise is normal as the cold start valves
are allowing air to escape from the air compressor lines. This noise
will also be heard when the unit shuts off because the unloader
valve, located in the pressure switch, is purging air from the lines.
5. Attach the hose and accessory.
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6. Adjust the regulator to the desired setting.
NOTE: If any unusual noise or vibration is noticed, stop the com-
pressor and refer to the troubleshooting section.
Shut-down
NOTE: NEVER stop the air compressor by unplugging it from the
power source. This could result in damage to the unit.
1. Move the ON/OFF lever to the OFF position.
NOTE: If finished using compressor, follow steps 2 - 7 below.
2. Unplug the cord from the outlet.
3. Turn the regulator knob counterclockwise until it is fully closed.
Ensure that the regulated pressure gage reads 0 PSI.
3. Remove the hose and accessory.
4. Drain the air tanks.
5. Allow the compressor to cool down.
6. Wipe compressor clean and store in a safe, non-freezing area.
Maintenance
The following procedures must be followed when maintenance or
service is performed on the air compressor.
1. Turn off the compressor.
2. Disconnect cord from electrical outlet.
3. Drain tanks.
4. Allow the compressor to cool down before starting service.
NOTE: All compressed air systems contain maintenance parts (e.g.
lubricating oil, filters, separators) which are periodically replaced.
These used parts may be, or may contain, substances that are
regulated and must be disposed of in accordance with local, state,
and federal laws and regulations.
NOTE: Take note of the positions and locations of parts during
disassembly to make reassembly easier. The assembly sequences
and parts illustrated may differ for your particular unit.
NOTE: Any service operations not included in this section should be
performed by authorized service personnel.
Maintenance Chart
Procedure
Check pump oil level
Oil leak inspection
Drain condensation in air tank(s)
Check for unusual noise/vibration
Check for air leaks**
Inspect air filter
Clean exterior of compressor
Check safety relief valve
Day Week Month
X
X
X
X
X
X
X
X
Change pump oil *
Replace air filter
* The pump oil must be changed after the first 20 hours of oper-
ation. Thereafter, every 200 hours or once a year, whichever comes
first. In harsh environments, maintenance must be performed on an
accelerated schedule. Always use DEWALT synthetic oil.
** Tocheck for air leaks apply a solution of soapy water around joints.
While the compressor is reaching the pressure cut-out limit and after
the pump cuts out, look for air bubbles around the joints.
200 Hrs.
X
X
Compressor Pump Oil Change
NOTE: Pump oil contains substances that are regulated and must be
disposed of in accordance with local, state, and federal laws and
regulations.
WARNING :Aftercooler, pump head, and surrounding parts are
very hot. Do not touch (see Hot Surfaces on page 4).
lO
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1. Ensure that the unit is off.
2. Allow the unit to cool.
3. Place a suitable container under the
drain plug (K).
4. Remove the oil dipstick (L) from crank-
case.
5. Remove the oil drain plug.
6. Allow ample time for all the oil to drain
out. (Tilting the compressor towards the K-
drain plug assists draining.)
7. Reinstall the oil drain plug.
8. Fill the pump with DEWALT synthetic compressor oil (See
Specifications).
9. Reinstall the oil dipstick.
Accessories
Recommended accessories for use with your tool are available for
purchase from your localdealer or authorized service center. If you
need assistance in locating any accessory for your tool, contact:
DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore,MD
21286 or call 1-800-4-DEWALT.
,_ CAUTION: The use of any other accessory not recommended
for use with this tool could be hazardous.
SERVICE
Please have the following information available for all service calls:
Model Number
Serial Number
Date and Place of Purchase
Repairs
Toassure product SAFETY and RELIABILITY, repairs, maintenance
and adjustment should be performed by authorized service centers
or other qualified service organizations, always using identical
replacement parts.
Full One Year Warranty
DEWALT heavy duty industrial tools are warranted for one year from
date of purchase. We will repair, without charge, any defects due to
faulty materials or workmanship. For warranty repair information, call
1-800-4-DEWALT. This warranty does not apply to accessories or
damage caused where repairs have been made or attempted by
others. This warranty gives you specific legal rights and you may
have other rights which vary in certain states or provinces.
FREE WARNING LABEL REPLACEMENT: Ifyour warning labels
become illegible or are missing, call 1-800-4-DEWALT for a free
replacement.
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This section provides a list of the more frequently encountered malfunctions, their causes and corrective actions. The operator or
maintenance personnel can perform some corrective actions, and others may require the assistance of a qualified DEWALT technician
or your dealer.
Problem Code
Compressor does not start or restart .............................................................................................. 16,17,18,19,20,36
Unit does not or is slow to come up to speed ................................................................................ 3,8,11,12,14,15,20,21,22,24,25,31
Air compressor not making enough air............................................................................................ 1,3,7,8,9,10,11,21,24,25,28,29
Insufficient pressure at air tool or accessory .................................................................................. 1,3,7,8,9,10,11,21,24,25,27,28,29
High oil consumption ........................................................................................................................ 2,6,9,10,11,12,15,30,32
Unit runs excessively hot ................................................................................................................ 1,2,4,5,10,11,12,13,15,19,30
Excessive starting and stopping ...................................................................................................... 7,20,21,24,25,29
Excessive noise during operation .................................................................................................. 2,3,4,5,8,9,10,11,12,15,25,29,30,31
Moisture in discharge air .................................................................................................................. 34,35
Moisture in crankcase or "milky" appearance in petroleum lubricant or rusting in cylinders .......... 6,7,9,10,15,25,26,33,35
Oil in discharge air (oil pumping) .................................................................................................... 2,6,8,9,10,11,15,31,32
Oil leaking from shaft seal ................................................................................................................ 12
Safety relief valve "pops" ................................................................................................................ 22,23
Air leaks at pump ............................................................................................................................ 24,25
Air leaks at fittings ............................................................................................................................ 25
Air leaks from tank .......................................................................................................................... 26
Abnormal piston ring or cylinder wear ............................................................................................ 2,4,5,6,9,10,11,13
'\ b/
TROUBLESHOOTING GUIDE
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5135175-02,01.qxd 3/30/05 8:32 PH Page 13
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Code Possible Cause
Extremel_ Run unit for Ionc
8,
Compressor pump check valve is loose, broken, Inspect valve. Clean or replace as required.
lO
Piston rings damaged or worn
(broken, rough, or scratched). Excessive end gap or
side clearance. Piston rings not seated, stuck
12
Worn connectinc rod, piston pin, or crankpin bearin(s. Inspect all. Repair or replace as required..
20
Fuse blown or circuit has tripped. Replace fuse or reset circuit breaker. Check for proper fuse. Use only
Possible Solution
Add )ricant to crankcase to
tu!
Install new rings.
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"Fusetron" type T fuses. Check for low voltage conditions. Disconnect
any other electrical appliances from circuit or operate the compressor
on its own branch circuit.
13
5135175-02,01.qxd 3/30/05 8:32 PH Page 14
'\ b/
Code Possible Cause
ressure re on pressure sw qas
not :led
25
Pressure switch does not shut off motor when
air compressor reaches "cut-out" pressure.
27 Defective switch.
31 Fittings nottight enough.
33 Pressure regulator knob not turned to high enough
35 Possible defective reed valve.
Possible Solution
sts,
contact DEWALT customer service at 1-800-4-DEWALT.
Move the pressure switch to the OFF position.
If the motor does not shut off, unplug the air compressor. Ifthe
electrical contacts are welded together, replace the pressure
switch.
Re switch.
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Warning: Drain air before tightening. Tighten fittings so air can
not be heard escaping. Check joint with soap solution. Do not
Adjust pressure regulator knob to proper setting or replace.
Remove pump head and inspect valve plate and reed valve.
Clear or re valves as re( uired.
)er level with
41 Compressor located in damp or humid location.
Relocate the compressor.
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