DeWalt D55153 TYPE 3 Owner’s Manual

If you have questions or comments, contact us.

Pour toute question ou tout commentaire, nous contacter.

Si tiene dudas o comentarios, cont&ctenos.

iNSTRUCTiON MANUAL

GUIDE D'UTILiSATION MANUAL DE INSTRUCCIONES

INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIO Y POLIZA DE GARANTiA. ADVERTENClA: LI_ASE ESTE INSTRUCTIVO ANTES DE USAR EL PRODUCTO.

D55151, D55152, D55153, D55155

Contractor's Electric 4 Gallon Hand Carry Air Compressor Compresseurs d'air portatifs 61ectriques de 4 gallons de classe entrepreneur Compresor de aire portatil electrico de 4 galones para contratistas

Air Compressor

A. On/Off Switch

B. Air Tank Pressure Gauge

C. Regulated Pressure Gauge

D. Pressure Regulator E. Quick Connects (if equipped)

F. Check Valve

G. Safety Valve

H. Air Tank Drain Valve

I. Power Cord Wrap

J. Pressure Switch

K. Pump Oil Dipstick

L. Pump Oil Drain Plug

M. Motor Reset

N. Air Intake Filter

FIG. 1

NOT A

STEP

Specifications

MODEL D55155

D55152

WEIGHT 56 Ibs. (25.4 kg) 58 Ibs. (28.3 kg) 61 Ibs. (27.7 kg)

HEIGHT 16.75" (425.5 mm) 16.75" (501.7 mm) 12.5" (317.5 mm)

WIDTH 18.0" (457.2 mm) 18.0" (457.2 mm) 21.75" (552.5 mm)

LENGTH 15.0 (381 mm) 15.0 (381 mm) 21.75" (552.5 mm)

AIRTANK CAPACITY (GALLONS) 4.0 (15.1 liters) 4.0 (15.1 liters) 4.0 (15.1 liters) APPROX CUT=INPRESSURE 95 PSi (655 kPa) 95 PSi (655 kPa) 100 PSi (689.5 kPa) APPROX. CUT=OUT PRESSURE 125 PSi (861.8 kPa) 125 PSi (861.8 kPa) 125 PSi (861.8 kPa)

SCFM @ 100 PSI (689.5 kPa) 3.2 3.8 4.5 MOTOR 1.1 HP (continuous) 1.1 HP (continuous) 1.2 HP (continuous)

Volts/Amps/Hertz 120V/12.5 A/60 Hz. 120V/14 A/60 Hz. 120V/15 A/60 Hz.

RPM 3450 3450 3450 Minumum Branch Circuit 15 Amp 15 Amp 15 Amp

Requirement

PUMP OIL CAPACITY 6 oz. (177.4 ml) 12 oz. (354.9 ml) 12 oz. (354.9 ml) 4 oz. (118.3 ml)

65 Ibs. (29.5 kg)

16.0" (406.4 ram)

18.0" (457.2 ram)

4.0 (15.1 liters) 95 PSI (655 kPa) 125 PSI (861.8 kPa)

3.8

1.1 HP (continuous) 120V/14 A/60 Hz.

3450 15 Amp

Hot Surfaces

FIG.2 CYLNDER

OUTLET TUBE CHECK /

PUMP

AND

VALVE /

Definitions: Safety Guidelines

The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols.

`&DANGER: Indicates an imminently hazardous

situation which, ff not avoided, wifl result in death or serious injury.

AWARNING: Indicates a potentially hazardous situation which, ff not avoided, could result in death

or serious injury. ,&CAUTION: Indicates a potentially hazardous

situation which, ff not avoided, may result in minor or moderate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, ff not avoided, may result inproperty damage.

OUTLET TUBE VALVE

CHECK

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT

THIS OR ANY DEWALT TOOL, CALL US TOLL FREE AT:

I=800=4=DEWALT (1-800=433=9258)

Important Safety Instructions

_, WARNING: Do not operate this unit until you read and understand

this instruction manual for safety, operation and maintenance instructions.

AWARNING: Some dust created by power sanding, sawing, grind- ing, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some example of these chemicals are:

* lead from lead-based paints * crystalline silica from bricks and cement and other masonry

products

* arsenic and chromium from chemically-treated lumber

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemi-

cals: work in a weft ventilated area, and work with approved safety equipment, always wear OSHA/MSHA/NIOSH approved, properly

fitting face mask or respirator when using such tools.

When using air tools, basic safety precautions should always be fol- lowed to reduce the risk of of personal injury,

_ 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.

SAVE THESE INSTRUCTION

,t_DANGER: RISK OF EXPLOSION OR FIRE

WHAT CAN HAPPEN HOWTO PREVENT iT

• It is normal for electrica! _ Always operate the compres_ contacts within the motor Sorin a well ventilated area

and pressure switch to free of combustible materials,

spark, gasoline, or solvent vapors.

• If electrical sparks from • If spraying flammable materi- compressor come into con- als, locate compressor at tact with flammable vapors, east 20 feet 16.1 m) away they may ignite, causing fire from spray area. An addi- or explosion, tional length of hose may be

required.

- Store flammable materials q a secure location away from

compressor.

• Restricting any of the com- • Never place objects against pressor ventilation openings or on top of compressor

will cause serious overheat- • Operate compressor in ing and could cause fire. an open area at least 12"

(30.5 cm) away from any wall or obstruction that would

restrict the flow of fresh air to

the ventilation openings.

• Operate compressor in a clean, dry well ventilated area.

Do no_operate unit indoors or

in any confined area.

Unattended operation of

this product could result in

personal injury or property damage. To reduce the risk of fire, do not allow the

compressor to operate unat- tended.

ADANGER: RISK TO BREATHING (ASPHYXIATION)

WHAT CAN HAPPEN HOWTO PREVENTIT

, The compressed air directly - Air obtained directly from the

from your compressor is not compressor should never safe for breathing. The air be used to supply air for

stream may contain carbon human consumption. In order monoxide, toxic vapors, to use air produced by this

or solid particles from the compressor for breathing air tank. Breathing these suitable filters and in-line

contaminant's can cause safety equipment must be serious injury or death, properly installed. In-line

• Always remain in attendance with the product when it is

operating.

• Always turn off and unplug

unit when not in use.

filters and safety equipment

used in conjunction with the

compressor must be capable of treating air to all applicable

local and federal codes prior to human consumption

Sprayedmaterialssuchas paint,paintsolvents,paint

remover,insecticides,weed killers,maycontainharmful

vaporsandpoisons.

Workinanareawithgood crossventilation.Readand

followthesafetyinstructions providedonthelabelorsafety

datasheetsforthematerials youarespraying.Alwaysuse

certifiedsafetyequipment: OSHA!MSHA/NIOSH

respiratoryprotectiondesigned forusewithyourspecific application.

_&DANGER:RISK OF INJURY OR PROPERTY DAMAGE WHEN

TRANSPORTING OR STORING

WHAT CAN HAPPEN HOWTO PREVENTIT

o Oil can leak or spilland could - Always place compressor

result infire or breathing on a protective mat when hazard; serious injury or transporting to protect against death can result.Oil leaks will damage to vehicle from leaks. damage carpet, paint or other Remove compressor from surfaces in vehicles ortrailers, vehicle immediately upon arrival

at your destination. Always keep compressor level and never lie

on its side.

_&WARNING: RISK OF BURSTING

AirTank: The airtank on your Air Compressor is designed and may be UM coded (for units with air tanks greater than 6 inch diameter) according to ASME Section VIII, Div. 1 rules. All pressure vessels should be inspected once every two years.To find your state pressure vessels inspector, look under the Division of Labor and Industries in the government section of a phone book or call 1-800-4-DEWALT for

assistance. The following conditions could lead to a weakening of the air tank,

and result in a violent air tank explosion:

WHAT CAN HAPPEN HOWTO PREVENT IT

Failure to properly drain _ Drain airtank daily or after

condensed water from air tank. causing rust and

thinning of the steel air tank.

Modifications or attempted - Never drill into.weld, or make repairs to the air tank, any modifications to the air

Unauthorized modifications

• • The airtank is designed to the safety valve or any other components which control air tank pressure.

each use. If air tank develops a leak. replace it immediately with a new air tank or replace the entire compressor.

tank or its attachments. Never

attempt to repair a damaged or leaking air tank. Replace with a

new airtank.

to withstand specific operating pressures. Never

make adjustments or parts substitutions to alter the factory set operating pressures.

Attachments& accessories:

Exceeding the pressure • Follow the equipment rating of air tools, spray guns. manufacturers air operated accessories, recommendation and never

tires, and other inflatables exceed the maximum

can cause them to explode allowable pressure rating or fly apart, and could result of attachments. Never use in senous injury, compressor to inflate small

low pressure objects such as children's toys, footballs,

basketballs, etc.

AWARNING: RiSK OF ELECTRICAL SHOCK

WHAT CAN HAPPEN HOWTO PREVENT iT

" Youiair c0mpress0r is . Never operate the

Like any other electrically is raining 0r in wet conditions. powered device, !fit iS not ,, Never operate comPressor

used proper!y it may cause with protective covers electric shock, removed or damaged.

• Repairs attempted by unqualified personnel can result in serious injury or death by electrocution.

• Any electrical wiring or repairs required on this product should be performed by a DEWALTfactory

service center or a DEWALT authorized service center in

accordance with national and local electrical codes.

- Electrical Grounding: = Make certain that the Failure to provide adequate electrical circuit to which the grounding to this product compressor is connected could result in serious injury provides proper electrical or death from electrocution, grounding, correct voltage See Grounding and adequate fuse protection.

instructions under

Installation.

AWARNING: RISK FROM FLYING OBJECTS

WHAT CAN HAPPEN

• 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 property damage or personal injury.

HOWTO PREVENT IT

• Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/CSA Z94.3) with side shields when using the compressor.

• Never point any nozzle or sprayer toward any part of the body or at other people or

animals. Always turn the compressor off

and bleed pressure from the air hose and air tank before

attempting maintenance, attaching tools or accessories.

AWARNING:RiSK OF HOT SURFACES

WHAT CAN HAPPEN HOWTO PREVENT JT

• Touching exposed metal - Never touch any exposed

such as the compressor metal parts on compressor

head. engine head, engine during or immediately after

exhaust or outlet tubes, can operation. Compressor will

result in serious burns, remain hot for several minutes

after operation.

• Do not reach around protective shrouds or attempt

maintenance until unit has been allowed to cool.

_, WARNING: RiSK FROM MOVING PARTS

WHAT CAN HAPPEN HOWTO PREVENT IT

Moving parts such as the pulley, flywheel, and belt can

cause serious injury ifthey come into contact with you or

your clothing.

• Never operate the compressor with guards or covers which

are damaged or removed.

• Keep your hair, clothing, and

gloves away from 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.

- Attempting to operate o Any repairs required on this compressor with damaged or product should be performed

missing parts or attempting by a DEWALTfactory

to repair compressor with service center or a DEWALT

protective shrouds removed authorized service center.

can expose you to moving

parts and can result in

serious injury.

AWARNING: RISK OF UNSAFE OPERATION

WHAT CAN HAPPEN HOWTO PREVENT IT

Unsafe operation of your air

compressor could lead to seri- ous injury or death to you or

others.

Review and understand all

instructions and warnings in this manual.

• Become familiar with the operation and controls of the

air compressor.

• Keep operating area clear of all persons, pets, and obstacles.

• Keep children away from the air compressor at all times.

• Do not operate the product when fatigued or under the

influence of alcohol or drugs. Stay alert at alltimes.

• Never defeat the safety fea- tures ofthis product.

• Equipareaofoperationwitha fireextinguisher.

• Donotoperatemachinewith missing,broken,orunautho- rizedparts.

WARNING: RiSK OF FALLING

WHAT CAN HAPPEN HOWTO PREVENTIT

A portable compressor _ Always operate compressor can fall from a table, in a stable secure position to workbench, or roof causing prevent accidental movement damage to the compressor of the unit. Never operate and could result in serious compressor on a roof or

njury or death to the other elevated position. Use

operator, additio nal air hose to reach

high locations.

A CAUTION: RISK FROM NOISE

WHAT CAN HAPPEN HOWTO PREVENT IT

Under some conditions and • Always wear certified safety duration of use, noise from equipment: ANSI S12.6 this product may contribute (S3.19) hearing protection. to hearing loss.

SAVE THESE INSTRUCTIONS

FOR FUTURE USE

FEATURES (Fig. 1)

ON/OFF SWITCH Place this switch (A) in the ON position to

provide automatic power to the pressure

switch and OFF to remove power at the

end of each use. PRESSURE SWITCH

The pressure switch (J) automatically starts the motor when the air tank pres- sure drops below the factory set cut-in

pressure. It stops the motor when the air tank pressure reaches the

factory set cut-out pressure.

PRESSURE RELEASE VALVE

The pressure release valve located on the side of the pressure switch,

is designed to automatically release compressed air from the compres- sor head and the outlet tube when the air compressor reaches cut-out pressure or is shut off.The pressure release valve allows the motor to

restart freely.When the motor stops running, air will be heard escaping from this valve for a few seconds. No air should be heard leaking when the motor is running orafter the unit reaches cut-out pressure.

SAFETY VALVE

If the pressure switch does not shut off the air compressor at its cut-out pressure setting, the safety valve (G) will protect against

high pressure by popping out at its factory set pressure (slightly

higher than the pressure switch cut-out setting).

CHECK VALVE When the air compressor is operating, the check

valve (F) is open, allowing compressed air to enter the air tank. When the air compressor reaches cut-

out pressure, the check valve closes, allowing air

pressure to remain inside the air tank.

TANKPRESSUREGAUGE Thetankpressuregauge(B)indi-

catesthereserveairpressurein thetank.

OUTLETPRESSUREGAUGE Theoutletpressuregauge(C)

indicatestheairpressureavailable attheoutletsideoftheregulator. Thispressureiscontrolledbytheregulatorandisalwayslessthan orequaltothetankpressure.

REGULATOR Theregulator(D)controlstheairpressureshownontheoutlet

pressuregauge.Turnregulatorknobclockwisetoincreasepres- sureandcounterclockwisetodecreasepressure.

UNIVERSALQUICKCONNECTBODIES(IFEQUIPPED) Theuniversalquickconnectbody(E)acceptsthethreemost

popularstylesofquickconnectplugs:Industrial,automotive,and ARO.Onehandpush-to-connectoperationmakesconnections simpleandeasy.Thetwoquickconnectbodiesallowtheuseoftwo

toolsatthesametime.

DRAIN VALVE

The drain valve (H) is located at the base of the air tank and is used to drain conden-

sation atthe end of each use. See Draining Air Tank under Maintenance.

COOLING SYSTEM This compressor contains an advanced design cooling system.

It is normal for this fan to blow air through the vent holes in large amounts. The cooling system is working when air is expelled.

AIR COMPRESSOR PUMP

The pump compresses air into the air tank. Working air is not

available until the compressor has raised the air tank pressure above that required at the air outlet.

MOTOR OVERLOAD PROTECTOR

This motor has a manual thermal overload

protector. If the motor overheats for any reason, the overload protector will shut off

the motor. The motor must be allowed to

cool down before restarting. To restart:

1. Ensure the On/Off switch (A) is in the OFF position.

2. Allow the motor to cool.

3. Depress the reset button (M) on the motor.

OIL DIPSTICK

The oil dipstick (K) indicates the amount of oil in the pump. Check

pump oil daily, see Compressor Pump Oil under Maintenance. AIR iNTAKE FILTER

The filter (N) is designed to clean air entering the pump. To ensure the pump continually receives a clean, cool, and dry air supply the filter must always be clean and the filter intake must be free from

obstructions.

INSTA£LATION

Assembly

iNSTALLING HOSES

WARNING: Risk of unsafe operation. Firmly grasp hose in hand

when installing or disconnecting to prevent hose whip.

1. Ensure regulated pressure gauge reads 0 PSI (0 kPa).

2. Grasp the hose at the quick connect plug and push the plug into the quick connect body (E). Coupler will snap into place.

3. Grasp the hose and pull to ensure coupler is seated.

DISCONNECTING HOSES

Ik WARNING: Risk of unsafe operation. Firmly grasp hose in hand when installing or disconnecting to prevent hose whip.

1. Ensure regulated pressure gauge reads 0 PSi (0 kPa).

2. Pull coupler on quick connect body back to release quick connect plug on hose.

Lubrication and Oil

CAUTION: The compressor was shipped with oil in the crankcase.

A shipping plug is used to prevent oil from leaking during shipment. Do not attempt to operate this air compressor without first checking

the oil level. Serious damage can result from even limited operation unless filled with oil and broken in correctly. Closely follow Initial

Set-up under Operation. CAUTION: Multi-viscosity motor oils, like 10W30, should not be

used in an air compressor. They leave carbon deposits on critical components, thus reducing performance and compressor like. Use

SAE 40, non-detergent air compressor oil only.

1. Place unit on a level surface.

2. Remove the shipping plug and install the dipstick.

3. Remove the dipstick (K) and check the oil level. Oil should not exceed top raised line on dipstick. If oil is below lower mark see Checking Oil under Compressor Pump Oil under Maintenance. NOTE: See Specifications for _ pump oil capacity.

CAUTION: Risk of unsafe operation. Overfilling with oil will cause premature compressor failure. Do not overfill.

4. Replace dipstick.

Grounding instructions

_&WARNING: Risk of electrical shock. In the event of a short circuit, grounding reduces the risk of shock by providing an escape wire for the electric current. This air compressor must be properly grounded.

The portable air compressor is equipped with a cord having a grounding wire with an appropriate grounding plug.

1. The cord set and plug (0) with this unit contains a grounding pin (P).This plug MUST be used with a grounded outlet (Q).

IMPORTANT: The outlet being used must be installed and grounded in accordance

with all local codes and ordinances.

2. Ensure the outlet being used has the same configuration as the grounded plug. DO NOT USE AN ADAPTER.

3. Inspect the plug and cord before each use. Do not use if there are signs of damage.

4. If these grounding instructions are not completely understood, or if in doubt as to whether the compressor is properly grounded, have the installation checked by a qualified electrician.

_DANGER: Risk of electrical shock. IMPROPER GROUNDING

CAN RESULT IN ELECTRICAL SHOCK.

* Do not modify the plug provided, ff it does not fit the available

outlet, a correct outlet should be installed by a quafified electri- cian.

* Repairs to the cord set or plug MUST be made by a quafified

electrician.

Extension Cords

Using extension cords is not recommended. The use of extension cords will cause voltage to drop resulting in power loss to the motor and overheating.

Instead of using an extension cord, increase the working reach of the air hose by attaching another length of hose to its end. Attach additional lengths of hose as needed. If an extension cord must be used, be sure it is:

• a 3-wire extension cord that has a 3-blade grounding plug, and a 3-slot receptacle that will accept the plug on the product

• in good condition

• no longer than 50 feet (15,2 m)

• 12 gauge (AWG) or larger. (Wire size increases as gauge num- ber decreases. 10 AWG and 8 AWG may also be used. DO NOT USE 14 OR 16 AWG.)

Voltage and Circuit Protection

Refer to the Voltage and Minimum Branch Circuit Requirements under Specifications.

_,CAUTION: Certain air compressors can be operated on a

15 amp circuit if the following conditions are met.

• Voltage supply to circuit must comply with the National Electrical

Code.

• Circu# is not used to supply any other electrical needs.

Extension cords comply with specifications. Circu# is equipped with a 15 amp circu# breaker or 15 amp

time delay fuse. NOTE: ff compressor is connected to a circu#

protected by fuses, use only time delay fuses. Time delay fuses should be marked "D" in Canada and "T" in the US.

If any of the above conditions cannot be met, or ff operation of the compressor repeatedly causes interruption of the power, it may be necessary to operate it from a20 amp circuit. It is not necessary to change the cord set.

Compatibility

Air tools and accessories that are run off the compressor must be compatible with petroleum-based products. If you suspect that a material is not compatible with petroleum products, an air line filter for removal of moisture and oil vapor in compressed air is required.

NOTE: Always use an air line filter to remove moisture and oil vapor when spraying paint.

Location

Place the air compressor in a clean, dry and well ventilated area at least 12" (30.5 cm) away from the wall or other obstructions that will interfere with the flow of air. 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.

The air compressor pump and shroud are designed to allow for proper cooling. The ventilation openings on the compressor are necessary to maintain proper operating temperature. Do not place rags or other containers on or near these openings.

Place the air compressor on a flat surface resting on the rubber feet.

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 1-800-4-DEWALT for assistance.

ELECTRICAL Refer to all safety instructions before using unit. Observe extension

cord safety instructions if necessary. Always move the On/Off switch (A) to the OFF position before removing the plug from the

outlet.

TRANSPORTING

When transporting the compressor in a vehicle, trailer, etc., ensure

that the tank is drained and the unit is secured. Use care when driv-

ing to avoid tipping the unit over in the vehicle. Damage can occur to

the compressor or surrounding items if the compressor is tipped.

MOVING

When moving the compressor, grasp the handle and carry the com- pressor as close to the body as possible.

_, WARNING: Risk of unsafe operation. Ensure proper footing and

use caution when carrying compressor to avoid a loss of balance.

PREPARATION FOR USE Pre-Start Checklist (Fig. 1)

1. Ensure the On/Off switch (A) is in the OFF position.

2. Plug the power cord into the correct branch circuit receptacle. See Voltage and Circuit Protection under Installation.

3. Ensure air tank is drained, see Draining Air Tank under

Maintenance.

4. Ensure the drain valve (H) is closed.

5. Ensure safety valve (G) is functioning properly, see Checking Safety Valve under Maintenance.

6. Check pump oil level, see Compressor Pump Oil under

Maintenance.

CAUTION: Do not operate without oil or with inadequate oil.DEWALT

is not responsible for compressor failure caused by inadequate oil.

7. Turn regulator knob (D) counterclockwise until fully closed. Ensure regulated pressure gauge reads 0 PSI (0 kPa).

8. Attach hose and accessories.

_kWARNING: Risk of unsafe operation. Firmly grasp hose in hand

when installing or disconnecting to prevent hose whip.

9. Ensure all covers and labels are in place, legible (for labels) and securely mounted. Do not use compressor until all items have

been verified.

• , WARNING: Risk of bursting. Too much air pressure causes a

hazardous risk of bursting. Check the manufacturer's maximum pressure rating for air tools and accessories. The regulator outlet pressure must never exceed the maximum pressure rating.

Initial Set.up (Fig. 1)

WARNING: Do not operate this unit until you read and understand

this instruction manual for safety, operation and maintenance

instructions.

BREAK-IN PROCEDURE

_kWARNING: Serious damage may result if the following break-in

instructions are not closely followed.

This procedure is required before the air compressor is put into service for the first time and when the check valve or a compressor pump/motor has been replaced.

1. Ensure the On/Off switch (A) is in the OFF position.

NOTE: If hose is not connected to Quick Connect body, pull coupler back until it clicks to prevent air from escaping through the quick

connect.

2. Plug the power cord into the correct branch circuit receptacle. See Voltage and Circuit Protection under Installation.

3. Open the drain valves (counter-clockwise) fully to permit air to escape and prevent air pressure build up in the air tank during the break-in period.

4. Move the On/Off switch to the ON position. The compressor will start.

5. Run the compressor for 20 minutes.

6. After 20 minutes, close the drain valves by turning clockwise. The tank will fill to cut-out pressure and the motor will stop.

7. Compressed air will be available until itis used or bled off.

OPERATING PROCEDURES Start-up (Fig. 1)

1. Follow Pre-Start Checklist under Preparation for Use.

2. Move the On/Off switch to the ON position and allow tank pres- sure to build. Motor will stop when tank pressure reaches cut-out pressure.

CAUTION: Risk of unsafe operation. Compressed air from the unit may contain water condensation and oil mist. Do not spray unfil- tered air at an item that could be damaged by moisture. Some air operated tools or devices may require filtered air. Read the instruc-

tions for the air tool or device.

3. Adjust regulator (D) to desired setting. See Regulator under

Features.

Shut-down (Fig. 1)

1 Move On/Off switch (A) is in the OFF position. NOTE: If finished

using compressor, follow Steps 2 - 6.

2. Turn regulator knob (D) counterclockwise until fully closed. Ensure

regulated pressure gauge reads 0 PSI (0 kPa).

3. Remove hose and accessory.

4. Drain the air tank, see Draining Air Tank under Maintenance. Ensure air tank pressure gauge reads 0 PSI (0 kPa).

_, WARNING: Risk of bursting. Drain air tank daily. Water will con-

dense in air tank. If not drained, water will corrode and weaken the air tank causing a risk of air tank rupture.

5. Allow the compressor to cool down.

6. Wipe air 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. Ensure On/Off switch is in the OFF position.

2. Remove air compressor plug from outlet.

3. Drain air tank.

4. Allow air compressor to cool down before starting service.

NOTE: All compressed air systems contain maintenance parts (e.g.,

oil, filters, separators) that are periodically replaced. These used parts

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.

NOTE: Any service operations not included in this section should be performed by a DEWALT factory service center or a DEWALT authorized service center.

Maintenance Chart

Procedure Daily Weekly IVlonthly

Check safety valve X Inspect air filter + X

Drain air tank X Check pump oil level X

Change pump oil**+ Oil leak inspection X

Check for unusual noise! vibration

Check for air leaks* X Clean compressor exterior X

* To check for air leaks apply a solution of soapy water around joints. While compressor is pumping to pressure and after pressure cuts out, look for air bubbles to form.

** The pump oil must be changed after the first 20 hours of operation. Thereafter, when using DEWALT synthetic or SAE 40, non-detergent air compressor oil, change oil every 200 hours of operation or once a year,

whichever comes first.

+ Perform more frequent !ndusty or humid condit!ons

1 year or

200 Hours

Checking Safety Valve (Fig. 1)

_WARNING: Hot surfaces. Risk of burn. Aftercooler, pump head, and surrounding parts are very hot, do not touch (see the Hot

Surfaces identified in Fig. 2). Allow compressor to cool prior to servicing.

_WARNING: Risk of bursting, ff the safety valve does not work

properly, over-pressurization may occur, causing air tank rupture or an explosion.

Before starting compressor, pull the ring on the safety valve to make sure that the safety valve operates freely. If the valve is stuck or does not operate smoothly, it must be replaced with the same type of valve.

Checking Air Filter Element (Fig. 1)

_,WARNING: Hot surfaces. Risk of burn. Aftercooler, pump head, and

surrounding parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 2). Allow compressor to cool prior to servicing.

1. Ensure the On/Off switch (A) is in the OFF position.

2. Allow unit to cool.

3. Remove air filter (N) from unit.

4. Carefully pry filter top from base.

5. Remove element from filter base.

6. If element needs cleaning, blow out with air. Replace if needed. Purchase replacement parts from your local dealer or authorized service center. Always use identical replacement parts.

7. Place element back in filter base.

8. Snap filter top to filter base.

9. Reassemble air filter to unit. Ensure exhaust outlet points down.

_CAUTION: Risk of unsafe operation. Do not operate without air

inlet filter

Draining Air Tank (Fig. 1)

_kWARNING: Risk of unsafe operation. Risk from noise. Air tanks

contain high pressure air. Keep face and other body parts away from outlet of drain. Use safety glasses [ANSI Z87.1 (CAN/CSA Z94.3)]

when draining as debris can be kicked up into face. Use ear protection [ANSI $12.6 ($3.19)] as 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 On/Off switch is in the OFF position.

2. Move compressor into an inclined position so drain valve (H) is at the lowest point (this will assist in removing moisture, dirt, etc. from air tanks)

3. Place a suitable container under the drain valve to catch discharge.

4. Grasp knurled knob on drain valve.

5. Slowly rotate knob to gradually bleed air from air tank.

_, WARNING: Risk of bursting. Drain air tank daily. Water will con-

dense in air tank. ff not drained, water will corrode and weaken the air tank causing a risk of air tank rupture.

CAUTION: Risk of property damage. Drain water from air tank may contain oil and rust, which can cause stains.

6. When air tank pressure gauge reads 10 PSi (68,9 kPa), rotate valve to the fully open position.

7. Close drain valve when finished.

Compressor Pump Oil (Fig. 1)

CHECKING OiL &WARNING: Hot surfaces. Risk of burn. Aftercooler, pump head,

and surrounding parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 2). Allow compressor to cool prior to servicing.

1. Ensure On/Off switch is in the OFF position.

2. Place unit on a flat level surface.

3. Remove dipstick (K) and wipe clean.

4. Reinsert dipstick fully into oil fill port for a few seconds to allow oil to collect on the dipstick. K

5. Remove oil dipstick to read oil level. Oil should not exceed top raised line on dipstick. If oil is below lower mark, add SAE 40, non-detergent air compressor oil and follow Steps 4 - 6.

NOTE: When filling the crankcase, the oil flows very slowly into the pump. If the oil is added too quickly, it will overflow and appear

to be full.

_,CAUTION: Risk of unsafe operation. Overfilling with

oil will cause premature compressor failure. Do not overfill.

6. Replace dipstick.

CHANGING OiL NOTE: Pump oil contains substances that are MAX,

regulated and must be disposed of in accordance with local, state and federal laws and regulations. MIN-

_&WARNING: Hot surfaces. Risk of burn. Aftercooler, pump head,

and surrounding parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 2). Allow compressor to cool prior to servicing.

1. Ensure On/Off switch is in the OFF position.

2. Allow the unit to cool.

3. Remove air compressor plug from outlet.

4. Drain air tank.

5. Locate a suitable container under pump drain plug (L).

6. Remove the dipstick (K) from crankcase.

7. Remove the oil drain plug (L).

8. Allow ample time for all oil to drain out. (Tilting the compressor towards the drain plug will assist in draining.)

9.Installtheoildrainplug.

10.FillpumpwithSAE40,non-detergentaircompressoroil.

11.Replacedipstick.

ACCESSORIES

Recommended accessories for use with your tool are available for purchase from your local dealer or authorized service center.

If you need assistance in locating any accessory for your tool, please contact DEWALT Industrial Tool Co., 701 East Joppa Road,

Baltimore, MD 21286, call 1-800-4-DEWALT (1-800-433-9258) or visit our website www.dewalt.com.

_kCAUTION: The use of any other accessory not recommended for

use with this tool could be hazardous. Use only accessories rated equal to or higher than the rating of the air compressor.

SERP'IC_ INFORMATION

Please have the following information available for all service calls: Model Number Serial Number

Date and Place of Purchase

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment should be performed by a DEWALT factory service center, a DEWALT authorized service center or other qualified service personnel. Always use 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.

LATIN AMERICA: This warranty does not apply to products sold

in Latin America. For products sold in Latin America, see country specific warranty information contained either in the packaging, call

the local company or see website for warranty information.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-800-4-DEWALT for a free

replacement.

GLOSSARY

CFM: Cubic feet per minute. SCFM: Standard cubic feet per minute; a unit of measure of air delivery.

PSI: Pounds per square inch; a unit of measure of pressure. kPa (ki[opasca[): Metric pressure measurement. 1 kilopascal equal 1000 pascals.

Code Certification: Products that bear one or more of the following marks: UL, CUL, ETL, CETL, have been evaluated by OSHA certified

independent safety laboratories and meet the applicable Underwriters Laboratories Standards for Safety.

Cut-In Pressure: While the motor is off, air tank pressure drops when accessory is used. When the tank pressure drops to a certain low

level the motor will restart automatically. The low pressure at which the motor automatically restarts is called cut-in pressure.

Cut-Out Pressure: When an air compressor is turned on and begins to run, air pressure in the air tank begins to build. It builds to a

certain high pressure before the motor automatically shuts off, protecting your air tank from pressure higher than its capacity. The

high pressure at which the motor shuts off is called cut-out pressure. Branch Circuit: The circuit carrying electricity from electrical panel to outlet. Duty Cycle: This air compressor pump is capable of running continuously. However, to prolong the life of your air compressor, it is

recommended that a 50%-75% average duty cycle be maintained; that is, the air compressor pump should not run more than 30- 45 minutes in any given hour.

Troubleshooting Guide

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

Excessive air tank pressure-safety valve pops off ...................................................................... 1,2

Air leaks .................................................................................................................................... 3

Air leaks in air tank or at air tank welds .................................................................................... 4

Air leaks between head and valve plate .................................................................................... 5

Air leaks from safety valve ......................................................................................................... 6

Knocking Noise .......................................................................................................................... 6,16,17

Pressure reading on the regulated pressure gauge drops when an accessory is used ........... 7

Compressor is not supplying enough air to operate accessories .............................................. 8,9,10,11,12,15

Regulator knob has continuous air leak .................................................................................... 13

Regulator will not shut off air outlet ........................................................................................... 13

Moisture in pump crankcase ...................................................................................................... 14,18

Motor will not run ....................................................................................................................... 11,19,20,21,22,23,24,25,26

Troubleshooting Codes

CODE POSSIBLE CAUSE POSSIBLE SOLUTION

Pressure switch does not Shut off moto[ when compressor set the On/Off switch to OFF, if the unit does not ShUt

reaches Cut_out pressure off c0ntact a DEWALT faCt0rY Seiv!Ce center 0r a DEWALT

2 Pressure switch cut-out too high Contact a DEWALT factory service center or a DEWALT

authorized service center.

CODE POSSIBLE CAUSE POSSIBLE SOLUTION

3 Tube fittings are not tight enough Tighten fittings Where air Can be heard eScaPingl cheCk

• fittings with soapy water solution. Do Not Overtighten.

4 Defective air tank Air tank must be replaced. Do not repair the leak.

&WARNING: Risk of bursting. Do not drill into, weld or

otherwise modify air tank or it will weaken. The air tank can rupture or explode.

contact a DEWALT factory service cente[ 0r a DEWALT

• authorized Service center.

6 Defective safety valve Operate safety valve manually by pulling on ring. If valve

still leaks, it must be replaced.

Regulator is not adjusted coirect!y foi access0iY being, !t is norma! for some pressure drop to occur when an acceS'

used .............................. sory is used, adjust the regulator as instructed in Regulator

under Features if pressure drop s excessive.

, NOTE: Adjust the iegulated pressure undei fl0w cond!tionS

wh e accessory s be ng used.

8 Prolonged excessive use of air Decrease amount of air usage.

compressoi is n0t laige en0ugh f0i acceSSorY Check the accessory air reqUiremenL If it is higher than

the SCFM or pressure Supp!ied by your air Compress0r, a

larger compressor is needed to operate accessory.

10 Hole in air hose Replace air hose. 11 ' Check valve restricted Remove; Clean or replace.

12 Air leaks Tighten fittings.

13 Regulator is damaged Replace:

CODE

POSSIBLE CAUSE

Unit operating in damp or humid conditions

Restricted air intake filter

Pump oil is low

POSSIBLE SOLUTION Move unit to a dry well ventilated area

clean or repiace air intake filter Add SAE 40, non-detergent air compressor oil to pump. See

Compressor Pump Oil under Maintenance. C0ntact a DEWALT fact0ry Service Center or a DEWALT

authorized service center:

18 Detergent type oil being used in pump

Drain oil and refill pump with SAE 40, non-detergent air

compressor oil.

19 MOtor overload protection switch has tripped

2o Extension cord is wrong length or gauge

see Motor overload UnderFeaturesl Check for proper gauge wire and cord length. See

Extension Cords under Installation.

21 LOOSeelectrical Connections contact a DEWALT factory servce Center or a DEWALT

I aUth0rized service center:

22 Possible defective motor or starting capacitor Contact a DEWALT factory service center or a DEWALT

authorized service center.

23 Pant sprayon nterna mot0r parts cQntact a DEWALT fact0ry service Centei era DEWALT

', authorized service center; Do not operate the c0mpress0r in

• the paint spray areal See flammable vapor warning.

CODE POSSIBLE CAUSE ............... POSSIBLE SOLUTION

24 Fuse blown, circuit breaker tripped 1. Check fuse box for blown fuse and replace as necessary.

Reset circuit breaker. Do not use afuse or circuit breaker with higher rating than that specified for your particular

branch circuit.

2. Check for proper fuse. Use only a time delay fuse.

3. Check for low voltage conditions and/or proper extension cord.

4. Disconnect the other electrical appliances from circuit or operate the compressor on its own branch circuit.

25 Tank Pressure exceeds pressure switch cut4n pressure Motor will start automatically when tank pressure drops

: below cut-in pressure of pressure switch.

26 Pressure release valve on pressure switch has not Set the On/Off switch to OFR If the valve does not open,

unloaded head pressure replace switch. Contact a DEWALT factory service center or

a DEWALT authorized service center.

+ 49 hidden pages