DeWalt D55250, D55251 Instruction Manual
5135176-00,01Gas Hand Carry 2/10/03 2:54 PM Page 1
DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 (FEB03) Form No. 5135176 Copyright © 2001 DEWA LTThe following are
trademarks for one or more DEWA LT power tools: the yellow and black color scheme; the “D” shaped air intake grill; the array of pyramids on the handgrip;
the kit box configuration; and the array of lozenge-shaped humps on the surface of the tool.
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D55250, D55251
Contractor’s Gas 4 Gallon Hand Carry Air Compressor
Compresseur d’air portatif à moteur à essence de 4 HP et de 4 gallons de classe
entrepreneur
Compresor de aire portátil de 4 galones a gasolina de 4 HP para contratistas
Questions? See us on the World Wide Web at www.dewalt.com
INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y P Ó L I Z A
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO A N T E S
DE USAR ELP R O D U C TO.
INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES
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SPECIFICATIONS
Weight: 68 lbs. 30.84 kg.
Height: 17.00 in. 431.8 mm
Width: 18.00 in. 457.20 mm
Length: 21.50 in. 546.10 mm
Pump Oil Capacity - 4 oz.
ENGINE
4 H.P. Honda GX-120
Internal Combustion, 4 stroke
3450 RPM
Engine Oil Capacity - .63 qt.
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1
1
AIR TANK
The tank on your Air 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 pressure vessels must be inspected once
every two years. To find your state pressure vessel
i n s p e c t o r, look under the Division of Labor and
Industries in the government section of a phone book
or call 1-800-4DEWA LT 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 with a
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
a t t a c h m e n t s .
3. Modifications of the pressure switch, safety valve, or any other
components that control tank pressure. The tank is designed to
withstand specific 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
i n j u r y. Follow the equipment manufacturers
recommendation and never exceed the maximum
allowable pressure rating of attachments. Never
use compressor to inflate small, low-pressure
objects such as children’s toys, footballs,
basketballs, etc..
RISK OF EXPLOSION OR FIRE
Always operate the compressor in a well-ventilated area free of
IF YOU HAVE A N YQUESTIONS OR COMMENTS ABOUT THIS
OR A N Y DEWA LT TOOL, CALL US TO L L FREE AT 1-800-4D E WA LT (1-800-433-9258).
WA R N I N G ! 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
i n j u r y.
SAVE THESE INSTRUCTIONS
Safety Instructions
WARNING: Some dust created by this product 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
To reduce your exposure to these chemicals, wear approved safety
equipment such as dust masks that are specially designed to filter
out microscopic particles.
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.
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.
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use with specific application.
RISK FROM MOVING PARTS
The compressor is designed to run continuously.
Always turn off the compressor, and bleed
pressure from the air hose and tank, before
performing maintenance or attaching tools and
accessories.
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. 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.
HOT SURFACES
Touching exposed metal such as the compressor head or outlet tube
can result in serious burns. Never touch any exposed metal parts
on the compressor during or immediately after operation. Compressor will remain hot for several minutes after operation. Do not
move the compressor while it is running. Hot motor parts could cause
combustible materials, gasoline or solvent vapors. If
sparks from the compressor come into contact with
flammable vapors, they may ignite, causing fire or
explosion. When spraying flammable materials,
locate the compressor at least 20 feet upwind from
the spray area. An additional length of hose may be
required.
Store flammable materials in a secure location away from
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 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 wear A N S I
Z28.1 approved safety glasses with side shields when using the
c o m p r e s s o r. Never direct air stream at people or animals. Use only
O S H Aapproved 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
r e m o v e r, insecticides, weed killers, etc. contain
harmful vapors and poisons. N O T E : Operate the 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
2
COMPRESSOR
CYLINDER
TRANSFER TUBE
(NOT SHOWN)
MUFFLER
COMPRESSOR
PUMP HEAD
HOT SURFACES
ENGINE
CYLINDER
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burns contributing to the dropping of the compressor, damaging the
compressor and/or injuring the operator.
ENGINE
Your air compressor is powered by a Honda®gasoline engine. Most
accidents with engines can be prevented if you follow all instructions
in this manual, the engine owner’s manual and on the engine. Some
of the most common hazards are discussed herein, along with the
best way to protect yourself and others:
• Know how to stop the engine quickly, and understand
the operation of all controls.
• Never permit anyone to operate the engine without proper
i n s t r u c t i o n s .
• Do not allow children to operate the engine.
• Keep children and pets away from the area of operation.
Refuel with care: ALLOW THE ENGINE TO COOL. Gasoline is
extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a well-ventilated area, with the engine off. Never smoke
near gasoline, and keep flames and sparks away. Always store gasoline in an approved container. If any fuel is spilled, move compressor to another location before starting the engine.
Carbon Monoxide Hazards:Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the engine
in a closed garage or confined area.
Introduction
Congratulations on the purchase of your new DEWA LTAir 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 and following the safety, 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.
DEWALT Air Compressor Features
Pilot Valve
Pilot valves maintain a constant pressure range while running
c o n t i n u o u s l y. The pilot valve may be used to operate a discharge line
unloader or an unloading device in the
compressor head. The DEWA LT c o mpressor unloads through the compressor head. Unloading occurs when
the receivers (tanks) reach a preset cutout pressure limit. The pilot valve opens, actuating the unloading
device that allows the compressor to run in an unloaded mode.
When the tank pressure drops to the preset cut-in pressure, the pilot
valve closes allowing the unloading device to close and the compressor once again pumps air into the tanks.
Manual Lock
The manual lock allows you to manually unload the compressor
with air pressure in the tank. To operate the unloading device in the
head, rotate the flip lever to an in-line position (dashed lines). Be sure
to return lever to the loaded position after
starting the engine or the pump will not operate
at preset pressures.
SAFETY RELIEF VALVE
This valve 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
3
A
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WARNING : Do not loosen
screw (C) more than 1 revolution as
screw is subjected to tank pressure
and can burst out which can harm
the user or surrounding personnel.
2 . Turn screw (C) clockwise to
increase cut-out pressure limit or counter clockwise to decrease
cut-out pressure. For example: if the cut-out pressure limit on the
tank gage reads 120 PSI. and desired cut out is 130 PSI, turn
screw (C) clockwise.
3 . Drain air from tanks through the drain valves until the pump
begins to charge tanks.
4 . Close the drain valves.
5 . Monitor tank pressure gage to ensure the new cut-out pressure
limit setting.
6 . Once setting is complete hold screw (C) firmly and tighten nut (D).
PILOT VALVE PRESSURE DIFFERENTIALADJUSTMENT
N O T E : The compressor can run during this adjustment.
WARNING :A f t e r c o o l e r, pump head, and surrounding parts are
very hot. Do not touch (see Hot Surfaces on page 2).
WARNING - Moving Parts: Keep your hair, clothing and gloves
away from moving parts. Loose clothing, 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.
1 . Hold (E) firmly and loosen nut (F).
WARNING : Do not loosen barrel (E) more than 1 revolution
because the barrel is subjected to tank pressure and can burst out
harming the user or surrounding persons.
2. Turn the barrel (E) clockwise to increase differential or counter
clockwise to decrease the differential. For example, if the pressure
d i fferential is 100 - 130 PSI and 100 - 120 PSI is desired, turn
(E) counter clockwise.
4
modified in any way.
AIR TANK DRAIN VALVE
The drain valve (A) is used to remove
moisture from the air tank after the air
compressor is shut off .
AIR INTAKE FILTER
This filter (B) is designed to clean air entering the pump. To ensure that 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.
TANK PRESSURE GAGE
The tank pressure gauge indicates air pressure in the air tank.
REGULATED PRESSURE GAGE
The regulated pressure gage indicates the air pressure available at
the outlet side of the regulator. This pressure is controlled by the
regulator and is always less than or equal to the air tank pressure.
PRESSURE REGULATOR
The regulator knob controls the air pressure coming from the air
t a n k .
Common Procedures
PILOT VALVE CUT-OUT PRESSURE ADJUSTMENT
N O T E : The compressor can run during this adjustment.
WARNING : A f t e r c o o l e r, pump head, and surrounding parts are
very hot. Do not touch (see Hot Surfaces on page 2).
WARNING - Moving Parts: Keep your hair, clothing and gloves
away from moving parts. Loose clothing, 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.
WARNING : The pilot valve is brass which is a soft metal. Do not
overtighten screw as threads can strip out.
1. Hold (E) firmly and loosen nut (D).
C
D E F
B
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move or is difficult to move.
CHECKING AIR FILTER ELEMENT
WA R N I N G : A f t e r c o o l e r, pump head, and
surrounding parts are very hot. Do not touch.
(see Hot Surfaces on page 2).
1 . Ensure that the compressor is not running
and the engine is off .
2. Allow the compressor to cool.
3 . Unscrew the filter from the pump head by
turning the filter counter clockwise.
4 . Separate the filter body into two halves.
5 . If the filter element needs cleaning blow it out with air. Replace
air filter assembly if unsure whether element can be cleaned
s u ff i c i e n t l y.
6 . Reconnect the halves of the filter body.
7 . Screw the filter into the pump head by turning clockwise until the
filter is hand tight.
STARTING UNIT
Follow the pre-start and start-up procedures in the operating
procedures section.
TURNING UNIT OFF
Follow the Stopping the Engine procedures in engine owner’s
m a n u a l .
ADJUSTING REGULATOR
1 . Pull regulator knob out.
2 . Turn 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 knob in to lock.
INSTALLING HOSES
WARNING: Firmly grasp the hose when installing or disconnect -
ing to prevent hose whip.
NOTE :Too narrow a differential can cause chatter of the pilot valve.
Increase the differential to eliminate chatter.
3 . Hold barrel (E).
4 . Hold (E) firmly and tighten nut (F).
CHECKING THE COMPRESSOR PUMP OIL LEVEL
WA R N I N G : A f t e r c o o l e r, pump head, and surrounding parts are
very hot. Do not touch (see Hot Surfaces on page 2).
1 , Ensure that the compressor is not running
and the engine is off .
2 . Place the compressor on a level horizontal
s u r f a c e .
3 . Remove dipstick (G) from oil fill port.
4 . Look for contaminants (water, dirt, etc.) in
the oil on dipstick.
5 . Wipe oil off of the dipstick.
6 . Reinsert dipstick fully into oil fill port for a few seconds to allow oil
to collect on the dipstick.
7 . Remove oil dipstick to read oil level. Oil should not exceed top
raised line on dipstick. If oil is below lower mark, add DEWA LT
synthetic oil and follow steps 5 - 7.
CHECKING SAFETY RELIEF VALVE OPERATION
WA R N I N G :A f t e r c o o l e r, pump head, and surrounding parts are
very hot. Do not touch (see the Hot Surfaces
identified on page 2).
1 . Ensure that the compressor is not running
and the engine is off .
2 . Ensure that the tank is empty by looking at
tank pressure gage. Drain the tanks if ne-
c e s s a r y.
3 . Grasp the wire ring on safety valve (H).
4 . Pull and release the ring a few times to ensure that the plunger
moves in and out. Replace the safety valve if the plunger does not
5
H
G
I
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6
4 . Grasp the knurled drain knob.
5 . Slowly rotate the knob counterclockwise to gradually bleed air
from tank.
6 . When the tank is at 10 psi, rotate valve to the fully open position.
7 . Close the drain valve when finished.
Preparation For Use
INITIAL SET-UP
Read safety instructions before setting-up the air compressor.
1 . Remove the oil plug.
2 . Pour DEWA LTsynthetic oil into crankcase (4 oz.).
WA R N I N G : THE COMPRESSOR IS SHIPPED WITHOUT OIL IN THE
CRANKCASE. ADD OIL.
3 . Insert the dipstick.
4 . Close the tank drain valve.
C A U T I O N : Do not operate without lubricant or with inadequate
lubricant. DEWA LT 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
C A U T I O N : In order to avoid damaging the air compressor, do not
allow the unit to be tilted more than 10˚ when operating.
Place air compressor at least 3 feet away from obstacles that may
prevent proper ventilation. Keep unit 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.
1 . Ensure that the regulated pressure gage reads 0 PSI.
2 . Grasp the hose at coupler.
3 . Pull back the collar on female quick-connect coupler located on
the compressor.
4 . Push the male connector into the female connector.
5 . Release the female connector.
6 . Grasp the hose and pull to ensure that the couplers are seated.
7 . Adjust the regulator to the desired pressure.
DISCONNECTING HOSES
WARNING: Firmly grasp the hose when installing or disconnect -
ing to prevent 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 TANKS
WA R N I N G :Tanks contain high pressure air. Keep the drain outlet
away from face and other body parts. Use safety glasses when
draining the tank because debris can be propelled into face. Use
ear protection because air flow noise is loud when draining tanks.
N O T E : 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 compressor is not running and the engine is off .
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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are certified safe for the compressor’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.
N O T E : 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.
Operating Procedures
Pre-Start Checklist
1 . Ensure that the ON/OFF lever on the engine is in the OFF
p o s i t i o n .
2 . Ensure that the tanks are 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 valves are closed.
6 . Check the oil level in the pump.
7 . Check the oil level in engine crankcase.
8 . 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 engine is in the OFF
p o s i t i o n .
7
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
p r e m a t u r e l y. 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.
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 baff l e
walls. Contact a DEWA LT service center or call 1-800-4DEWA LTf o r
a s s i s t a n c e .
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 in the vehicle. The compressor
or surrounding items can be damaged if the compressor is tipped.
MOVING
When moving the compressor into a position for use, grasp the handle grip and carry the compressor as close to your body as possible.
WARNING: Ensure proper footing and use caution when carrying
the compressor to avoid a loss of balance.
Air Inlet Filter
C A U T I O N : 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
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8
1 . Turn off the air compressor.
2 . Drain the air tanks.
3 . Allow the air compressor to cool down before starting service.
4. Disconnect the spark plug wire.
N O T E : 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.
N O T E : 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.
N O T E :Any service operations not included in this section should be
performed by authorized service personnel.
MAINTENANCE CHART 200 Hrs.
P r o c e d u r e D a y We e k M o n t h or Ye a r l y
Check pump oil level X
Oil leak inspection X
Drain condensation in air tank(s) X
Check for unusual noise/vibration X
Check for air leaks** X
Inspect air filter X
Clean exterior of compressor X
Check safety relief valve X
Change pump oil * X
Replace air filter X
Engine - Follow maintenance chart in
engine owner’s manual.
* The pump oil must be changed after the first 20 hours of operation.
T h e r e a f t e r, every 200 hours or once a year, whichever comes first. In
2 . Pull out and turn the regulator knob counterclockwise until it is
fully closed. Push the knob in to lock it. The regulated pressure
gage should read 0 PSI.
3 . Ensure that there is fuel in the fuel tank.
4 . Turn the ON/OFF lever on the engine to the ON position.
5 . Rotate the manual lock on the pilot valve into the in-line position
to assist with start up.
6 . Follow the “Starting the Engine” procedures in the engine’s owner
m a n u a l .
7 . Rotate the manual lock on the pilot valve into a perpendicular
position so that the pump can charge the tanks.
8 . Allow compressor to pump up to the cut-out pressure limit.
N O T E : If any unusual noise or vibration is noticed, stop the com-
pressor and refer to the troubleshooting section.
9 . Attach the hose and accessory.
1 0 . Adjust the regulator to the desired setting.
SHUT-DOWN
1 . Follow the “Stopping the Engine” procedures in engine owner’s
m a n u a l .
N O T E : When finished using compressor, follow steps 2 - 6 below.
2 . 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 tank(s). Ensure that the tank pressure gage reads 0
P S I .
5 . Allow the compressor to cool down.
6 . Wipe the air compressor clean and store in a safe, non-freezing
a r e a .
Maintenance
The following procedures must be followed when maintenance or
service is performed on the air compressor.
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harsh environments, maintenance must be performed on an acceler ated schedule.
** 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.
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
r e g u l a t i o n s .
WARNING :A f t e r c o o l e r, pump head, and surrounding parts are
very hot. Do not touch (see Hot Surfaces on page 2).
1 . Ensure that the ON/OFF lever on the engine is in the OFF
p o s i t i o n .
2 . Allow the compressor to cool.
3 . Place a suitable container under the drain
plug (J).
4 . Remove the oil dipstick (K) from crankcase.
5 . Remove the oil drain plug.
6 . Allow ample time for all the oil to drain out.
( Tilting the compressor towards the drain
plug will assist in draining.)
7 . Re-install the oil drain plug.
8 . Fill the pump with DEWA LT synthetic compressor oil (4 oz).
9 . Re-install oil dipstick.
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, contact:
DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore,MD
21286 or call 1-800-4-DEWALT.
C A U T I O N : The use of any other accessory not recommended
for use with this tool could be hazardous.
Service Information
Please have the following information available for all service calls:
Model Number ___________________________
Serial Number ___________________________
Date and Place of Purchase ________________
Important
To assure product SAFETYand RELIABILITY, repairs, maintenance
and adjustment should be performed by authorized service centers
or other qualified service personnel, always using identical
replacement parts.
Full One Year Warranty
DEWA LT 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 - 8 0 0 - 4 - DEWA LT. 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 LABELR E P L A C E M E N T: If your warning labels
become illegible or are missing, call 1-800-4-DEWA LT for a free
r e p l a c e m e n t .
SAVE THESE INSTRUCTIONS
FOR FUTURE USE
9
K
J
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10
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 DEWA LT t e c h n i c i a n
or your dealer.
P r o b l e m C o d e
Compressor does not start or restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 6 , 1 7 , 1 8 , 1 9 , 2 0 , 3 6
Unit does not or is slow to come up to speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 , 8 , 11 , 1 2 , 1 4 , 1 5 , 2 0 , 2 1 , 2 2 , 2 4 , 2 5 , 3 1
Air compressor not making enough air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 , 3 , 7 , 8 , 9 , 1 0 , 11 , 2 1 , 2 4 , 2 5 , 2 8 , 2 9
I n s u fficient pressure at air tool or accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 , 3 , 7 , 8 , 9 , 1 0 , 11 , 2 1 , 2 4 , 2 5 , 2 7 , 2 8 , 2 9
High oil consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 1 1 , 1 2 , 1 5 , 3 0 , 3 2
Unit runs excessively hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 , 2 , 4 , 5 , 1 0 , 11 1 3 , 1 5 , 1 9 , 3 0
Excessive starting and stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 , 2 0 , 2 1 , 2 4 , 2 5 , 2 9
Excessive noise during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 , 3 , 4 , 5 , 8 , 9 , 1 0 , 11 0 , 3 1
Moisture in discharge air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 4 , 3 5
Moisture in crankcase or "milky" appearance in petroleum lubricant or rusting in cylinders. . . . . . . . . .6 , 7 , 9 , 1 0 , 1 5 , 2 5 , 2 6 , 3 3 , 3 5
Oil in discharge air (oil pumping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 , 6 , 8 , 9 , 1 0 , 11 , 1 5 , 3 1 , 3 2
Oil leaking from shaft seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2
Safety relief valve "pops" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2 , 2 3
Air leaks at pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Air leaks at fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 5
Air leaks from tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 6
Abnormal piston ring or cylinder wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 , 4 , 5 , 6 , 9 , 1 0 , 11 , 1 3
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TROUBLESHOOTING CODES
C o d e Possible Cause Possible Solution
1 Clogged or dirty inlet and/or discharge line filter. Clean or replace air inlet or discharge line filter.
2 Lubricant viscosity too low. Drain existing lubricant and refill with DEWA LT Synthetic lubricant.
3 Air leaks in air discharge piping. Check tubing and connections.
4 Lubricant viscosity too high. Drain existing lubricant and refill with DEWA LT Synthetic lubricant.
5 Lubricant level too low. Add lubricant to crankcase to proper level. Check for bearing damage.
6 Detergent type lubricant being used. Drain existing lubricant and refill with DEWA LT Synthetic lubricant.
7 Extremely light duty cycles. Run unit for longer duty cycles.
8 Compressor pump check valve is loose, broken, Inspect valves. Clean or replace as required.
or has carbon buildup.
9 Carbon build up on top of compressor pump piston. Clean piston. Repair or replace as required.
1 0 Compressor pump piston rings damaged or worn Install new rings.
(broken, rough, or scratched).
Compressor pump piston rings show excessive end gap or
side clearance.
Compressor pump piston rings not seated, stuck in grooves
or end gaps are not staggered.
11 Compressor cylinder or piston scratched, worn, or scored. Repair or replace as required.
1 2 Compressor connecting rod, piston pin, Inspect all. Repair or replace as required
or crankpin bearings worn or scored.
1 3 Compressor crankshaft seal worn or crankshaft scored. Replace seal or crankshaft assembly.
1 4 Extremely dusty atmosphere. Install more effective filtration or relocate the compressor.
1 5 Ambient temperature too low. Relocate compressor to warmer environment. Ensure that DEWA LT
synthetic oil is in crankcase.
1 6 Worn compressor cylinder finish. Deglaze cylinder with 180 grit flex-hone.
1 7 Air compressor is not large enough for air required. Check accessory air requirement. If higher than the CFM or pressure
supply of air compressor, then larger air compressor is required.
5135176-00,01Gas Hand Carry 2/10/03 2:54 PM Page 11
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