DeWalt D55270T User Manual

DEWA LT The 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.

Gas Manual 10-5-01 2/10/03 2:31 PM Page 2

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES DE USAR EL PRODUCTO.

INSTRUCTION MANUAL GUIDE D'UTILISATION MANUAL DE INSTRUCCIONES

D55270, D55270T, D55271, D55271T, D55275, D55276 Contractor’s Gas Wheeled Portable Air Compressor Compresseurs d’air portatif à moteur à essence sur roues de classe entrepreneur Compresor de aire portátil a gasolina con ruedas para contratistas

Questions? See us on the World Wide Web at www.dewalt.com

Gas Manual 10-5-01 2/10/03 2:31 PM Page 3

1 .Pump Air Filter 2 .Engine Air Filter 3 .Tank Pressure Gauge 4 .Regulated Pressure Gauge 5 .Pressure Regulator 6 .Pilot valve 7 .Safety Va l v e 8 .Tank Drain(s)

3 4

8 GALLON PORTABLE

D55271, D55271T* - 8 HP Honda Engine

17 GALLON PORTABLE

D55276 - 5.5 HP Honda Engine

17 GALLON PORTABLE

D55275 - 8 HP Honda Engine

8 GALLON PORTABLE

D55270, D55270T* - 5.5 HP Honda Engine

*Denotes 2-wheeled version.

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Engine Specifications

5.5 Hp Honda GX-160 8 Hp Honda GX-240

Internal Combustion Internal Combustion 4-stroke 4-stroke 3450 RPM 3450 RPM

G Pump Specifications

V - twin 4 cylinder Single Stage Oil Lubricated Cast Iron crankcase, cylinder, and head Bore: 2-1/2 “ (63.5 mm) Stroke: 2-3/8” (60.33 mm) Weight: 69 lbs. (31.3 kg.) Oil Capacity: 30 oz.

K Pump Specifications

Inline, vertical twin cylinder Single Stage Oil Lubricated Cast Iron crankcase, cylinder, and head Bore: 2-1/2“ (63.5 mm) Stroke: 2” (50.8 mm) Weight: 47 lbs. ( 21.32 kg.) Oil Capacity: 14 oz.

SPECIFICATIONS

MODEL WEIGHT HEIGHT WIDTH LENGTH Typical values @ 100 psi

CFM D55270 160 lbs. (72.57 Kg.) 25 in. (635 mm.) 18.25 in. (463.55 mm.) 43 in. (1092.2 mm.) 8.9 D55271 213 lbs. (96.62 Kg.) 27.75 in. (704.85 mm.) 18.25 in. (463.55 mm.) 43 in. (1092.2 mm.) 16.2 D55275 238 lbs. (107.96 Kg.) 33.75 in. (857.25 mm.) 20.25 in. (514.35 mm.) 43 in. (1092.2 mm.) 16.2 D55276 185 lbs. (83.91 Kg.) 31 in. (787.4 mm.) 20.25 in. (514.35 mm.) 43 in. (1092.2 mm.) 8.9

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(for units with 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 1-800-4DEWA LT for a s s i s t a n c e .

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 can 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. Do not modify the safety valve, or any other components that control tank pressure. The tank is designed to withstand specific operating pressures. Never make adjustments or parts substi tutions 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, and could result 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 c h i l d r e n ’s toys, footballs, basketballs, etc.

RISK OF EXPLOSION OR FIRE

Always operate the compressor in a well-ventilated area free of combustible materials, gasoline or solvent vapors. If sparks from compressor come into contact with flammable vapors, they may ignite,

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWA LT TOOL, CALL US TOLL FREE AT 1-800-4D E WA LT (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 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.

AIR TANK

The tank on your Air Compressor is designed and may be UM coded

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causing fire or explosion. If spraying flammable materials, locate compressor at least 20 feet up wind from spray area. An additional length of hose may be r e q u i r e d .

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 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 ANSI 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 r e m o v e r, insecticides, weed killers, etc. contain harmful vapors and p o i s o n s. 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 the specific application.

RISK FROM MOVING PARTS

The compressor is designed to run continuously.

Always turn off the compressor, bleed pressure from the air hose and tank, and disconnect from power source 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

COMPRESSOR

CYLINDER & HEAD

PUMP

CRANKCASE

GASOLINE

ENGINE

HOT SURFACES

COMPRESSOR

CYLINDER & HEAD

AFTERCOOLER

PUMP

CRANKCASE

ENGINE

MUFFLER ENGINE

HEAD

HOT SURFACES

ENGINE

MUFFLER

AFTERCOOLER

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removed. Never stand on the compressor.

HOT SURFACES

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 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

C A U T I O N : Wear appropriate personal hearing protection during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

ENGINE

Your air compressor is powered by a Honda®g a s o l i n e 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 ENGINE TO COOL. Gasoline is extremely

flammable, and gasoline vapor can explode. Refuel outdoors, in a wellventilated area, with the engine off. Never smoke near gasoline, and keep other 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.

A LWAYS STORE COMPRESSOR IN A HORIZONTAL POSITION, ON ALL FOUR RUBBER MOUNTS.

Introduction

Congratulations on the purchase of your new DEWA LT 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 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 n o t i c e .

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 deck of the air compressor and pump bearing cap. Please write the serial number in the space provided in the service section for future reference.

Features

PILOT VALVE:

Pilot valves are used to 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 compressor unloads through the compressor head. Unloading occurs when the receivers (tanks) reach a

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preset cut-out pressure. 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 into the t a n k s .

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 (A) 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 removed or modified in any way.

AIR INTAKE FILTER(S):

The filter(s) (B) are designed to clean air entering the pump. To ensure the pump continually

receives a clean, cool, and dry air supply the

filter(s) must always be clean and the filter intake must be free from obstructions.

AIR TANK DRAIN VALVE(S):

The drain valve(s) (C) are used to remove moisture from the air tank after the air compressor is shutoff .

TANK PRESSURE GAUGE:

The tank pressure gauge (D) indicates air pressure in the air tank.

REGULATED PRESSURE GAUGE:

The regulated pressure gauge (E) indicates the air pressure available at the outlet side of the regulator. This pressure is controlled by the regulator and is always less or equal to the air tank pressure.

PRESSURE REGULATOR:

The regulator knob (F) controls the air pressure coming from the air t a n k .

PILOT VALVE CUT-OUT PRESSURE ADJUSTMENT N O T E : Unit can remain running while performing 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 the Hot Surfaces identified 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 p r o d u c t .

WARNING : The pilot valve is brass which is a soft metal. Do not overtighten screw as threads can strip out.

1. Hold “I” firmly and loosen nut “H”.

WARNING : Do not loosen screw “G” 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 “G” clockwise to

increase cut-out pressure limit or counter clockwise to decrease cutout pressure. (example: if the cut-out pressure on the tank gauge reads 120 psi. and desired cut out is 130 psi, turn screw “G” c l o c k w i s e )

3 . Drain air from tanks through drain valves until pump begins to

charge tanks. 4 . Close drain valves. 5 . Monitor cut-out pressure to verify the new setting

D E

H I J

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6 . Once setting is complete hold screw “G” firmly 7 . Hold “G” firmly and tighten nut “H”

PILOT VALVE PRESSURE DIFFERENTIAL ADJUSTMENT N O T E : Unit can remain running while performing 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 the Hot Surfaces identified on page 2)

1 . Hold “I” firmly and loosen nut “J”

WARNING : Do not loosen barrel “I” more than 1 revolution as barrel is subjected to tank pressure and can burst out which can harm the user or surrounding personnel.

2. Turn barrel “I” clockwise to increase differential or counter clockwise to decrease differential. (for example: if pressure differential is 100 130 psi and 100 - 120 psi is desired, turn “I” counter clockwise)

NOTE : Too narrow of a differential can cause chatter of the pilot valve. Increase differential to eliminate chatter.

3 . Hold barrel “I” 4 . Hold “I” firmly and tighten nut “J”

CHECKING 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 the Hot Surfaces identified on page 2)

1 . Ensure Unit is off .

2. Locate unit onto a flat horizontal surface. 3 . Remove knurled filler knob (K) from crankcase. 4 . Insert a clean screwdriver into the crankcase and remove it.

5 . Look for visual signs of contaminants (water, dirt, etc.) Change

pump oil if contaminants are present.

6 . Oil should not exceed top raised line on side of crankcase (oil will be

even with bottom of threads in crankcase fill port). If necessary fill with DEWA L T synthetic oil.

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 unit is off. 2 . Ensure tanks are empty by looking at tank pressure gage. Drain

tanks if necessary. 3 . Grasp wire ring on safety valve. 4 . Pull and release ring a few times to ensure plunger moves in and

o u t .

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 the Hot Surfaces identified on page 2)

1 . Ensure unit is off . 2 . Allow unit to cool. 3 . Unscrew filter top from filter base by turning counter clockwise

about 5 degrees. 4 . Separate filter top from base. 5 . Remove element from filter base. 6 . If element needs cleaning, blow out with air. Replace element if

u n s u r e . 7 . Place element back in filter base. 8 . Reconnect filter top to filter base and while pushing in, rotate top

clockwise 5 degrees.

STARTING UNIT

Follow the pre-start and start-up procedures in the operating procedure

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s e c t i o n .

TURNING UNIT OFF

Follow the shut-down procedure in the operating procedures section.

ADJUSTING REGULATOR

1 . Pull regulator knob (L) 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

l o c k .

INSTALLING HOSES

WARNING: Firmly grasp hose in hand

when installing or disconnecting to prevent hose whip.

1 . Ensure regulated pressure gage reads 0 PSI. 2 . Grasp hose in hand at coupler location. 3 . Pull back collar on female quick connect coupler (M) located on

c o m p r e s s o r. 4 . Push male connector into female connector. 5 . Release female connector 6 . Grasp hose and pull to ensure couplers are seated 7 . Adjust regulator to desired pressure.

DISCONNECTING HOSES

WARNING: Firmly grasp hose in hand when installing or disconnecting to prevent hose whip.

1 . Ensure regulated pressure gage reads 0 PSI. 2 . Grasp hose in hand at coupler location 3 . Pull back collar on female quick connect coupler located on

c o m p r e s s o r. 4 . Pull male connector out of female connector.

5 . Release female connector

DRAINING TANKS

WA R N I N G : Tanks contain high pressure air. Keep face and other body parts away from outlet of drain. Use safety glasses when draining as debris can be kicked up into face. Use ear protection as air flow noise is loud when draining.

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 ON/OFF switch is in the OFF position. 2 . Move compressor into an inclined position so drain valve(s) are at

the lowest point (this will assist in removing moisture, dirt, etc. from

t a n k s ) 3 . Place a suitable container under the drains to catch discharge. 4 . Grasp black lever on one drain valve. 5 . Slowly rotate lever so as to gradually bleed air from tank. 6 . Grasp black lever on other drain valve and rotate to approximately

the same position as the first. (For twin tank units) 7 . When tank pressure gauge reads 10 psi, rotate valve(s) to the fully

open position. 8 . Close drain valve(s) when finished.

Preparation For Use

INITIAL SET-UP:

Read safety instructions before setting-up air compressor.

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 run off the compressor must be

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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.

N O T E : 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, vapor and volatile fumes in the atmosphere which may clog and gum up the intake filter and valves, causing inefficient operation.

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 baffle walls. Contact a DEWA LT service center or call 1-800-4DEWA LT for a s s i s t a n c e .

TRANSPORTING:

WARNING: Unit weighs more than 160 lbs. Do not move or lift

without assistance.

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

the tanks are drained and the unit is secured and placed on a flat horizontal surface. Use care when driving so to avoid tipping the unit over in the vehicle. Damage can occur to the unit or surrounding items if unit is tipped. Use a ramp if loading or unloading the unit from a height of more than 12”.

MOVING:

When moving the unit into a position for use, grasp handle grips at rear of compressor, and lift compressor high enough so unit can be rolled on the front tire.

WARNING: Ensure proper footing and use caution when rolling compressor so that unit does not tip or cause loss of balance.

When location is reached slowly lower rear of compressor to ground.

A LWAYS STORE COMPRESSOR IN A HORIZONTAL POSITION, ON ALL FOUR RUBBER MOUNTS.

NOTE: Should the unit tip over, hard starting and smoking will occur

due to oil spillage.

Air Inlet Filter

C A U T I O N : Do not operate without 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 units 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

If installing a condensate discharge line, the piping must be at least one size larger than the connection, as short and direct as possible, secured tightly and routed to a suitable drain point. Condensate must be disposed of in accordance with local, state and federal laws and r e g u l a t i o n s .

N O T E : All compressed air systems generate condensate that

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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 the ON/OFF lever on the engine is in the OFF position. 2 . Ensure tank(s) is/are drained so that moisture, dirt, etc. can be

e l i m i n a t e d . 3 . Ensure tank pressure gauge reads 0 psi. 4 . Ensure safety and drain valve(s) is /are functioning properly.

5. Ensure the drain valve(s) is / are closed. 6 . Check oil level in pump. 7 . Check oil level in engine crankcase. 8 . Visually inspect drive belt. Replace belt if frayed, cracked, or worn.

9. Ensure all guards, covers, and labels are in place, legible (for labels)

and securely mounted. Do not use compressor until all items have

been verified.

START-UP

1 . Ensure the ON/OFF lever on the engine is in the OFF position. 2 . Pull out and turn regulator knob counterclockwise until fully closed.

Push in to lock. Regulated pressure gage should read 0 psi.

3. Ensure fuel is in 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 the pump can charge the tanks.

8 . Allow compressor to pump up to “cut out” pressure. N O T E : If any unusual noise or vibration is noticed, stop the

compressor and refer to the troubleshooting section. 9 . Attach hose and accessory.

10. Adjust regulator to 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 : If finished using compressor, follow steps 2 - 6 below.

2. Turn regulator knob counterclockwise until fully closed. Ensure regulated pressure gage reads 0 PSI.

3 . Remove hose and accessory. 4 . Drain the air tank(s). Ensure tank pressure gage reads 0 PSI 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 . Turn off air compressor 2 . Disconnect spark plug wire 3 . Drain tank(s) 4 . Allow air compressor to cool down before starting service N O T E : All compressed air systems contain maintenance parts (e.g.

lubricating 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 r e g u l a t i o n s .

N O T E : Take note of the positions and locations of parts during

Gas Manual 10-5-01 2/10/03 2:31 PM Page 9

disassembly to make reassembly easier. N O T E : Any service operations not included in this section should be

performed by authorized service personnel.

MAINTENANCE CHART P r o c e d u r e I Year or

D a y We e k M o n t h 200 Hrs.

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 belt X Inspect air filter X

P r o c e d u r e I Year or

D a y We e k M o n t h 200 Hrs.

Clean exterior of compressor X Check safety relief valve X Check belt adjustment X

Change pump oil ** X E n g i n e See engine owner’s manual.

* 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 or operation. T h e r e a f t e r, when using DEWA LT synthetic oil, change oil every 200 hours of operation or once a year, whichever comes first. In harsh environments, maintenance must be performed on a more accelerated s c h e d u l e .

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 the Hot Surfaces identified on page 2)

1 . Ensure unit is off . 2 . Allow the unit to cool. 3 . Locate a suitable container under drain plug

( O ) . 4 . Remove the knurled filler knob (N) from crankcase. 5 . Remove the oil drain plug. 6 . Allow ample time for all oil to drain out. (Tilting the compressor

towards the drain plug will assist in draining.) 7 . Install the oil drain plug. 8 . Fill pump with DEWA LT synthetic compressor oil. Oil should not

exceed top raised line on side of crackcase. (Oil will be even with

bottom of threads in crankcase fill port.) 9 . Install knurled filler knob.

CHECKING BELT TENSION

WARNING : 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 unit is off and unplugged from wall.

2. Allow unit to cool down so pump can be touched. 3 . F O R K P U M P U N I T S

Remove six belt guard mounting fasteners (2 on the pump head

and 4 on the deck)

F O R G P U M P U N I T S

Remove seven belt guard mounting fasteners (2 on the pump head,

1 J-hook, and 4 on the deck) 4 . Remove guard. 5 . Place a 12" ruler perpendicular to belt and at the middle of the

longest span.

Gas Manual 10-5-01 2/10/03 2:31 PM Page 10

6 . Push up and down on the belt in the middle of the span with

approximately 8 lbs. of force and notice the amount of deflection using the ruler. Belt should not move more than 1/2"; if so, see ADJUSTING BELT TENSION section.

7 . Replace belt guard

ADJUSTING BELT TENSION

WA R N I N G :Pump and surrounding components are hot.

1 . Follow procedures 1 - 4 in checking belt tension section. 2 . Scribe a mark at the base of the pump on the deck to be used

as a reference.

3. Loosen four pump mounting bolts.

4. Remove the belt.

5. Scribe a mark approximately 1/8" from the original mark.

6. Slide the pump to the new mark and retighten the pump mounting bolts.

WARNING : Use caution when rolling belt onto flywheel as fingers

can get caught between the belt and flywheel.

7. With the pump secure, roll the belt over the flywheel and the pulley.

8. Check the belt tension again.

9. If tension is good, retighten the engine brace and replace belt guard.

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: DEWA LT 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 _____________________________

Repairs

To assure 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

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 LABEL REPLACEMENT: 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

Gas Manual 10-5-01 2/10/03 2:31 PM Page 11

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.

P r o b l e m C o d e

Compressor does not start or restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 6 , 3 2 , 3 3 , 3 4 , 3 6

Compressor Stalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 6 , 3 4 , 3 6

Unit does not or is slow to come up to speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 , 9 , 1 0 , 1 2 , 1 3 , 1 5 , 1 6 , 2 6 , 2 7 , 3 3 , 3 4 , 3 6

Air compressor not making enough air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 , 3 , 8 , 9 , 1 0 , 11 , 1 4 , 1 6 , 1 7 , 2 0 , 2 1 , 2 4 , 2 5

I n s u fficient pressure at air tool or accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 , 3 , 8 , 9 , 1 0 , 11 , 1 4 , 1 6 , 1 7 , 2 0 , 2 1 , 2 3 , 2 4 , 2 5

High oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 , 7 , 1 0 , 1 2 , 1 3 , 1 6 , 2 6 , 2 8

Unit runs excessively hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 , 2 , 5 , 11 , 1 2 , 1 3 , 1 6 , 2 6

Excessive starting and stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 , 8 , 1 7 , 2 0 , 2 1 , 2 5 , 3 0

Excessive noise during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 , 4 , 5 , 6 , 8 , 9 , 1 0 , 11 , 1 2 , 1 3 , 1 6 , 2 1 , 2 5 , 2 6 , 2 7

Moisture in discharge air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 0 , 3 1

Moisture in crankcase or "milky" appearance

in petroleum lubricant or rusting in cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 , 1 0 , 11 , 1 6 , 2 2 , 2 9 , 3 1

Oil in discharge air (oil pumping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 , 7 , 9 , 1 0 , 11 , 1 6 , 2 7 , 2 8

Oil leaking from shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3

Safety relief valve "pops" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 8 , 1 9

Air leaks at pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 0 , 2 1

Air leaks at fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1

Air leaks from tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2

Abnormal piston ring or cylinder wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 , 5 , 6 , 11 , 1 2 , 1 4

Gas Manual 10-5-01 2/10/03 2:31 PM Page 12

C o d e Possible Cause Possible Solution

1 Clogged or dirty inlet and/or discharge line filter. Clean or replace 2 Lubricant Viscosity too low Drain existing lubricant and refill with DEWA LTSynthetic lubricant 3 Air leaks in air discharge piping Check tubing and connections 4 Lubricant viscosity too high Drain existing lubricant and refill with DEWA LTSynthetic 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 LTSynthetic lubricant 7 Extremely light duty cycles. Run unit for longer duty cycles 8 Compressor check valve leaky, broken, carbonized or loose Inspect valves.Clean or replace as required. 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 (broken, rough, Install new rings

or scratched). Excessive end gap or side clearance. Piston rings

not seated, are stuck in grooves or end gaps not staggered. 11 Compressor pump cylinder or piston scratched, worn, or scored. Repair or replace as required 1 2 Compressor pump connecting rod, piston pin, or crankpin bearings worn or scored Inspect all. Repair or replace as required. 1 3 Compressor pump crankshaft seal worn or crankshaft scored Replace seal or crankshaft assembly 1 4 Extremely dusty atmosphere Install more effective filtration or relocate unit 1 5 Ambient temperature too low Relocate unit to warmer environment. Ensure DEWA LT synthetic oil

is in crankcase. 1 6 Compressor pump worn cylinder finish Degalze cylinder with 180 grit flex-hone 1 7 Air compressor is not large enough for air required Check the accessory air requirement. If it is higher than the CFM or

pressure supply of the air compressor, you need a larger air

c o m p r e s s o r. 1 8 Possible defective safety/relief valve Operate safety relief valve manually by pulling on test ring. If it still

leaks, replace. 1 9 Excessive air tank pressure Adjust pilot valve. If problem still exists replace pilot valve.

Gas Manual 10-5-01 2/10/03 2:31 PM Page 13

+ 36 hidden pages

DeWalt D55270T User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual