DeWalt D55250 User manual

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DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 (FEB03) Form No. 5135176 Copyright © 2001 DEWALT The following are
trademarks for one or more DEWALT 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 PÓLIZA
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVOANTES
DE USAR ELPRODUCTO.
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)accordingtoASME Section VIII, Div.
1 rules. All pressure vessels must be inspected once
every two years. To find your state pressure vessel
inspector, look under the Division of Labor and
Industries in thegovernment sectionof a phone book
or call 1-800-4DEWALT 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
attachments.
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
injury. Follow the equipment manufacturers
recommendation and never exceed themaximum
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 ANY QUESTIONS OR COMMENTS ABOUT THIS
OR ANY DEWALT TOOL, CALL US TOLL FREE AT 1-800-4-
DEWALT (1-800-433-9258).
WARNING! Read and understand all instructions before
operating this compressor. Failure to follow all instructions listed
below may result in electric shock, fire, and/or serious personal
injury.
SAVE THESE INSTRUCTIONS
Safety Instructions
WARNING:Some dust created by 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 notremovethe 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 suchas the compressor head or outlettube
can result in serious burns. Never touch any exposed metal parts
on the compressor during or immediately after operation. Com-
pressor will remain hot for several minutes after operation. Do not
move thecompressor whileit is running. Hot motorpartscouldcause
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 ANSI
Z28.1 approved safety glasses with side shields when using the
compressor. Never direct air stream at people or animals. Use only
OSHAapproved air blow guns.
RISK TO BREATHING
The compressed air fromyour compressor is not safe
for breathing! The air stream may contain carbon
monoxide,toxic vapors orsolid particles. Never inhale
air from the compressor either directly or from a
breathing device connected to the compressor.
Sprayed materials such as paint, paint solvents, paint
remover, insecticides, weed killers, etc. contain
harmful vapors and poisons. NOTE: Operate 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 youfollow 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
instructions.
• 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 out-
doors, in a well-ventilated area, with the engine off. Never smoke
near gasoline, and keep flames and sparks away. Always store gas-
oline in an approvedcontainer. If any fuel is spilled, move compress-
or to another location before starting the engine.
Carbon Monoxide Hazards: Exhaust gas contains poisonous car-
bonmonoxide.Avoidinhalationof exhaustgas. Never run the engine
in a closed garage or confined area.
Introduction
Congratulations on the purchase of your new DEWALT Air Com-
pressor! 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, en-
durance 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
Inspectfor signs ofobvious orconcealed freight damage. Reportany
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 com-
pressor 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
continuously. The pilot valve may be used tooperate a discharge line
unloader or an unloading device in the
compressor head. The DEWALTcom-
pressor unloads through the com-
pressor head. Unloading occurs when
the receivers (tanks) reach a preset cut-
out 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 com-
pressor 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 leverto an in-line position (dashed lines). Be sure
to return lever to the loaded position after
starting theengineor 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 predeter-
mined level.The valveis preset by themanufacturer 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 iscomplete hold screw (C) firmlyand tightennut (D).
PILOT VALVE PRESSURE DIFFERENTIALADJUSTMENT
NOTE: The compressor can run during this adjustment.
WARNING : Aftercooler, 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
awayfrom movingparts. Loose clothing,jewelry, or longhair can be
caught in moving parts. Air vents may cover moving parts and
should be avoided as well. Do notremovethe 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 todecrease the differential. For example, if the pressure
differential 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
Thisfilter (B) is designed to clean air enter-
ing 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
tank.
Common Procedures
PILOT VALVE CUT-OUT PRESSURE ADJUSTMENT
NOTE: The compressor can run during this adjustment.
WARNING : Aftercooler, 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
awayfrom movingparts. Loose clothing,jewelry, or longhair can be
caught in moving parts. Air vents may cover moving parts and
should be avoided as well. Do notremovethe 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).
CD E F
B
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move or is difficult to move.
CHECKING AIR FILTER ELEMENT
WARNING: Aftercooler, 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
sufficiently.
6. Reconnect the halves of the filter body.
7. Screw the filter into the pump head by turning clockwise until the
filter is handtight.
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
manual.
ADJUSTING REGULATOR
1. Pull regulator knob out.
2. Turn knob clockwise to increase regulated pressure and counter
clockwise to decrease regulated pressure.
3. When desiredpressure is shown on the regulated pressuregage
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
WARNING: Aftercooler, 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
surface.
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 dipstickfullyinto oil fill port fora 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 DEWALT
synthetic oil and follow steps 5 - 7.
CHECKING SAFETY RELIEF VALVE OPERATION
WARNING: Aftercooler, 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-
cessary.
3. Grasp the wire ring on safety valve (H).
4. Pull and release the ring a few times to ensure that the plunger
moves inand out. Replace thesafetyvalve if the plungerdoes 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 DEWALT synthetic oil into crankcase (4 oz.).
WARNING: THE COMPRESSOR IS SHIPPED WITHOUT OIL IN THE
CRANKCASE. ADD OIL.
3. Insert the dipstick.
4. Close the tank drain valve.
CAUTION: Do not operate without lubricant or with inadequate
lubricant. DEWALT is not responsible for compressor failure caused
by inadequate lubrication.
Compatibility
Air tools and accessories that are operated with the compressor
must be compatible with petroleum based products. If you suspect
that a material is not compatible with petroleum products, use an air
line filter for removal of moisture and oil vapor in compressed air.
NOTE: Always usean airline filterto remove moisture and oil vapor
when spraying paint.
Location
CAUTION: In order to avoid damaging the air compressor, do not
allow the unit to be tilted more than 10˚ 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
WARNING: 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.
NOTE: All compressed air systems generate condensate that
accumulatesin any drain point (e.g. tanks, filter, aftercoolers, dryers).
This condensate contains lubricating oil and/or substances which
may be regulatedand must bedisposed of in accordancewithlocal,
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 asshortand direct
a pipe as possible. Condensate must be disposed of in accordance
with local, state, and federal laws and regulations.
NOTE: All compressed air systems generate condensate that
accumulatesin any drain point (e.g. tanks, filter, aftercoolers,dryers).
This condensate contains lubricating oil and/or substances which
may be regulatedand must bedisposed 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
position.
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
position.
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
prematurely. Excessive moisture is especially likely to occur if the
unit is located in an unheated area that is subject to large
temperature changes. Two signs of excessive humidity are external
condensation on the bare pump when it cools down and a “milky”
appearance in compressor lubricant. You may be able to prevent
moisture from forming in the bare pump by increasing ventilation or
operating for longer intervals.
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 1-800-4DEWALTfor
assistance.
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 han-
dle 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
CAUTION: Do not operate without the air inlet filter
General Requirements
The piping, fittings, receiver tank, etc. must be certified safe for at
least the maximum working pressure of the unit. Use hard welded
or threaded steel or copper pipes, cast iron fittings and hoses that
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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.
NOTE: All compressed air systems contain maintenance parts (e.g.
lubricating oil, filters, separators) which are periodically replaced.
These used parts may be, or may contain, substances that are
regulated and must be disposed of in accordance with local, state,
and federal laws and regulations.
NOTE: Take note of the positions and locations of parts during
disassembly to make reassembly easier. The assembly sequences
and parts illustrated may differ for your particular unit.
NOTE: Any service operations not included in this section should be
performed by authorized service personnel.
MAINTENANCE CHART 200 Hrs.
Procedure Day Week Month or Yearly
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.
Thereafter, every 200 hours oronce a year, whichever comesfirst.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. Followthe “Starting theEngine”proceduresin the engine’s owner
manual.
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.
NOTE: If any unusual noise or vibration is noticed, stop the com-
pressor and refer to the troubleshooting section.
9. Attach the hose and accessory.
10. Adjust the regulator to the desired setting.
SHUT-DOWN
1. Follow the “Stopping the Engine” procedures in engine owner’s
manual.
NOTE: 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
PSI.
5. Allow the compressor to cool down.
6. Wipe the 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.
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harsh environments, maintenance must beperformed on an acceler -
ated schedule.
** To check forair leaks apply a solution of soapy water around joints.
While compressor ispumping topressure and after pressurecuts out
look for air bubbles.
COMPRESSOR PUMP OIL CHANGE
NOTE:Pump oilcontains substances that are regulatedand must be
disposed of in accordance with local, state and federal laws and
regulations.
WARNING : Aftercooler, pump head, and surrounding parts are
very hot. Do not touch (see Hot Surfaces on page 2).
1. Ensure that the ON/OFF lever on the engine is in the OFF
position.
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 DEWALT 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.
CAUTION: 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 SAFETY and 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
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 orworkmanship. Forwarranty repair information, call
1-800-4-DEWALT. This warranty does not apply to accessories or
damage caused where repairs have been made or attempted by
others. This warranty gives you specific legal rights and you may
have other rights which vary in certain states or provinces.
FREE WARNING LABEL REPLACEMENT:If your warning labels
become illegible or are missing, call 1-800-4-DEWALT for a free
replacement.
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 DEWALTtechnician
or your dealer.
Problem Code
Compressor does not start or restart ..............................................................................................16,17,18,19,20,36
Unit does not or is slow to come up to speed ................................................................................3,8,11,12,14,15,20,21,22,24,25,31
Air compressor not making enough air............................................................................................1,3,7,8,9,10,11,21,24,25,28,29
Insufficient pressure at air tool or accessory ..................................................................................1,3,7,8,9,10,11,21,24,25,27,28,29
High oil consumption........................................................................................................................2,1 1,12,15,30,32
Unit runs excessively hot ................................................................................................................1,2,4,5,10,1113,15,19,30
Excessive starting and stopping......................................................................................................7,20,21,24,25,29
Excessive noise during operation ..................................................................................................2,3,4,5,8,9,10,110,31
Moisture in discharge air..................................................................................................................34,35
Moisture in crankcase or "milky" appearance in petroleum lubricant or rusting in cylinders..........6,7,9,10,15,25,26,33,35
Oil in discharge air (oil pumping) ....................................................................................................2,6,8,9,10,11,15,31,32
Oil leaking from shaft seal................................................................................................................12
Safety relief valve "pops" ................................................................................................................22,23
Air leaks at pump ............................................................................................................................25
Air leaks at fittings............................................................................................................................25
Air leaks from tank ..........................................................................................................................26
Abnormal piston ring or cylinder wear ............................................................................................2,4,5,6,9,10,11,13
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11
TROUBLESHOOTING CODES
Code 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 DEWALT Synthetic lubricant.
3 Air leaks in air discharge piping. Check tubing and connections.
4 Lubricant viscosity too high. Drain existing lubricant and refill with DEWALT 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 DEWALT 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.
10 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.
12 Compressor connecting rod, piston pin, Inspect all. Repair or replace as required
or crankpin bearings worn or scored.
13 Compressor crankshaft seal worn or crankshaft scored. Replace seal or crankshaft assembly.
14 Extremely dusty atmosphere. Install more effective filtration or relocate the compressor.
15 Ambient temperature too low. Relocate compressor to warmer environment. Ensure that DEWALT
synthetic oil is in crankcase.
16 Worn compressor cylinder finish. Deglaze cylinder with 180 grit flex-hone.
17 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.
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12
Code Probable Cause Probable Solution
18 Possible defective safety/relief valve. Operate safety relief valve manually by pulling on test ring. If it still
leaks, replace it.
19 Excessive air tank pressure. Adjust the pilot valve. If the problem still exists, replace pilot valve.
20 Defective gaskets. Replace and torque head bolts to 6 - 7 ft lbs.
21 Fittings not tight enough. Warning : Drain air before tightening. tighten fittings so air can not
be heard escaping. Check joint with soap solution. Do not
overtighten
22 Defective or rusted air tank Air tank must be replaced. Do not attempt to repair air tank.
23 Pressure regulator knob not turned to high enough pressure Adjust pressure regulator knob to proper setting or replace.
or defective pressure regulator.
24 Hose or hose connections are to small or long. Replace with larger hose or connectors.
25 Possible defective (reed) valve. Remove pump head and inspect valve plate and (reed) valve.
Clear or replace valves as required.
26 Air compressor on uneven surface. Do not incline the air compressor more than 10˚ in any direction
while running.
27 Compressor crankcase overfilled with oil. Drain oil, Refill to proper level with DEWALT synthetic oil.
28 Plugged oil dipstick vent. Clean.
29 Water in oil due to condensation. Drain oil. Refill to proper level with DEWALTsynthetic oil.
30 Condensation in air tank caused by high level of Drain air tank after every use. Drain air tank more often in humid
atmospheric humidity. weather and use an air line filter.
31 Compressor located in damp or humid location. Relocate the compressor.
32 Engine oil too low. Low oil shut off is on. Add engine oil.
33 Manual lock on pilot valve is in the loaded position. Move manual lock into an in-line position.
34 Engine idle speed too low. Increase idle speed.
35 Engine problem. See “Taking care of unexpected problems” in engine owners
manual.
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13
CARACTÉRISTIQUES
Poids: 30.84 kg. 68 lbs.
Hauteur: 431.8 mm 17.00 in.
Largeur: 457.20 mm 18.00 in.
Longueur: 546.10 mm 21.50 in.
Capacité en huile de la pompe : 4 oz
ENGINE
4 Hp Honda GX-120
Combustion interne, 4 courses
3450 tr / min
Capacité en huile : - .63 qt.
5135176-00,01Gas Hand Carry 2/10/03 2:54 PM Page 13

SI VOUS AVEZ DES QUESTIONS OU VOUS VOULEZ NOUS
FAIRE PART DE VOS COMMENTAIRES CONCERNANT CET
OUTIL OU TOUT AUTRE OUTIL DEWALT, COMPOSER SANS
FRAIS LE : 1 800 433-9258.
AVERTISSEMENT! Lire etcomprendre toutesles directives avant
d’utiliser cet outil, car lenon-respect desdirectivessuivantes pourrait
entraîner un choc électrique, un incendie ou des blessures graves.
CONSERVER CES DIRECTIVES
Consignes de sécurité
AVERTISSEMENT: Une partie de la poussière créée par ce
produit contient des produits chimiques qui, dans l’État de la
Californie, sont reconnus comme étant susceptibles de causer le
cancer, d’entraîner des malformations congénitales ou d’être nocifs
pour le système reproducteur. Parmi ces produits chimiques,
mentionnons notamment :
• les composés dans les engrais;
• les composés dans les insecticides, les herbicides et les pesticides;
• l’arsenic et le chrome dans le bois d’œuvre traité chimiquement.
Pour réduire le risque d’exposition à ces produits chimiques, porter
un équipement de sécurité approuvé, comme des masques
antipoussières, qui sont spécialement conçus pour filtrer les
particules microscopiques.
AVERTISSEMENT : l’utilisation de ce produit augmente les
risques d’exposition à des produits chimiques qui, dans l’État de la
Californie, sont reconnus comme étant susceptibles de causer le
cancer, d’entraîner des malformations congénitales ou d’être nocifs
pour le système reproductif. Éviter d’inhaler les vapeurs
environnantes. Se laver les mains après chaque utilisation.
AVERTISSEMENT:Ce produit contient des produits chimiques, y
compris du plomb, qui, dans l’État de la Californie, sont reconnus
comme étant susceptibles de causer le cancer, d’entraîner des
malformations congénitales ou d’être nocifs pour le système
reproducteur. Se laver les mains après la manipulation.
L’utilisateur de cet appareil doit comprendre toutes ces directives.
Toute personne qui utilise cet outil doit être sain d’esprit et faire
preuve d’intégrité physique totale et ne pas être sous l’influence
d’une substance susceptible de réduire son acuité visuelle ou sa
dextérité ou nuire à son jugement.
RÉSERVOIR D’AIR
Le réservoir dont est doté le compresseur d’air peut porter le code
UM (dans le cas d’appareils munis de réservoirs
supérieurs à 15,2 cm ou 6 pouces de diamètre) et il
est conçu conformément à la Section VIII, Div. 1 de
l’ASME.Tous les appareils sous pressiondoivent être
inspectés tousles deuxans. Pour trouver l’inspecteur
des appareils sous pression de votre région,
consulter la section appropriée des organismes
gouvernementaux de l’annuaire téléphonique ou composer le
1800 433-9258 pour obtenir de l’aide.
Les conditions indiquées ci-après peuvent affaiblir le réservoir et
entraîner une violente explosion à l’intérieur de celui-ci :
1. Le fait de ne pas purger convenablement l’eau condensée du
réservoir, entraînant la corrosion et l’amincissement des parois
en acierdu réservoir. Purger le réservoir quotidiennement ou après
chaque utilisation. Si le réservoir présente une fuite, le remplacer
immédiatement par un nouveau réservoir ou un nouvel équipement
de compresseur.
2. Modifications apportées au réservoir du compresseur ou
tentatives de réparation.
Ne jamais percer un trou dans le réservoir ou ses accessoires, y
effectuer des soudures ou y apporter quelque modification que ce
soit.
3. Modifications apportéesau pressostat, à la soupape de sûreté ou
à tout autre composant contrôlant la pression du réservoir. Le
réservoir est conçu pour résister à des pressions d’utilisation
14
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précises. Ne jamais effectuer de réglages ou remplacer des pièces
en vue de modifier les pressions d’utilisation réglées en usine.
ACCESSOIRES
Lorsque lapression nominale des outils pneumatiques, des pistolets
pulvérisateurs, des accessoires à commande
pneumatique, des pneus et autres produits
gonflables est excédée, ces composants pourraient
exploser, ou se détacher et se projeter en l’air, et
entraîner des blessures graves. Respecter les
recommandations des fabricants d’équipement et
ne jamais excéder les pressions nominales
maximales permises des accessoires. Ne jamais utiliser le
compresseur pour gonfler de petits objets nécessitant une basse
pression comme des jouets d’enfant, des ballons de football et de
basket-ball, etc.
RISQUE D’EXPLOSION OU D’INCENDIE
Toujours faire fonctionner le compresseur dans un
endroitbienaéré,exemptdematériauxcombustibles,
d’essence ou de vapeurs de solvants. Si des
étincelles électriques provenant du compresseur
entrent en contact avec des vapeurs inflammables,
celles-ci peuvent s’enflammer et entraîner un
incendie ou une explosion. Lorsqu’on pulvérise des matériaux
inflammables, installer le compresseurà au moins 6,10 m (20 pi) en
amont de la zone de pulvérisation; il pourrait s’avérer nécessaire
d’utiliser une section supplémentaire de boyau.
Entreposer les matériaux inflammables en un lieu sûr, loin du
compresseur.
Toute obstruction des prises d’air de ventilation du compresseur
risque de provoquer une surchauffe importante et entraîner un
incendie. Ne jamais placerd’objets sur le dessus du compresseur ou
contre celui-ci. Faire fonctionner le compresseur dans une zone
dégagée, située à au moins 0,91 m (3 pi) d’un mur ou de tout
obstacle pouvant restreindre l’apport d’air frais aux prises d’air de
ventilation.
RISQUES CAUSÉS PAR LES OBJETS PROJETÉS EN L’AIR
Le flux d’aircomprimépeut endommager les tissus mous de la peau
exposée et peut projeter à haute vitesse des impuretés, des
fragments, des particules détachées et de petits objets pouvant
causer des blessures graves. Lorsqu’on utilise le compresseur,
toujours porter des lunettes de sécurité approuvées, conformes à la
normeANSI Z28.1, et dotées d’écrans latéraux. Ne jamais diriger le
flux d’air vers des personnes ou vers des animaux. N’utiliser que les
soufflettes approuvées par la OSHA.
RISQUES CAUSÉS PAR LA RESPIRATION DE L’AIR
COMPRIMÉ
Il est dangereux de respirer l’air comprimé sortant du compresseur!
Le flux d’air peut contenir du monoxyde de carbone,
des vapeurs toxiques ou des particules solides. Ne
jamais inhaler l’air comprimé du compresseur
directement ou au moyen d’un appareil respiratoire
raccordé au compresseur.
Les matériaux pulvérisés comme la peinture, les
solvants de peinture, les décapants, les insecticides,
les herbicides, etc. contiennent des vapeurs nocives et des poisons.
REMARQUE :ne faire fonctionner le compresseur que dans un
endroit bien aéré. Lire et respecter les consignes de sécurité
indiquées sur l’étiquette ou les fiches signalétiques du produit
pulvérisé. Utiliser un appareil respiratoire approuvé par
NIOSH/MSHA et conçu pour une utilisation
particulière.
RISQUES CAUSÉS PAR LES PIÈCES
MOBILES
Le compresseur est conçu pour être utilisé en
mode de fonctionnement continu.Toujours mettre
le compresseur hors tension et purger la
15
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pression duboyaud’airet du réservoiravantd’en effectuer l’entretien
ou d’y fixer des outils ou des accessoires.
Toujours garder les cheveux, les vêtementset les gants éloignés des
pièces mobiles; les vêtements amples, les bijoux ou les cheveux
long peuvent y rester coincés. On doit aussi éviter les évents qui
recouvrent les pièces mobiles, le cas échéant. Ne pas retirer les
couvercles de protection de cet appareil. Ne jamais faire fonctionner
le compresseur si les dispositifs ou les couvercles de protection
sont endommagés ou retirés. Ne jamais se tenir debout sur le
compresseur.
SURFACES CHAUDES
Ne pas toucher au métal à découvert (comme la tête de
compresseur ou le refroidisseur complémentaire) afin d’éviter les
risques de brûlures graves. Ne jamais toucher les pièces de métal à
découvert du compresseur pendant ou immédiatement après son
fonctionnement. Le compresseur demeure chaud pendant plusieurs
minutes après son arrêt. Ne pas déplacer le compresseur lorsqu’il
est en marche. Les pièces chaudes du moteur peuvent causer des
brûlures à l’utilisateur, qui risque de l’endommager ou de se
blesser en l’échappant.
MOTEUR
Cet outil est entraîné par un moteur à essence Honda. On peut
prévenir la plupart des accidents causés par un moteur en suivant
toutes les directives du présent guide, du guide d’utilisation du
moteur ainsi que celles inscrites sur le moteur. Ces directives
expliquent quelques-uns des risques les plus courants et décrivent
les meilleures façons de se protéger et de protéger les autres :
• S’assurer de savoir comment arrêter le moteur rapidement et
bien comprendre le fonctionnement des commandes.
• Ne jamais permettre à qui que ce soit de mettre le moteur en
marche avant d’avoir compris toutes les directives.
• Ne jamais permettre à un enfant de démarrer le moteur.
• Tenir les enfants et les animaux domestiques éloignés de la
zone de travail.
Précautions à prendre lorsqu’on fait le plein : LAISSER
REFROIDIR LE MOTEUR. L’essence est une substance
extrêmement inflammable qui peut faire exploser les vapeurs
environnantes. Faire le plein à l’extérieur, dans un endroit bien aéré,
une fois le moteur arrêté. Ne jamais fumerà proximité de l’essence.
Éviter de créer des étincelles et des flammes. Toujours entreposer
l’essence dans un contenant approuvé. En cas de déversement,
déplacer le compresseur avant de démarrer le moteur.
Risques associés au monoxyde de carbone : les gaz
d’échappement contiennent du monoxyde de carbone toxique.
Éviter d’inhaler ces gaz. Ne jamais faire fonctionner le moteur dans
un garage fermé ou un espace clos.
Introduction
Nous vous félicitons d’avoir fait l’acquisition d’un compresseur d’air
DEWALT! Nous tenons à vous assurer que cet appareil a été
construit selon le plus haut niveau d’exactitude et de précision.
Chaque composant a été rigoureusement mis à l’essai par des
techniciens en vue degarantir la qualité, l’endurance etle rendement
CYLINDRE DU
COMPRESSEUR
TUBE DE
TRANSFERT (NON
ILLUSTRÉ)
SILENCIEUX
TÊTE DE
POMPE DU
COMPRESSEUR
SURFACES CHAUDES
CYLINDRE
DU
MOTEUR
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