DXCM603 - Compressor DEWALT - Free user manual and instructions

USER MANUAL DXCM603 DEWALT

DANGER: Indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING: Indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage. IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US TOLL FREE AT: 1-888-895-4549 Important Safety Instructions

WARNING: Do not operate this unit until you read this instruction manual

for safety, operation and maintenance instructions.

WARNING: CONTAINS LEAD. May be harmful if eaten or chewed. May

generate dust containing lead. Wash hands after use. Keep out of reach children.

WARNING: This product can expose you to chemicals including lead,

which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warn- ings.ca.gov.

• It is normal for electrical contacts within the motor and pressure switch to spark.

• Always operate the air com- pressor in a well ventilated area free of combustible materials, gasoline, or solvent vapors.

• If electrical sparks from air compressor come into con- tact with flammable vapors, they may ignite, causing fire or explosion.

• If spraying flammable mate- rials, locate air compressor at least 20' (6.1 m) away from spray area. Longer air hose may be required.

• Store flammable materials in a secure location away from air compressor.

• Restricting any of the air compressor ventilation openings will cause serious overheating and could cause fire.

• Never place objects against or on top of air compressor.

• Operate air compressor in an open area at least 12" (30.5 cm) away from any wall or obstruction that would restrict the flow of fresh air to the ventilation openings.

• Operate unit in a clean, dry, well ventilated area. Do not operate unit in any confined area. Store indoors.3 English WHAT CAN HAPPEN HOW TO PREVENT IT

• Unattended operation of this product could result in personal injury or property damage. To reduce the risk of fire, do not allow the air compressor to operator unattended.

• Always remain in atten- dance with the product when it is operating.

• Always turn off and unplug unit when not in use.

DANGER: Risk to breathing (asphyxiation).

WHAT CAN HAPPEN HOW TO PREVENT IT

• Compressed air from your air compressor is not safe for breathing. The air stream may contain carbon monox- ide, toxic vapors, or solid particles from the tank. Breathing these contam- inants can cause serious injury or death.

• Never use air obtained di- rectly from the air compres- sor to supply air for human consumption. The air compressor is not equipped with suitable filters and in-line safety equipment for human consumption. WHAT CAN HAPPEN HOW TO PREVENT IT

• Exposure to chemicals in dust created by power sanding, sawing, grinding and other construction ac- tivities may be harmful.

• Sprayed materials such as paint, paint solvents, paint remover, insecticides, weed killers, may contain harmful vapors and poisons.

• Work in an area with good cross ventilation. Read and follow the safety instruc- tions provided on the label or safety data sheets for the materials you are spraying. Always use certified safety equipment: NIOSH/OSHA respiratory protection or properly fitting face mask designed for use with your specific application.

DANGER: Risk of Bursting.

Tank: On February 26, 2002, the U.S. Consumer Product Safety Commission published Release # 02-108 concerning air com- pressor tank safety: Air air compressor receiver tanks do not have an infinite life. Tank life is dependent upon several factors, some of which include operating conditions, ambient conditions, proper installations, field modifications, and the level of mainte- nance. The effect of these factors on the tank life is unpredict- able. If proper maintenance procedures are not followed, internal corrosion to the inner wall of the tank can cause the tank to unexpectedly rupture allowing pressurized air to suddenly and forcefully escape, posing risk of injury to consumers. Your air compressor’s tank must be removed from service by the end of the year shown on the tank warning label.

DANGER: Risk of explosion or fire.4

English Attachments & Accessories: WHAT CAN HAPPEN HOW TO PREVENT IT

• Exceeding the pressure rat- ing 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 man- ufacturers recommendation and never exceed the max- imum allowable pressure rating of attachments. Never use air compressor to inflate small low pressure objects such as children’s toys, footballs, basketballs, etc. Tires: WHAT CAN HAPPEN HOW TO PREVENT IT

• Over inflation of tires could result in serious injury and property damage.

• Use a tire pressure gauge to check the tires pressure before each use and while inflating tires; see the tire sidewall for the correct tire pressure. NOTICE: Tanks, air compressors and similar equipment can inflate small tires rapidly. Adjust pressure regulator on air supply to no more than the rating of the tire pressure. Add air in small increments and frequently use the tire gauge to prevent over inflation. WHAT CAN HAPPEN HOW TO PREVENT IT

• Failure to properly drain condensed water from tank causes 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 replace the entire air compressor.

• Modifications or attempted repairs to the tank.

• Never drill into, weld or make any modifications to the tank or its attachments. Never attempt to repair a damaged or leaking tank. Replace with a new tank.

• Unauthorized modifications to the safety valve, or any other components which control tank pressure.

• The tank is designed to withstand specific operating pressures. Never make ad- justments or part substitu- tions to alter the factory set operating pressures. The following conditions could lead to a weakening of the tank, and result in a violent tank explosion:

DANGER: Risk of injury or property damage when moving or storing.

WHAT CAN HAPPEN HOW TO PREVENT IT

• Oil can leak or spill and could result in fire or breath- ing hazard; serious injury or death can result. Oil leaks will damage carpet, paint or other surfaces in vehicles or trailers.

• Always place air compressor on a protective mat when transporting to protect against vehicle damage from leaks. Remove air compres- sor from vehicle immedi- ately upon arrival at your destination. Always keep air compressor level and never lie on its side.

WARNING: Risk of hot surfaces.

WHAT CAN HAPPEN HOW TO PREVENT IT

• Touching exposed metal such as the air compressor head or outlet tubes, can result in serious burns.

• Never touch any exposed metal parts on air com- pressor during or imme- diately after operation. Air compressor will remain hot for several minutes after operation.

• Do not reach around pro- tective shrouds or attempt maintenance until unit has been allowed to cool.

WARNING: Risk from flying objects.

WHAT CAN HAPPEN HOW TO PREVENT IT

• 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 personal injury or property damage.

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

• Never point nozzle or sprayer toward any part of the body, other people or animals.

• Always turn air compressor off and bleed pressure from the air hose and tank before attempting maintenance, attaching tools or accessories.6 English

WARNING: Risk from moving parts.

WHAT CAN HAPPEN HOW TO PREVENT IT

• Moving parts such as the pulley, flywheel and belt can cause serious injury if they come into contact with you or your clothing.

• Never operate the air compressor with guards or covers which are damaged or removed.

• Keep your hair, clothing and gloves away from moving parts.

• Loose clothes, jewelry or long hair can be caught in moving parts.

• Air vents may cover moving parts and should be avoided as well.

• Attempting to operate air compressor with dam- aged or missing parts or attempting to repair air compressor with protective shrouds removed can expose you to moving parts and can result in serious injury.

• Any repairs required on this product should be performed by a DEWALT factory service center or a DEWALT authorized service center.

WARNING: Risk of electrical shock.

WHAT CAN HAPPEN HOW TO PREVENT IT

• Your air compressor is powered by electricity. Like any other electrically powered device, if it is not used properly it may cause electric shock.

• Never operate the air com- pressor outdoors when it is raining or in wet conditions.

• Never operate air compres- sor with protective covers removed or damaged.

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

• Any electrical wiring or repairs required on this product should be performed by authorized service center personnel in accordance with national and local electrical codes.

WARNING: Make certain that the electrical circuit to which the air

compressor is connected provides proper electrical grounding, correct voltage and adequate protection. Failure to provide adequate electrical grounding to this product could result in serious injury or death from electrocution. Refer to grounding instructions paragraph in the installation section on pages 13 and 14.7 English

WARNING: Risk of unsafe operation.

WHAT CAN HAPPEN HOW TO PREVENT IT

• Unsafe operation of your air compressor could lead to serious injury or death to you or others.

• Review and understand all instructions and warnings in this manual.

• Become familiar with the operation and controls of the air compressor.

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

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

• Do not operate the product when fatigued or under the influence of alcohol or drugs. Stay alert at all times.

• Never defeat the safety features of this product.

• Equip area of operation with a fire extinguisher.

• Do not operate machine with missing, broken or unauthorized parts.

• Never stand on the air compressor.

WARNING: Risk of injury from lifting.

WHAT CAN HAPPEN HOW TO PREVENT IT

• Serious injury can result from attempting to lift too heavy an object.

• The air compressor is too heavy to be lifted by one person. Obtain assistance from others before lifting. CAUTION: Risk from noise. WHAT CAN HAPPEN HOW TO PREVENT IT

• Under some conditions and duration of use, noise from this product may contribute to hearing loss.

• Always wear certified safety equipment: ANSI S12.6 (S3.19) hearing protection. Important Safety Instructions READ THIS INSTRUCTION MANUAL AND SAFETY RULES BEFORE OPERATING THE UNIT. Compare the illustrations with the unit to familiarize yourself with the location of various controls and adjustments. Save this manual for future reference.Fig. 1 Fig. 2

English Pump Specifications 2 cylinder Single stage Oil lubricated Cast iron crankcase, cylinder and aluminum head Weight: 35.7 lbs (16.2 kg.) Oil capacity: 32 fl. oz (946 mL) Pump Part and Description (Fig. 3) U Full V Add W Oil drain plug X Oil level sight glass Y Oil fill plug Hot Surfaces (Fig. 4) J Air compressor cylinder and head K Outlet tube L Pump crankcase OFF

Place this switch (E) in the AUTO (1) position to provide automatic power to the pressure switch and OFF (0) to remove power at the end of each use. NOTICE: ALWAYS ensure the switch (E) is in the OFF (0) position and unit is unplugged before removing or replacing pressure switch cover. PRESSURE SWITCH The pressure switch (not shown) automatically starts the motor when the tank pressure drops below the factory set cut-in pressure. It stops the motor when the tank pressure reaches the factory set cut-out pressure. SAFETY VALVE This valve (A) is designed to prevent system failures by relieving pressure from the system when the compressed air reaches a predeter- mined level. The valve is preset by the manu- facturer and must not be removed or modified in any way. CHECK VALVE When air compressor is operating, the check valve (B) is open, allowing compressed air to enter the tank. When the air compressor reach- es cut-out pressure, the check valve closes, allowing air pressure to remain inside the tank.

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

The drain valve (I) is located at the base of the tank and is used to drain condensation at the end of each use. See Draining Tank under Maintenance, page 20.

The tank pressure gauge (G) indicates the reserve air pressure in the tank. REGULATOR (Sold separately, not shown) An air pressure regulator or a separate air transformer which combines the functions of air regulation and/ or moisture and dirt removal is recommended for most applications. See Air Distribution System paragraph under Installation, page 15.

WARNING: Risk of Bursting. Too much air pressure causes a hazardous

risk of bursting. Check the manufacturer’s maximum pressure rating for air tools and accessories. The outlet pressure must never exceed the maximum pressure rating of the tools or accessories.Fig. 12 Fig. 13 Fig. 14

English PUMP The pump compresses air into the tank. Working air is not available until the pump has raised the tank pressure above that required at the air outlet.

MOTOR OVERLOAD PROTECTOR

The motor has a thermal overload protector. If the motor over- heats for any reason, the overload protector will shut off the mo- tor. The motor must be allowed to cool down before restarting. To restart:

1. Set the Auto/Off switch to OFF (0) and unplug unit.

2. Allow the motor to cool.

3. Depress the red reset button (T) on the motor.

4. Plug power cord into the correct branch circuit receptacle.

5. Set the Auto/Off switch to AUTO (1).

Installation Unpack the air compressor. Inspect the unit for damage. If the unit has been damaged in transit, contact the carrier and com- plete a damage claim. Do this immediately because there are time limitations to damage claims. The Carton Should Contain Description Quantity Air compressor 1 Instruction manual 1 Check the air compressor serial label to ensure that you have received the model ordered, and that it has the required pressure rating for its intended use. INSTALLING HOSES

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

installing or disconnecting to prevent hose whip.

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

2. Apply sealant tape to hose threads.

3. Assemble hose to air outlet (H). IMPORTANT: Do not assem-

ble splitters directly to the air outlet (H) (Fig 2). NOTICE: Assembling quick connect bodies to air outlet and quick connect plugs to hose ends make connecting and disconnecting hoses simple and easy. Quick connect bodies and plugs are available for purchase from your local dealer or authorized service center.12 English DISCONNECTING HOSES

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

when installing or disconnecting to prevent hose whip.

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

2. Remove hose from air outlet (H) (Fig 2).

AIR COMPRESSOR LUBRICATION AND OIL

The air compressor pump was filled WITH oil at the manufactur- er. Check pump oil level before operating unit. See Air Com- pressor Pump Oil under Maintenance, page 21. COMPATIBILITY Air tools and accessories that are run off the air compressor must be compatible with petroleum based products. If you sus- pect that a material is not compatible with petroleum products, an air line filter for removal of moisture and oil vapor in com- pressed air is required. NOTICE: Always use an air line filter to remove moisture and oil vapor when spraying paint. LOCATION

• Locate air compressor in a clean, dry and well ventilated area.

• Place air compressor at least 12" (30.5 cm) away from wall or other obstructions that will interfere with the flow of air.

• Place the air compressor as close to the main power supply as possible to avoid using long lengths of electrical wiring. NOTICE: Long lengths of electrical wiring could cause power loss to the motor.

• The air filter must be kept clear of obstructions which could reduce air flow to the air compressor. HUMID AREAS In frequently humid areas, moisture may form in the pump and produce sludge in the oil, causing parts to wear out premature- ly. 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 conden- sation on the pump when it cools down and a "milky" appear- ance in air compressor oil. You may be able to prevent moisture from forming in the pump by increasing ventilation or operating for longer intervals.

ANCHORING OF THE AIR COMPRESSOR

WARNING: Risk of bursting. Excessive vibration can weaken the

tank and cause an explosion. Air compressor must be properly mounted. The air compressor MUST be bolted to a level, solid surface. Use 3/8" lag screws, vibration pads and anchors. If help is needed anchoring the air compressor consult a licensed contractor.

1. Place the air compressor on a level, solid surface. Make

sure the surface is in good condition with no cracks or damage.

2. Mark the surface using the holes in the air compressor feet

as a template.13 English

3. Drill holes in the surface for the anchors. Install anchors.

4. Line-up holes in surface with holes in air compressor feet.

5. Place the vibration pads (not supplied) between the floor

and air compressor feet, see Fig 15. If needed, use shims to level the unit.

6. Place the 3/8" lag screws through the air compressor feet,

vibration pads and into the anchors.

7. Torque 3/8" lag screws to 7-10 ft.-lbs (9.5-13.5 Nm).

3/8" Lag Screw (not supplied) Fig. 15

Vibration Pad (not supplied) P Surface Line

Concrete Anchor (not supplied) ELECTRICAL WIRING

WARNING: Improper electrical installation of this product may void its

warranty and your fire insurance. Have circuit wiring performed by qualified personnel such as a licensed electrician who is familiar with the national electrical code and any prevailing local electrical codes.

WARNING: Risk of electrical shock. Improper electrical grounding can

result in electrical shock. The wiring should be done by a qualified electrician. A qualified electrician needs to know the following before wiring:

1. The amperage rating of the electrical box is adequate. Refer

to the Specifications, page 8, for this information.

2. The supply line has the same electrical characteristics

(voltage, cycle, phase) as the motor. Refer to the motor nameplate for this information. NOTICE: The wiring used must be rated for the motor nameplate voltage, plus or minus 10%. Refer to local codes for recommended wire sizes, correct wire size and maximum wire run. Undersized wire causes high amp draw and overheating to the motor. NOTICE: A circuit breaker is recommended. If the air compressor is connected to a circuit protected by a fuse, use only time delay fuses.

WARNING: Risk of electrical shock. Electrical wiring must be located

away from hot surfaces such as manifold assembly, air compressor outlet tubes, heads or cylinders. GROUNDING INSTRUCTIONS

WARNING: Risk of electrical shock. In the event of a short circuit,

grounding reduces the risk of shock by providing an escape wire for the electric current. This air compressor must be properly grounded.14 English This product must be connected to a grounded, metallic, permanent wiring system, or an equipment-grounding terminal or lead on the product.

DANGER: Risk of electrical shock. Improper grounding can result in

Refer to the Voltage and Minimum Branch Circuit Requirements under Specifications, page 8.

• Voltage supply to circuit must comply with the National Electrical Code.

• Circuit is not used to supply any other electrical needs.

MAIN POWER DISCONNECT SWITCH

Install a main power disconnect switch in the line from the panel to the air compressor. The main power disconnect switch must be located near the air compressor, for ease of use and safety. When turned OFF, the main power disconnect switch shuts off all power to the air compressor. When turned ON, the air compressor will start and stop automatically, controlled by the pressure switch.

AIR DISTRIBUTION SYSTEM

WARNING: Risk of bursting. Plastic or PVC pipe is not designed to use

compressed air. Regardless of its indicated pressure rating, plastic pipe can burst from air pressure. Use only metal pipe for air distribution lines. NOTICE: Compressed air from oil lubed air compressors will contain water condensation and oil mist. Several drains, traps and filters will be needed to supply air without water (including aerosols) or oil to spray equipment, air tools and accessories requiring filtered air. Always read the instructions for the air tools and accessories being used.

• Use pipe that is the same size as the tank outlet. Piping that is too small will restrict the flow of air.

• If piping is over 100' (30.5 m) long, use the next larger size.

• Bury underground lines below the frost line and avoid pockets where condensation can gather and freeze. Apply pressure before underground lines are covered to make sure all pipe joints are free of leaks.

• A flexible coupling is recommended to be installed between the globe valve/air discharge outlet and main air distribution line to allow for vibration.

• A separate regulator is recommended to control the air pressure. Air pressure from the tank is usually too high for individual air driven tools.

• DO NOT install lubricators between the tank and any spray equipment, air tool or accessory requiring oil-free filtered air.

• Drain all traps, filters and dirt legs daily.15 English Part Description A Drain Legs B Drain Valves C Lubricator D Air Tool E Regulator F Filter / Moisture Trap G Air Usage Lines H Dirt Legs I Air Discharge Valve J Feeder Lines Slope with Air Flow K Main Distribution Air Lines L 5 Micron Filter M .01 Micron Filter N Spray Gun O Ball Fitter P Flexible Coupling R Air Flow S Air Outlet NOTICE: Slope pipe in direction of air flow. Water condensate flows along bottom of pipe to drain legs, preventing it from entering feeder lines. NOTICE: For Best Performance - The distance between the air compressor and the moisture trap should be as long as possible.

WARNING: Do not operate this unit until you

read this instruction manual for safety, operation and maintenance instructions. For proper operation of your air compressor, it is recommended that a 50% duty cycle be maintained; that is, the air compressor should not run more than 30 minutes in any 60 minute period. BREAK-IN PROCEDURE NOTICE: Risk of property damage. Serious damage may result if the following break-in instructions are not closely followed. This procedure is required before the air compressor is put into service and when the check valve or a complete pump has been replaced.

1. Make sure the Auto/Off switch is in the "OFF (0)" position.

2. Check oil level in pump. See Checking Oil paragraph,

page 21 in Maintenance for instructions.

3. Recheck all wiring. Make sure wires are secure at all

terminals connections. Make sure all contacts move freely and are not obstructed.

4. Open the drain valve (clockwise) fully to permit air to

escape and prevent air pressure build up in the tank during the break-in period.

6. Run the air compressor for 30 minutes.

Make sure the drain valve and all air lines are open so there is only a minimal air pressure build-up in tank. NOTICE: After about 30 minutes, If the unit does not operate properly, SHUT DOWN IMMEDIATELY, and contact Product Service at: 1-888-895-4549.

7. Check all air line fittings and connections/piping for air leaks

by applying a soap solution. Correct if necessary. NOTICE: Minor leaks can cause the air compressor to overwork, resulting in premature breakdown or inadequate performance.

8. Check for excessive vibration. Re-adjust or shim air

air compressor feet, if necessary.

9. After 30 minutes, turn the Auto/Off switch to the "OFF (0)"

11. Turn the Auto/Off switch to the "AUTO (1)" position. The tank

will fill to "cut-out" pressure and the motor will stop. The air compressor is now ready for use.17 English

BEFORE EACH START-UP

1. Every day check the sight glass to ensure that the level of

oil in the pump is at the required level.

2. Place Auto/Off switch to "OFF (0)".

3. Close the drain valve.

4. Visually inspect air lines and fittings for leaks.

5. Check safety valve. See Check Safety Valve under

Maintenance, page 20.

6. Attach hose and accessories.

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

installing or disconnecting to prevent hose whip.

WARNING: Risk of unsafe operation. Do not use damaged or worn

accessories. NOTICE: The hose or accessory will require a quick connect plug if the air outlet is equipped with a quick connect socket. NOTICE: A regulator MUST be used if the air pressure required for the accessory is less than the maximum air pressure supplied from the air compressor.

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

risk of bursting. Check the manufacturer’s maximum pressure rating for air tools and accessories. The regulator outlet pressure must never exceed the maximum pressure rating. CAUTION: Risk of unsafe operation. Compressed air from the unit may contain water condensation and oil mist. Do not spray unfiltered air at an item that could be damaged by moisture. Some air tools and accessories may require filtered air. Read the instructions for the air tools and accessories.

1. Turn the Auto/Off switch to "AUTO (1)" and allow tank pres-

sure to build. Motor will stop when tank pressure reaches "cut-out" pressure.

2. When the tank pressure reaches "cut-out" pressure open

the air discharge valve. NOTICE: When using a regulator and other accessories refer to the manufacturer’s instructions.

WARNING: Risk of bursting. If any unusual noise or vibration is noticed,

stop the air compressor immediately and have it checked by a trained service technician. The air compressor is ready for use. SHUT-DOWN (Fig 5)

2. Drain the tank, see Draining Tank under

Maintenance, page 20. Ensure tank pressure gauge reads 0 PSI (0 kPa).18 English SHUT-DOWN (continued)

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

installing or disconnecting to prevent hose whip.

3. Remove hose and accessory.

WARNING: Risk of bursting. Drain tank daily. Water will condense in

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

4. Allow the air compressor to cool down.

5. Wipe air compressor clean and store in a safe, non-freezing

area. Maintenance To ensure efficient operation and longer life of the air compressor, a routine maintenance schedule should be prepared and followed. The following routine maintenance schedule is geared to an air compressor in a normal working environment operating on a daily basis. If necessary, the schedule should be modified to suit the conditions under which the air compressor is used. The modifications will depend upon the hours of operation and the working environment. An air compressor in an extremely dirty and/or hostile environment will require a greater frequency of all maintenance checks.19 English Maintenance Schedule Procedure Daily Weekly Monthly 1 Year or 100 Hours See Tank Warning Check safety valve √ Inspect air filter √+ Drain tank √ Check pump oil level √ Change pump oil √** Oil leak inspection √ Inspect drive belt √ Check drive belt tension √ Check pulley/flywheel alignment √ Check for unusual noise/vibration √ Check for air leaks √* Clean air compressor exterior √ Remove tank from service √++

• To check for air leaks apply a solution of soapy water around joints. While air compressor is pumping to pressure and after pressure cuts out, look for air bubbles to form. ** The pump oil must be changed after the first 20 hours of operation. Thereafter, when using full synthetic non-detergent air compressor oil, change oil every 100 hours of operation or once a year, whichever comes first. + Perform more frequently in dusty or humid conditions. ++ For more information, call 1-888-895-4549 .20 English

WARNING: Risk of unsafe operation. Unit cycles automatically when

power is on. When performing maintenance, you may be exposed to voltage sources, compressed air, or moving parts. Personal injuries can occur. Before performing any maintenance or repair, disconnect power source from the air compressor and bleed off all air pressure.

CHECKING SAFETY VALVE

WARNING: Hot surfaces. Risk of burn. Tubes, pump head, and surround-

ing parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 4, page 9). Allow air compressor to cool prior to servicing.

WARNING: Risk of bursting. If the safety valve does not work properly,

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

WARNING: Risk from flying objects. Always wear certified safety

equipment: ANSI Z87.1 eye protection (CAN/CSA Z94.3) with side shields.

WARNING: Risk from noise. Use ear protection (ANSI S12.6 (S3.19) as air

flow noise is loud when draining. Before starting air compressor, pull the ring on the safety valve (A) to make sure that the safety valve operates freely. If valve is stuck or does not operate smoothly, it must be replaced with the same type of valve.

WARNING: Hot surfaces. Risk of burn. Tubes, pump head, and surround-

ing parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 4, page 9). Allow air compressor to cool prior to servicing. A dirty air filter will not allow the air compressor to operate at full capacity. Keep the air filter clean at all times.

1. Ensure Auto/Off switch is in the OFF (0) Position.

2. Allow unit to cool.

3. Unsnap/Rotate the air filter cover to

blow compressed air through the filter element for 10-15 seconds or replace if needed. If the filter is filled with paint, replace it.

5. Place element into housing and reattach the air filter cover.

CAUTION: Risk of unsafe operation. Do not operate without air filter. DRAINING TANK (Fig. 5, page 9)

WARNING: Risk of unsafe operation. Tanks contain high pressure air.

Keep face and other body parts away from outlet of drain. Use eye protection [ANSI Z87.1 (CAN/CSA Z94.3)] when draining as debris can be kicked up into face.

WARNING: Risk from noise. Use ear protection (ANSI S12.6 (S3.19) as air

flow noise is loud when draining. NOTICE: All compressed air systems generate condensation 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.

2. Pull ring on safety valve allowing air to bleed from the tank

until tank pressure is approximately 20 PSI. Release safety valve ring.

3. Drain water from tank by opening drain valve (clockwise) on

WARNING: Risk of bursting. Water will condense in the tank. If not

drained, water will corrode and weaken the tank causing a risk of tank rupture. NOTICE: Risk of property damage. Water from tank may contain oil and rust which can cause stains.

4. After the water has been drained, close the drain valve

(counterclockwise). The air compressor can now be stored. NOTICE: If drain valve is plugged, release all air pressure. The valve can then be removed, cleaned then reinstalled. AIR COMPRESSOR PUMP OIL (FIG. 3, page 9) NOTICE: Risk of property damage. Use air compressor oil only. Multi-weight automotive engine oils like 10W30 should not be used in air compressors. They leave carbon deposits on critical components, thus reducing performance and air compressor life. NOTICE: Use full synthetic, non-detergent air compressor oil. NOTICE: Crankcase oil capacity is approximately 32 fluid ounces (946 ml). CHECKING OIL

1. The oil level should be to the middle of the sight glass (X).

2. If needed, remove oil fill plug (Y) and slowly add oil until it

reaches the middle of the sight glass. CHANGING OIL

WARNING: Drain tank to release air pressure before removing the oil fill

plug or oil drain plug.

1. Remove the oil fill plug (Y).

2. Remove the oil drain plug (W) and drain oil into a suitable

3. Replace the oil drain plug (W) and tighten securely.

4. Slowly add air compressor oil until it reaches the middle of

the sight glass (X). NOTICE: When filling the crankcase, the oil flows very slowly into the pump. If the oil is added too quickly, it will overflow and appear to be full. CAUTION: Overfilling with oil will cause premature pump failure. Do not overfill.

5. Replace oil fill plug (Y) and tighten securely.

WARNING: This unit starts automatically. ALWAYS shut off and unplug

the air compressor, and bleed all pressure from the system before servicing the air compressor, and when the air compressor is not in use. Do not use the unit with the shrouds or belt guard removed. Serious injury could occur from contact with moving parts. Hot surfaces. Risk of burn. Pump head, and surrounding parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 4, page 9). Allow air compressor to cool prior to servicing.22 English

1. Set the Auto/Off lever

to "OFF (0)", unplug the unit, and relieve all air pressure from the tank.

2. Remove the outer belt

mounting screws and slide the motor toward the air compressor pump.

5. Remove the belt and replace with a new one.

6. See the Adjusting Belt Tension before tightening motor

1. Slide motor into original position, line the motor up with the

mark made earlier on saddle.

2. Tighten two outside motor mounting screws enough to hold

the motor in place for checking pulley and flywheel align- ment.

3. The belt should deflect 1/4" (6.5 mm) at midway between

the pulley and the flywheel when a 10 pound (4.5 kg.) weight is applied at the mid- way point.

tension is achieved, tighten motor mount- ing screws. Torque to 20-25 ft-lbs (27.1-33.9 Nm). NOTICE: Once the motor pulley has been moved from its factory set location, the grooves of the flywheel and pulley must be aligned to within 1/16" (1.6 mm) to prevent excessive belt wear. Verify the alignment by performing the following Motor Pulley/ Flywheel - Alignment.

The air compressor flywheel and motor pulley hub must be in-line (in the same plane) within 1/16" (1.6 mm) to assure belt retention within flywheel belt grooves. To correct misalignment, perform the following steps: Downward Force Deflection Fig. 2323 English

1. Set the Auto/Off lever to "OFF (0)", unplug the unit, and

relieve all air pressure from the tank.

2. Remove the outer belt guard.

3. Loosen the motor mounting bolts.

4. Loosen the set screws on the motor pulley.

5. Align the motor pulley with the pump flywheel.

7. Adjust the proper belt tension.

8. Retighten the motor mounting bolts. Torque to 20-25 ft.-lbs

9. Reinstall the outer belt guard. All moving parts must be

Once a year have a Trained Service Technician check the pump intake and exhaust valves. INSPECT AIR LINES AND FITTINGS FOR LEAKS

1. Turn the Auto/Off switch to "Auto (1)" and allow tank pres-

sure to build. Motor will stop when tank pressure reaches "cut-out" pressure.

2. Set the Auto/Off switch to "Off (0)" and unplug unit.

3. Apply a soap solution to all air-line fittings and connections/

piping to find leaks.

4. Pull ring on safety valve allowing air to bleed from the tank

until tank pressure is approximately 20 PSI. Release safety valve ring.

5. Drain water from tank by opening

6. Correct any leaks found.

NOTICE: Even minor leaks can cause the air compressor to overwork, resulting in premature breakdown or inadequate performance.

PUMP HEAD BOLTS - TORQUE

The pump head bolts should be kept properly torqued. Check torque of the head bolts after the first five hours of operation. Torque to 15-20 ft.-lbs. (20.3-27.1 Nm). Service and Adjustments ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE PERFORMED BY TRAINED SERVICE TECHNICIAN.

WARNING: Risk of unsafe operation. Unit cycles automatically

when power is on. When servicing, you may be exposed to voltage sources, compressed air, or moving parts. Before servicing unit unplug or disconnect electrical supply to the air compressor, bleed tank of pressure, and allow the air compressor to cool.24 English Additional Service Disassembly or service of the air compressor beyond what is covered in this manual is not recommended. If additional service is required, contact nearest Authorized Warranty Service Center. Accessories Recommended accessories for use with your tool are available for purchase from your local dealer or authorized service center. If you need assistance in locating any accessory for your tool, please call 1-888-895-4549 or visit www.dewalt.com.

WARNING: The use of any other accessory not recommended

for use with this tool could be hazardous. Use only accessories rated equal to or higher than the rating of the air compressor. Service Information Please have the following information for all service calls: Model Number ____________ Serial Number ___________ Date and Place of Purchase ____________________________ Repairs To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment should be performed by a DEWALT factory service center, a DEWALT authorized service center or other qualified service personnel. Always use identical replacement parts. Limited Warranty The Manufacturer warrants from the date of purchase. 2 Year – Limited warranty on oil-lubricated pumps. 1 Year – Limited warranty on all other air compressor components. This warranty is not transferable to subsequent owners. The Manufacturer will repair or replace, without charge, at their option, any defects due to faulty materials or workmanship. For further detail of warranty coverage and warranty repair information, call 1-(888)-895-4549 or visit dewalt.com. This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty also does not apply to merchandise sold by the Manufacturer which has been manufactured by and identified as the product of another company, such as gasoline engines. Such manufacturer’s warranty, if any, will apply. ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE OR EXPENSE THAT MAY RESULT FROM ANY DEFECT, FAILURE OR MALFUNCTION OF THE PRODUCT IS NOT COVERED BY THIS WARRANTY. Some states do not allow the exclusion of limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. IMPLIED WARRANTIES, INCLUDING THOSE OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR

PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you. What the Manufacturer Will Do: (the Manufacturer) will cover parts and labor to remedy substantial defects due to materials and workmanship during the first year of ownership, with the exceptions noted below. Parts used in repair of whole goods or accessories are warranted for the balance of the original warranty period.25 English What is not covered Under This Warranty? Failures by the original retail purchaser to install, maintain, and operate said equipment in accordance with standard industry practices. Modifications to the product, or tampering with components, or failure to comply with the specific recommendations of the Manufacturer set forth in the owner’s manual, will render this warranty null and void. The Manufacturer shall not be liable for any repairs, replacements, or adjustments to the equipment, or any costs for labor performed by the purchaser without the Company’s prior written approval. The effects of corrosion, erosion, surrounding environmental conditions, cosmetic defects, and routine maintenance items, are specifically excluded from this warranty. Routine maintenance items such as: oil, lubricants, and air filters, as well as changing oil, air filters, belt tensioning, etc… fall under the owner’s responsibility. Additional exclusions include: freight damage, failures resulting from neglect, accident, or abuse, induction motors when operated from a generator, oil leaks, air leaks, oil consumption, leaky fittings, hoses, drain valve, bleeder tubes, and transfer tubes.

• The following components are considered normal wear items and are not covered after the first year of ownership: Belts, pulleys, flywheels, check valves, pressure switches, outlet tube, pressure relief tube, throttle controls, electric motors, brushes, regulators, o-rings, pressure gauges, tubing, piping, fittings, fasteners, wheels, quick couplers, gaskets, seals, air filter housings, piston rings, connecting rods and piston seals.

• Labor, service calls, and travel charges, are not covered after the first year of ownership on stationary air compressors (air compressors without handles, or wheels). Repairs requiring overtime, weekend rates, or any other charges beyond the standard shop labor rate are not covered.

• Time required for orientation training for the service center to gain access to the product, or additional time due to inade- quate egress.

• Damage caused by incorrect voltage, improperly wired, or failure to have a certified licensed electrician install the air compressor, will render this warranty null and void.

• Damage caused from inadequate filter maintenance.

• Pump wear or valve damage caused by using oil not specified.

• Pump wear or damage caused by any oil contamination.

• Pump wear or valve damage caused by failure to follow proper maintenance guidelines.

• Operation below proper oil level or operation without oil.

• If product is equipped with a gasoline engine, see engine manual for specific engine manufacturer’s warranty coverage.26 English Parts purchased separately: The warranty for parts purchased separately such as: pumps, motors, etc., are as follows: From Date of Purchase

• All single & two stage pumps: 1 year

• Induction electric motors: 90 days

• Universal electric motor/pump: 30 days

• All other parts: 30 days

• No return authorization will be issued for electrical compo- nents once items are installed. How do You Get Service? In order to be eligible for service under this warranty you must be the original retail purchaser, and provide proof of purchase from one of the Manufacturer’s dealers, distributors, or retail outlet stores. Portable air compressors or components must be delivered, or shipped, to the nearest Authorized Service Center. All associated freight costs and travel charges must be borne by the consumer. Please call our toll free number 1-888-895-4549 for assistance. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

IMPLIED WARRANTIES, INCLUDING ANY WARRANTY

AND ALL WARRANTIES, OTHER CONTRACTS, NEGLIGENCE, OR OTHER TORTS IS EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW. FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-888-895-4549 for a free replacement. GLOSSARY CFM: Cubic feet per minute. SCFM: Standard cubic feet per minute; a unit of measure of air delivery. PSI: Pounds per square inch; a unit of measure of pressure. Cut-in pressure: Factory set low pressure point that starts the air compressor to repressurize the tank to a higher pressure. Cut-out pressure: Factory set high pressure point that stops27 English the air compressor from increasing the pressure in the tank above a certain level. Well-ventilated: A means of providing fresh air in exchange for dangerous exhaust or vapors. Dedicated circuit: An electrical circuit reserved for the exclusive use of the air compressor. ASME: American Society of Mechanical Engineers. Indicates that the components are manufactured, tested and inspected to the specifications set by ASME. CSA: Canadian Standards Association. Indicates that the products that have this marking have been manufactured, tested and inspected to standards that are set by CSA. Canadian Standards Association (USA): Indicates that the products that have this marking have been manufactured, tested and inspected to standards that are set by CSA. These products also conform to U.L. standard 1450. California Code: Unit may comply with California Code 462 (l) (2)/ (M) (2). Specification/model label is on the side of the tank on units that comply with California Code.

Troubleshooting Guide This section provides a list of the more frequently encountered malfunctions, their causes and corrective actions. The operator or maintenance personnel can perform some corrective actions, and others may require the assistance of a qualified DEWALT technician or your dealer. Problem Code Air leaks 1 Air leaks in tank or at tank welds 2 Air leaks between head and valve plate 3 Air leaks from safety valve 4 Air compressor is not supplying enough air to operate accessories 1,5,6,7,9,10 13, 19, 20, 21, 23, 24, 25, 26, 27 Restricted air intake 9 Oil in discharge air 19 Knocking Noise 10,11,12,13,14 Excessive belt wear 10,11,14,15 Squealing sound 10 Moisture in pump crankcase 1,3,8,17,18,19,20,21,22 Excessive current draw 14,23,24,25 Air compressor won’t start in cold temperatures 17,31,32 Air compressor stalls 25,26,27 Overheating 23,24,25,29,3028 English Troubleshooting Codes Code Possible Cause Possible Solution 1 Fittings are not tight. Tighten fittings where air can be heard escaping. Check fittings with soapy water solution. DO NOT OVERTIGHTEN. 2 Defective tank. Tank must be replaced. Do not repair the leak.

DANGER: Risk of bursting. Do

not drill into, weld or otherwise modify tank or it will weaken. The tank can rupture or explode. 3 Leaking seals. Contact a DEWALT factory service center or a DEWALT authorized service center. 4 Defective safety valve. Operate safety valve manually by pulling on ring. If valve still leaks, it must be replaced.

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

Air compressor is not large enough for accessory. Check the accessory air requirement. If it is higher than the SCFM or pressure supplied by your air compressor, a larger air compressor is needed to operate accessory. Code Possible Cause Possible Solution 7 Hole in air hose. Check air hose, replace if required.

Operating in damp or humid conditions. Move unit to a dry, well ventilated area. 9 Restricted air intake filter. Clean or replace air intake filter. 10 Loose belt. Check belt tension, see Adjusting Belt Tension under Maintenance, page 22. 11 Loose pulley. Tighten pulley set screw, torque to 120-130 in.-lbs (13.6-14.7 Nm). 12 Loose flywheel. Tighten flywheel screw, torque to 20-24 ft-lbs (27-32 Nm).

Carbon build-up in pump. Contact a DEWALT factory service center or a DEWALT authorized service center. 14 Belt too tight. Check belt tension, see Adjusting Belt Tension under Maintenance, page 22. 15 Pulley misalignment. See Motor Pulley/ Flywheel Alignment under Maintenance, page 22. 16 Pump oil is low. Add full synthetic, non- detergent air compressor oil to pump. See Air Compressor Pump Oil under Maintenance, page 21.29 English Code Possible Cause Possible Solution

Detergent type oil being used in pump. Drain oil and refill pump with full synthetic non-detergent air compressor oil. 18 Very light duty cycles. Run longer duty cycles.

Piston rings damaged or worn. Contact a DEWALT factory service center or a DEWALT authorized service center.

Cylinder or piston damaged or worn. Contact a DEWALT factory service center or a DEWALT authorized service center.

Air compressor cylinder finish worn. Contact a DEWALT factory service center or a DEWALT authorized service center. 22 Water in pump oil. Drain oil and refill pump with full synthetic non-detergent air compressor oil.

Low voltage/motor overload. Check that power supply is adequate and that air compressor is on a dedicated circuit. If air compressor is connected to a circuit protected by a fuse, use time delay fuses. Code Possible Cause Possible Solution

Restricted air passages. Inspect and replace transfer tubes or check valve, as required. 25 Low voltage motor. Furnish adequate power. 26 Bad check valve. Replace check valve. 27 Seized pump. Contact a DEWALT factory service center or a DEWALT authorized service center. 28 Oil level too high. Reduce to proper level. See Air Compressor Pump Oil under Maintenance, page 21. 29 Poor ventilation. Relocate air compressor to an area with cool, dry, well circulated air, at least 12 in. from nearest wall. 30 Dirty cooling surfaces. Clean all cooling surfaces.

Too much back pressure in tank. Open drain valve when starting motor.