DXCMH1608WB - Compressor DEWALT - Free user manual and instructions

USER MANUAL DXCMH1608WB DEWALT

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160cc, Gas Wheeled Portable Air Compressor

C. Engine On/Off Switch

D. Air Tank Pressure Gauge

E. Regulated Pressure Gauge

F. Pressure Regulator

G. Air Outlet

H. Unloader Valve

I. Safety Valve

J. Air Tank Drain Valve(s)

K. Pump Oil Dipstick/Oil Fill Plug

L. Pump Oil Drain Plug

M. Fixed Throttle

N. Choke Control

O. Fuel Valve Lever

P. Starter Grip

Pump Specifications

Inline, vertical twin cylinder

Single stage

Oil lubricated

Cast iron crankcase and cylinder

Weight: 46 lbs. (20.9 kg)

Oil Capacity: 24.7 oz. (730 mL)

FIG. 1

C A B P M N O H L I J DEWALT Actual unit may vary slightly.

Engine Specifications

Honda 160 cc

Internal Combustion

4-stroke

High RPM 2000-3600

Idle RPM 1250-1600

Specifications

MODEL	DXCMH1608WB
WEIGHT	171 lbs. (77.6 kg)
HEIGHT	25.25" (641.4 mm)
WIDTH	18.25" (463.6 mm)
LENGTH	43" (1092.2 mm)
AIR TANK CAPACITY	8 gallons (30.3 liters)
APPROX BLOW OFF PRESSURE	150 psi
SCFM @ 100 PSI	9.0 *
* Tested per ISO 1217

Hot Surfaces

FIG. 2 ENGINE MUFFLER COMPRESSOR CYUNDER & HEAD OUTLET TUBE DEWALT GASOLINE ENGINE PUMP CRANKCASE

Definitions: Safety Guidelines

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

DANGER: Indicates an imminently hazardous situation which, 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 D WALT TOOL, CALL US TOLL FREE AT: 1-888-895-4549

Important Safety Instructions

A DANGER: Carbon Monoxide. Using an engine indoors can kill you in minutes. Engine exhaust contains high levels of carbon monoxide (CO), a poisonous gas you cannot see or smell. You may be breathing CO even if you DO NOT smell engine exhaust.

• NEVER use an engine inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air.
• ONLY use outdoors and far away from open windows, doors and vents. These openings can pull in engine exhaust.
• Even when the engine is used correctly, CO may leak into your home. ALWAYS use a battery-powered or battery backup CO alarm (not supplied) in the home. Read and follow all directions for CO alarm before using. If you start to feel sick, dizzy or weak at anytime, move to fresh air immediately. See a doctor. You could have carbon monoxide poisoning.

A WARNING: Do not operate this unit until you read this instruction manual and the engine instruction manual for safety, operation and maintenance instructions.

WARNING: This product may not be equipped with a spark-arresting muffler. If the product is not equipped and will be used around flam ma ble ma teri als or on land covered with materials such as agricultural crops, forest, brush, grass or other similar items, then an ap proved spark arrester must be installed and is legally required in the state of California. It is a violation of California statutes section 130050 and/or sections 4442 and 4443 of the California Public Re sourc es Code, unless the engine is equipped with a spark arrester, as defined in section 4442, and maintained in ef fec tive work ing order. Spark arresters are also required on some U.S. For est Service land and may also be legally required under other statutesandordinances.

WARNING: This product contains chemicals known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling.

▲WARNING: Some dust contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm such as asbestos and lead in lead based paint.

WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

SAVE THESE INSTRUCTIONS

ADANGER: RISK OF EXPLOSION OR FIRE

WHAT CAn HAPPen HoW to PreVent It

- Spilled gas o line and it's vapors can be come ignited from cigarette sparks, electrical arcing, exhaust gas es and hot engine components such as the muffler.

- Heat will expand fuel in the tank which could result in spillage and pos si ble fire or explosion.

• Shut off engine and allow it to cool before adding fuel to the tank.
• Use care in filling tank to avoid spill ing fuel. Move unit away from fueling area before starting engine.
• Keep maximum fuel level 1/2" (12.7 mm) be low bottom of filler neck to allow for expansion.

• Combustible materials which come into contact with hot engine parts can become ignited.

- Improperly stored fuel could lead to acciden tal ignition. Fuelimproperlysecured could get into the hands of childrenorotherunqualified persons.

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

- Add fuel outdoors in a well ventilated area. Make sure there are no sources of ignition, such as cigarettes near refueling location.

- Operate compressor in a clean, dry, well ventilated area a minimum of 48" (1.22 m) from any building, object or wall. Do not operate unit indoors or in any confined area.

- Operate compressor in an open area away from dry brush, weeds or other combustible materials.

- Store fuel in an OSHA-approved con tain er, in a se cure location away from work area.

• Always remain in attendance with the product when it is operating.

▲ DANGER: RISK TO BREATHING (ASPHYxIATION) WHAT CAN HAPPEN HOW TO PREVENT IT

- Breathing exhaust fumes will cause serious injury or death! En gine exhaust contains carbon monoxide, an odorless and deadly gas.

- The compressed air directly from your compressor is not safe for breathing. The air stream may contain carbon monoxide, toxic vapors, or solid particles from the air tank. Breathing these contaminants can cause serious injury or death.

- Always operate air compressor outside in a clean, well ventilated area. Avoid enclosed areas such as garages, basements, storage sheds, which lack a steady exchange or air. Keep children, pets and others away from area of operation.

- Never use air obtained directly from the compressor to supply air for human consumption. The compressor is not equipped with suitable filters and in-line safety equipment for human consumption.

• Exposure to chemicals in dust created by power sanding, sawing, grinding, drilling and other construction activities may be harmful.
• Sprayed materials such as paint, paint solvents, paint remover, insecticides, weed killers, may contain harmful vapors and poisons.

▲ WARNING: RISK Of BURSTING

Air Tank: On February 26, 2002, the U.S. Consumer Product Safety Commission published Release # 02-108 concerning air compressor tank safety:

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 maintenance. The exact effect of these factors on air receiver life is difficult to predict.

If proper maintenance procedures are not followed, internal corrosion to the inner wall of the air receiver tank can cause the air tank to unexpectedly rupture allowing pressurized air to suddenly and forcefully escape, posing risk of injury to consumers.

Your compressor air tank must be removed from service by the end of the year shown on your tank warning label.

The following conditions could lead to a weakening of the air tank, and result in a violent air tank explosion:

WHAT CAN HAPPEN HOW TO PREVENT IT

• Failure to properly drain condensed water from air tank, causing rust and thinning of the steel air tank.

• Modifications or attempted repairs to the air tank.

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

• Excessive vibration can weaken the air tank and cause rupture or explosion. Excessive vibration will occur if the compressor is not properly mounted or if engine operates above recommended RPM.

• Drain air tank daily or after each use. If air tank develops a leak, replace it immediately with a new air tank or replace the entire compressor.

• Never drill into, weld or make any modifications to the air tank or its attachments. Never attempt to repair a damaged or leaking air tank. Replace with a new air tank.
• The air tank is designed to withstand specific operating pressures. Never make adjustments or parts substitutions to alter the factory set operating pressures.
• Do not remove the stiffener bar connecting the compressor pump to the engine, except to adjust belt tension. Then securely tighten the stiffener bar bolts. This bar controls unit vibration.

Attachments & accessories:

- Exceeding the pressure rating of air tools, spray guns, air operated accessories, tires and other inflatables can cause them to explode or fly apart, and could result in serious injury.

- Follow the equipment manufacturers recommendation and never exceed the maximum allowable pressure rating of attachments. Never use compressor to inflate small low pressure objects such as children's toys, footballs, basketballs, etc.

Tires:

• 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.

NOTE: Air tanks, compressors and similar equipment used to inflate tires can fill small tires very 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.

WARNING: RISK FROM FIYING 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 property damage or personal injury.

• Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/CSA Z94.3) with side shields when using the compressor.
- Never point any nozzle or sprayer toward any part of the body or at other people or animals.
- Always turn the compressor off and bleed pressure from the air hose and air tank before attempting maintenance, attaching tools or accessories.

▲ WARNING: RISK Of HOT SURFACES

WHAT CAN HAPPEN HOW TO PREVENT IT

- Touching exposed metal such as the compressor head, engine head, engine exhaust or outlet tubes, can result in serious burns.

- Never touch any exposed metal parts on compressor during or immediately after operation. Compressor will remain hot for several minutes after operation - Do not reach around protective shrouds or attempt maintenance until unit has been allowed to cool.

WARNING: RISK FROM MOVING PARTS

WHAT CAN HAPPEN HOW TO PREVENT IT

• The engine can start accidentally if the flywheel is turned by hand or moved by pulling on the starter rope.
- Moving parts such as the pulley, flywheel, and belt can cause serious injury if they come into contact with you or your clothing.

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

• Always disconnect the spark plug and bleed pressure from the air tank before performing maintenance.
- Never operate the compressor with guards or covers which are damaged or removed.
- Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
• Air vents may cover moving parts and should be avoided as well.
- Any repairs required on this product should be performed by a D WALT factory service center or a D WALT authorized service center.

WARNING: RISK OF UNSAFE OPERATION

WHAT CAN HAPPEN

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

HOW TO PREVENT IT

• 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 compressor.

WARNING: RISK FROM NOISE

WHAT CAN HAPPEN HOW TO PREVENT IT

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

and Always wear certified safety equipment: ANSI S12.6 (S3.19) hearing protection.

WARNING: RISK Of INJURY FROM IIFTING

WHAT CAN HAPPEN HOW TO PREVENT IT

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

- The compressor is too heavy to be lifted by one person. Obtain assistance from others before lifting.

WARNING: RISK Of INJURY OR PROP ER TY DAMAGE WHEN TRANSPORTING OR STORING WHAT CAN HAPPEN HOW TO PREVENT IT

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

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

SAVE THESE INSTRUCTIONS FOR FUTURE USE

FEATURES

UNLOADER VALVE

When the maximum air tank pressure is obtained, the unloader valve (H) will blow-off. This will cause the compressor to exhaust the air to the atmosphere and not the tank. The valve is preset by the manu facturer and must not be removed or modified in any way.

Manual Lock: The manual lock allows you to manually unload the compressor with air pressure in the air tank. To operate the manual lock:

Rotate the manual lock unloader lever to the open position to prevent air tank pressure buildup. Rotate manual lock unloader lever to the closed position after starting the engine to allow air tank pressure to build. NOTE: Air will not build in tank when manual lock unloader lever in the open position.

SAFETY VALVE

This valve (I) 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.

AIR INTAKE FILTER

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

AIR TANK DRAIN VALVES

The drain valve (J) is used to remove moisture from the air tank after the air compressor is shut off.

AIR TANK PRESSURE GAUGE

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

REGULATED PRESSURE GAUGE

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

tank pressure.

REGULATOR

The regulator knob (F) controls the air pressure coming from the air tank.

To Adjust Regulator:

1. Pull regulator knob (F) out to unlock.
2. Turn knob clockwise to increase regulated pressure and counterclockwise to decrease regulated pressure.
3. When desired pressure is shown on the regulated pressure gauge push knob in to lock.

⚠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.

THROTTLE CONTROL

When maxi mum air tank presure is reached and the unloader valve vents air, it activates the throttle control on the engine. This gas saving feature holds the engine at a factory-set idling speed until air pressure in the air tank drops to reset pressure. The unloader valve then reactivates the throttle control and accelerates the engine to full throttle.

LOW OIL SHUT DOWN SENSORS

The air compressor engine is equipped with low oil shutdown sensors. These are safety devices designed to protect your engine from damage in the event the oil level in the crankcase is below minimum.

If the oil in engine gets low while the air compressor is running it will automatically shut down the engine and will not restart until oil is added to the engine. If the oil is low before start-up, the engine will not start until oil is added.

NOTE: The low oil shutdown sensors are very sensitive. You must fill the engine to the full mark on the dipstick to inactivate this safety device.

INSTALLATION

Assembly (Fig. 1)

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.
2. Apply sealant tape to hose threads.
3. Assemble hose to air outlet (G).

NOTICE: Do not assemble splitters directly to the air outlet (G).

NOTE: Assembling quick connect bodies to air outlet (G) 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.

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.
2. Remove hose(s) from air outlet(s) (G).

Lubrication and Oil

ENGINE

1. The engine was filled WITH oil at the manufacturer. Check engine oil level before operating unit. If necessary, fill engine

to the appropriate level with recommended oil, see engine's instruction manual supplied by engine manufacturer for correct procedure.
2. Add fuel to engine. See engine's instruction manual supplied by engine manufacturer for correct procedure.
WARNING: Risk of explosion or fire. Gasoline vapor is highly flammable. Refuel outdoors preferably, or only in well-ventilated areas. Do not refuel or check gasoline level while the engine is running. Do not store, spill, or use gasoline near an open flame, a source of sparks (such as welding), or near operating electrical equipment.

AIR COMPRESSOR

The air compressor pump was filled WITH oil at the manufacturer. Check air compressor pump oil level before operating unit. See Compressor Pump Oil under Maintenance.

Compatibility

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

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

Location

▲ DANGER: Risk of breathing. Exhaust from the gasoline engine contains deadly carbon monoxide, which is odorless and toxic. Operate engine only in well ventilated areas.

NOTICE: Risk of property damage. 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 4 feet (1.2 m) away from obstacles that may prevent proper ventilation. Keep unit away from areas that have dirt, vapor and volatile tumes in the atmosphere which may clog and gum up the intake filter and valves, causing inefficient operation.

HUMID AREAS

In frequently humid areas, moisture may form in the pump and produce sludge in the oil, 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 pump when it cools down and a "milky" appearance in compressor oil. You may be able to prevent moisture from forming in the 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 baffle walls. Contact a D WALT service center or call 1-888-895-4549 for assistance.

TRANSPORTING

WARNING: Risk injury from lifting. Unit weighs more than 171 lbs. (77.6 kg) Do not move or lift without assistance.

NOTICE: Risk of property damage. The wheels and handle do not provide adequate clearance, stability or support for pulling the unit up and down stairs or steps. The unit must be lifted, or pushed up a ramp.

NOTICE: Risk of property

damage. Place engine fuel valve lever (O) in the OFF position before moving or transporting unit.

When transporting the compressor in a vehicle, trailer, etc. ensure that the air tank is drained and the unit is secured and placed on a protective mat on a flat horizontal surface. DO NOT store in a standing position.

NOTE: Use recommended tie down points (Q) when transporting. Use care when driving so to avoid tipping the unit over in the vehicle. Damage can occur to the unit or surrounding items if unit is tipped. Use a ramp if loading or unloading the unit from a height of more than 12" (30.5 cm).

LIFTING

Always lift from the recommended lift points (R).

WARNING: Risk injury from lifting. Unit weighs more than 171 lbs.

(77.6 kg) Do not move or lift without assistance.

NOTICE: Risk of property damage. Place engine fuel valve lever (O) in the OFF position before moving or transporting unit.

MOVING

1. Grasp handle (S) of compressor, and lift compressor high enough so unit can be rolled on the front tire(s).

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

NOTICE: Risk of property damage. Place engine fuel valve lever (O) in the OFF position before moving or transporting unit.

1. When location is reached slowly lower rear of compressor to ground. Always store compressor in a horizontal position. DO NOT store in a standing position.

NOTE: Should the unit tip over, hard starting and smoking will occur due to oil spillage.

PREPARATION FOR USE

Pre-Start Checklist (Fig. 1)

1. Ensure engine ON/OFF switch (C) is in the OFF position.
2. Ensure air tank is drained, see Draining Air Tank under Maintenance.
3. Ensure the drain valve (J) is closed.
4. Ensure safety valve (I) is functioning properly, see Checking Safety Valve under Maintenance.
5. Check pump oil level, see Compressor Pump Oil under Maintenance.

NOTICE: Do not operate without oil or with inadequate oil. D. WALT is not responsible for compressor failure caused by inadequate oil.

1. Check engine's oil and fuel level, see engine's instruction manual for correct procedures.

2. Visually inspect drive belt. Replace belt if frayed, cracked, or worn. NOTE: Outer belt cover must be removed to inspect drive belt.

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

Initial Set-up (Fig. 1)

WARNING: Do not operate this unit until you read and understand this instruction manual and the engine instruction manual for safety, operation and maintenance instructions.

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 used for the first time.

• When the unloader valve has been displaced.
  • When the compressor pump has been replaced.
• Follow Pre-Start Checklist under Preparation for Use.
• Rotate the unloader's manual lock to the open position to prevent air tank pressure buildup.
• Open the pressure regulator. Pull regulator knob (F) out and rotate clockwise until it stops.
  WARNING: Do not operate this unit until you read and understand the engine instruction's manual for safety, operation and maintenance instructions.

The procedure:

1. Prepare engine for first time use, see engine's instruction manual for correct procedure.

2. Turn the engine ON/OFF switch (C) to the ON position.

3. Place the fuel valve lever (O) in the ON position.

4. If the engine is cold, move the choke (N) to the CLOSED position as shown. If the engine is hot, move the choke to the OPEN position.

WARNING: Risk of unsafe operation. Pull starter grip slowly until resistance is felt. Then pull starter grip (P) rapidly to avoid kickback and prevent hand or arm injury. NOTICE: Do not allow the starter grip to snap back. Return it gently by hand.

NOTE: If the engine does not start, check the oil level and add oil as needed.

NOTE: To ensure maximum oil lubrication, place the unit on a level surface.

1. As the engine warms up, move the choke to the OPEN position.
2. Run the air compressor for 30 minutes to seat the rings and lubricate all the internal surfaces. Ensure there is no pressure build up in the air tank by observing the reading on the air tank pressure gauge.
3. Rotate the manual lock on the unloader valve into the closed position so the air tank pressure can build.
4. Close the pressure regulator. Rotate the regulator knob (F) counterclockwise to its built-in stop and push knob in to lock in place. This will allow air to build pressure in the air tank.
5. Compressed air will be available from the hose air outlet until it is used up or bled off.

OPERATING PROCEDURES

Start-up (Fig. 1)

1. Follow Pre-Start Checklist under Preparation for Use.
2. Pull out and turn regulator knob (F) counterclockwise until fully closed. Push in to lock. Regulated pressure gauge should read 0 psi.
3. Rotate the manual lock unloader lever to the open position to assist with start up.
4. Turn the engine ON/OFF switch (C) to the ON position.
5. Place the fuel valve lever (O) in the ON position.
6. If the engine is cold, move the choke (N) to the CLOSED position as shown. If the engine is hot, move the choke to the OPEN position.

⚠ WARNING: Risk of unsafe operation. Pull starter grip slowly until resistance is felt. Then pull starter grip (P) rapidly to avoid kickback and prevent hand or arm injury.

NOTICE: Do not allow the starter grip to snap back. Return it gently by hand.

NOTE: If the engine does not start, check the oil level and add oil as needed.

NOTE: To ensure maximum oil lubrication, place the unit on a level surface.

1. As the engine warms up, move the choke to the OPEN position.

2. Rotate manual lock unloader lever to the closed position to allow air tank pressure to build. NOTE: Pump will not operate with the manual lock unloader lever in the open position.

3. Allow compressor to pump up to blow off pressure.

⚠ WARNING: Risk of unsafe operation. If any unusual noise or vibration is noticed, stop the compressor and refer to the troubleshooting section.

NOTE: The air compressor pump is capable of running continuously. To prolong the air compressor's life, it is recommended to run at high throttle 50-75% of the run time and idle for 25% of the run time

1. Attach hose and accessory.

⚠ 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: Risk of property damages. Compressed air from the unit may contain water condensation and oil mist. Do not spray un fil tered air at an item that could be damaged by moisture. Some air operated tools or de vic es may require filtered air. Read the in struc tions for the air tool or device.

1. Adjust regulator (F) to desired setting. See Regulator under Features.

Shut-down

1. Place the engine ON/OFF switch (C) to the OFF Position.
2. Place the fuel valve lever (O) in the OFF position.

NOTE: If finished using compressor, follow Steps 3-7.

1. Turn regulator knob (F) counterclockwise until fully closed. Ensure regulated pressure gauge reads 0 psi.
2. Remove hose and accessory.
3. Drain the air tank. See Draining Air Tank under Maintenance.
   NOTICE: Risk of property damage. Place engine fuel valve lever (O) in the OFF position before moving or transporting unit
   WARNING: Risk of bursting. Drain air tank daily. Water will condense in air tank. If not drained, water will corrode and weaken the air tank causing a risk of air tank rupture.
4. Allow the compressor to cool down.
5. Wipe air compressor clean and store in a safe, non freezing area.

MAINTENANCE

WARNING: The following procedures must be followed when maintenance or service is performed on the air compressor.

1. Ensure engine ONOFF switch (C) is in the OFF position.

2. Disconnect spark plug wire.

3. Drain air tank.

4. Allow air compressor to cool down before starting service

NOTE: AI compressed air systems contain maintenance parts (e.g. oil, filters, separators) that are periodically replaced. These used parts may contain substances that are regulated and must be disposed of in accordance with local, state, and federal laws and regulations.

NOTE: Take note of the positions and locations of parts during disassembly to make reassembly easier.

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

Maintenance Chart

Procedure	Daily	Weekly	Monthly	1 year or 200 Hours	See tank warning label
Check safety valve	X
Inspect air filter		X^+
Drain air tank	X
Check pump oil level	X
Change pump oil				X^++
Oil leak inspection	X
Inspect drive belt	X
Check drive belt tension			X
Check pulley/flywheel alignment				X
Check for unusual noise/vibration	X
Check for air leaks	X^*
Clean compressor exterior		X
Remove tank from service					X^++
Engine	See engine instruction manual.
* To check for air leaks apply a solution of soapy water around joints. While compressor is pumping to pressure and after pressure cuts out, look for air bubbles to form.
** The pump oil must be changed after the first 20 hours or operation. Thereafter, when using D WALT synthetic compressor oil, change oil every 200 hours of operation or once a year, whichever comes first.

• Perform more frequent in dusty or humid conditions.
  ++ For more information, call 1-888-895-4549

Checking Safety Valve (Fig. 1)

WARNING: Hot surfaces. Risk of burn. Aftercooler, pump head, and surrounding parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 2). Allow compressor to cool prior to servicing.

⚠WARNING: Risk of bursting. If the safety valve does not work properly, over-pressurization may occur, causing air 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 when using the compressor.

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

Checking Air Filter Element (Fig. 1)

WARNING: Hot surfaces. Risk of burn. Aftercooler, pump head, and surrounding parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 2). Allow compressor to cool prior to servicing.

1. Ensure engine ON/OFF switch (C) is in the OFF position.
2. Allow unit to cool.
3. Remove filter (A) top from filter base by turning filter counterclockwise about 5 degrees.
4. Separate filter top from base.
5. Remove element from filter base.
6. If element needs cleaning, blow out with air. Replace if needed.

Purchase replacement parts from your local dealer or authorized service center. Always use identical replacement parts.

1. Place element back in filter base.
2. Reconnect filter top to filter base. While pushing in, rotate clockwise 5 degrees.

NOTICE: Risk of unsafe operation. Do not operate without air inlet filter.

Draining Air Tank (Fig. 1)

▲WARNING: Risk of unsafe operation. Risk from noise. Air tanks contain high pressure air. Keep face and other body parts away from outlet of drain. Use 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.

note: All compressed air systems generate condensate that accumulates in any drain point (e.g., tanks, filter, aftercoolers, dryers). This condensate contains lubricating oil and/or substances which may be regulated and must be disposed of in accordance with local, state, and federal laws and regulations.

1. Ensure engine ON/OFF switch (C) is in the OFF position.
2. Place a suitable container under the drain valve to catch discharge.
3. Grasp black lever on drain valve.

WARNING: Risk of bursting. Drain air tank daily. Water will condense in air tank. If not drained, water will corrode and weaken the air tank causing a risk of air tank rupture.

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

1. Slowly rotate lever to gradually bleed air from air tank.
2. When air tank pressure gauge reads 10 psi, rotate valve to the

fully open position.

1. Close drain valve when finished.

Compressor Pump Oil (Fig. 1)

CHECKING OIL

WARNING: Hot surfaces. Risk of burn. Aftercooler, pump head, and surrounding parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 2). Allow compressor to cool prior to servicing.

1. Ensure engine ON/OFF switch (C) is in the OFF Position.
2. Place unit on a flat level surface.
3. Remove distick (K) and wipe clean.
4. Insert and remove dipstick without threading dipstick into crankcase as shown in figure.
5. Check the oil level on dipstick. If oil level is at or below "Add", oil needs to be added. Add D WALT

synthetic oil to the proper maximum level as shown in figure. NOTE: When filling the crankcase, the oil flows very slowly into the pump. If the oil is added too quickly, it will overflow and appear to be full.

NOTICE Risk of property damage. Overfilling with oil will cause premature compressor failure. Do not overfill.

1. Replace dipstick and tighten securely.

CHANGING OIL

NOTE: Pump oil contains substances that are regulated and must be disposed of in accordance with local, state and federal laws and regulations.

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

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

1. Ensure engine ON/OFF switch (C) is in the OFF Position.
2. Allow the unit to cool.
3. Disconnect spark plug wire.
4. Drain air tank
5. Locate a suitable container under pump drain plug (L).
6. Remove the dipstick (K) from crankcase.
7. Remove the oil drain plug (L).
8. Allow ample time for all oil to drain out. (Tilting the compressor towards the drain plug will assist in draining.)
9. Install the oil drain plug
10. Fill pump with D WALT synthetic compressor oil. Oil should not exceed top raised line on side of crackcase. (Oil will be even with bottom of threads in crankcase fill port.)
11. Install dipstick
12. Reconnect spark plug wire.

Checking Belt Tension (Fig. 1)

WARNING: Hot surfaces. Risk of burn. Aftercooler, pump head and surrounding parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 2). Allow compressor to cool prior to servicing.

1. Ensure engine ON/OFF switch (C) is in the OFF position.
2. Allow the unit to cool
3. Disconnect spark plug wire.
4. Drain air tank.
5. Remove two belt guard mounting screws on pump head.

6. Loosen but do not remove the four belt guard mounting screws on the saddle.

7. Remove outer belt cover.

8. Measure belt tension. Proper tension is achieved when a three (3) pound (1.36 kg) weight or equivalent finger pressure applied midway between the motor pulley and compressor flywheel causes a 1/4" (6.35 mm) deflection of the belt. If adjustment is needed see Adjusting Belt Tension under Maintenance.
9. Replace belt guard.
10. Reconnect spark plug wire.

Adjusting Belt Tension

WARNING: Hot surfaces. Risk of burn. Aftercooler, pump head and surrounding parts are very hot, do not touch (see the Hot Surfaces identified in Fig. 2). Allow compressor to cool prior to servicing.

1. Follow procedures 1-8 in Checking Belt Tension under Maintenance.
2. Scribe a mark at the base of the engine on the deck to be used as a reference.
3. Loosen but do not remove four engine mounting nuts.
4. Loosen but do not remove bolt securing stiffener bracket to engine.
5. Remove the belt.
6. Scribe a mark approximately 1/8" (3.2 mm) from the original mark.
7. Slide the engine to the new mark and retighten the engine mounting nuts.

⚠WARNING: Risk of moving parts. Use caution when rolling belt onto flywheel, fingers can get caught between the belt and flywheel.

1. With the engine secure, roll the belt over the flywheel and the pulley.

2. Check the belt tension again. See Step 8 in Checking Belt Tension under Maintenance.

3. When tension is correct, torque four engine mounting nuts (engine torque to 10–20 ft.-lbs./13.5–27.1 Nm), stiffener bracket bolt (Torque to 10–20 ft.-lbs./13.5–27.1 Nm), and replace belt cover.
4. Reconnect spark plug wire.

Pulley and Fly wheel Alignment

The air compressor flywheel and engine pulley must be in-line (in the same plane) within 1/16" (1.6 mm) to ensure belt retention within flywheel belt grooves. To check alignment:

1. Ensure engine ON/OFF switch (C) is in the OFF Position.
2. Allow the unit to cool.
3. Disconnect spark plug wire.
4. Drain air tank.

5. Remove outer belt cover.

6. Place a straightedge (T) against the outside of the flywheel (U) and the engine drive pulley (V).

7. Measure the distance between the edge of the belt (W) and the

U A1 W A2 B1 B2 V T A1 A2 B1 B2

straightedge at points A1 and A2 in Figure. The difference between mea sure ments should be no more than 1/16" (1.6 mm).

1. If the difference is greater than 1/16" (1.6 mm), loosen the setscrew holding the engine drive pulley to the shaft and adjust the pulley's position on the shaft until the A1 and A2 mea surements are within 1/16" (1.6 mm) of each other.
2. Tighten the engine drive pulley setscrew. Torque to 145–180 in.-

lbs. (16.4 - 20.3 Nm)

1. Visually inspect the engine drive pulley to verify that it is perpendicular to the drive motor shaft. Points B1 and B2 of Figure should appear to be equal. If they are not, loosen the setscrew of the engine drive pulley and equalize B1 and B2, using care not to disturb the belt alignment performed in Step 8.
2. Retighten the engine drive pulley setscrew. Torque to 145-180 in-lbs. (16.4-20.3 Nm).
3. Reinstall belt guard.
4. Reconnect spark plug wire.

ACCESSORIES

Recommended accessories for use with your tool are available for purchase from your local dealer or authorized service center. If you need assistance in locating any accessory for your tool, please contact D WALT Industrial Tool Co., 213 Industrial Drive, Jackson, TN 38301, call 1-888-895-4549 or visit our website www.dewat.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 available for all service calls: Model Number Serial Number

Date and Place of Purchase

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment should be performed by a D WALT factory service center; a D WALT authorized service center or other qualified service personnel. Always use identical replacement parts.

Full One Year Warranty

D. WALT heavy duty industrial tools are warranted for one year from date of purchase. We will repair, without charge, any defects due to faulty materials or workmanship. For warranty repair information, call 1-888-895-4549. This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained either in the packaging, call the local company or see website for warranty information.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-888-895-4549 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.

Code Certification: Products that bear one or more of the following marks: UL ^® , CUL, ETL ^® , CETL, have been evaluated by OSHA certified independent safety laboratories and meet the applicable Standards for Safety.

*UL® is a registered trademark of Underwriters Laboratories and ETL® is a registered trademark of Electrical Testing Laboratories.

California Code: Unit may comply with California Code 462 (I) (2)/(M) (2). Specification/model label is on the side of the air tank on units that comply with California Code.

Unloader Blow-Off Pressure: All models are continuous running units controlled by air tank pressure. When the maximum air tank pressure is obtained, the unloader valve will blow-off. This will cause the compressor to exhaust the air to the atmosphere and not the tank. This decreases the load on the engine and allows it to run at a near no-load condition.

Unloader Reset Pressure: When the air tank pressure drops to a predetermined point, the unloader valve closes. The air tank pressure will now increase until it reaches the unloader blow-off pressure.

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 D WALT technician or your dealer.

Problem

Code

Excessive air tank pressure-safety valve pops off

Air leaks

Continuous air leak at unloader valve.

Air leaks in air tank or at air tank welds ____

Air leaks between head and valve plate

Air leaks from safety valve

Compressor is not supplying enough air to operate

accessories

2,7,8,9,10,12,13

Restricted air intake.

Excessive vibration

14, 15

Problem Code

Knocking Noise....6, 13, 14, 15, 16, 17, 18, 19

Excessive belt wear 13,14,16,19,20

Squealing sound 13

Engine will not run 21, 22, 23, 34

Pressure reading on the regulated pressure gauge drops when an accessory is used ....24

Regulator knob has continuous air leak 25

Regulator will not shut off air outlet 25

Moisture in pump crankcase. 2, 5, 11, 26, 27, 28, 29, 30, 31

Pump will not run 32

Air tank pressure will not build 32, 33

Troubleshooting Codes

CODE	POSSIBLE CAUSE	POSSIBLE SOLUTION
1	Unloader valve does not release pressure when air tank reaches blow-off pressure	Unloader valve must be replaced. Contact a D WALT factory service center or a D WALT authorized service center.
2	Fittings are not tight	Tighten fittings where air can be heard escaping. Check fittings with soapy water solution. DO NOT OVERTIGHTEN.
3	Defective unloader valve	Turn off engine, rotate manual lock unloader lever to the closed perpendicular position. If air leaks out of air tank through unloader valve, replace unloader valve.
4	Defective air tank	Air tank must be replaced. Do not repair the leak. ▲WARNING: Risk of bursting. Do not drill into, weld or otherwise modify air tank or it will weaken. The air tank can rupture or explode.
5	Leaking seals	Contact a D WALT factory service center or a D WALT authorized service center.
6	Defective safety valve	Operate safety valve manually by pulling on ring. If valve still leaks, it must be replaced.
7	Prolonged excessive use of air	Decrease amount of air usage.
8	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 compressor is needed to operate accessory.
9	Hole in air hose	Check and replace air hose, if required.
10	Unloader valve restricted	Remove, clean or replace.
11	Unit operating in damp or humid conditions	Move unit to a dry well ventilated area.
12	Restricted air intake filter	Clean or replace air intake filter.
13	Loose belt	Check belt tension, seeAdjusting Belt Tension under Maintenance.
14	Engine mounting bolts are loose	Tighten mounting screws. Torque engine mounting bolts to 10-20 ft-lbs. (13.5-27.1 Nm).⚠WARNING: Risk of bursting. Excessive vibration could weaken the air tank and cause it to rupture or explode. Mounting screws must be kept tightened.
15	Pump stiffener bracket bolt is loose	Check bolt and tighten if required. Torque pump stiffener bracket bolt to 10-20 ft-lbs. (13.5-27.1 Nm).⚠WARNING: Risk of bursting. Excessive vibration could weaken the air tank and cause it to rupture or explode. Stiffener bracket bolt must be kept tightened. Never operate the unit unless equipped with the stiffener bracket.

CODE	POSSIBLE CAUSE	POSSIBLE SOLUTION
16	Loose pulley	Tighten pulley set screw, torque to 145-180 in.-Ibs. (16.4-20.3 Nm).
17	Loose flywheel	Tighten flywheel screw, torque to 22-26 ft.-Ibs. (29.8-35.3 Nm).
18	Carbon build-up in pump	Contact a D WALT factory service center or a D WALT authorized service center.
19	Belt to tight	Check belt tension, seeAdjusting Belt Tension under Maintenance.
20	Pulley misalignment	SeeMotor Pulley/Flywheel Alignmentunder Maintenance.
21	Air tank pressure is too high	Open the regulator and reduce air tank pressure to less than 40 psi.
22	Engine problem	Contact a D WALT factory service center or a D WALT authorized service center.
23	Engine or pump oil is low	Add D WALT synthetic compressor oil to pump. SeeCompressor Pump Oil under Maintenance.
24	It is normal forsomepressure drop to occur	If there is an excessive amount of pressure drop when the accessory is used, adjust the regulator as instructed in Regulator under Features.NOTE: Adjust the regulated pressure under flow conditions while accessory is being used.
25	Damaged regulator	Replace.
26	Detergent type oil being used in pump	Drain oil and refill pump with D WALT synthetic compressor oil.
27	Extremely light duty cycles	Run unit for longer duty cycles. It is recommended to run at high throttle 50-75% of the run time and die for 25% of the run time.
28	Piston rings damaged or worn	Contact a D WALT factory service center or a D WALT authorized service center.

English

English

CODE	POSSIBLE CAUSE	POSSIBLE SOLUTION
29	Cylinder or piston damaged or worn	Contact a D WALT factory service center or a D WALT authorized service center.
30	Compressor cylinder finish worn	Contact a D WALT factory service center or a D WALT authorized service center.
31	Water in pump oil	Drain oil and refill pump with D WALT synthetic compressor oil.
32	Manual lock unloader lever in open position	Rotate manual lock unloader lever to the closed perpendicular position.
33	Regulator open	Rotate the regulator knob counterclockwise to its built-in stop and push knob in to lock in place.
34	Engine fuel tank empty	Add gasoline, see engine's instruction manual for correct procedure.

Compresseur d'air

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GLOSSAIRE

Vibrations excessives

14, 15

Clouetis....6.13.14.15.16.17.18.19

Usue excessive de la courpie.... 13, 14, 16, 19, 20

Sètlement 13

U A1 W A2 B1 B2 V A1 T A2 B1 B2

Local D, Col. Obrera (55) 5588 9377

MerIDA, yuC

Calle 63 #459-A - Col. Centro [phone]

Monterrey, n.l.

Av. Francisco I. Madero 831 Poniente - Col. Centro [phone]

PueBIA, Pue

17 Norte #205 - Col. Centro [phone]

QueretAro, Qro

Av. San Roque 274 - Col. San Gregorio [phone]

sAn luls Potosl, sIP

Ruido de golpeteo 6, 13, 14, 15, 16, 17, 18, 19

Desgaste excesivo de la correa 13, 14, 16, 19, 20

D WALT Industrial Tool Co., 213 Industrial Drive, Jackson, TN 38301

(OCT11) Part No. E105102 DXCMH1608WB Copyright © 2007, 2009, 2011 D WALT

The following are trademarks for one or more D WALT 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.