DEWALT 1330 Gasoline Engine Driven Two Stage Air Compressor Instruction Manual

DEWALT 1330 Gasoline Engine Driven Two Stage Air Compressor

Specifications

• Model: DXCMCGW1330
• Length: 49.125″
• Air Tank Capacity: 30 gallons (113.6 Liters)
• Approx. Blow Off Pressure: 175 psi
• Weight: 555 lbs.
• Height: 40.5″
• Width: 23″

Safety Guidelines
This manual contains important safety, operational, and maintenance information. Please read and save these instructions. Protect yourself and others by observing all safety information.

Important Safety Information
This manual contains information that is very important to know and understand for safety and to prevent equipment problems. It provides safety symbols and hazards to be aware of while using the product. Always follow the safety guidelines provided in the manual.

Product Usage Instructions

Pump Air Intake Filter
Ensure the pump air intake filter is clean and free from debris to maintain proper air intake for the compressor.

B. Engine Air Filter
Regularly check and clean the engine air filter to ensure optimal engine performance.

Frequently Asked Questions (FAQ)

• Q: What is the recommended maintenance schedule for this product?
  

  • A: The recommended maintenance schedule includes checking and changing oil, inspecting filters, and ensuring all components are in good working condition. Refer to the user manual for detailed maintenance instructions.

• Q: Can this product be used indoors?
  

  • A: This product should only be operated in well-ventilated areas due to emissions and exhaust gases. Using it indoors can lead to serious health hazards.

If you have questions or comments, contact us.

• 1-888-895-4549
• dewalt.com

INSTRUCTION MANUAL

DXCMCGW1330
Gasoline Engine Driven Two Stage Air Compressor/Generator/Welder

WARNING
To reduce the risk of injury, read and follow these instructions before operating product.

MAT Industries, LLC, Long Grove Il 60047
(March 24) Part No. 200-3237 DXCMCGW1330 Copyright © 2024 DEWALT

Unit Specifications

• A. Pump Air Intake Filter
• B. Engine Air Filter
• C. Engine START/RUN/OFF Switch
• D. Air Tank Pressure Gauge
• E. Air Outlet
• F. Unloader Valve
• G. Safety Valve
• H. Air Tank Drain Valve
• I. Pump Oil Fill Plug
• J. Pump Oil Drain Plug
• K. Fixed Throttle
• L. Choke Control
• M. Fuel Valve Lever
•  N. Starter Grip
• O. Tool Gauge

Pump Specifications

• 2 Cylinder
• Two Stage
• Oil Lubricated
• Cast iron crankcase cylinder, and head
• Oil Capacity· oz. 14.1 oz

Generator/Welder Specifications

• 5500 Continuous Watts
• 200 Amp DC Stick Welder
• Duty Cycle
  • 150 Amps @ 100% DC
  • 180 Amps @ 60% DC
  • 200 Amps @ 50% DC

Engine Specifications

• Honda 389 cc
• 4-stroke
• Loaded Engine RPM 3600

Specifications

Safety Guidelines
This manual contains information that is very important to know and understand. This information is provided for SAFETY and
to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

• DANGER Danger indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
• WARNING Warning indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
• CAUTION Caution indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.
• NOTICE Notice indicates important information, that if not followed, may cause damage to equipment.
• IMPORTANT: Information that requires special attention.

Safety Symbols

The following Safety Symbols appear throughout this manual to alert you to important safety hazards and precautions.

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Important Safety Information
This manual contains important safety, operational and maintenance information. If you have any questions, please call 1-888-895-4549 for customer assistance.

Reminder: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

CALIFORNIA PROPOSITION 65

WARNING CONTAINS LEAD. May be harmful if eaten or chewed. May generate dust containing lead. Wash hands after use. Keep out of reach of 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.P65Warnings.ca.gov

EMISSIONS
NOTICE Engines that are certified to comply with U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certified to operate on regular unleaded gasoline, and may include the following emission control systems: (EM) Engine Modifications and (TWC) Three-Way Catalyst (if so equipped).

DANGER Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poisonous gas you cannot see or smell.

• NEVER use inside a house, garage or below ground level. EVEN IF doors and windows are open.
• Only use OUTSIDE and far away from windows, doors and vents.

GENERAL SAFETY

• Before starting or servicing any unit, read and understand all instructions. Failure to follow safety precautions or instructions can cause equipment damage and or serious personal injury or death. Engine instructions for these units are contained in a separate manual. Retain all manuals for future reference.
• Wear safety glasses and use hearing protection when operating the unit.

DANGER Never operate this unit in an explosive, flammable and / or combustible atmosphere.

• Never use this unit for any application other than that specified by the manufacturer. Never operate this unit under conditions not approved by the manufacturer. Never attempt to modify this unit to perform in any manner not intended by the manufacturer.
• If the equipment should start to vibrate abnormally, STOP the engine / motor and check immediately for the cause. Vibration is generally a warning of trouble.
• For maintenance and repairs, use only products and parts recommended by the manufacturer.
• Be sure that the unit is properly grounded to an external ground path prior to operation. Refer to the section entitled “Grounding” on page 8 for proper grounding procedures.
• Be sure that the unit is operated only by persons who have read and understand these instructions.
• Be sure that the unit is placed or mounted on a flat level surface prior to and during operation. The unit must not slide or shift during operation.
• Keep all persons away from the unit during operation.
• NEVER allow children in the work area.
• Do not allow persons wearing loose clothing or jewelry to start or operate the unit. Loose clothing or jewelry may become entangled in moving components, causing equipment damage and or personal injury.
• Keep all persons away from parts that move or become hot during operation.
• Use only unleaded fuel. Do not refill the fuel tank while the engine is running. Use precautions to prevent fuel spillage during refills. Be sure the fuel tank cap is securely in place before starting the engine. Clean up any spilled fuel before starting the engine. Allow engine to cool for at least two minutes before refueling. Do not add fuel while smoking or if unit is near any sparks or open flames. Do not overfill tank – allow room for fuel to expand. Always keep nozzle in contact with tank during fueling. Never fuel the unit indoors. Failure to follow these instructions could result in death or serious injury.
• To reduce fire hazard, keep engine / equipment exterior free of oil, solvent, or excessive grease.

Caution Never mix oil with gasoline for this engine. This is a four cycle engine designed to run on pure gasoline. Oil is used for engine lubrication purposes only.

• All installation, maintenance, repair and operation of this equipment should be performed by qualified persons only in accordance with national, state, and local codes.
• Verify that all components of the unit are clean and in good condition prior to operation. Be sure that the insulation on all cables, electrode holders, and power cords is not damaged. Inspect compressed air system, fuel system and electrical components for signs of damage, deterioration, weakness or leakage. Always repair or replace damaged components before operating the unit. Always keep panels, shields, etc. in place when operating.
• Check all fasteners at frequent intervals for proper tightness.
• Always operate the unit in a clean, dry, well ventilated area. Do not operate the unit in humid, wet, rainy, or poorly ventilated areas.
• Always shut the equipment off prior to moving the unit.
• Do not use any part of the unit as a work surface.
• Do not tamper with governor setting on engine. Overspeeding the unit severely shortens engine life and may also be very hazardous.

DANGER Shut off the engine and disconnect the spark plug wire before performing any service or maintenance to the unit.

GENERATOR SAFETY

• Be sure all powered devices are shut off prior to connecting them to the unit.
• Be sure that all tools and appliances are in good repair and are properly grounded. Use devices that have three prong power cords. If an extension cord is used, be sure that it has three prongs for proper grounding.
• This unit may be used for emergency stand-by service. In such cases, a manual transfer switch must be installed between the electric utilities meter and the electrical distribution box. This switch should be installed by a licensed electrician.

WELDER SAFETY

WARNING Always keep a fire extinguisher accessible while performing arc Improper use of electric arc welding operations.

WARNING Improper use of electric arc welders can cause electric shock, injury, and death! Take all precautions described in this manual to reduce the possibility of electric shock

• Always wear dry protective clothing and welding gloves, and insulated footwear.
• Be sure that the work piece is properly supported and grounded prior to beginning any electric arc welding operation.
• Coiled welding cable should be spread out before use to avoid overheating and damage to insulation.

DANGER Never immerse the electrode or electrode holder in water. If the unit becomes wet for any reason, be absolutely certain that it is completely clean and dry prior to attempting use!

• Always attach the ground lead first.
• Verify that the work piece is securely grounded.
• Always shut off the unit when not in use and remove the electrode from the holder.
• Never allow any part of the body to touch the electrode and ground or grounded work piece at the same time.
• Awkward welding conditions and positions can be electrically hazardous. When crouching, kneeling or at elevations, be sure to insulate all conductive parts, wear appropriate protective clothing, and take precautions to prevent injury from falls.
• Never attempt to use this equipment at current settings or duty cycles higher than those specified on the equipment labels.
• Never use an electric arc welder to thaw frozen pipes.

WARNING Flying sparks and hot metal can cause injury. As welds cool, slag can be thrown off. Take all precautions described in this manual to reduce the possibility of injury from flying sparks and hot metal.

• Wear ANSI compliant face shield or safety glasses with side shield protection when chipping or grinding metal parts.
• Wear ear plugs and other personal protective equipment when welding overhead to prevent spatter or slag from burning hair or skin.

WARNING Electric arc welding operations produce intense light and heat and ultraviolet (UV) rays. This intense light and UV rays can cause injury to eyes and skin. Take all precautions described in this manual to reduce the possibility of injury to eyes and skin.

All persons operating this equipment or in the area while equipment is in use must wear protective welding gear including: welding helmet or shield with at least a shade 10 welding lens, flame resistant clothing, leather welding gloves, and full foot protection.

WARNING Never look at arc welding operations without eye protection as described above. Never use a shade filter lens that is cracked, broken, or rated below number 10. Warn others in the area not to look at the arc.

WARNING Electric arc welding operations cause sparks and heat metal to temperatures that can cause severe burns! Use protective gloves and clothing when performing any metal working operation. Take all precautions described in this manual to reduce the possibility of skin and clothing burns.

• Make sure that all persons in the welding area are protected from heat, sparks, and ultraviolet rays. Use additional face shields and flame resistant barriers as needed.
• Never touch work pieces until completely cooled.

WARNING
Heat and sparks produced during electric arc welding and other metal working operations can ignite flammable and explosive materials! Take all precautions described in this manual to reduce the possibility of flames and explosions.

• Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
• Take precautions to be sure that flying sparks and heat do not cause flames in hidden areas, cracks, behind bulkheads, etc.

WARNING Fire and explosion hazard! Do not weld on containers or pipes that contained flammable / combustible materials or gases.

WARNING
Arc welding closed cylinders or containers such as tanks or drums can cause explosion if not properly vented! Verify that any cylinder or container to be welded has an adequate ventilation hole, so that expanding gases can be released.

WARNING
Do not breathe fumes that are produced by the arc welding operation. These fumes are dangerous. If the welding area cannot be adequately ventilated, be sure to use an air-supplied respirator.

• Keep your head out of the welding fumes.
• Do not perform electric arc welding operations on metals that are galvanized or cadmium plated, or contain zinc, mercury, or beryllium without completing the following precautions:
• Remove the coating from the base metal.
• Make sure that the welding area is well ventilated.
• Use an air-supplied respirator.

Extremely toxic fumes are created when these metals are heated

WARNING The electromagnetic field that is generated during arc welding may interfere with the operation of various electrical and electronic devices such as cardiac pacemakers. Persons using such devices should consult with their physician prior to performing any electric arc welding operations.

• Route the electrode and work cables together and secure with tape when possible.
• Never wrap arc welder cables around the body.
• Always position the electrode and work leads so that they are on the same side of the body.
• Exposure to electromagnetic fields during welding may have other health effects which are not known.

WARNING Always be sure that the welding area is secure and free of hazards (sparks, flames, glowing metal or slag) prior to leaving. Be sure that the equipment is turned off and electrode is removed. Be sure that cables are loosely coiled and out of the way. Be sure that all metal and slag has cooled.

COMPRESSOR SAFETY

WARNING Never operate compressor without a beltguard. Compressors can start automatically without warning. Personal injury or property damage could occur from contact with moving parts.

WARNING Do not wear loose clothing or jewelry that will get caught in the moving parts of the unit.

CAUTION Compressor parts may be hot even if the unit is stopped. Keep fingers away from a running compressor; fast moving and hot parts will cause injury and/or burns.

WARNING Never remove or attempt to adjust safety valve. Keep safety valve free from paint and other accumulations.

WARNING This compressor is equipped with an ASME code safety valve with a pressure setting of 200 psi for two-stage compressors. Should this ASME code safety valve require replacement, the replacement valve must have the same flow and pressure ratings as the original valve to protect the pressurized components from bursting. The flow and pressure ratings can be found on the valve. NEVER REMOVE AND REPLACE THIS SAFETY VALVE WITH A PLUG. The safety valve in the intercooler of a two-stage compressor does not provide system protection.

CAUTION Maximum operating pressure is 175 psi for two-stage compressors. Do not operate with pilot valves set higher than 175 psi.

DANGER Never attempt to repair or modify a tank! Welding, drilling or any other modification will weaken the tank resulting in damage from rupture or explosion. Always replace worn or damaged tanks.

Tanks rust from moisture build-up, which weakens the tank. Make sure to drain tank regularly and inspect periodically for unsafe conditions such as rust formation and corrosion.

NOTICE Drain liquid from tank daily.
Fast moving air will stir up dust and debris which may be harmful. Release air slowly when draining moisture or depressurizing the compressor system.

SPRAYING PRECAUTIONS

WARNING Do not spray flammable materials in vicinity of open flame or near ignition sources including the compressor unit.

• Do not smoke when spraying paint, insecticides, or other flammable substances.
• Use a face mask / respirator when spraying and spray in a well ventilated area to prevent health and fire hazards.
• Do not direct paint or other sprayed material at the compressor. Locate compressor as far away from the spraying area as possible to minimize overspray accumulation on the compressor.
• When spraying or cleaning with solvents or toxic chemicals, follow the instructions provided by the chemical manufacturer

SAFETY STANDARDS AND SUGGESTED READING
ANSI Standard Z49.1 from American Welding Society, 550 N.W. LeJune Rd. Miami, FL 33126

• Safety and Health Standards
  OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

• National Electrical Code
  NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

• The DANGER, WARNING, CAUTION, and NOTICE notifications and instructions in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that caution is a factor which cannot be built into this product, but must be supplied by the operator.

• Safe Handling of Compressed Gases in Cylinders
  CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

• Code for Safety in Welding and Cutting
  CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

• Cutting And Welding Processes
  NFPA Standard 51B, from National Fire Protection Association,
  1 Battery March Park, P.O. Box 9146, Quincy, MA 02269-9959.

• Practice For Occupational And Educational Eye And Face Protection
  ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036

• Arc Welding and Your Health: A Handbook of Health Information for Welding
  From The American Industrial Hygiene Association, 2700 Prosperity Avenue, Suite 250, Fairfax, VA 22031-4319.

• Cutting and Welding Processes
  NFPA Standard 51B from National Fire Protection Association, 1 Battery March Park, P.O. Box 9146, Quincy, MA 02269-9959.

• OSHA Hazard Communication Standard 29 CFR 1910.1200
  OSHA General Industry Standard 29 CFR 1910 Subpart Q from the Occupational Safety and Health Administration,www.osha.org or contact your local OSHA office.

• Applications Manual for the Revised NIOSH Lifting Equation
  From The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Road, Atlanta, GA 30333
  Refer to the Material Safety Data Sheets (MSDS) and the manufacturers’ instructions for metals, electrodes, coatings and cleaners.

SAVE THESE INSTRUCTIONS

DANGER

DO NOT DISCARD
Important Safety Information (Continued) Breathable Air Warning This compressor / pump is NOT equipped and should NOT be used “as is” to supply breathing quality air. For any application of air for human consumption, you must fit the air compressor / pump with suitable in-line safety and alarm equipment. This additional equipment is necessary to properly filter and purify the air to meet minimal specifications for Grade D breathing as described in Compressed Gas Association Commodity Specification G 7.1 – 1966, OSHA 29 CFR 1910. 134, and/or Canadian Standards Associations (CSA).

DISCLAIMER OF WARRANTIES
In the event the compressor is used for the purpose of breathing air application and proper in-line safety and alarm equipment is not simultaneously used, existing warranties shall be voided, and disclaims any liability whatsoever for any loss, personal injury or damage.

Glossary of Terms

• AC or Alternating Current – electric current that reverses direction periodically. Sixty cycle current travels in both directions sixty times per second.
• Arc Length – the distance from the end of the electrode to the point where the arc makes contact with the work surface.
• Base Metal – the material to be welded.
• Butt Joint – a joint between two members aligned approximately in the same plane.
• Crater – a pool, or pocket, that is formed as the arc comes in contact with the base metal.
• DC or Direct Current – electric current which flows only in one direction. The polarity (+ or -) determines which direction the current is flowing.
• DC Reverse Polarity – occurs when the electrode holder is connected to the positive pole of the welding machine. Reverse Polarity directs more heat into melting the electrode rather than the work piece. It is used on thinner material.
• DC Straight Polarity – occurs when the electrode holder is connected to the negative pole of the welding machine. With straight polarity more heat is directed to the work piece for better penetration on thicker material.
• Electrode – a coated metal wire having approximately the same composition as the material being welded.
• Fillet Weld – approximately a triangle in cross-section, joining two surfaces at right angles to each other in a lap, T or corner joint.
• Flux – a coating, when heated, that produces a shielding gas around the welding area. This gas protects the parent and filler metals from impurities in the air.
• Flux Cored Arc Welding (FCAW) – also called Gasless, is a welding process used with a wire-feed welding machine. The weld wire is tubular with flux material contained inside for shielding.
• Gas Metal Arc Welding (GMAW) – also called MIG, is a welding process used with a wire feed welding machine. The wire is solid and an inert gas is used for shielding.
• Gas Tungsten Arc Welding (GTAW) – also called TIG, is a welding process used with welding equipment with a high frequency generator. The arc is created between a non-consumable tungsten electrode and the work piece. Filler metal may or may not be used.
• Lap Joint – a joint between two overlapping members in parallel planes.
• Open Circuit Voltage (OCV) – the voltage between the electrode and the work clamp of the welding machine when no current is flowing (not welding). The OCV determines how quickly the arc is struck.
• Overlap – occurs when the amperage is set too low. In this instance, the molten metal falls from the electrode without actually fusing into the base metal
• Porosity – gas pockets, or cavities, formed during weld solidification. They weaken the weld.
• Penetration – the depth into the work piece that has been heat effected by the arc during the welding process. A good weld achieves 100% penetration meaning that the entire thickness of the work piece has been heated and solidified. The heat effected area should be easily seen on the opposite side of the weld.
• Shielded Metal Arc Welding (SMAW ) – also called Stick, is a welding process that uses a consumable electrode to support the arc. Shielding is achieved by the melting of the flux coating on the electrode.
• Slag – a layer of flux soot that protects the weld from oxides and other contaminants while the weld is solidifying (cooling). Slag should be removed after weld has cooled.
• Spatter – metal particles thrown from the weld which cool and harden on the work surface. Spatter can be minimized by using a spatter resistant spray on the work piece before welding.
• Tack Weld – weld made to hold parts in proper alignment until final welds are made.
• Travel Angle – the angle of the electrode in the line of welding. It varies from 5º to 45º depending on welding conditions.
• T Joint – made by placing the edge of one piece of metal on the surface of the other piece at approximately a 90º angle.
• Undercut – a condition that results when welding amperage is too high. The excessive amperage leaves a groove in the base metal along both sides of the bead which reduces the strength of the weld.
• Weld Pool or Puddle – a volume of molten metal in a weld prior to its solidification as weld metal.
• Weld Bead – a narrow layer or layers of metal deposited on the base metal as the electrode melts. Weld bead width is typically twice the diameter of the electrode.
• Work Angle – the angle of the electrode from horizontal, measured at right angles to the line of welding.

Pre-Operation

LOCATION
Selecting the proper location can significantly increase performance, reliability and life of the unit.

• For best results locate the unit in an environment that is clean and dry. Dust and dirt in the unit retain moisture and increase wear of moving parts
• There are mounting holes in the bottom of the open frame to permanently mount the unit if desired. The bolt pattern is 18 inches x 18.76 inches and will accept 1/2 inch bolts.
• Store electrodes in a clean, dry location with low humidity to preserve the flux coating.

LUBRICATION

NOTICE
CHECK ENGINE AND PUMP OIL LEVELS BEFORE OPERATING!
Follow lubrication instructions before operating compressor.

1. Oil is NOT mixed with the gasoline, however adequate oil supply is necessary for proper engine lubrication. Refer to the Engine Manual for SAE, API and fill quantity specifications.
2. Remove pump fill plug and fill pump with 14.1 oz. of oil.
   Use full synthetic, non-detergent air compressor oil. Additives in regular oil can cause valve deposits and reduce pump life. For pumps with an oil sight glass, oil level can be monitored and maintained as shown in Figure 3.

BATTERY SET-UP AND CONNECTIONS

This unit DOES NOT come with a battery or battery cables. A 12 Volt battery must be connected to the unit. The 12 Volt battery must be at least a U1 size lawn and garden battery with 180 minimum Cold Cranking Amps. Using at least 8 AWG battery cables, a connection must be made from the distribution post to an in line 30 amp fuse, and then to the positive terminal of the 12 Volt battery. From the negative battery terminal, a connection must be made to the ground screw located on the left side of the frame. Please refer to the wiring schematics in this manual. If you have any questions, please contact customer service at 1-888-895-4549.

NOTICE All manufacturer’s warranties are void if the battery connections are not made as specified in this manual.

Grounding

1. Use the ground terminal and nut on the frame to connect the unit to a suitable ground source. Securely fasten the end terminal of the ground wire (not provided) to the ground terminal on the frame. Tighten the washer and nut on top of the ground wire end terminal.

2. The ground wire should be made of #8 gauge wire. Do not use wire with a higher gauge number. Higher gauge numbers indicate thinner wire, which may not provide an adequate ground path.

3. The other end of the ground wire must be securely fastened to an approved ground source.
   The following are ground sources approved by the National Electric Code. Other ground sources may be acceptable. Refer to the National Electric Code and local regulations for further ground source information. If not sure of regulations or procedures, obtain assistance from a qualified (licensed or certified) electrical technician.

   • An underground water pipe at least ten feet in length
   • A non-corrosive underground pipe at least eight feet in length and 3/4 inch diameter
   • A steel or iron underground rod at least eight feet in length and 5/8 inch diameter
   • A non-ferrous rod at least eight feet in length, 1/2 inch in diameter, and approved for grounding purposes

Any rod or pipe used for grounding must be driven to eight feet deep or buried in the deepest possible trench.

STARTING (see Figure 5 for replica of actual unit decal)

1. Connect the unit to a suitable ground source (see Grounding section).
2. Remove all electrical loads from the unit.
3. Set the unloader valve to the unloaded position (the arrow on the unit decal is pointing towards the unloader valve’s location).
4. Move fuel shut-off lever as far as possible to the right to enable fuel flow.
5. For a cool engine, slide the choke lever to the left.
6. Turn & hold Honda engine’s key to start and release when engine starts.
7. As the engine warms up and stabilizes, slide the choke lever back to the right.
8. Set the unloader valve to the LOADED position so that the unit will begin to build pressure.

IMPORTANT: After each start up, allow the engine to run for 2 to 3 minutes with no load. Always refer to this Owner’s manual for operation instructions.

CAUTION Engine speed is preset to provide proper output voltage. Never attempt to modify or adjust engine speed or output voltage

ENGINE BREAK-IN
After initial start-up, the engine should be broken in according to the manufacturer’s instructions. Refer to the engine manual for the proper break- in procedure.

COMPRESSOR BREAK-IN
Open the drain valve located underneath the tank. Allow the pump to run without a load for 30 minutes. After 30 minutes, close the drain valve and pressure will begin to build in the tank.

SHUT-OFF

1. Shut off and remove all electrical load devices from the unit
2. Allow the engine to run for 2-3 minutes with no electrical loads.
3. Turn engine key to the OFF position.
4. Verify that the unit has completely stopped.
5. Close the fuel supply valve.
6. Allow the unit to cool before installing any covers or storing unit

LOW OIL SHUTDOWN
A low oil shutdown switch is provided to protect the engine. When engine oil level drops too low for proper engine operation, the low oil shutdown switch causes the engine to shut off. If oil level is low when attempting to start the engine, the low oil level shutdown switch prevents the engine from starting. If engine does not start, check oil level.

NOTE: It is important to keep the unit on a level surface. The oil level shutdown switch can prevent the engine from starting even if oil level is sufficient, when the unit is placed on an uneven surface.

Generator Operation
THE CURRENT RANGE SELECTOR SWITCH (LOCATED AT THE TOP RIGHT OF THE ALTERNATOR CONTROL PANEL) MUST BE SET TO NUMBER 3 (FAR RIGHT POSITION) FOR 120VAC & 240VAC OPERATION. REFER TO FIGURE 6
(PAGE 13)

1. All load devices and extension cords should use three prong terminals. Refer to Table 1 (page 13) for extension cord and cable size requirements.
2. Allow the engine to run for 2-3 minutes before applying any electrical loads.
3. The 120 volt duplex receptacles are rated for 20 amps and may be used in any combination of 120 volt loads and also with 240 volt loads through the 240 volt receptacles.
   All receptacles are part of a circuit protected by a Ground Fault Circuit Interrupters (GFCI). Ground Fault Circuit Interrupters can significantly reduce the possibility of injury if an electrical short occurs. The engine must be running and the front panel switches set to supply power to the receptacles before the GFCI can be reset.
   WARNING****

A Ground Fault Circuit Interrupter may not be effective if the unit is not grounded! Refer to the section entitled Grounding for proper steps to ground the unit.
The 120 / 240 volt twist lock receptacle is rated for 30 amps and may be used in any combination of 120 volt and 240 volt loads.

4. Individual receptacles should not be loaded beyond the amperage rating.

5. Total combined load through any combination of receptacles must not exceed the rated load limits of the unit. Refer to the identification plate on the unit for amp and wattage specifications.

6. Always shut off and remove loads before starting or shutting off the engine.

7. When plugging multiple electrical load devices into the receptacles, be sure to connect and activate the highest power draw item first. Allow the engine to stabilize, then connect and activate the next highest power draw device. The smallest power draw device should be connected to the receptacle and activated last.
   NOTE: Power draw can be calculated by multiplying volts and amps. The resulting number is wattage.
   Never exceed the posted maximum wattage for the unit or any individual receptacle. Refer to owner’s manuals and product tags to determine the wattage of all electrical load devices.
   Remember that devices which generate heat during operation such as heaters, incandescent light bulbs, motors and hair dryers have a higher power draw than devices which generate little heat during operation such as florescent bulbs, radios, and clocks.
   Long power cords and extension cords also draw additional power. Keep cords at minimum possible length.
   Refer to Table 1 (page 13) for maximum limits for lengths of extension cords.

8. Circuit protection is provided by circuit breakers. The main circuit breaker is a rocker type rated for 30 amps. This is the maximum total current draw for all receptacles in combination. A 20 amp circuit breaker supplies each of the two duplex receptacles. The circuit breaker opens when the load exceeds its maximum capacity or a short circuit occurs. If the circuit breaker opens, perform the following procedures to correct the problem:

   • Shut off and disconnect all electrical loads.
   • Attempt to determine the cause of the electrical problem – overloading or short circuit.
   • Do not use any devices that have short circuits. Avoid overloading the unit.
   • Press the circuit breaker pushbutton or rocker to reset the circuit breaker.

CAUTION Repeated cycling of the circuit breaker indicates a problem and may cause damage to the unit or load devices. Do not operate the unit if repeated cycling of the circuit breaker occurs.

INSTALLATION FOR STAND-BY USE

Precautions must be taken to prevent electrical back feeding into utility systems. This requires isolation of the electrical system. To isolate the electrical system, perform the following procedures:

1. Turn off the main electrical system switch prior to connecting the unit.
2. In accordance with national and local standards, a double throw transfer switch must be installed in the system.

WARNING Always shut off main power prior to temporary connection of the unit to a building electrical system.
WARNING Installation of the unit as a backup electrical source must be performed by a qualified (licensed or certified) electrical technician.

Table Reference Information

TABLE 1 – EXTENSION CORDS
Maximum Recommended Lengths (in feet)

Amps| Watts 120V| Watts 240V| #8 Wire| #10 Wire| #12 Wire| #14 Wire| #16 Wire
---|---|---|---|---|---|---|---
2.5| 300| 600| | 1000| 600| 375| 250
5| 600| 1200| | 500| 300| 200| 125
7.5| 900| 1800| | 350| 200| 125| 100
10| 1200| 2400| | 250| 150| 100| 50
15| 1800| 3600| | 150| 100| 65| N/A
20| 2400| 4800| 175| 125| 75| 50| N/A
25| 3000| 6000| 150| 100| 60| N/A| N/A
30| 3600| 7200| 125| 65| N/A| N/A| N/A
40| 4800| 9600| 90| N/A| N/A| N/A| N/A
TABLE 2 – WELDING CABLES

Total Cable Length *| 0 – 20 feet (0 – 6 m)| 20 – 50 feet (6 – 15 m)| 50 – 100 feet (15 – 30 m)
Maximum Welding Current| Recommended Sizes of Copper Welding Cables
200 A| 4 AWG (25 mm2)| 2 AWG (35 mm2)| 1/0 AWG

• Total cable length is the sum of the ground and electrode cable lengths.|

Welder Operation

WELDING LEAD ASSEMBLIES
Welding lead assemblies are not included with all units. Use custom copper welding cables in the size specified in Table 2 (page 13).

1. Verify that the surfaces of metals to be joined are free from dirt, rust, paint, oil, scale or other contaminants. These contaminants make welding difficult and cause poor welds.
   WARNING All persons operating this equipment or in the area while equipment is in use must wear protective welding gear including: eye protection with a properly shaded lens (minimum shade 10), flame resistant clothing, leather welding gloves, and full foot protection.
   WARNING If heating, welding, or cutting materials that are galvanized, zinc plated, lead, or cadmium plated refer to the General Safety Information Section for instructions. Toxic fumes may be created when these materials are heated.

2. Connect the GROUND CLAMP to the work piece. Make sure the contact is on bare metal and not obstructed by paint, varnish, corrosion, or non-metallic materials.

3. Insert the exposed part of the electrode (the end with no flux) into the jaws of the electrode holder.

4. Set the desired current range with the range selector switch located at the upper right hand corner of the Alternator control panel. Refer to Figure 6 (page 13). White number 123, indicates low range, Black number 123 for medium range, and Red number 123, for high range.

5. Set the welding current adjustment knob (see figure 6) to the proper amperage for the electrode diameter. Refer to the electrode manufacturer for proper current settings.
   NOTICE Operating the welder above 200 amps exceeds engine capacity. Do not weld with the welding current adjustment knob in any of the last four positions while in the highest toggle switch setting. Doing so may result in damage to the engine.
   WARNING The electrode holder and rod are electrically “live” (current potential) when the engine is running.

6. Before striking an arc to begin the welding operation, disconnect ALL loads from the Generator.

7. Position the electrode to begin weld, lower the welding helmet or position the hand shield, and strike an arc. Adjust weld amperage as needed.

8. When finished welding, turn engine off and store unit properly.

DUTY CYCLE / THERMOSTATIC PROTECTION
Welder duty cycle is the percentage of actual weld time that can occur in a ten minute interval. For example, at a 10% duty cycle, actual welding can occur for one minute, then the welder must cool for nine minutes.

Internal components of the alternator are protected from overheating with an automatic thermal switch.

Compressor Operation
Before starting the compressor, thoroughly read all component instructions manuals, especially the engine manual.

NOTICE Before starting the compressor, thoroughly read all component instructions manuals, especially the engine manual.

1. Start unit per STARTING instructions on page 11.

2. Adjust the regulator knob to vary the outlet pressure according to the requirements of the tool(s) being used.

3. Connect air hose(s) to outlet connector(s) and connect tool(s) to hose(s).

4. An ASME safety valve in the manifold will automatically release air if the tank pressure exceeds the preset maximum.

5. The discharge tube carries compressed air from the pump to the check valve. This tube becomes very hot during use. To avoid the risk of severe burns, never touch the discharge tube.

6. The check valve allows air to enter the tank(s), but prevents air in the tank(s) from flowing back into the compressor pump.

7. There is a drain valve underneath the air tank. Use this valve to drain moisture from the tank daily to reduce the risk of corrosion. Reduce tank pressure below 10 psi, then drain the moisture from the tank daily to avoid tank corrosion.
   NOTICE Drain liquid from tank daily.

8. All lubricated compressor pumps discharge some condensed water and oil with the compressed air. Install appropriate water / oil removal equipment and controls as necessary for the intended application.
   NOTICE Failure to install appropriate water / oil removal equipment may result in damage to machinery or workpiece.
   CAUTION Do not attach air tools to open end of the hose until startup is complete and the unit checks okay.

MOISTURE IN COMPRESSED AIR
Moisture in compressed air will form into droplets as it comes from an air compressor pump. When humidity is high or when a compressor is in continuous use for an extended period of time, this moisture will collect in the tank. When using a paint spray or sandblast gun, this water will be carried from the tank through the hose, and out of the gun as droplets mixed with the spray material.

IMPORTANT: This condensation will cause water spots in a paint job, especially when spraying other than water based paints. If sandblasting, it will cause the sand to cake and clog the gun, rendering it ineffective. A filter or air dryer in the air line, located as near to the gun as possible, will help eliminate moisture.

Maintenance

WARNING
Release all pressure from the system before attempting to install, service, relocate or perform any maintenance

In order to maintain efficient operation of the compressor system, check the air intake filter on the pump, oil level of the pump and oil and gasoline levels of the engine before each use. The ASME safety valve should also be checked weekly. Pull ring on safety valve and allow the ring to snap back to normal position. This valve automatically releases air if the tank pressure exceeds the preset maximum. If air leaks after the ring has been released, or the valve is stuck and cannot be actuated by the ring, the ASME safety valve must be replaced.

WARNING Do not attempt to tamper with the ASME safety valve.

With engine OFF, clean debris from engine, flywheel, tank, air lines and pump cooling fins.

TANK

WARNING Never attempt to repair or modify a tank! Welding, drilling or any other modification will weaken the tank resulting in damage from rupture or explosion. Always replace
worn, cracked or damaged tanks.

NOTICE Drain liquid from tank daily.

The tank should be carefully inspected at a minimum of once a year. Look for cracks forming near the welds. If a crack is detected, remove pressure from tank immediately and replace.

PUMP AND ALTERNATOR DRIVE BELTS
The alternator uses a multi-V drive belt transmitting a significant amount of power. Belt tension is critical to belt life. New belts will stretch after installation and use. When properly adjusted, the belt deflects 1/4 inch with firm pressure applied midway between the engine pulley and the alternator pulley.

To adjust alternator belt tension:

1. Remove belt guard.
2. Loosen the 4 bolts holding the engine to the base plate.
3. Use the adjustment screw located below the engine on the frame to obtain the proper tension. Make sure the pump belt is not over tightened. The belt must be properly aligned when the adjustment is made.
4. To align belt, lay a straight edge against the face of the alternator pulley, touching the rim at two places. The straight edge should be parallel with the belt.
5. Adjust alternator or engine pulley so that the belt runs parallel to the straight edge.
6. The pulleys are attached to the shafts using tapered bushings. The two set-screws must be removed and one reinserted into the hole with threads on the inner half. Tighten this screw to press the pulley and bushing apart.
7. Once the bushing is moved to the correct position, move the two set-screws back to their original locations in the holes with threads on the outer half and tighten to 175 in-lbs.
8. Recheck tension and alignment. If correct, reinstall belt guard.

INFREQUENT USAGE
If the unit is used infrequently, starting difficulty may occur. To help prevent this, the engine should be run for approximately 30 minutes per week.

STORAGE
If the unit is not to be used for extended periods of time, the following pre- storage procedures should be performed:

1. Make sure engine oil is filled to the proper level.
2. Drain moisture from air tank.
3. Drain all fuel from the tank, lines, carburetor and fuel valve.
4. Remove the spark plug, and pour approximately one teaspoon of oil into the spark plug hole.
5. Pull the starter cord several times to spread the oil throughout the cylinder.
6. Slowly pull the starter cord, until resistance is felt. This indicates that the piston is moving upward on the compression cycle, and the intake and exhaust valves are closed. (The piston pushes a small amount of air from the spark plug hole on compression.)

Use of fuel stabilizers or anti-gumming agents in the fuel system can help prevent the build up of gum and varnish.
Whenever the unit is stored, be sure that the fuel shut-off valve is in the closed position.
Refer to the engine manual that accompanies this unit for instructions regarding maintenance of engine components

WARNING The Engine is factory set to 3600 RPM with NO load. Never tamper with engine speed settings or frequency settings. Any governor adjustments should be made by qualified personnel only.

WELD CABLES

1. Check condition of weld cables and immediately repair or replace any cables with damaged insulation.
2. Check condition of electrode holder insulating pieces and immediately replace cracked or missing parts.

EVERY 3 MONTHS
Replace any unreadable labels on the unit. Use compressed air to blow all dust and lint from the ventilation openings.

MAINTENANCE SCHEDULE

PROCEDURE| DAILY| WEEKLY| MONTHLY| 1 YEAR OR 100 HOURS| SEE TANK WARNING
Check safety valve| l| | | |
Inspect air filter| | l+| | |
Drain tank| l| | | |
Check pump oil level| l| | | |
Change pump oil| | | | l|
Oil leak inspection| l| | | |
Inspect drive belt| l| | | |
Check drive belt tension| | | l| |
Check pulley/flywheel alignment| | | | l|
Check for unusual noise/vibration| l| | | |
Check for air leaks| l| | | |
Clean air compressor exterior| | l| | |
Remove tank from service| | | | | l++
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

Welding Guidelines

GENERAL

• This line of welding machines utilizes a process known as Shielded Metal-Arc Welding (SMAW). This process is used to bond metals by heating them with an electric arc created between the electrode and the work piece.
• Electrodes used for shielded metal arc welding have two parts. The inner core is a metal rod or wire that should be similar in composition to the base metal. The outer coating is called flux. Various types of flux exist. Each coating is used for a particular welding situation.
• While the metal is molten, it can be contaminated by elements in the air. This contamination could weaken the weld. The flux coating creates a protective barrier called slag that protects the molten metal from contaminants.
• When current (amperage) flows through the circuit to the electrode, an arc is formed between the end of the electrode and the work piece. The arc melts the electrode and the work piece. The melted metal of the electrode flows into the molten crater and forms a bond with the work piece as shown in Figure 7.

NOTE: Discontinue using and discard electrodes that burn down to 1 to 2 inches from the electrode holder.

STRIKING AN ARC
Place the bare end of the electrode in the holder. Grip the holder lightly to reduce tiring of the hand and arm.

NOTE: Always keep the jaws of the holder clean to insure good electrical contact with the electrode

WARNING B e careful not to touch the work piece or welding bench with the electrode as this causes arc flashes.

The best method of striking an arc is the scratching method. Drag the electrode at an angle along the surface much like striking a match. Upon contact with the plate, lift the electrode approximately 1/16 inch off the surface or it will stick (See Figure 8).

NOTE: Should the electrode stick to the work piece, break it loose by quickly twisting or bending at the holder while pulling upward. If the electrode does not break loose, disengage the electrode by releasing it from the holder.

ELECTRODE TYPE AND SIZE
Four types of electrodes are recommended for this welder. The electrodes are commonly known by the AWS (American Welding Society) designation as follows:

1. E-6011 Deep penetrating
   • 6011 is for ALL position welding.
   • Flat bead with deep penetrating arc.
   • For rusted or dirty mild steel general repair work.
2. E-6013 General Purpose
   • 6013 is for flat position welding.
   • All position, smooth deposit rod with low spatter.
   • For all mild steel and general purpose work.
3. E-7014 Fast fill
   • Smooth bead and fast deposition.
   • Ideal for joints with poor fitup and general repair work.
4. E-7018-AC High Strength
   • Ideal for pipes and structural applications.
   • Low hydrogen reduces porosity for a strong weld.

ARC WELDING BASICS
Four basic techniques affect weld quality. These are: amperage setting, weld angle, arc length, and travel speed. Proper use of these techniques is necessary for good weld quality.

AMPERAGE SETTING

The correct amperage involves the adjustment of the welding machine to the required amp setting. This is regulated by a current range selector switch and a welding current selector knob. The amperage required depends on the size (diameter) of electrode used and the thickness of the work piece.

Consult specifications listed on the welder. Excessive amps burn through light metals and the weld bead is flat and porous (See Figure 7). The bead appears high and irregular if the amperage is too low.

ARC LENGTH
Arc length is the distance from the work piece to the tip of the electrode, the distance which the arc must travel. A proper arc length is essential to generate the heat needed for welding (See Figure 9). An arc that is too long produces an unstable arc, reduces penetration, increases spatter, and causes flat and wide beads. Too short an arc does not create enough heat to melt the work piece, the electrode has a tendency to stick, penetration will be poor, and uneven beads with irregular ripples result. A proper arc should be no longer than the diameter of the rod.

The sound of a proper arc is a steady, crisp sizzle, similar to bacon frying.

TRAVEL SPEED
The travel speed is the rate at which the electrode is moved across the weld area (See Figure 8). When the speed is too fast, the bead is narrow and bead ripples are pointed as shown. When the speed is to slow, the weld metal piles up and the bead is high and wide. To control travel speed, watch the width of the weld bead (not the arc) when welding. The weld bead is the orange, molten metal behind the arc. The width should be approximately twice the diameter of the welding rod. Control travel speed to obtain a consistent bead width.

SLAG REMOVAL

WARNING Wear ANSI compliant safety glasses (ANSI Standard Z87.1) and protective clothing when removing slag. Hot, flying debris can cause personal injury to anyone in the area.

After completing the weld, wait for the welded sections to cool. A protective coating called slag now covers the weld bead which prevents contaminants in the air from reacting with the molten metal. Once the weld cools to the point that it is no longer glowing red, the slag can be removed. Removal is done with a chipping hammer. Lightly tap the slag with the hammer and break it loose from the weld bead. The final clean-up is done with a wire brush. When making multiple weld passes, remove the slag before each pass

WELD ANGLE

• Weld angle is the angle at which the electrode is held during the welding process. Using the correct angle ensures proper penetration and bead formation. Electrode angle involves two positions – travel angle and work angle (See Figure 10).
• Travel angle is the angle in the line of welding and may vary from 5º to 45º from the vertical, depending on welding conditions.
• Work angle is the angle from horizontal, measured at right angles to the line of welding.
• For most applications, a 45º travel angle and 45º work angle is sufficient. For specific applications, consult an arc welding handbook.
  NOTE: Right handed welders should weld from left to right. Left handed welders should weld from right to left. The electrode should always point into the weld puddle as shown.

WELDING POSITIONS
Four basic welding positions can be used; flat, horizontal, vertical, and overhead. Welding in the flat position is easier than any of the others because welding speed can be increased, the molten metal has less tendency to run, better penetration can be achieved, and the work is less fatiguing.

Other positions require different techniques such as a weaving pass, circular pass, and jogging. A higher skill level is required to complete these welds.

All work should be performed in the flat position if possible. For specific applications, consult an arc welding handbook

WELD PASS
Sometimes more then one pass is necessary to fill the joint. The root pass is first, followed by filler passes and the cover pass (See Figures 11 and 12). If the pieces are thick, it may be necessary to bevel the edges that are joined at a 60º angle. Remember to remove the slag before each pass.

Troubleshooting Chart

General

1. Engine switch is set to “OFF”.
2. Fuel valve is turned to “CLOSE”.
3. Choke is open.
4. Engine is out of gas.
5. Engine is filled with contaminated or old gas
6. Spark plug is dirty.
7. Spark plug is broken.
8. Unit is not on level surface.
9. Oil is low.

|

1. Set engine switch to “ON”.
2. Turn fuel valve to “OPEN” position.
3. Close the choke.
4. Add gas.
5. Change the gas in the engine.
6. Clean spark plug.
7. Replace spark plug.
8. Move unit to a level surface to prevent low oil shutdown from triggering.
9. Add or replace oil.

Engine runs but there is no

electrical output

|

1. Circuit reset button or GFCI breaker is off.
2. Bad connecting of wires / cables.
3. ] Bad electrical device connected to unit.

|

1. Wait for 2 minutes and push the circuit reset button to the “ON” position and flip the GFCI breaker to the “ON” position.
2. If you are using an extension cord, use only heavy-duty extension cords that are specifically designed for outdoor use. Make sure the wattage rating for each cord exceeds the total wattage of all appliances connected to the unit.
3. Try connecting a different device.

Unit runs but does not support all electrical devices connected|

1. Unit is overloaded
2. Short in one of the connected devices.
3. Air cleaner is dirty.

|

1. Turn off all electrical devices. Unplug all electrical devices. Turn off unit. Wait several minutes. Restart unit. Try connecting fewer electrical loads to the unit.
2. Try disconnecting any faulty or short-circuited electrical loads.
3. Clean or replace air filter.

Generator

1. Engine speed is too slow
2. Open, shorted, or incorrect wiring
3. Faulty capacitor
4. Open or shorted field windings
5. Open diodes
6. Front panel switch set incorrectly
7. Circuit breaker tripped

|

1. Adjust engine speed H
2. Referring to the wiring diagram, clean and reconnect all wiring H
3. Replace capacitor H
4. Test winding resistance, replace field winding if necessary H
5. Test diodes, replace if necessary H
6. Set front panel switch to Number 3
7. Reset circuit breaker

Low output voltage with no load|

1. Engine speed is too slow
2. Open diodes
3. Faulty capacitor
4. Open or shorted field windings
5. Range setting on front panel incorrect

|

1. Adjust engine speed H
2. Test diodes, replace if necessary H
3. Replace capacitor H
4. Test winding resistance, replace field winding if necessary H
5. Adjust setting on front panel to number 3

High output voltage with no load|

1. Faulty capacitor
2. Engine speed is too fast
3. Range setting on front panel incorrect

|

1. Replace capacitor H
2. Adjust engine speed H
3. Adjust setting on front panel to number 3

Low output voltage under load|

1. Open diode
2. Engine speed too slow at full load
3. Excessive load applied
4. Range setting on front panel incorrect

|

1. Test diodes, replace if necessary H
2. Adjust engine speed H
3. Reduce the applied load
4. Adjust setting on front panel to number 3

Erratic output voltage|

1. Unbalanced engine
2. Dirty, corroded, or loose wiring connection
3. Unstable load applied

|

1. Refer to engine manual
2. Referring to the wiring diagram, clean and reconnect all wiring H
3. Remove all loads, then apply each one individually to determine which one is causing erratic function

Noisy operation|

1. Loose unit or engine bolt (s)
2. Short circuit in unit field or load
3. Faulty bearing

|

1. Tighten all mountings

2. Test winding resistance, replace field winding if necessary H
   Test load devices for shorts. Replace defective load device.

3. Replace bearing

H These diagnostic and repair procedures should be performed by an authorized service center.

Welder

1. Inadequate current at electrode
2. Poor connections at welder
3. Open, shorted, or incorrect wiring
4. Faulty capacitor
5. Open or shorted field windings
6. Open diodes

|

1. Check work clamp, cable and connection to work piece. Check electrode cable and clamp
2. Check all welder external connections
3. Referring to the wiring diagram, clean and reconnect all wiring H
4. Replace capacitor H
5. Test winding resistance, replace field winding if necessary H
6. Test diodes, replace if necessary H

Welder gives trickle shocks|

1. Accidental contact with work piece
2. Current leakage caused by moist clothing or work area

|

1. Avoid contact with work piece
2. Make sure clothing and work area are dry

Arc difficult to strike|

1. Wrong type of electrode.
2. Electrode diameter too large
3. Work piece not properly grounded
4. Engine speed is too slow

|

1. Verify that electrode is for alternating current (AC)
2. Use smaller diameter electrode
3. Verify proper grounding. (No paint, varnish or corrosion)
4. Adjust engine speed H

H These diagnostic and repair procedures should be performed by an authorized service center.

Welds

1. Inconsistent travel speed
2. Output amp setting incorrect

|

1. Carefully watch and control the width of the molten weld bead
2. Adjust output amp setting or change to smaller diameter electrode

Ragged depressions at edge of weld|

1. Travel speed too fast
2. Arc length too short
3. Output amp setting too high

|

1. Watch orange molten weld puddle and control bead width
2. Practice running electrode across workpiece with welder OFF
3. Reduce output amp setting

Weld bead does not penetrate base metal|

1. Inconsistent travel speed
2. Output amp setting too low
3. Electrode diameter too large

|

1. Decrease and maintain constant travel speed
2. Increase output amp setting
3. Change to smaller diameter electrode

Electrode sticks to workpiece|

1. Arc length short
2. Amp setting low
3. Incorrect electrode

|

1. Lift electrode to correct arc length as soon as arc is struck
2. Increase amp setting or change to smaller diameter electrode
3. Verify electrode is suitable for 62.5 V open circuit voltage

Electrodes sputter and stick| 1. Damp electrodes| 1. Use dry electrodes and store in dry location

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 your 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 our website 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 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 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 air compressor 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.

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, air unloaders, 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 compressors (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 inadequate egress.
• Damage caused by incorrect voltage, improperly wired, or failure to have a certified licensed electrician install the 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.
• Gas Engines, if product is equipped with a gas engine, see engine manual for specific engine manufacturer’s warranty coverage.

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
• Electric motors 90 days
• Universal motor/pump 30 days
• All other parts 30 days
• No return authorization will be issued for electrical components 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 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. THE MANUFACTURER MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE. ALL IMPLIED WARRANTIES, INCLUDING ANY WARRANTY OF ERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. LIABILITY FOR CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER ANY AND ALL WARRANTIES, OTHER CONTRACTS, NEGLEGENCE, OR OTHER TORTS IS EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW.

References

• DEWALT® Power Tools Official Site | Guaranteed Tough®
• P65Warnings.ca.gov
• DEWALT® Power Tools Official Site | Guaranteed Tough®
• osha.org
• P65Warnings.ca.gov

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