Doosan HP450 Operator Manual

OPERATION and MAINTENANCE

MANUAL

COMPRESSOR MODEL

P600/XP535WCU-T4i (E90)

HP450/VHP400WCU-T4i (E91)

This manual contains important safety information.

Do not destroy this manual. This manual must be available to the personnel who operate and maintain this compressor.

Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 DoosanPortablePower.com

P/N: 46614501 (07-2012) Rev A

TABLE OF CONTENTS

Operation & Maintenance Manual

TITLE PAGE

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Compressor Noise Emission Control Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

A. Compressed Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

B. Safety and Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

C. Acoustic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

D. Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

E. Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

F. Air Intake and Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

G. Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

H. Isolation Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

I. Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

J. Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

General Data Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Control/Gauge Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

TABLE OF CONTENTS

Operation & Maintenance Manual

TITLE PAGE

Before Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Compressor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Service Air Connection(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Air Hose Restraint Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Compressor Oil Cooler, Engine Radiator, and other Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . 65

Air Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Fuel Filter Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Charge Air Cooler Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Running Gear/Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Running Gear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Pressure Regulator Adjusting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

TABLE OF CONTENTS

Operation & Maintenance Manual

TITLE PAGE

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Compressor Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Portable Compressor Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Think Before Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Do the Simplest Things First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Double Check Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Find and Correct Basic Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Engine Diagnostic Codes - Cummins Engine with CM2250 Controller . . . . . . . . . . . . . . . . . . . . . . 89

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

IQ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

IQ System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Foreword

Operation & Maintenance Manual Foreword

Information

The contents of this manual are considered to be proprietary and confidential to Doosan Infracore Portable Power (herein referred to as “Portable Power”), and should not be reproduced without the prior written permission of Portable Power.

Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Portable Power products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such products, which are available upon request.

This manual contains instructions and technical data to cover all routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be referred to an authorized Portable Power Service department.

All components, accessories, pipes, and connectors added to the compressed air system should be:

• of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Portable Power.

• clearly rated for a pressure at least equal to the compressor safety valve setting.

• compatible with the compressor oil.

• accompanied with instructions for safe installation, operation, and maintenance.

Details of approved equipment are available from the Portable Power Service departments. The use of repair parts other than those included within the approved parts list may create hazardous conditions over which Portable Power has no control. Therefore, Portable Power cannot be held responsible for equipment in which non-approved repair parts are installed.

Portable Power reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.

The intended uses of this compressor are outlined below and examples of unap proved usage are also given. However, Portable Power cannot anticipate every application or work situation that may arise. If in doubt, consult supervision.

This compressor has been designed and supplied for above ground operation to be used for compression of normal ambient air containing no additional gases, vapors, or particles within the ambient temperature range specified in the General Data Section of this manual.

Foreword Operation & Maintenance Manual

This compressor should NOT be used:

A. For direct or indirect human consumption of the compressed air. B. Outside the ambient temperature range specified in the General Data Section

of this manual.

C. When an actual or forese eable risk of hazardou s levels of fla mmable g ases or

vapors exists. D. With other than Portable Power approved components. E. With guards, controls, or switches missing or disabled. F. For storage or transportation of materials inside or on the enclosure.

Portable Power accepts no responsibility for errors in translation of this manual from the original English version.

You, as the customer, are expected to provide certain service and maintenance items. Your Portable Power dealer will provide all other more detailed service and maintenance items on a special preventive maintenance schedule for each compressor. It is very important that the minimum service and maintenance requirements explained in this manual be performed at the required intervals. Exceeding these intervals may reduce the reliability of the compressor.

The purpose of this manual is to train the operator with functions, operation, and basic service and maintenance requirements of the compressor. During the preparation of this manual, every effort was made to ensure the accuracy and adequacy of the contents.

Your Portable Power dealer will assist with setup and initial startup of the compressor and will also provide brief operating and service instructions. Before starting the compressor, this manual and instructions should be carefully read to obtain a thorough knowledge of the duties to be performed. Please take pride in the compressor, keep it clean and in good mechanical condition.

To enable proper maintenance records, Portable Power provides a Noise Emission Control Maintenance Log in the Noise Emission Section of this manual. The Noise Emission Section contains a recommended Maintenance schedule and provides space in the log for the technician to note what service and maintenance was done, by whom, where, and when.

Operation & Maintenance Manual Foreword

Safety

Operation & Maintenance Manual Safety

Safety Precautions

Never operate the compressor without first observing all safety warnings and carefully reading the Operation and Maintenance Manual shipped from the factory with this compressor.

Ensure the operator reads and understands the decals and consults the manuals before operation or performing maintenance.

Ensure all maintenance personnel are adequately trained, competent, and have read the manuals.

Ensure all protective covers are in place and the canopy/doors are closed during operation. The specification of this compressor is such that the compressor is not suitable for use in

flammable gas risk areas. If such an application is required, all local regulations, codes of practice, and site rules must be observed. To ensure the compressor can operate in a safe and reliable manner, additional equipment such as gas detection, exhaust spark arrestors, and intake (shut-off) valves may be required, dependent on local regula tions or the degree of risk involved.

A weekly visual check must be made of all fasteners/fixing screws securing mechanical parts. In particular, safety-related parts such as coupling hitch, drawbar components, wheels, tires, and lifting bail should be checked for total security.

All components which are loose, damaged, or unserviceable must be rectified without delay. Air discharged from this compressor may contain carbon monoxide or other contaminants

which will cause serious injury or death. Do not breathe discharged air. This compressor produces loud noise with the doors open or service valve vented. Extended

exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open or service valve is vented.

Never inspect or service the compressor without first disconnecting battery ca ble(s) to prevent accidental starting.

Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result in serious illness. Wear eye protection while cleanin g the compressor with compressed air to prevent debris from injuring eye(s).

Rotating fan blade can cause serious injury. Do not operate without fan guard in place. Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver,

and air discharge piping, etc.). Ether is an extremely volatile, highly flammable gas. When it is specified as a starting aid, use

sparingly. Do not use Ether if the engine has glow plugs or inlet heater starting aids. Engine damage will result.

Never operate the compressor with guards, covers, or screens removed. Keep hands, hair, clothing, tools, blow gun tips, etc. well away from moving parts.

Safety Operation & Maintenance Manual

Compressed Air

Compressed air can be dangerous if incorrectly handled. Prior to performing maintenance or service on the compressor, ensure all pressure is vented from the system and the compressor cannot be started accidentally.

Ensure the compressor is operating at the rated pressure and the rated pressure is known to all relevant personnel.

All air pressure equipment installed in, or connected to, the compressor must have safe working pressure ratings of at least the compressor safety valve setting.

If more than one compressor is connected to one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, to ensure one compressor cannot accidentally be pressurized or over pressurized by another.

Compressed air must NOT be used for a direct feed to any form of breathing apparatus or mask.

Compressed air can cause serious injury or death. Relieve pressure before removing filler plugs/caps, fittings, or covers.

Air pressure can remain trapped in air supply line which can result in serious injury or death. Always carefully vent air supply line at tool or vent valve before performing any service or maintenance.

Discharged air contains a very small percentage of compressor lubricating oil and ca re should be taken to ensure downstream equipment is compatible.

If discharged air is to be ultimately released into a confined space, adequate ventilation must be provided.

When using compressed air, always use appropriate personal protective equipment. All pressure containing parts, especially flexible hoses and their couplings, must be regularly

inspected, be free from defects, and be replaced according to the manual instructions. Avoid bodily contact with compressed air. The safety valve located in the separator tank must be checked periodically for correct

operation. Whenever the compressor is stopped, air will flow back into th e compressor from downstream

devices or systems unless the service valve is closed. Install a check valve at the compressor service valve to prevent reverse flow in the event of an unexpected shutdown when the service valve is open.

Disconnected air hoses whip and can cause serious injury or death. Always attach a safety flow restrictor to each hose at the source of supply or branch line in accordance with OSHA Regulation 29CFR Section 1926.302(b).

Never allow the compressor to sit stopped with pressure in the separator tank or piping.

Operation & Maintenance Manual Safety

Exhaust System

Hot engine exhaust gas and hot exhaust system surfaces are produced during and after compressor operation. Avoid contact with exhaust gas and hot exhaust system surfaces. Ke ep flammable and combustible materials away. Do not operate compressor on, under, or near flammable or combustible materials.

The potential for higher temperatures is present when the exhaust aftertreatment system undergoes regeneration. Refer to Engine Manual for further safety instructions and information on the exhaust aftertreatment system and controls.

Materials

The following substances may be produced during the operation of this compressor:

• brake lining dust

• engine exhaust fumes

WARNING

Avoid inhalation of material substances.

Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times.

The following substances are used in the manufacture of this compressor and may be hazardous to health if used incorrectly:

• antifreeze

• compressor oil

• engine oil

• preservative grease, lubricating grease

• rust preventative

• diesel fuel

• battery electrolyte

WARNING

Avoid ingestion, skin contact, and inhalation of fumes.

Should compressor oil come into contact with the eyes, irrigate with water for at least 5 minutes.

Safety Operation & Maintenance Manual

Should compressor oil come into contact with the skin, wash off immediately. Consult a physician if large amounts of compressor oil are ingested or if compressor oil is inhaled. Never give fluids or induce vomiting if the patient is unconscious or having convulsions.

Safety data sheets for compressor and engine oils should be obtained from the oil supplier. Do NOT start or operate this compressor in a confined area. Avoid breathing exhaust fumes

when working on or near the compressor. This compressor may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air

filters, and batteries which may require proper disposal when performing maintenance or service tasks. Contact local authorities for proper disposal of these materials.

Battery

A battery contains sulfuric acid and can produce gases which are corrosive and potentially explosive. Avoid contact with skin, eyes, and clothing. In case of contact, flush area immediately with water.

WARNING

Do not attempt to jump-start a frozen battery since this may cause it to

explode.

Exercise extreme caution when using an external method to jump-start a unit. Verify the electrical systems on the weak battery system and the external jump system are the same voltage type system, 12VDC or 24VDC. Connect the Positive (+) terminal of the external system to the Positive (+) terminal on the weak system. Connect the Negative (-) terminal of the external system to the Negative (-) terminal of the weak system. Always disconnect the two systems in reverse order.

Radiator

Hot engine coolant and steam can cause injury. Ensure the Radiator Pressure Cap is removed with due care and attention.

Do not remove the pressure cap from a HOT radiator. Allow radiator to coo l be fore r emoving pressure cap.

Operation & Maintenance Manual Safety

WARNING

Hot engine coolant and steam can cause injury. When adding coolant or antifreeze solution to the engine radiator, stop the engine and allow radiator to cool prior to releasing the radiator pressure cap. Using a cloth to protect the hand, slowly release the radiator pressure cap, absorbing any released fluid with the cloth. Do not remove the radiator pressure cap until all excess fluid is released and the engine cooling system fully depressurized.

WARNING

Follow the instructions provided by the antifreeze supplier when adding or draining the antifreeze solution. It is advisable to wear personal protective equipment to prevent skin and eye contact with the antifreeze solution.

Transport

When loading or transporting the compressor, ensure that the specified lifting and tie down points are used.

When loading or transporting the compressor, ensure that the towing vehicle, its size, weight, towing hitch, and electrical supply are all suitable to provide safe and stable towing at sp eeds either, up to the legal maximum for the country in which it is being towed or as specified for the compressor model if lower than the legal maximum. Do not exceed gross vehicle weight rating.

Before towing the compressor, ensure:

• the tires and towing hitch are in a serviceable condition and tires are properly inflate d.

• the canopy is secure.

• all ancillary equipment is stored in a safe and secure manner.

• the brakes and lights are functioning correctly and meet necessary road traffic requirements.

• breakaway cables/safety chains are connected to the towing vehicle.

The compressor must be towed in a level attitude in order to maintain correct handling, braking, and lighting functions. This can be achieved by correct selection and adjustment of the vehicle towing hitch and, on variable height running gear, adjustment of the drawbar.

1. Ensure wheels, tires, and drawbar connectors are in safe operating condition and drawbar is properly connected before towing.

2. When parking, always use the handbrake and, if necessary, suitable wheel chocks.

Safety Operation & Maintenance Manual

Safety chains/breakaway cable and their adjustment (where fitted).

Ensure breakaway cable is securely coupled to the towed compressor and also to a substantial anchorage point on the towing vehicle.

Ensure cable length is as short as possible, while still allowing enough slackness for the towed compressor to articulate without the brake being applied.

Attach safety chains to the towing vehicle at substantial anchorage points of suitable strength. Ensure effective chain length is as short as possible while still allowing normal articulation of

the towed compressor and proper operation of the breakaway cable.

Operation & Maintenance Manual Safety

Decals

Decals are located on the compressor to point out potential safety hazards. Read and follow these instructions. If you do not understand these instructions, inform your supervisor.

DANGER

(Red Background)

Indicates the presence of a hazard which WILL cause serious injury, death, or property damage, if ignored.

WARNING

(Orange Background)

Indicates the presence of a hazard which CAN cause serious injury, death, or property damage, if ignored.

CAUTION

(Yellow Background)

Indicates the presence of a hazard which WILL or CAN cause injury or property damage, if ignored.

NOTICE

(Blue Background)

Indicates important set-up, operating, or maintenance information.

Safety Operation & Maintenance Manual

Free Safety Decals

To promote communication of Safety Warnings on products manufactured by the Portable Power Division in S tatesville, N.C., Safety Decals are available FREE of charge. Safety Decals are identified by the decal heading: DANGER, WARNING, CAUTION, NOTICE.

Decal part numbers are located in the lower right hand corner of each decal and are also listed in the compressor Parts Manual. Submit orders for Safety Decals to the Statesville Parts Service Dept. The no charge order should contain only Safety Decals.

Help promote product safety! Ensure decals are present on the compressor. Replace decals that are not readable.

Operation & Maintenance Manual Safety

Do not breathe this air.

Close service valve and operate tool to vent trapped air before performing any service.

5 S

When using air tools attach safety device (OSHA Valve) at source of air supply for each tool.

54749163 REV. C

54629902 REV. C

Hot

54568795 REV. C

465598

Safety Operation & Maintenance Manual

Operation & Maintenance Manual Safety

Safety Operation & Maintenance Manual

Operation & Maintenance Manual Safety

Decals

Graphic Form and Meaning of ISO Symbols

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical Shock Risk

WARNING: Pressure Control WARNING: Corrosion Risk WARNING: Air/Gas Flow or

WARNING: Pressurized Vessel WARNING: Hot and harmful exhaust

WARNING: Pressurized Component or System

gas

WARNING: Hot Surface

Air Discharge

WARNING: Maintain correct tire

pressure (Refer to the GENERAL

INFORMATION section of this manua

Safety Operation & Maintenance Manual

WARNING: Flammable Liquid

WARNING: Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved

WARNING: Before connecting the tow bar or commencing to tow consult the Operation and Maintenance Manual

WARNING: Consult the Operation and Maintenance manual before commencing any maintenance

WARNING: For operating temperature

below 0 C, consult the Operation and Maintenance Manual

Do not Breathe the compressed air from this machine

Do not remove the Operation and Maintenance manual and manual

Do not stack Do not operate the machine without

the guard being fitted

holder from this machine

Operation & Maintenance Manual Safety

Do not stand on any service valve or other parts of the pressure system

Do not operate with doors or enclosure open

Do not use fork lift truck from this side

km/h

Do not exceed trailer speed limit No open flames

Use fork lift truck from this side only Emergency stop Tie down point

Lifting point ON (power) OFF (power)

Do not open service valve before the air hose is attached

Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken

DIESEL

Diesel fuel No open flames

When parking use prop stand, handbrake, and wheel chocks

Parking Brake Rough Service Designation

Compressor oil filling

IP541,5m

Wet Location Operation

Safety Operation & Maintenance Manual

Replace any cracked protective shield Oil drain

Fuel level / point

Battery charging condition

Engine malfunction

Pressure control Malfunction

Low pressure

High Compressor Temperature

Engine Oil

High pressure

Compressor malfunction

Low engine oil pressure

Engine high temperature

Operation & Maintenance Manual Safety

Noise Emission

Operation & Maintenance Manual Noise Emission

Noise Emission

This section pertains only to compressors distributed within the United States.

WARNING

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any persons, other than for purposes of

maintenance, repair, or replacement, of any device or element of design incorpo rated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the compressor after such device or element of design has been removed or rendered inoperative by any person.

Among those acts included in the prohibition against tampering are these:

1. Removal or rendering inoperative any of the following: a. the engine exhaust system or parts thereof

b. the air intake system or parts thereof c. enclosure or parts thereof

2. Removal of any of the following: a. fan shroud

b. vibration mounts c. sound absorption material

3. Operation of the compressor with any of the enclosure doors open.

Compressor Noise Emission Control Information

A. The removal or rendering inoperative, other than for the purpose of

maintenance, repair, or replacement of any noise control device or element of design incorporated into this compressor in compliance with the noise control act;

B. The use of this compressor after such device or element of design has been

removed or rendered inoperative.

NOTE: the above information applies only to compressors that are built in compliance with the U.S. Environmental Protection Agency.

Portable Power reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.

The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor.

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