Doosan HP450 Operator Manual

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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.

Noise Emission Operation & Maintenance Manual

Maintenance Log

COMPRESSOR MODEL_________________________

SERIAL NO. __________________________________

USER UNIT NO. _______________________________

UNIT IDENTIFICATION

Engine Make & Model:_________________

Serial No.:__________________________ __________________________________

Purchaser or Owner:__________________ __________________________________

Address: ___________________________ Date Purchased:_____________________

The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations, specifically 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 in corporated into 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.

DEALER OR DISTRIBUTOR FROM WHOM PURCHASED:

Noise Emission Warranty

The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built and equipped to conform at the time of sale to the first retail purchaser, with all applicable U.S. EPA Noise Control Regulations.

This warranty is not limited to any particular part, componen t, or system of the air compressor. Defects in the design, assembly or in any part, component, or system of the compressor which, at the time of sale to the first retail purchaser, caused noise emissions to exceed Federal Standards are covered by this warranty for the life of air compressor.(40CFR204.58-1)

Operation & Maintenance Manual Noise Emission

Introduction

The compressor for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air Compressors.

The purpose of this book is to provide (1) the Maintenance Performance Schedule for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when. The Maintenance Schedule and detailed instructions on the maintenance items are given on following page.

Maintenance Schedule

ITEM AREA PERIOD

A. Compressed Air Leaks As Detected B. Safety and Control Systems As Detected C. Acoustic Materials Daily D. Fasteners 100 hours E. Enclosure Panels 100 hours F. Air Intake & Engine Exhaust 100 hours G. Cooling Systems 250 hours H. Isolation Mounts 250 hours I. Engine Operation See Operator’s Manual J. Fuels & Lubricants See Operator’s Manual

A. Compressed Air Leaks

Correct all compressed air leaks during the first shutdown period after discovery. If severe enough to cause serious noise problems and efficiency loss, shut down immediately and correct the leak(s).

B. Safety and Control Systems

Repair or replace all safety and control systems or circuits as malfunction occurs. No compressor should be operated with either system bypassed, disabled, or nonfunctional.

C. Acoustic Materials

In daily inspections, observe these materials. Maintain all acoustic material as nearly as possible in its original condition. Repair or replace all sections that have: 1) sustained damage,

2) have partially separated from panels to which they were attached, 3) are missing, or have otherwise deteriorated due to severe operating or storage conditions.

Noise Emission Operation & Maintenance Manual

D. Fasteners

All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be inspected for looseness after each 100 hours of operation. They should be retightened, repaired, or if missing, replaced immediately to prevent subsequent damage and noise emission increase.

E. Enclosure Panels

Enclosure panels should be inspected at 100 hour operational intervals. All panels that are warped, punctured, torn, or otherwise deformed, such that their noise containment function is reduced, should be repaired or replaced before the next operation interval. Doors, access panels, and hatch closures especially, should be checked and adjusted at this time to ensure continuous seating between gasket or acoustic material and the mating frame.

F. Air Intake and Engine Exhaust

Engine and compressor air intake and engine exhaust systems should be inspected after each 100 hours of operation for loose, damaged, or deteriorated components. Repairs or replacements should be made before the next period of use.

G. Cooling Systems

All components of the cooling system for engine water and compressor oil shou ld be inspected every 250 hours of use. Any discrepancies found should be corrected before placing the compressor back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at all times during operation.

H. Isolation Mounts

Engine/airend isolation mounts should be inspected after each 250 hours of operation. Those mounts with cracks or splits in the molded rubber or with bent or broken bolts due to operation or storage in severe environments should be replaced with equivalent parts.

I. Engine Operation

Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer.

J. Fuels and Lubricants

Use only the types and grades of fuels and lubricants recommended in the Operator and Maintenance Manual and Engine Manual.

Operation & Maintenance Manual Noise Emission

MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY

ITEM NO.

DESCRIPTION OF WORK HOURMETER

READING

MAINT/ INSPECT DATE

LOCATION CITY/ STATE

WORK DONE BY (NAME)

General Data

Operating & Maintenance Manual General Data

General Data Information

MODEL

COMPRESSOR

Air Delivery - cfm (m Rated Operating Pressure -

psi (ba r) Safety Valve Setting - psi

(bar)

ENGINE

Manufacturer Cummins Model QSB 6.7 Rated Power at Full Load

Speed - hp (kw) Full Load Speed - rpm 2200 1950

Idle Speed - rpm 1500 Idle Speed (warm-up) - rpm 1600

/min)

P600WCU-

T4i

600 (170) 525 (14.9)

100 (6.9) 125 (8.6)

200 (13.8)

XP525WCU-

T4i

HP450WCU-

450 (12.7) 400 (11.3) 150 (10.3) 200 (13.8)

173 (129) @ 2200 RPM

VHP400WC

T4i

U-T4i

250 (17.2)

2200 1950

Electrical System 24V FLUID CAPACITIES - U.S. Gallons (liters) Compressor Oil 9.5 (36) Engine Oil, including filter 4.6 (17.5) Engine Coolant 7.0 (26.5) Fuel Tank 73 (276)

AMBIENT TEMPERATURE RANGE

With Standard Features 10°F(-12°C) to 120°F (49°C) With Required Options -10°F(-23°C) to 120°F (49°C) With Aftercooler or IQ System 32°F (0°C) to 110°F (43°C)

OUT-OF-LEVEL

Out-Of-Level Operating Limit 15°

General Data Operating & Maintenance Manual

MEASUREMENTS/WEIGHTS

Overall Length - feet (meters) (incl. bumper)

Overall Height - feet (meters) 6.7 (2.0) Overall Width - feet (meters) 6.5 (1.98) Operating Weight, with fuel - lb (kg) 4700 (2132) Shipping Weight, less fuel - lb (kg) 4178 (1895)

RUNNING GEAR

Tire Size ST235/80R16 Tire Inflation Pressure - psi (bar) 65 (4.5) Maximum Towing Speed - mph (km/hr) 65 (105)

CAUTION

Any departure from the specifications may make this equipment unsafe.

14.8 (4.5)

Operating & Maintenance Manual General Data

Operating Instructions

Operating & Maintenance Manual Operating Instructions

Control Panel

Control/Gauge Panel

1. Air Pressure Gauge: Indicates pressure (PSI) in the separator tank

2. Engine Tachometer: Indicates engine speed (RPM).

3. Compressor Temperature Gauge: Indicates airend discharge temperature.

4. Engine Coolant Temperature Gauge: Indicates engine coolant temperature.

5. Fuel Level Gauge: Indicates level of fuel in tank.

6. Engine Oil Pressure Gauge: Indicates engine oil pressure (PSI).

7. MidPort Displays compressor operating parameters and diagnostic codes.

8. Main Power Button: St art and Shutdown compressor control system and gauge panel.

9. KeyPad: Used to start and shutdown the compressor.

Operating Instructions Operating & Maintenance Manual

STOP: Shutdown the compressor.

START: Initiates engine cranking.

SERVICE AIR: Allows operator to load compressor after warm-up.

HI PRESSURE: Allows operator to switch to high pressure mode.

LO PRESSURE: Allows operator to switch to low pressure mode.

UP: Pressing and releasing the UP Button scrolls up through parameter lists and

menu choices or increases a value one item/unit at a time. Pressing and holding the UP Button continuously scrolls up through parameter lists, menu choices, or increases a value until the end of the parameter list, menu choices, or maximum parameter value is reached.

DOWN: The DOWN Bu tton functions identical to the UP Button with the exception that its direction for all displays, menu choices, and values is down or decreasing.

ENTER: Pressing and releasing this button provides enter functionality when the display requires you to choose a menu item, parameter selection, or value input. Pressing and holding this switch for approximately three seconds while any of the Main Screens are displayed brings up the Main Menu. Pressing the ENTER Button after an alert or fault has been displayed acknowledges the message and the display unit returns to the Default Screen.

Operating & Maintenance Manual Operating Instructions

FAULT AND ALERT

If a FAULT occurs, the display unit will display the SPN, FMI, OC, and description for Engine Fault or the CPR Code and Description for Compressor Error. An engine fault will be displayed only when the engine is shutdown. The Fault has to be acknowledged by the user by pressing the ENTER Button. The unit does not time out in the fault display. After 60 seconds, if the Fault is still active, the fault display will appear again on the screen and will remain until acknowledged by the user. This will continue to occur as long as the Fault is active.

See Figure 1.

Figure 1

When present, an ALERT with the number of alert conditions will popup on the screen, the user will press the UP or DOWN Button to display the alert, or press the ENTER Button to acknowledge an alert has occurred. If there are multiple alerts, pressing the DOWN Button will scroll through the various alerts. All Faults and Alerts will be displayed until the engine shuts down and then the most severe Fault will be displayed as a Fault. Pre ssing the ENTER Button after the Alert has been displayed, acknowledges the message and the d isplay unit returns to the Default Screen of Engine Hours. See Figure 2.

Figure 2

Operating Instructions Operating & Maintenance Manual

SERVICE INTERVAL

Service will popup on the screen after one of the two hour service channels has decremented to 5 hours. The user will press the UP or DOWN Button to display the service channels or press the ENTER Button to acknowledge a service has occurred. Pre ssing the ENTER Button after the service channels have been displayed, acknowledges the message and the display unit returns to the default screen. If service is between 5 and 0 hours or it remains at 0 hours, the SERVICE DUE display will appear every hour. To disable, the user can reset the hours to the OFF position by decreasing the value to OFF. See Figure 3.

Figure 3

The service intervals can be changed by pressing the ENTER Button while on the default screen that displays the engine hours. Using the UP or DOWN Buttons to highlight the desired interval and press the ENTER Button to select. Use the UP and DOWN Buttons to increase or decrease the number of hours. Hours will decrement with every hour on the engine. Use the DOWN Button to highlight the Main Screen menu item and press the ENTER Button to return to the Default Screen of Engine Hours. See Figure 4.

Figure 4

Operating & Maintenance Manual Operating Instructions

LANGUAGES AND UNITS

The MidPort is user configured to display in English, Spanish, or French languages and in either English or Metric units. The Language and Display units can be changed by accessing the Setup Menu. To access the Setup Menu, press and hold the ENTER Button while the Default Screen of Engine Hours is displayed until the Main Menu appears. Scroll to the Setup option using the DOWN Button then press the ENTER Butto n. Use the DOWN or UP Buttons to highlight the chosen unit and PRESS the ENTER Button to select. To return to the Default Screen of Engine Hours, use the DOWN Button to highlight the Main Screen menu item and press the ENTER Button. See Figure 5.

Figure 5

Operating Instructions Operating & Maintenance Manual

QUICKVIEW SCREENS (ENGINE AND COMPRESSOR PARAMETERS)

The Quick View Screens allow for easy viewing of up to 18 commonly used parameters by pressing the UP and DOWN Buttons. Pressing the UP and DOWN Buttons continuously loops through the Quick View Screens (i.e., when the last screen is reached pressing the DOWN Button displays the first screen and vice versa).

Figure 6

Note 1: Only the parameters that are available from the engine or compressor will be

displayed. Note 2: Unit times out after 3 minutes of inactivity and returns to the Default Screen of Engine

Hours. Note 3: Pressing the Enter Button while viewing a Quickview Screen will return to the Default

Screen of Engine Hours.

Operating & Maintenance Manual Operating Instructions

DISPLAY SETUP

The Display Menu functions give users the ability to configure the LCD. Options for configuring the display include intensity, contrast, and viewing mode. To access the Display Menu:

1. Press and hold the ENTER Button while the Default Screen of Engine Hours is displayed until the Main Menu appears.

2. Scroll to the Setup option using the DOWN Button and press the ENTER Button.

3. Scroll to the Display option using the DOWN Button and press the ENTER Button.

4. Use the DOWN or UP Buttons to highlight and the ENTER Button to select the desired display setting. See Figure 7.

5. To return to the Default Screen of Engine Hours, use the DOWN Button to highlight the Main Screen menu item and press the ENTER Button. Note: Main Screen menu item returns the user back to the Default Screen of Engine Hours.

Figure 7

Operating Instructions Operating & Maintenance Manual

AUTO POWER OFF

The Compressor Control System has a power save feature designed to prevent drain on the batteries when the compressor engine is not running. If the Control Panel is powered ON and the engine has not run for 3 minutes (above 45°F (7°C) or 15 minutes at or below 45 °F (7° C)), the control system will automatically power OFF. Power can be restored by pressing the Main Power Button.

In the event of a fault, this feature is not active and the power will remain on until the fault has been acknowledged or the control system is manually powered off.

WAIT TO START

When the Main Power Button is pressed, the display will initialize and the Wait to Start message will be displayed. While the Wait to Start message is displayed, the engine will receive heat from the intake heater if required. It is best to start the engine immediately after the Wait to Start message changes to Engine Total Hours.

Lifting

The central lifting bail allows the compressor to be lifted from a single point. Use hoist or crane capable of lifting compressor weight (See General Data).

WARNING

Falling off the compressor can cause serious injury or death. Use ladder

and handholds to access lifting bail.

Before Towing

Ensure the tires, wheels and running gear are in good condition and secure.

High Speed Running Gear

• Use jack to raise or lower drawbar.

• Use tow vehicle whose towing capacity is greater than the weight of the compressor (See General Data).

• Do not tow the compressor in excess of the maximum towing speed (See General Data).

• Place wheel chocks under tires and/or set parking brake before disconnecting from towing vehicle.

• When raising or lowering drawbar, always stand to one side.

Operating & Maintenance Manual Operating Instructions

Setting Up

Place the compressor in an open, well-ventilated area. Ensure sufficient clearance for ventilation and exhaust requirements. Adequate clearance needs to be allowed around and above the compressor to permit safe access for specified maintenance tasks.

Position as level as possible. Do not exceed the out-of-level operating limit (See General Data).

When the compressor is to be operated out-of-level, it is imp ortant: (1) to ke ep the engine oil level near the high level mark (with the compressor level), and (2) to have the compressor oil level gauge show no more than mid-scale (with the compressor running at full load). Do not overfill either the engine oil or the compressor oil.

Ensure the compressor is positioned securely and on a stable foundation. Any risk of movement should be removed by suitable means, especially to avoid strain on air discharge piping.

Chock wheels and/or set parking brake. Ensure all transport and packing materials are removed.

Compressor Mounting

Portable compressors, which are modified to remove the running gear and mount the compressor directly to trailers, truck beds, or frames, etc. may experience failure of the enclosure, frame, and/or other components. It is necessary to isolate the compressor package from the carrier base with a flexible mounting system. Such a system must also prevent detachment of the package from the carrier base in the event the isolators fail. Contact your Portable Power representative for flexible mounting kits.

Warranty does not cover failures attributable to mounting of the compressor package to the carrier base unless it is a Portable Power provided system.

Service Air Connection(s)

WARNING

All air pressure equipment installed in or connected to the compressor must have safe working pressure ratings of at least the safety valve setting and materials compatible with the compressor oil (Refer to the General Data).

Operating Instructions Operating & Maintenance Manual

WARNING

Do not connect the air discharge on this compressor onto a common header with any other unit of any description, or any other source of compressed air, without first ensuring a check-valve is used between the header and the compressor. If this compressor is connected in parallel with another compressor of higher discharge pressure and capacity a safety hazard could occur in a back-flow condition.

WARNING

Unrestricted air flow from a hose will result in a whipping motion of the hose which can cause serious injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure in case of hose failure or other sudden pressure release. Reference: OSHA regulation 29 CFR Section 1926.302 (b).

Air Hose Restraint Installation

Safety devices such as hose restraints (whipchecks) must be used to pre vent hose whipping if a connection fails. Whipchecks are to be constructed of woven stainless steel, galvanized steel wire rope, or chain with a minimum strength adequate for the supplied pressure and hose diameter. Whipchecks must be fastened to suitable mounting points or shackles.

The mounts and/or shackles are to be of the same or greater strength as the whipchecks. An engineer should be consulted about suitability of whipchecks, mounts, mounting points, shackles, and fittings as well as strength rating of materials. Whipchecks must be used at the hose origination, termination, and each hose to hose connection.

Hoses can fail in areas other than at connecting points and require daily inspection of the hoses for:

• Cuts, cracks, or kinks

• Weakened clamps due to rust and corrosion

• Damaged connections

• Deformity

• Incorrect or incompatible components or fittings

• Any visual damage

Hoses must be selected that are rated for the application as to the maximum pressure and temperature to be encountered as well as compatible with the materials being conveyed inside the hose. Hoses must be compatible with the compressor oil.

Operating & Maintenance Manual Operating Instructions

Before Starting

Open Manual Blowdown Valve to ensure the separator tank has been vented of all pressure. Close the valve before starting. Inspect the complete installation including remote fuel lines (if any) and air hose routing and connections. Check battery for proper connections and condition.

WARNING

Combustible gas can cause severe burns, blindness, or death. Keep sparks and open flame away from battery.

Check the compressor oil level. Maintain the oil level between bottom and midway of the sight glass on the separator tank.

Check engine oil level. The proper level is labeled on the engine dipstick. Add oil when required. Do not overfill.

CAUTION

Exercise extreme caution when using an external method to jumpstart 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.

WARNING

Do not remove the pressure cap from a HOT engine radiator. The sudden release of pressure from a heated cooling system can result in a loss of coolant and possible severe personal injury.

WARNING

Hot pressurized fluid can cause serious burns. Do not open radiator while hot.

Check coolant to ensure coolant level is at or above minimum level when the engine is cold. Check engine coolant level at radiator pressure cap. Add coolant as required. Ensure pressure cap is installed properly and tightened.

Operating Instructions Operating & Maintenance Manual

NOTICE

If the appropriate mixture of antifreeze is not used during freezing temperatures, failure to drain the engine may cause costly engine damage. Never use water only, as corrosion inhibitors are required in engine coolant fluid.

CAUTION

No smoking, sparks, or open flame near fuel.

Check the fuel level and add fuel as necessary. Ultra-low sulfur diesel fuel (ULSD), with a maximum sulfur content of 15 ppm is required. If ultra-low sulfur diesel is not used, the engine could possibly not meet emissions regulations and the engine or aftertreatment system may be damaged. Refer to the Engine Operator Manual for fuel specifications.

NOTICE

To minimize condensation (water) in the fuel tank, it is recommended to fill the tank at the end of each day.

NOTE: Compressor will not allow engine starting if the fuel level is below the minimum fuel shut off level.

WARNING

Compressor produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve(s) are open.

Close the doors to maintain a cooling air path and to avoid recirculation of hot air. This will maximize the life of the engine and compressor and protect the hearing of surrounding personnel.

Ensure no one is IN or ON the compressor. Ensure that the location of the Emergency Stop Button (if equipped) is known and recognized

by its markings. Ensure that it is functioning correctly and that the method of operation is known.

Operating & Maintenance Manual Operating Instructions

WARNING

Ensure that the access panels for heat exchanger cleaning are closed and secure before starting the compressor. Rotating fan blades can cause serious injury or death. Do not operate without all guards in place.

Starting

CAUTION

Do not use ether or any other starting fluid. Starting fluids can cause an explosion, fire, and severe engine damage. The engine is equipped with an electric heater starting aid.

NOTICE

This compressor is equipped with a battery disconnect switch which disconnects power for long term storage. The switch is located on the fuel tank side.

This switch must be in the ON position to provide power to the Control Panel for starting the compressor.

1. Press the Main Power Button.

2. When the Wait To Start message on the MidPort changes to Total Engine Hours =, press and release Green Start Button .

3. Engine will crank until engine starts or engine starting time limit is reached. The first Green light on the Start Button will illuminate.

4. If engine fails to start, press Main Power Button to remove power from engine, then repeat steps 1-3.

5. When engine starts, the first two lights on the Start Button will illuminate.

6. Wait for Engine Temperature to reach 150°F (65°C). Press Service Air Button. The third light on the Start Button will illuminate.

7. The compressor will start in the Low Pressure Mode and the Low Pressure Light will be illuminated on the Low Pressure Button.

8. To change to the High Pressure Mode, press the High Pressure Button. Three lights on the button will illuminate.

Operating Instructions Operating & Maintenance Manual

CAUTION

To ensure an adequate flow of oil to the airend, never allow the discharge

pressure to fall below 50 psi.

Normal Operation

The operator may observe and monitor operating parameters using the MidPort and gauges. In the event the compressor controller detects a parameter outside normal operating limits, the compressor will alert and/or shutdown, and display a diagnostic code.

In the event the compressor controller detects a parameter at a dangerously high or low level, the compressor will be automatically shut down with the cause of the shutdown shown on the MidPort.

Two Pressure Modes of Operation

The compressor is capable of operating at two pressure modes:

1. The Low Pressure Mode is activated by pressing the Lo Pressure Button. In this

mode, the compressor will regulate according to the air demand, between 0 and rated air delivery (See General Data) at the lower regulated set pressure (See General Data). The regulated set pressure of this mode can be regulated as low as 80 psi.

2. The High Pressure Mode is activated by pressing the Hi Pressure Button. In High

Pressure Mode, the compressor will regulate according to air demand, between 0 and rated air delivery (See General Data) at the higher regulated set pressure (See General Data). The regulated set pressure of this mode can be regulated as low as 80 psi.

The mode of the compressor can be changed between the Low and High at anytime. Engine speed will be lower at the HI Pressure Mode setting.

Operation - Loaded

Assume engine has been started and is running in the unload state at idle speed. If there is air demand (pressure falls below the load point pressure), compressor will load at idle speed by opening the inlet valve. As air demand rises and falls, engine speed is controlled between idle speed and full load speed to match the required flow while maintaining load point pressure.

Operation - Unloaded

If there is no air demand at idle speed (pressure rises above the unload point pressure), the compressor will unload by closing the inlet valve. The compressor then runs at idle speed unloaded with no air delivery. If air demand increases (pressure falls below the load point pressure), the compressor reloads to meet the required air demand.

Operating & Maintenance Manual Operating Instructions

Shutdown

1. Close the Service Valve.

2. Allow the engine to idle for 3 minutes to cool down.

3. Press the Red Stop Button.

4. Press the Main Power Button xxxxxxxxx when use of the compressor is not needed.

Note: Until Main Power Button is pressed, the gauges can be read and the MidPort

can be navigated using the UP, DOWN, and ENTER Buttons.

5. If the Main Power Button is not pressed within 3 minutes (if ambient temperature is above 45°F (7°C) or 15 minutes if ambient temperature is 45°F (7°C) or below of the keypad use the compressor will automatically shut off.

NOTICE

Failure to allow turbocharger cool down prior to stopping can cause turbocharger damage.

NOTICE

This compressor is equipped with a battery disconnect switch which disconnects power for long term storage. The switch is located on the fuel tank side.

Do not use the battery disconnect switch for normal stopping. Wait 1 minute after stopping engine before turning the battery disconnect switch to the OFF position.

CAUTION

Use the Emergency Stop, if equipped, only for emergency conditions. Do not use for normal stopping. Emergency Stop must be reset before starting can be accomplished.

Operating Instructions Operating & Maintenance Manual

NOTICE

Once the engine stops, the Automatic Blowdown Valve will relieve pressure from the separator tank. If the Automatic Blowdown Valve fails to operate, pressure must be relieved from the system by means of the Manual Blowdown Valve.

WARNING

Pressure will remain in the system between the Minimum Pressure Valve and the Service Valve after shutdown and operation of the Automatic Blowdown Valve. This pressure must be relieved by disconnecting any downstream equipment and opening the Discharge Valve to atmosphere.

CAUTION

Never allow the compressor to sit stopped with pressure in the separator tank or piping. As a precaution, open the Service Valve.

Decommissioning

When the compressor is to be permanently decommissioned or dismantled, it is important to ensure that all hazard risk are either eliminated or recepient of the compressor notified. In particular:

• Do not destroy batteries or components containing asbestos without containing the materials safely.

• Do not dispose of any pressure vessel that is not clearly marked with its relevant data plate information or rendered unusable by drilling, cutting, etc.

• Do not allow lubricants or coolants to be released into land surfaces, water, or drains.

• Do not dispose of a complete compressor without documentation relating to instructions for its use.

Operating & Maintenance Manual Operating Instructions

Maintenance

Operation & Maintenance Manual Maintenance

General Information

This section refers to the various components which require periodic maintenance and replacement.

The Maintenance Schedule indicates the various components' descriptions and the intervals when maintenance has to take place. Fluid capacities can be found in the General Data Section of this manual. For any specification or specific requirement on service or pre ventative maintenance for the engine, refer to the Engine Manual.

Compressed air can be dangerous if incorrectly handled. Review all maintenance precautions listed below before attempting any maintenance work on the compressor.

Maintenance Precautions

Prior to attempting any maintenance work, ensure:

1. All pressure is vented from the system and the compressor cannot be started accidentally.

2. If the Automatic Blowdown Valve fails to operate, pressure must be gradually relieved by operating the Manual Blowdown Valve.

3. The discharge pipe/manifold area is depressurized by opening the discharge valve while keeping clea r of any air flow.

4. Maintenance personnel are adequately trained, competent, and have read t he Operation and Maintenance Manual.

WARNING

Prior to opening or removing panels or covers inside a compressor, ensure:

1. Anyone entering the compressor is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts.

2. The compressor cannot be started. Post warning signs and/or fit anti-start devices.

3. Battery cables are disconnected.

Maintenance Operation & Maintenance Manual

Prior to attempting any maintenance work on a running compressor, ensure:

1. The work carried out is limited to only those tasks which require the compressor

to run.

2. The work carried out with safety protection devices disabled or removed is

limited to only those tasks which require the compressor to be running with safety protection devices disabled or removed.

3. All hazards present are known (e.g. pressurized components, electrically live

components, removed panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving parts, safety valve discharge).

4. Appropriate personal protective equipment is worn.

5. Loose clothing, jewelry, long hair etc. is made safe.

6. Warning signs indicating that Maintenance Work is in Progress are posted in a

position that can be clearly seen.

Upon completion of maintenance task and prior to returning the compressor into service, ensure:

1. The compressor is suitably tested.

2. All guards and safety protection devices are refitted.

3. All panels are replaced, canopy and doors closed.

4. Hazardous materials are effectively contained and disposed of.

NOTICE

The maintenance schedule in this manual describes the service intervals that should be followed for normal applications of this compressor. This page may be reproduced and used as a checklist by service personnel.

In more severe applications (i.e., sandblasting, quarry drilling, well drilling, and oil and gas drilling) more frequent service intervals will be required to ensure long component life.

Dust and dirt, high humidity, and high temperatures will affect lubricant life and service intervals for components such as inlet air filters, oil separation elements, and oil filters.

Operation & Maintenance Manual Maintenance

Maintenance Schedule

Initial

500 miles

/850 km

Compressor Oil Level C Engine Oil Level C *Radiator Coolant Level C Gauges/Lamps C *Air Cleaner Service Indicators C Fuel Tank (Fill at end of day) C D *Fuel/Water Separator Drain C Oil Leaks C Fuel Leaks C Drain Water From Fuel Filters D Coolant Leaks C Radiator Filler Cap C *Emergency Stop T *Lubricator (Fill) C

Daily Weekly Monthly

Every 3 Months

500 hrs.

Every 6 Months

1000 hrs.

Every 12

Months

2000 hrs.

Air Cleaner Precleaner Dumps C Fan/Alternator Belts C Battery Connections/Electrolyte C Hoses (Oil, Air, Intake, etc.) C Automatic Shutdown System C Air Cleaner System C Compressor Oil Cooler Exterior C *Engine Rad/Oil Cooler Exterior C Engine Charge Air Cooler Exterior C *Aftercooler Exterior C Safety Valve C Fasteners, Guards C

*Disregard if not appropriate for this particular compressor. D = Drain

(1) or 3000 miles/5000km whichever is the sooner G = Grease W I = or when indicated if earlier.

C = Check (adjust, clean or replace as necessary) R = Replace CBT = Check before towing. T = Test

CR = Check and report

Maintenance Operation & Maintenance Manual

Initial

500 miles

/850 km

Air Cleaner Elements R/WI *Fuel/Water Separator Element R Fuel Filter Element R Engine Oil Change R Engine Oil Filter R *Engine Coolant Cond. Element R Compressor Oil Filter Element R Compressor Oil R Oil Separator Element R Separator Tank Exterior (2) CR *Engine Coolant C R Engine Crankcase Breather

Element *Water Pump Grease. G Shutdown Switch Settings T

Daily Weekly Monthly

Every

6Months

500 hrs.

Every 12

Months

1000 hrs

Every 48

Months

5000 hrs

Scavenge Orifice & Related Parts C Scavenge Line C *Valve Clearance Check C *Feed Pump Strainer Cleaning C *Injection Nozzle Check C

*Disregard if not appropriate for this particular compressor. D = Drain (1) or 3000 miles/5000km whichever is the sooner G = Grease (2) or as defined by local or national legislation R = Replace

C = Check (adjust, clean or replace as necessary) T = Test CBT = Check before towing. W I = or when indicated if earlier. CR = Check and report

Operation & Maintenance Manual Maintenance

Initial

500 miles

/850 km

*Brake linkage C C *Brakes C C *Lights (running, brake, & turn) CBT *Pintle Eye Bolts CBT *Tire Pressure and Condition C *Wheel Lug Nuts C *Running gear linkage G *Running gear bolts(1) C *Wheels (Bearings, Seals, etc.) CG

Daily Weekly Monthly

3 Months

500 hrs.

6 Months

1000 hrs

Months

2000 hrs

2 Yrs4 Yrs6 Yrs

Safety valve C Hoses R Separator tank (2) interior C

*Disregard if not appropriate for this particular compressor. D = Drain (1) or 3000 miles/5000km whichever is the sooner G = Grease (2) or as defined by local or national legislation R = Replace

C = Check (adjust, clean or replace as necessary) T = Test CBT = Check before towing. W I = or when indicated if earlier. CR = Check and report Refer to specific sections of the operator's manual for

more information.

Maintenance Operation & Maintenance Manual

Scavenge Line

The scavenge line runs from the combined orifice/check valve at drop tube in the separator tank to the fitting located in the airend.

Check that the scavenge line and tube are clear of any obstruction. Refer to the Maintenance Schedule for recommended servicing intervals. Any blockage will result in oil carryover into the discharge air.

Compressor Oil Filter

Refer to the Maintenance Schedule for the recommended servicing intervals.

Removal

WARNING

Do not remove the filter(s) without first ensuring the compressor is shut off and the system has been completely relieved of all air pressure. (Refer to STOPPING in the OPERATING INSTRUCTIONS section of this manual).

Clean the exterior of the filter housing and remove the spin-on element.

lnspection

Inspect the oil filter head to be sure the gasket was removed with the oil filter element. Clean the gasket seal area on the oil filter head.

CAUTION

If there is any indication of the formation of varnishes, shellacs, or lacquers on the filter element, it is a warning that the compressor lubricating and cooling oil has deteriorated and should be changed immediately. Refer to LUBRICATION section.

NOTICE

Installing a new oil filter element when the old gasket remains on the filter head will cause an oil leak and can cause property damage.

Reassembly

Clean the filter gasket contact area and install the new element. Tighten until the gasket makes contact with the filter housing. Tighten an additional 1/2 to 3/4 of a revolution.

Operation & Maintenance Manual Maintenance

CAUTION

Start the compressor (refer to BEFORE STARTING and STARTING in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the compressor is put back into service.

Compressor Oil Separator Element

Refer to the Maintenance Schedule in this section for the recommended servicing intervals. If the element has to be replaced, then proceed as follows:

Removal

WARNING

Disconnect all hoses and tubes from the separator tank cover plate. Remove the drop tube from the separator tank cover plate and remove the cover plate. Remove the separator element.

lnspection

Examine the separator element. Examine all hoses and tubes, and replace if necessary.

Reassembly

Thoroughly clean the orifice/drop tube and filter gasket contact area before reassembly. Install the new element.

WARNING

DO NOT remove the staple from the anti-static gasket on the separator element since it serves to ground any possible static build-up. DO NOT use gasket sealant since this will affect electrical conductance.

Maintenance Operation & Maintenance Manual

Reposition the cover plate, taking care not to damage the gasket. Replace the cover plate screws tightening in a criss-cross pattern to the recommended torque (refer to the torque values in this section).

Reconnect all hoses and tubes to the separator tank cover plate. Replace the compressor oil (refer to LUBRICATION section).

CAUTION

Start the compressor (refer to BEFORE STARTING and STARTING in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the compressor is put back into service.

Compressor Oil Cooler, Engine Radiator, and other Heat Exchangers

When grease, oil, and dirt accumulate on the exterior surfaces of the heat exchangers, the efficiency is impaired. It is recommended that the heat exchangers be cleaned per the Maintenance Schedule in this manual by a jet of compressed air. This should remove any accumulation of oil, grease, and dirt from the exterior cores of the cooler so the entire cooling area can radiate heat into the air stream. Access doors are located on each side of the compressor to provide access to aid in cleaning the heat exchangers.

WARNING

Ensure the heat exchanger access doors are closed and secure before starting the engine.

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 pressure cap, absorbing any released fluid with the cloth. Do not remove the pressure cap until all excess fluid is released and the engine cooling system fully depressurized.

Operation & Maintenance Manual Maintenance

WARNING

Air Filter Elements

The air filter elements should be replaced regularly (refer to the Maintenance Schedule) or when indicated on the Control Panel, whichever comes first. The aircleaner precleaner dumps should be cleaned as indicated in the Maintenance Schedule (more frequently in dusty operating conditions).

Removal

CAUTION

Never remove and replace element(s) when the compressor is running.

Clean the exterior of the filter housing and remove the filter element by following instructions on the filter.

If the safety element is to be replaced, thoroughly clean the interior of the filter housing prior to removing the safety element.

Inspection

Check for cracks, holes, or any other damage to the element by holding it up to a light source or by passing a lamp inside.

CAUTION

If inspection reveals damage to the main element, the safety element must be replaced.

Check the seal at the end of the element and replace if any sign of damage is evident.

Reassembly

Assemble the new element into the filter housing ensuring the seal seats properly. Secure element following instructions on the filter.

Before restarting the compressor, ensure all clamps are tight.

Maintenance Operation & Maintenance Manual

Ventilation

Ensure air inlets and outlets are clear of debris etc.

Cooling Fan Drive

Every 3 months check to ensure fan drive mounting bolts to the engine have not loo sened. If, for any reason, it becomes necessary to remove or re-tighten the mounting bolts, apply a good grade of commercially available thread locking compound to the bolt threads and tighten to 23Nm (17 ft-lbF) of torque.

The fan belt(s) should be checked monthly for wear and correct tensioning. This compressor is equipped with a variable speed fan clutch and requires no periodic

maintenance.

Fuel System

The fuel tank(s) should be filled daily or every eight hours. To minimize condensation in the fuel tank(s), it is advisable to top up after the compressor is shut down or at the end of each working day. Drain any sediment or condensate that may have accumulated in the tank(s). Refer to Maintenance Schedule.

Fuel Filter Water Separator

The fuel filter water separator contains a filter element which should be replaced as required by the Maintenance Schedule.

Charge Air Cooler Pipework

Foreign particles can damage the engine and turbocharger. Maintain internal cleanliness and integrity of the air filtration, intake piping, and charge air cooler piping to help avoid damage. Monthly inspect systems for leaks and that hoses, clamps, and connections are sealed. Check for damaged or deteriorated components. Pay careful attention to keep the internal surfaces clean, particularly when parts are removed for inspection or service.

Hoses

All components of the fuel, engine cooling, and air intake system should be checked monthly to keep the engine at peak efficiency.

At the recommended intervals, (see the Maintenance Schedule), inspect all of the intake lines to the air filter, and all flexible hoses used for air lines, oil lines, and fuel lines.

Every 3 months inspect all pipework for cracks, leaks, etc. and replace immediately if damaged.

Operation & Maintenance Manual Maintenance

Electrical System

WARNING

Disconnect the battery cables before performing any maintenance or service.

Check the security of electrical devices and sensors to ensure terminals and/or connectors are tight. Loose connections may cause local hot spot oxidation.

When removing connectors from electrical devices and sensors, inspect the terminals to ensure they have electrical grease on them. If electrical grease is not present or very minimal, add a small amount of Doosan Part No. 22409114 Electrical Grease to the terminals.

Dirty and/or corroded electrical terminals can be cleaned using electrical contact cleaner. Inspect the components and wiring for signs of overheating (i.e., discoloration, charring of

cables, deformation of parts, acrid smells, and blistered paint).

Battery

Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion. The battery restraint should be kept tight enough to prevent the battery from moving.

Pressure System

Regularly, it is necessary to inspect the external surfaces of the pressure system, from the Airend through to the Service Valve(s) including hoses, tubes, tube fittings, and the separator tank for visible signs of impact damage, excessive corrosion, abrasion, tightness, and chafing. Any suspect parts should be replaced before the compressor is put back into service.

Tire Pressure

See the General Data Section of this manual.

Running Gear/Wheels

Check wheel nut torque 20 miles (30 kilometers) after refitting the wheels. Refer to Torque Values later in this section.

Lifting jacks should only be used under the axle. Bolts securing the running gear to the chassis should be checked for tightness (refer to the

Maintenance Schedule for frequency). Re-tighten where necessary. Refer to Torque Values later in this section.

Maintenance Operation & Maintenance Manual

Lubrication

CAUTION

Always check the oil levels before a new compressor is put into service.

If, for any reason, the compressor oil has been drained, it must be re-filled with new oil before putting into operation.

Engine Oil

The engine oil and oil filter element should be changed at the engine manufacturer's recommended intervals. Refer to the Engine Operator Manual.

The Tier 4 engine in this compressor requires engine lubricating oil to ensure proper Aftertreatment System operation and engine durability. Doosan Tier 4 Premium Engine Oil is recommended. Refer to the Engine Operator Manual for engine oil specifications.

Compressor Oil

Refer to the Maintenance Schedule in this section for service intervals.

NOTE: If the compressor has been operating under adverse conditions or has suffered long shutdown periods, more frequent service intervals will be required.

WARNING

DO NOT, under any circumstances, remove any drain plugs or the oil filler plug from the compressor lubricating and cooling system without first ensuring the compressor is stopped and the system has been completely relieved of all air pressure (refer to STOPPING in the Operating Instructions Section of this manual).

Completely drain the separator tank, piping, and oil cooler by removing the drain plug(s) and collecting the used oil in a suitable container.

Replace the drain plug(s) ensuring that each one is secure.

NOTE: If the oil is drained immediately after the compressor has been in operation, most of the sediment will be in suspension and will drain more readily.

Operation & Maintenance Manual Maintenance

CAUTION

Some oil mixtures are incompatible and result in the formation of varnishes, shellacs, or lacquers which may be insoluble. Refer to the Portable Compressor Oil Chart.

Running Gear Wheel Bearings

Wheel bearings should be greased per the Maintenance Schedule in this manual. The type of grease used should conform to specifications below:

Grease

Thickener Type Lithium Complex Dropping Point 215°C (419°F) Minimum Consistency NLGI No.2 Additives EP, Corrosion & Oxidation Inhibitors Viscosity Index 80 Minimum

Maintenance Operation & Maintenance Manual

Pressure Regulator Adjusting Instructions

Low Pressure Regulator

Before Starting

1. Select Low Pressure Mode by pressing the LO Pressure Button.

2. At the Low Pressure Regulator, loosen the jam nut and turn screw counterclockwise until

tension is no longer felt at the screw. Turn screw clockwise one full turn.

3. If high pressure regulation needs adjustment, repeat Step 2 at High Pressure Regulator.

4. Close Service Valves.

After Starting Unit

5. Push the Service Air Button on the Control Panel. The unit should speed up and then u nload

(and drop back to IDLE). With the unit unloaded, turn the adjusting screw on the Low Pressure Regulator clockwise until the discharge pressure gauge indicates 25 psi over the rated pressure. Tighten the pressure regulator jam nut.

6. To adjust the high pressure regulation, repeat Step 5 on High Pressure Regulator except

adjust pressure at idle to 25 psi over the rated pressure while in High Pressure Mode. Note: The High Pressure Regulator must be set at a higher pressure than the Low Pressure

Regulator.

High Pressure Regulator

Operation & Maintenance Manual Maintenance

Torque Values

TABLE 1 INCH FASTENERS

SAEJ249

Maintenance Operation & Maintenance Manual

Note: Cooling Fan Drive Bolts (10.9 M8x1.25) should be torqued to 23Nm (17ft-lbF).

TABLE 3

Wheel Torque Chart - Inch Wheel Torque Chart - Metric

1/2” lug nuts Torque (Ft-Lbs) Torque (N-m) Torque (ft-Lbs)

13” Wheel 80-90 15” Wheel 105-115 M12 Bolts 85-95 62-70 16” Wheel 105-115 M14 Bolts 145-155 107-115

16.5” Wheel 105-115 M16 Bolts 175-185 129-137

5/8” Lug Nuts

16” Wheel 190-210 17” Wheel 190-210

9/16” Clamp nuts/Demountable Wheels

14.5” Wheel 105-115

WHEEL TORQUE CHART

M18 Bolts 205-215 151-159

Operation & Maintenance Manual Maintenance

Lubrication

Operation & Maintenance Manual Lubrication

General Information

Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the compressor. Different lubricants are needed and some components require more frequent lubrication than others. Therefore, it is important that th e instructions regarding types of lubricants and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures.

The Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed. A regular service program should be developed to in clude all items and fluids. These intervals are based on average operating conditions. In the event of extremely severe (hot, cold, dusty, or wet) operating conditions, more frequent lubrication than specified may be necessary.

All filters and filter elements for air and compressor oil must be obtained through Portable Power to ensure the proper size and filtration for the compressor.

Compressor Oil Change

These compressors are furnished with an initial supply of oil sufficient to allow operation until the first service interval indicated in the Maintenance Schedule. If a compressor has been drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to specifications in the Portable Compressor Oil Chart.

NOTICE

Some oil types are incompatible when mixed and result in the formation of varnishes, shellacs, or lacquers which may be insoluble. Such deposits can cause serious troubles including clogging of the filters. DO NOT mix oils of different types and avoid mixing different brands. A type or brand change is best made at the time of a complete oil drain and refill.

If the compressor has been operated for the time/hours indicated in the Maintenance Schedule, it should be drained of oil. If the compressor has been operated under adverse

conditions, or after long periods in storage, an earlier change may be necessary as oil deteriorates with time as well as by operating conditions.

CAUTION

In most severe applications (i.e., sandblasting, quarry drilling, well drilling, and oil and gas drilling) more frequent service intervals will be required to ensure long component life.

Lubrication Operation & Maintenance Manual

WARNING

High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers, or other parts from pressurized air system. Ensure that the air pressure gauge reads zero (0) pressure and ensure there is no air discharge when opening the manual blowdown valve.

An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.

Completely drain the separator tank, piping, and cooler. Note: If the compressor has been operating under adverse conditions or has suffered long shutdown periods, more frequent service intervals will be required. If the oil is drained immediately after the compressor has been run for some time, most of the sediment will be in suspension and, therefore, will drain more readily. However, the oil will be hot and care must be taken to avoid contact with the skin or eyes.

After the compressor has been drained of all old oil, close the drain valves and/or plugs and install new oil filter elements. Add oil in the specified quantity at the filler plug. Tighten the filler plug and run the compressor to circulate the oil. Check the oil level. DO NOT OVERFILL.

NOTICE

Portable Power provides compressor oil specifically formulated for Portable Compressors. Use of these fluids is required to obtain extended limited airend warranty.

Operation & Maintenance Manual Lubrication

Portable Compressor Oil Chart

Refer to this chart for the correct compressor oil required. Note that the selection of oil is dependent on the rated operating pressure of the compressor and the ambient temperature expected to be encountered before the next oil change.

NOTE: Oils listed as “preferred” are required for extended warranty.

Compressor oil carryover (oil consumption) may be greater with the use of alternative oils.

Rated Operating

Pressure

100 psi to 200 psi (

(6.9 to 13.8 bar)

Ambient

Tem per atu re

-10°F to 120°F (-23°C to

49°C)

Below -10°F (-

(Below -23°C)

Compressor Oil

Specification

Preferred: PRO-TEC™

Alternate: ISO Viscosity Grade 46 PAO, with rust and oxidation inhibitors, for rotary screw compressor service.

Consult Factory

Preferred Oils - Use of these oils with Doosan branded filters can extend airend warranty. Refer to the warranty policy for details or contact your representative.

Table 1:

Preferred Oils 1 gal. (3.8 Liter) 5 gal. (19.0 Liter) 55 gal. (208 Liter) 275 gal. (1041 Liter)

Pro-Tec 36899698 36899706 36899714 36899722 Tier 4 Engine Oil 46557017 46557016 46557015

Troubleshooting

Operation & Maintenance Manual Troubleshooting

Introduction

Troubleshooting for a portable air compressor is an organized study of a pa rticular problem or series of problems and a planned method of procedure for investigation and correction. The troubleshooting chart that follows includes some of the problems that an operator may encounter during the operation of a portable compressor.

The chart does not attempt to list all of the complaints that may occur, nor does it attempt to give all of the solutions for correction of the complaints. The chart does list the complaints that are most likely to occur. To use the Troubleshooting Chart:

A. Find the complaint depicted as a bold heading. B. Follow down that column to find the potential cause or causes. The causes are

listed in order to suggest an order to follow in troubleshooting.

Think Before Acting

Study the problem thoroughly and ask yourself these questions:

1. What were the warning signals that preceded the problem?

2. Has a similar problem occurred before?

3. What previous maintenance work has been done?

4. If the compressor will still operate, is it safe to continue operating to make further checks?

Do the Simplest Things First

Most problems are simple and easily corrected. For example, most complaints are “low capacity” which may be caused by too low an engine speed or “compressor overheats” which may be caused by low oil level.

Always check the easiest and most obvious things first. Following this simple rule will save time and trouble.

Double Check Before Disassembly

The source of most compressor troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a compressor can be partially disassembled in search of the cause of a certain problem and all evidence is destroyed during disassembly. Check again to be sure an easy solution to the problem has not been overlooked.

Find and Correct Basic Cause

After a mechanical failure has been corrected, be sure to locate and correct the cause of the problem so the same failure will not be repeated. For example, a complaint of “premature breakdown” may be corrected by repairing any improper wiring connections but something caused the defective wiring. The cause may be excessive vibration.

Troubleshooting Operation & Maintenance Manual

2. Compressor won t start or

Battery disconnect switch off.

Check switch position and operation.

Troubleshooting Chart

Complaint Cause Correction

1. Compressor has stopped ectedl

unex

Out of fuel. Add clean fuel.

Compressor oil temperature too high. See Complaint #6.

Engine coolant temperature too high. Check coolant level. If low, add

coolant. See Complaint #3.

ine oil pressure too low. See Complaint #4.

En Loose or broken belts. Ti Loose wire connection. Check wires at switches and

Low fuel level fault. If adequate fuel in the tank, check fuel

Defective sensor. Identify and check sensor. Replace if

Malfunctioning relay. Identify and check relay. Replace if

Blown fuse. Identify and replace fuse. See

Engine malfunctioning. See troubleshooting in Engine manual.

hten or replace belt set.

connectors to find loose connection. Make repairs. See Electronic Service Manual.

level sender device. Replace if determined faulty. See Electronic Service Manual.

necessary. See Electronic Service Manual.

Electronic Service Manual.

run

irend malfunctioning. See Complaint #6.

Emergency stop pushed. Check emergency stop switch position

and operation.

Low battery voltage. Check battery condition; recharge if

necessary. Check electrolyte level; add if necessary. Check cable connections; clean and tighten as needed.

Blown fuse. Identify and replace fuse. See

Electronic Service Manual.

Malfunctioning main power switch. Check switch. Replace if necessary.

See Electronic Service Manual.

Clogged fuel filters. Service fuel filters. See Engine

manual. Out of fuel. Compressor oil temperature too high. See Complaint #6.

Engine coolant temperature too high. Check coolant level. If low, add

ine oil pressure too low. See Complaint #4.

En Loose wire connection. Check wires at switches and

dd clean fuel.

coolant.

See Complaint #3.

connectors to find loose connection.

Make repairs. See Electronic Service

Manual.

Operation & Maintenance Manual Troubleshooting

Checko

, add o

4. Low Engine Oil Pressure

oegeoee

C ec o e e o , add o

Complaint Cause Correction

(continued)

2. Compressor won't start or run

3. High engine Coolant erature

Tem

Defective sensor. Identify and check sensor. Replace if

necessary. See Electronic Service Manual.

Malfunctioning relay. Identify and check relay. Replace if

necessary. See Electronic Service Manual.

Engine malfunctioning. See troubleshooting in Engine manual.

irend malfunctioning. See Complaint #6.

Low coolant level. Check coolant level. If low, add

coolant. Loose or broken belts. Ti Ambient temperature above rated ambient temperature ran Dirty operating conditions. Move compressor to cleaner

Dirt

cooler(s). Clean exterior of cooler(s). Compressor tilted beyond out-of-level operatin Operating pressure too high. Reduce pressure to rated operating

Recirculation of cooling air. Close enclosure doors. Close and

Loose wire connection. Check wires at switches and

Lowengineoil level.

limit.

hten or replace belt set.

Operate in cooler environment.

environment.

Reposition or relocate compressor to be more level.

pressure.

secure access panels. Check for loose or missin

connectors to find loose connection. Make repairs. See Electronic Service Manual.

belly pans.

il level. If low

il.

5. Low electrical system e

volta

Compressor tilted beyond out-of-level operatin Wrong engine oil. Change engine oil. Review engine oil

Clo Engine malfunctioning. See troubleshooting in Engine manual.

Loose wire connection. Check wires at switches and

Loose or broken belts. Tighten or replace belt set.

Loose wire connection. Check wires at switches and

Low battery voltage. Check battery condition; recharge if

Malfunctionin

limit.

ed engine oil filter. Replace engine oil filter.

alternator. Repair or replace alternator.

Reposition or relocate compressor to be more level.

specification.

connectors to find loose connection. Make repairs. See Electronic Service Manual.

necessary. Check electrolyte level; add if necessary. Check cable connections; clean and tighten as needed.

Troubleshooting Operation & Maintenance Manual

Complaint Cause Correction

6. High compressor oil temperature

7. Low engine speed

Ambient temperature above rated ambient temperature range. Compressor tilted beyond out-of-level operating limit. Low compressor oil level. Add compressor oil. Look for and

Wrong compressor oil. Change compressor oil. Review

Dirty cooler(s). Clean exterior of cooler(s). Dirty operating conditions. Move compressor to cleaner

Clogged compressor oil filter(s). Replace compressor oil filter(s) and

Loose or broken belts. Tighten or replace belt set. Operating pressure too high. Reduce pressure to rated operating

Recirculation of cooling air. Close enclosure doors. Close and

Malfunctioning compressor oil thermostat.

Loose or broken belts. Tighten or replace belt set. Malfunctioning minimum pressure valve. Blocked or restricted oil lines. Clean by flushing, or replace lines. Airend malfunctioning. See Complaints #11, #12. Clogged fuel filters. Service fuel filters. See Engine

Operating pressure too high. Reduce pressure to rated operating

Clogged air filter element(s). Clean or replace air filter element(s). Wrong air filter element(s). Install correct air filter element(s). Engine malfunctioning. See troubleshooting in Engine manual.

gp,

Operate in cooler environment.

Reposition or relocate compressor to be more level.

repair any leaks.

compressor oil specification.

environment.

change compressor oil.

pressure.

secure access panels. Check for loose or missing belly pans. Replace thermostat element in conventional bypass valve, if equipped. Replace valve.

Repair or replace valve.

manual. Drain and clean fuel tanks. Add clean fuel.

pressure.

irend malfunctioning. See Complaints #11, #12.

8. Excessive vibration

Rubber mounting isolators loose or

ed.

dama Defective or imbalanced fan. Replace fan. Defective airend drive couplin Engine malfunctioning. See troubleshooting in Engine manual.

irend malfunctioning. See Complaints #7, #11, #12.

Engine idle speed too low. See Complaint #7. See Engine

. Replace coupling.

Tighten or replace.

manual.

Operation & Maintenance Manual Troubleshooting

o 3

Complaint Cause Correction

9. Low air delivery / low cfm

Clogged air filter element(s). Clean or replace air filter element(s).

10. Short air filter life

11. Compressor will not unload

12. Safety valve opens

13. Excessive carryover (compressor oil in the

pressed air)

com

Incorrect pressure regulation adjustment. Malfunctioning inlet unloader / butterfly

valve

Wrong air filter element(s). Install correct air filter element(s). Low engine speed See Complaint #7. See Engine

Compressed air leaks. Locate and repair leaks. Dirty operating conditions. Move compressor to cleaner

Wrong air filter element(s). Install correct air filter element(s). Inadequate air filter element cleaning. Install new air filter element(s).

Incorrect stopping procedure. Comply with procedure in this manual.

Malfunctioning inlet unloader / butterfly

valve.

Malfunctioning pressure regulator. Check pressure regulator.

Ice in regulation lines and/or regulation orifice.

Plugged vent leak. Clean and/or replace. Operating pressure too high. Reduce pressure to rated operating

Malfunctioning inlet unloader / butterfl Inspect valve. Make adjustments per

valve.

Defective safety valve. Replace safety valve. Compressor will not unload fast enough. Ice in regulation lines and/or regulation orifice.

Blocked separator scavenge line. Check scavenge line, drop tube, and

Deteriorated separator element. Replace separator element. Separator tank pressure too low. Check the minimum pressure valve.

Make adjustments per this manual.

Inspect valve. Make adjustments per this manual.

manual.

environment.

Inspect valve. Make adjustments per this manual.

Check regulation lines for leaks. Apply heat to lines and/or orifice. Check operation of DC electric heaters, if equipped.

pressure.

pjp

this manual.

Check pressure regulator. Check regulation lines for leaks. Apply heat to lines and/or orifice. Check operation of DC electric heaters, if equipped.

orifice. Clean and replace as needed.

Repair or replace as necessary.

Diagnostic Codes

The MidPort displays diagnostic codes for the compressor system and the engine. Listi of these codes are provided in this section.

The engine diagnostic codes can also be read with the engine manufacturer's service t service tool connector is provided in the electrical harness, providing access to the J19 network. For advanced engine troubleshooting, it is recommended that the manufacture service tools and service literature be used.

Troubleshooting Operation & Maintenance Manual

Engine Diagnostic Codes - Cummins Engine with CM2250 Controller

LCD Display Display Name Description

CPR CODE 1 LOW ENGINE SPEED CPR CODE 2 HIGH ENGINE SPEED CPR CODE 3 WAIT 30 SEC RETRY START CPR CODE 4 OUT OF FUEL CPR CODE 10 ENG SPEED RESPONSE CPR CODE 11 A/S ATTEMPT EXCEEDED CPR CODE 12 FUEL LEVEL LOW CPR CODE 29 ENGINE SHUTDOWN ?? CPR CODE 30 HIGH AIREND TEMP CPR CODE 32 AIREND DISC TEMP SENSOR CPR CODE 33 SEP TANK PRES SENSOR CPR CODE 34 HIGH PRES AT START CPR CODE 35 HIGH SEP TANK PRES CPR CODE 36 SAFETY VALVE OPEN CPR CODE 38 AIR FILTERS RESTRICTED CPR CODE 39 LOW SYSTEM VOLTAGE CPR CODE 42 FUEL LEVEL SENSOR CPR CODE 43 LOW SEP TANK PRES CPR CODE 44 HIGH IQ FILTERS RSTR

Low Engine Speed

High Engine Speed

Engine Crank Timeout

Out of Fuel

Engine Speed Response

Autostart Attempts Exceeded

Low Fuel Level

Engine Shutdown Unknown

High Airend Discharge Temperature Airend Discharge Temperature Sensor Separator Tank Pressure Sensor

High Separator Pressure at Start

High Separator Tank Pressure

Safety Value Open

Intake Air Filters Restricted Intake filters restricting air flow.

Low System Voltage / Alternator Not Charging Fuel Level Sensor Fuel level sensor reading out of

Low Separator Tank Pressure

High IQ Filter Restriction

Engine speed less than 1100 RPM for 30 seconds.

Engine speed greater than 2300 RPM for 30 seconds.

Engine crank attempt longer than 15 seconds above 50°F or longer than 30 seconds below 32°F.

Fuel level in tank below usable limit.

Engine target idle speed not met within 10 seconds after loading compressor.

Compressor not started after 3 crank attempts.

Fuel level in tank approaching empty.

Engine stopped without an engine diagnostic code.

Airend discharge temperature greater than or equal to 248

Airend discharge temperature sensor reading out of range.

Separator tank pressure sensor reading out of range.

Separator tank pressure greater than 20 psi at crank attempt.

Air pressure in the separator tank exceeded limit.

Safety relief valve on separator tank opened.

Electrical system voltage below

25.5VDC.

range.

Separator tank pressure below 40 psi after compressor is loaded.

IQ filters restricting air flow. ALERT

Type

FAULT

ALERT

FAULT

ALERT

FAULT

ALERT

FAULT

ALERT

FAULT

Operation & Maintenance Manual Troubleshooting

LCD Display Display Name Description

CPR CODE 50 HIGH SEP TANK TEMP CPR CODE 51 COMPRESSOR ID INVALID CPR CODE 52 IQ FILTERS RESTRICTED CPR CODE 53 SEP TANK TEMP SENSOR CPR CODE 54 REG SYSTEM PRES SENSOR CPR CODE 55 E-STOP ACTIVATED CPR CODE 58 AMBIENT TEMP SENSOR CPR CODE 61 IQ FILTER PRES ERROR CPR CODE 63 IQ DIFF PRES SENSOR CPR CODE 71 ENG ECM COMMS CPR CODE 73 AUTOSTART CTRL COMMS CPR CODE 75 IQ TCU CTRL COMMS CPR CODE 76 CPR CTRL COMMS CPR CODE 77 KEYPAD COMMS

High Separator Tank Temperature

Compressor ID Invalid

IQ Filter Restricted IQ filters restricted past usable

Separator Tank Temperature Sensor Regulation System Pressure Sensor

Emergency Stop Activated

Ambient Temperature Sensor IQ Filter Pressure Error

IQ Differential Pressure Sensor

Engine ECM Communication

Auto Start Controller Communication IQ TCU Controller Communication

Compressor Controller Communication Keypad Communication

Separator tank temperature greater than or equal to 248

The Titan controller and MidPort Display do not have a valid compressor ID.

level.

Separator tank temperature sensor reading out of range.

Regulation system pressure sensor reading out of range.

Emergency Stop button has been activated.

Ambient temperature sensor reading out of range.

IQ filter outlet pressure reading higher than inlet pressure.

IQ differential pressure sensor reading out of range.

Communication between Titan controller and engine ECM not functional. Communication between Titan controller and AutoStart controller not functional. Communication between Titan controller and OTC controller not functional. Communication between Titan controller and Engine Tachometer with MidPort Display not functional. Communication between Titan controller and Keypad not functional.

Type

FAULT

ALERT

FAULT

ALERT

FAULT

Troubleshooting Operation & Maintenance Manual

Incorrect

Engine Diagnostic Codes - Cummins Engine with CM2250 Controller

EGR Valve Position Circuit - Voltage Below Normal, or Shorted to Low Sour ce

Engine Particulate Trap Inlet Pressure - Data Valid But Above Nor mal Oper at ing

Range - Moderately Severe Level

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Accelerator Pedal or Lever Position Sensor Circuit – Abnormal Frequency, Pulse

Width, or Period

Vehicle Speed Sensor Circuit tampering has been detected – Abnormal Rate of

Accelerator Pedal or Lever Position Sensor Circuit – Abnormal Frequency, Pulse

Change

Data Valid but Above Normal Operational

Range - Most Severe Level

Data Valid but Below Normal Operational

Width, or Period

Range - Most Severe Level

Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above Nor mal, or

Accelerator Pedal or Lever Position Sensor 1 and 2 - Data Erratic, I n t er mitt e nt , or

Incorrect

Voltage Above Normal, or Shorted to High

Shorted to High Source

Source

Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Nor mal, or

Voltage Below Normal, or Shorted to Low

Shorted to Low Source

SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor System - Abnormal

Source

update rate

Fuel Filter Differential Pressure - Data Valid But Above Normal Operating Range -

Moderately Severe Level

Water in Fuel Sensor Circuit - Voltage Above Normal, or Short e d t o High Sour ce

Water in Fuel Sensor Circuit - Voltage Below Normal, or Short e d t o Low Sour ce

Water in Fuel Indicator High - Data Valid but Above Normal Operat ional Range –

Least Severe Level

Water in Fuel Indicator - Data Valid but Above Normal Operat ional Range -

Moderately Severe Level

Oil Pressure Low – Data Valid but Below Normal Operational Range - Most Severe

SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error -

Received Network Data In Error

Auxiliary Constrained Operation Curve Validation Switch - Data Erratic, Intermittent,

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Range - Least Severe Level

Level

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Data Valid but Below Normal Operational

Range - Most Severe Level

Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted t o High Sour ce

Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

J1939 SPN Description J1939 FMI Description Cummins Description

Engine Exhaust Gas Recirculation 1 Valve

Position

Engine Diesel Particulate Filter Intake

Pressure

Wheel-Based Vehicle Speed Data Erratic, Intermittent or Incorrect Vehicle Speed Sensor Circuit - Data Erratic, Intermittent, or Incorrect

Wheel-Based Vehicle Speed Abnormal Rate of Change

Accelerator Pedal Position 1

Accelerator Pedal Position 1 Data Erratic, Intermittent or Incorrect

Accelerator Pedal Position 1

Accelerator Pedal Position 1 Abnormal Update Rate

Accelerator Pedal Position 1 Received Network Data in Error

Engine Net Brake Torque Data Erratic, Intermittent or Incorrect

Fuel Pressure

Water in Fuel Indicator

Engine Oil Pressure

Engine Oil Pressure Data Erratic, Intermittent or Incorrect Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

Engine Oil Pressure

Code

Cummins

FMI

J1939

27 4 2272

81 16 2754

84 2 241

84 10 242

91 0 148

91 1 147

91 2 1242

91 3 131

91 4 132

91 9 3326

91 19 287

93 2 528

95 16 2372

97 3 428

97 4 429

97 15 418

97 16 1852

100 1 415

100 2 435

100 3 135

SPN

J1939

100 4 141

Operation & Maintenance Manual Troubleshooting

Severe Level

Coolant Temperature High - Data Valid but Above Normal Operational Range - Most

Coolant Temperature Sensor Circuit – Voltage Above Normal, or Short ed t o High

Source

Coolant Temperature Sensor Circuit – Voltage Below Normal, or Short ed t o Low

Source

Coolant Temperature High - Data Valid but Above Normal Operational Range -

Moderately Severe Level

Engine Coolant Temperature - Data Valid But Below Normal Operating Range -

Moderately Severe Level

Coolant Level Low - Data Valid but Below Normal Operational Range - Most Severe

Level

Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted to High Sour ce

Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted to Low Sour ce

Coolant Level - Data Valid But Below Normal Operating Range - Least Severe Level

Coolant Level - Data Valid but Below Normal Operational Range - Moderately

Severe Level

Fuel Pressure High - Data Valid but Above Normal Operational Range –

Moderately Severe Level

Injector Metering Rail 1 Pressure - Data Valid but Above Normal Operat ional Range

- Most Severe Level

Injector Metering Rail 1 Pressure - Data Valid but Below Normal Operat ional Range

Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Above Normal, or

Shorted to High Source

Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Below Normal, or

Most Severe Level

Shorted to Low Source

Data Valid but Above Normal Operational

Range - Most Severe Level

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Data Valid but Below Normal Operating

Range - Moderately Severe Level

Data Valid but Below Normal Operational

Range - Most Severe Level

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Below Normal Operating

Range - Least Severe Level

Data Valid but Below Normal Operating

Range - Moderately Severe Level

Data Valid but Above Normal Operational

Range - Most Severe Level

Data Valid but Above Normal Operational

Range - Most Severe Level

Data Valid but Below Normal Operational

Range - Most Severe Level

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

J1939 SPN Description J1939 FMI Description Cummins Description

Barometric Pressure Abnormal Update Rate Turbocharger 1 Compressor Inlet Pressure - Abnormal Update Rate

Barometric Pressure Received Network Data in Error Turbocharger 1 Compressor Inlet Pressure - Received Network Data In Error

Engine Coolant Temperature

Engine Coolant Temperature Special Instructions Engine Coolant Temperat ur e - Special I nstructions

Engine Coolant Temperature

Engine Coolant Temperature Not Available or Condition Exists Engine Coolant Temperature - Condition Exists

Engine Coolant Level

Engine Coolant Level Data Erratic, Intermittent or Incorrect Coolant Level - Data Erratic, Intermittent, or Incorrect

Engine Coolant Level

Engine Injector Metering Rail 1 Pressure

Code

Cummins

FMI

J1939

108 9 3372

108 19 3373

110 0 151

110 3 144

110 4 145

110 14 1847

110 16 146

110 18 2789

110 31 2646

110 31 2659

111 1 235

111 2 422

111 3 195

111 4 196

111 17 2448

111 18 197

157 0 449

157 0 1911

157 1 2249

157 3 451

SPN

J1939

157 4 452

Troubleshooting Operation & Maintenance Manual

Injector Metering Rail #1 Pressure High – Data Valid but Above Normal Oper at ional

Range - Moderately Severe Level

Injector Metering Rail #1 Pressure Low – Data Valid but Below Normal Oper at ional

Range - Moderately Severe Level

Battery #1 Voltage High - Data Valid but Above Normal Operat ional Range –

Moderately Severe Level

Battery #1 Voltage Low - Data Valid but Below Normal Operat ional Range –

Moderately Severe Level

Engine Speed High - Data Valid but Above Normal Operational Range - Most

Severe Level

Engine Crankshaft Speed/Position - Data Valid But Above Normal Operating Range

Turbocharger 1 Compressor Inlet Temperature Sensor - Received Network Data In

Error

Moderately Severe Level

Transmission Output Shaft Speed - Data Valid but Above Normal Operational

Range - Moderately Severe Level

Transmission Output Shaft Speed - Data Valid but Below Normal Operational

Range - Moderately Severe Level

Exhaust Gas Recirculation (EGR) Valve Delta Pressure - Data Err at ic, I ntermittent

or Incorrect

Exhaust Gas Recirculation (EGR) Valve Delta Pressure Sensor Circuit - Volt age

Above Normal, or Shorted to High Source

Exhaust Gas Recirculation (EGR) Valve Delta Pressure Sensor Circuit - Volt age

Below Normal, or Shorted to Low Source

Exhaust Gas Recirculation (EGR) Temperature Sensor Circuit - Voltage Above

Normal, or Shorted to High Source

Exhaust Gas Recirculation (EGR) Temperature Sensor Circuit - Volt age Below

Normal, or Shorted to Low Source

Exhaust Gas Recirculation (EGR) Temperature - Data Valid But Above Normal

Operating Range - Least Severe Level

Exhaust Gas Recirculation (EGR) Temperature - Data Valid But Above Normal

Operating Range - Moderately Severe Level

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Data Valid but Below Normal Operating

Range - Moderately Severe Level

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Data Valid but Below Normal Operating

Range - Moderately Severe Level

Data Valid but Above Normal Operational

Range - Most Severe Level

Data Valid but Above Normal Operational

Range - Most Severe Level

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Data Valid but Below Normal Operating

Range - Moderately Severe Level

Data Erratic, Intermittent or Incorrect

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Range - Least Severe Level

Data Valid but Above Normal Operating

Range - Moderately Severe Level

J1939 SPN Description J1939 FMI Description Cummins Description

Engine Injector Metering Rail 1 Pressure

Engine Rated Power Data Erratic, Intermittent or Incorrect Cylinder Power Imbalance Between Cylinders - Data erratic, intermit t ent or incorrect

Battery Potential / Power Input 1

Ambient Air Temperature Abnormal Update Rate Turbocharger 1 Compressor Inlet Temperature Sensor - Abnormal Update Rate

Ambient Air Temperature Received Network Data in Error

Engine Speed

Engine Speed Data Erratic, Intermittent or Incorrect Primary Engine Speed Sensor Error – Data Erratic, Intermittent, or Incorrect

Engine Speed Data Erratic, Intermittent or Incorrect Engine Speed / Position Sensor #1 - Data Erratic, Intermittent, or Incorrect

Transmission Output Shaft Speed Abnormal Update Rate Transmission Output Shaf t Speed - Abnor mal update r at e

Transmission Output Shaft Speed

Engine Exhaust Gas Recirculation 1

Differential Pressure

Engine Exhaust Gas Recirculation 1

Differential Pressure

Engine Exhaust Gas Recirculation 1

Differential Pressure

Engine Exhaust Gas Recirculation 1

Temperature

Engine Exhaust Gas Recirculation 1

Temperature

Engine Exhaust Gas Recirculation 1

Temperature

Engine Exhaust Gas Recirculation 1

Temperature

Code

Cummins

FMI

J1939

157 16 553

157 18 559

166 2 951

168 16 442

168 18 441

171 9 3369

171 19 3371

190 0 234

190 0 2468

190 2 689

190 2 2321

191 9 3328

191 16 349

191 18 489

411 2 1866

411 3 2273

411 4 2274

412 3 2375

412 4 2376

412 15 2961

SPN

J1939

412 16 2962

Operation & Maintenance Manual Troubleshooting

Range

Moderately Severe Level

Range Moderately Severe Level

Operational

Range

Moderately

Severe

Level

Auxiliary Temperature Sensor Input # 1 Circuit - Voltage Above Normal, or Shorted

to High Source

Auxiliary Temperature Sensor Input # 1 Circuit - Voltage Below Normal, or Shorted

to Low Source

Accelerator Pedal or Lever Idle Validation Circuit - Data Erratic, Intermittent, or

Incorrect

Brake Switch Circuit - Voltage Above Normal, or Shorted to High Sour ce

Brake Switch Circuit - Voltage Below Normal, or Shorted t o Low Sour ce

OEM Intermediate (PTO) Speed switch Validation - Data Erratic, Intermittent, or

Sensor Supply 4 Circuit-Voltage Below Normal, or Shorted to Low Sour ce

Incorrect

Fuel Inlet Meter Device - Data Valid but Above Normal Operational Range -

Moderately Severe Level

Fuel Inlet Meter Device Flow Demand Lower Than Expected - Data Valid But Below

Red Stop Lamp Driver Circuit - Voltage Below Normal, or Shorted t o Low Sour ce

Engine Speed/Position Sensor Circuit lost both of two signals from the magnetic

pickup sensor - Data Erratic, Intermittent, or incorrect

Engine Control Module Warning internal hardware failure - Bad I nt e lligent Device or

Component

J1939 SPN Description J1939 FMI Description Cummins Description

Code

Cummins

FMI

J1939

SPN

J1939

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Auxiliary Temperature 1

441 3 293

441 4 294

Auxiliary Temperature 1 Special Instructions Auxiliary Temperature Sensor Input 1 - Special Instructions

441 14 292

Voltage Above Normal, or Shorted to High

Source

Auxiliary Temperature 1 Special Instructions Auxiliary Temperature Sensor Input 1 - Special Instructions

Accelerator Pedal 1 Low Idle Switch Data Erratic, Intermittent or Incorrect

Accelerator Pedal 1 Low Idle Switch Out of Calibration Accelerator Pedal or Lever Idle Validation Circuit - Out of Calibration

Brake Switch

441 14 1381

558 2 431

558 13 432

597 3 769

Voltage Below Normal, or Shorted to Low

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Brake Switch

System Diagnostic Code #1 Data Erratic, Intermittent or Incorrect

System Diagnostic Code #1

597 4 771

611 2 523

611 4 2186

611 16 2292

Range - Moderately Severe Level

Data Valid but Below Normal Operating

System Diagnostic Code #1

611 18 2293

Voltage Below Normal, or Shorted to Low

Source

System Diagnostic Code #2 Data Erratic, Intermittent or Incorrect

Red Stop Lamp

612 2 115

623 4 244

Power Supply Data Erratic, Intermittent or Incorrect Power Lost With Ignition On - Data Erratic, Intermittent, or Incorrect

627 2 1117

Power Supply Bad Intelligent Device or Component Injector Power Supply - Bad Intelligent Device or Component

Controller #1 Bad Intelligent Device or Component

629 12 343

627 12 351

Engine Fuel Actuator 1 Control Command Not Available or Condition Exists Fueling Actuator #1 Circuit Error – Condit ion Exists

633 31 2311

J1939 Network #1, Primary Vehicle Network Data Erratic, Intermittent or Incorrect J1939 Network #1 - Data erratic, intermittent or incorrect

639 2 426

J1939 Network #1, Primary Vehicle Network Abnormal Update Rate SAE J1939 Multiplexing PGN Timeout Error - Abnormal Update Rate

639 9 285

J1939 Network #1, Primary Vehicle Network Out of Calibration SAE J1939 Multiplexing Configuration Er r or – Out of Calibration

639 13 286

Troubleshooting Operation & Maintenance Manual

VGT Actuator Driver Circuit (Motor) - Mechanical System Not Responding or Out of

Adjustment

VGT/VFT Actuator Driver Over Temperature (Calculated) - Data Valid But Above

Normal Operating Range - Least Severe Level

External Speed Input (Multiple Unit Synchronization) - Dat a Er r at ic, I n t er mit t ent , or

Fan Control Circuit - Voltage Above Normal, or Shorted t o High Sour ce

Incorrect

Fan Control Circuit - Voltage Below Normal, or Shorted t o Low Sour ce

Starter Relay Driver Circuit- Voltage Above Normal, or Shorted to High Source

Auxiliary PWM Driver #1 - Voltage Above Normal, or Shor t ed t o High Sour ce

Auxiliary PWM Driver #1 - Voltage Below Normal, or Shor ted to Low Source

Auxiliary Input/Output 2 Circuit - Voltage Above Normal, or Shor ted to High Source

Auxiliary Input/Output 3 Circuit - Voltage Above Normal, or Shor ted to High Source

J1939 SPN Description J1939 FMI Description Cummins Description

Code

Cummins

FMI

J1939

SPN

J1939

Mechanical System not Responding or Out

of Adjustment

Abnormal Update Rate VGT Actuator Driver Circuit - Abnormal Update Rate

Bad Intelligent Device or Component VGT Actuator Controller - Bad intelligent Device or Component

Engine External Protection Input Special Instructions Auxiliary Commanded Dual Output Shutdown - Special Instructions

Engine Variable Geometry Turbocharger

Actuator #1

Engine Variable Geometry Turbocharger

Actuator #1

Engine Variable Geometry Turbocharger

Actuator #1

640 14 599

641 7 2387

641 9 2636

641 12 2634

Out of Calibration VGT Actuator Controller - Out of Calibration

Data Valid but Above Normal Operating

Range - Least Severe Level

Engine Variable Geometry Turbocharger

Actuator #1

Engine Variable Geometry Turbocharger

Actuator #1

Engine Variable Geometry Turbocharger

641 13 2449

641 15 1962

Not Available or Condition Exists VGT Actuator Driver Circuit - Condition Exists

641 31 2635

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Actuator #1

Engine External Speed Command Input Data Erratic, Intermittent or Incorrect

Engine Fan Clutch 1 Output Device Driver

644 2 237

647 3 2377

647 4 245

Engine Injector Cylinder #01 Current Below Normal or Open Circuit Injector Solenoid Cylinder #1 Cir cuit – Cur rent Below Normal, or Open Circuit

651 5 322

Engine Injector Cylinder #02 Current Below Normal or Open Circuit Injector Solenoid Cylinder #2 Cir cuit – Cur rent Below Normal, or Open Circuit

652 5 331

Engine Injector Cylinder #03 Current Below Normal or Open Circuit Injector Solenoid Cylinder #3 Cir cuit – Cur rent Below Normal, or Open Circuit

653 5 324

Engine Injector Cylinder #04 Current Below Normal or Open Circuit Injector Solenoid Cylinder #4 Cir cuit – Cur rent Below Normal, or Open Circuit

654 5 332

Engine Injector Cylinder #05 Current Below Normal or Open Circuit Injector Solenoid Cylinder #5 Cir cuit – Cur rent Below Normal, or Open Circuit

655 5 323

Voltage Above Normal, or Shorted to High

Source

Engine Injector Cylinder #06 Current Below Normal or Open Circuit Injector Solenoid Cylinder #6 Cir cuit – Cur rent Below Normal, or Open Circuit

Engine Starter Motor Relay

656 5 325

677 3 584

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Auxiliary PWM Driver #1

697 3 2557

697 4 2558

Source

Voltage Above Normal, or Shorted to High

Source

Auxiliary I/O #02

Auxiliary I/O #03

702 3 527

703 3 529

Operation & Maintenance Manual Troubleshooting

Low

Source

Warning Auxiliary Equipment Sensor Input # 3 (OEM Switch) - Root Cause Not

Known

Engine Speed/Position #2 Mechanical Misalignment Between Camshaft and

Crankshaft Sensors - Mechanical System Not Responding Properly or Out of

Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High Source

Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted to Low Source

Remote Accelerator Pedal or Lever Position Sensor Circuit – Voltage Above

Normal, or Shorted to High Source

Remote Accelerator Pedal or Lever Position Sensor Circuit – Voltage Below Normal,

or Shorted to Low Source

SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data Error - Received

Network Data In Error

Engine Brake Actuator Driver Output 2 Circuit - Volt age Above Nor mal, or Shor t ed

to High Source

Fuel Priming Pump Control Signal Circuit – Voltage Above Normal, or Shorted to

High Source

Fuel Priming Pump Control Signal Circuit – Voltage Below Normal, or Shorte d t o

Low Source

Engine Brake Actuator Driver 3 Circuit - Voltage Above Normal, or Shorted to High

Source

Engine Brake Actuator Driver Output 3 Circuit - Volt age Below Normal, or Shorted

to Low Source

ECM Internal Temperature Sensor Circuit - Voltage Above Normal, or Shor ted to

High Source

ECM Internal Temperature Sensor Circuit - Voltage Below Normal, or Shorted to

Low Source

Turbocharger 1 Compressor Inlet Temperature Circuit-Volt age Above Nor mal, or

Shorted to High Source

Engine Turbocharger Wastegate Actuator 1 Position - Data err atic, intermittent or

Engine Brake Actuator Driver Output 2 Circuit - Volt age Below Normal, or Shorted

incorrect

J1939 SPN Description J1939 FMI Description Cummins Description

Code

Cummins

FMI

J1939

SPN

J1939

Auxiliary I/O #03 Root Cause Not Known

703 11 779

Auxiliary I/O #03 Special Instructions Auxiliary Equipment Sensor Input 3 Engine Protection Critical - Special Instructions

703 14 2195

Engine Speed 2 Data Erratic, Intermittent or Incorrect Engine Speed Sensor (Camshaft) Error – Data Erratic, Intermittent, or I ncor r ect

723 2 778

Mechanical System not Responding or Out

of Adjustment

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Engine Speed 2 Data Erratic, Intermittent or Incorrect Engine Speed / Position Sensor #2 - Data Erratic, Intermittent, or Incorrect

Engine Speed 2

Engine Intake Air Heater Driver #1

723 2 2322

723 7 731

729 3 2555

729 4 2556

Source

Remote Accelerator Pedal Position

974 3 133

Voltage Below Normal, or Shorted to Low

Source

Remote Accelerator Pedal Position

974 4 134

Voltage Above Normal, or Shorted to High

Source

Remote Accelerator Pedal Position Received Network Data in Error

Engine (Compression) Brake Output #2

974 19 288

1073 3 2367

Voltage Below Normal, or Shorted to Low

Voltage Above Normal, or Shorted to High

Source

Engine (Compression) Brake Output #2

Engine Electric Lift Pump for Engine Fuel

Supply

1073 4 2363

1075 3 2265

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Engine Electric Lift Pump for Engine Fuel

Supply

Engine (Compression) Brake Output #3

1075 4 2266

1112 3 2368

Source

Voltage Below Normal, or Shorted to Low

Source

Engine (Compression) Brake Output #3

1112 4 2365

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Engine ECU Temperature

Engine Turbocharger 1 Compressor Intake

1136 3 697

1136 4 698

Source

Data Erratic, Intermittent or Incorrect

Temperature

Engine Turbocharger Wastegate Actuator 1

Position

Engine Exhaust Gas Pressure Data Erratic, Intermittent or Incorrect Exhaust Gas Pressure - Data Erratic, Intermittent or Incorrect

1172 3 691

1188 2 3925

1209 2 2554

Troubleshooting Operation & Maintenance Manual

Source

Exhaust Gas Pressure Sensor Circuit - Voltage Above Normal, or Shorted t o High

Source

Exhaust Gas Pressure Sensor Circuit - Voltage Below Normal, or Short e d t o Low

Source

Exhaust Gas Pressure - Data Valid But Above Normal Operating Range -

Moderately Severe Level

High Fuel Pressure Solenoid Valve Circuit – Voltage Above Normal, or Shorted to

High Source

High Fuel Pressure Solenoid Valve Circuit – Voltage Below Normal, or Shorted to

Low Source

High Fuel Pressure Solenoid Valve #1 – Mechanical System Not Responding

Properly or Out of Adjustment

Auxiliary Pressure Sensor Input # 2 Circuit - Volt age Above Nor mal, or Shor t ed t o

High Source

Auxiliary Pressure Sensor Input # 2 Circuit - Volt age Below Nor mal, or Shor t ed to

Battery Temperature - Data Valid but Above Normal Operational Range -

Moderately Severe Level

Battery Temperature - Data Valid but Below Normal Operational Range -

Moderately Severe Level

Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Above Nor mal, or

Shorted to High Source

Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Below Nor mal, or

Shorted to Low Source

J1939 SPN Description J1939 FMI Description Cummins Description

Code

Cummins

FMI

J1939

SPN

J1939

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Engine Exhaust Gas Pressure

1209 3 2373

1209 4 2374

Range - Moderately Severe Level

Engine Exhaust Gas Pressure

1209 16 2764

J1939 Network #2 Data Erratic, Intermittent or Incorrect J1939 Net wor k #2 - Data Erratic, Intermittent or I ncor r ect

1231 2 3329

Voltage Above Normal, or Shorted to High

Source

J1939 Network #3 Data Erratic, Intermittent or Incorrect J1939 Net wor k #3 - Data Erratic, Intermittent or I ncor r ect

Engine Fuel Pump Pressurizing Assembly #1

1235 2 3331

1347 3 272

Voltage Below Normal, or Shorted to Low

Source

Mechanical System not Responding or Out

of Adjustment

Engine Fuel Pump Pressurizing Assembly #1

Engine Synchronization Switch Data Erratic, Intermittent or Incorrect Multiple Unit Synchronization Switch Circuit - Data Erratic, Intermittent, or Incorrect

Engine Oil Change Interval Not Available or Condition Exists Change Lubricating Oil and Filter – Condition Exists

1347 4 271

1347 7 281

1377 2 497

1378 31 649

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Auxiliary Pressure #2

1388 3 297

1388 4 298

Auxiliary Pressure #2 Special Instructions Auxiliary Pressure Sensor I nput 1 - Special Instructions

1388 14 296

Tachograph Output Shaft Speed Data Erratic, Intermittent or Incorrect Tachograph Output Shaft Speed - Received Network Data In Error

1623 2 3213

Tachograph Output Shaft Speed Abnormal Update Rate Tachograph Output Shaft Speed - Abnormal update rate

1623 9 3186

Engine Torque Limit Feature Special Instructions Engine Torque Limit Feat ur e - Special Instructions

1632 14 2998

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Data Valid but Below Normal Operating

Range - Moderately Severe Level

Engine Starter Mode Root Cause Not Known Engine Starter Mode Overcrank Protection - Condition Exists

Battery 1 Temperature

1675 11 3737

1800 16 2263

1800 18 2264

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Accelerator Pedal #1 Channel 2

2623 3 1239

2623 4 1241

Operation & Maintenance Manual Troubleshooting

Range

Moderately Severe Level

Range Moderately Severe Level

Range

Moderately

Severe

Level

Engine Charge Air Cooler Outlet Temperature - Voltage Above Normal, or Short ed

to High Source

Engine Charge Air Cooler Outlet Temperature - Voltage Below Normal, or Short ed

to Low Source

Turbocharger Turbine Inlet Temperature (Calculated) - Data Valid but Above

Normal Operational Range – Least Severe Level

EGR Valve Control Circuit - Voltage below normal, or shorted t o low sour ce

EGR Valve Control Circuit - Mechanical system not responding or out of adjustment

Aftertreatment Diesel Oxidation Catalyst System - Data Valid But Below Normal

Operating Range - Least Severe Level

Aftertreatment Diesel Oxidation Catalyst System - Data Valid But Below Normal

Aftertreatment Exhaust Gas Temperature 1 Circuit - Voltage Below Normal, or

Shorted to Low Source

Aftertreatment Exhaust Gas Temperature 1 Circuit - Voltage Below Normal, or

Shorted to Low Source

Aftertreatment Diesel Particulate Filter Intake Gas Temperature – Data valid but

above normal operational range – Most Severe Level

Aftertreatment 1 Diesel Particulate Filter Intake Temperature - Data erratic,

intermittent or incorrect

Aftertreatment 1 Diesel Particulate Filter I ntake Temperature Sensor Circuit -

Voltage above normal, or shorted to high source

Aftertreatment 1 Diesel Particulate Filter I ntake Temperature Sensor Circuit -

Voltage below normal, or shorted to low source

J1939 SPN Description J1939 FMI Description Cummins Description

Code

Cummins

FMI

J1939

SPN

J1939

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Range - Least Severe Level

Engine Charge Air Cooler 1 Outlet

Temperature

Engine Charge Air Cooler 1 Outlet

Temperature

Engine Turbocharger 1 Calculated Turbine

Intake Temperature

2630 3 2571

2630 4 2572

2789 15 2346

Voltage Below Normal, or Shorted to Low

Source

Engine Exhaust Gas Recirculation 1 (EGR1)

Valve Control

2791 4 2351

Current Below Normal or Open Circuit EGR Valve Control Circuit - Current below normal or open circuit

Engine Exhaust Gas Recirculation 1 (EGR1)

Valve Control

2791 5 2349

Current Above Normal or Grounded Circuit EGR Valve Contro l Cir cuit - Cur r ent above normal or grounded circuit

Mechanical System not Responding or Out

of Adjustment

Out of Calibration EGR Valve Controller - Out of Calibration

Engine Exhaust Gas Recirculation 1 (EGR1)

Valve Control

Engine Exhaust Gas Recirculation 1 (EGR1)

Valve Control

Engine Exhaust Gas Recirculation 1 (EGR1)

Valve Control

Engine Injector Group 1 Out of Calibration Engine Injector Bank 1 Barcodes - Out of Calibration

2791 6 2353

2791 7 2357

2791 13 1896

2797 13 2765

Data Valid but Below Normal Operating

Range - Least Severe Level

Data Valid but Below Normal Operating

Catalyst Bank 1 System Monitor Root Cause Not Known Aftert r eatment Diesel Oxidation Catalyst Face Plugged - Root Cause Not Known

Catalyst Bank 1 System Monitor

3050 11 2637

3050 17 2638

3050 18 1691

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operational

Range - Most Severe Level

Data Erratic, Intermittent or Incorrect

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

EGR System Monitor Not Available or Condition Exists Engine Exhaust Gas Recirculation (EGR) System - Condition Exists

Aftertreatment 1 Exhaust Gas Temperature 1 Data Erratic, Intermittent or Incorrect Aftertreatment Exhaust Gas Temperature 1 - Data Erratic, Intermittent or Incorrect

Aftertreatment 1 Exhaust Gas Temperature 1

Aftertreatment 1 Exhaust Gas Temperature 1 Out of Calibration Aftertreatment Exhaust Gas Temperatur e 1 Swapped - Out of Calibr at ion

Aftertreatment 1 Diesel Particulate Filter

Intake Gas Temperature

Aftertreatment 1 Diesel Particulate Filter

Intake Gas Temperature

Aftertreatment 1 Diesel Particulate Filter

Intake Gas Temperature

Aftertreatment 1 Diesel Particulate Filter

Intake Gas Temperature

3058 31 2774

3241 2 1667

3241 3 1666

3241 4 1665

3241 13 1663

3242 0 3311

3242 2 3318

3242 3 3317

3242 4 3316

Troubleshooting Operation & Maintenance Manual

Least Severe Level

Range

Least

Severe

Level

ftertreatment 1 Diesel Particulate Filter Intake Temperature - Data Valid But Above

Normal Operating Range - Least Severe Level

Normal Operating Range - Moderately Severe Level

Aftertreatment Exhaust Gas Temperature 3 Circuit - Volt age Above Nor mal, or

Shorted to High Source

Aftertreatment Exhaust Gas Temperature 3 Circuit - Voltage Below Normal, or

Shorted to Low Source

Aftertreatment Exhaust Gas Temperature 3 - Data Valid But Above Nor mal

Operating Range - Moderately Severe Level

Aftertreatment Diesel Particulate Filter Outlet Gas Temperature – Data valid but

above normal operational range – Most Severe Level

Aftertreatment Exhaust Gas Temperature 2 Circuit - Voltage Below Normal, or

Shorted to Low Source

Aftertreatment Exhaust Gas Temperature 2 Circuit - Voltage Below Normal, or

Shorted to Low Source

Aftertreatment Exhaust Gas Temperature 2 - Data Valid But Above Nor mal

Operating Range - Moderately Severe Level

Aftertreatment Exhaust Gas Temperature 2 - Data Valid But Below Normal

Operating Range - Moderately Severe Level

Aftertreatment Exhaust Gas Temperature 2 - Data Valid But Below Normal

Aftertreatment Particulate Filter Differential Pressure - Data Valid But Above Normal

Operational Range - Most Severe Level

Aftertreatment Particulate Filter Differential Pressure Sensor - Data Erratic,

ftertreatment Particulate Filter Differential Pressure Sensor Circuit - Voltage Above

Intermittent or Incorrect

Aftertreatment Particulate Filt er Differential Pressure Sensor Circuit - Voltage Below

Normal, or Shorted to High Source

Normal, or Shorted to Low Source

Aftertreatment Particulate Filter Differential Pressure - Data Valid But Above Normal

Operating Range - Least Severe Level

Aftertreatment Particulate Filter Differential Pressure - Data Valid But Above Normal

Operating Range - Moderately Severe Level

Aftertreatment Fuel Rate - Data Valid But Above Nor mal Operating Range -

Moderately Severe Level

Sensor Supply Voltage #1 Circuit – Voltage Above Normal, or Short ed to High

Source

Data Valid but Above Normal Operating

J1939 SPN Description J1939 FMI Description Cummins Description

Aftertreatment 1 Diesel Particulate Filter

Code

Cummins

FMI

J1939

SPN

3242 15 3254

J1939

Range - Least Severe Level

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Intake Gas Temperature

Aftertreatment 1 Diesel Particulate Filter

Intake Gas Temperature

Aftertreatment 1 Exhaust Gas Temperature 3 Data Erratic, Intermittent or Incorrect Aftertreatment Exhaust Gas Temperature 3 - Data Erratic, Intermittent or Incorrect

3242 16 3253

3245 2 1878

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Aftertreatment 1 Exhaust Gas Temperature 3

3245 3 1876

3245 4 1877

Range - Moderately Severe Level

Data Valid but Above Normal Operational

Range - Most Severe Level

Aftertreatment 1 Exhaust Gas Temperature 3

Aftertreatment 1 Diesel Particulate Filter

Outlet Gas Temperature

Aftertreatment 1 Exhaust Gas Temperature 2 Data Erratic, Intermittent or Incorrect Aftertreatment Exhaust Gas Temperature 2 - Data erratic, intermittent or incorrect

3245 16 1972

3246 0 3312

3249 2 1676

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Aftertreatment 1 Exhaust Gas Temperature 2

3249 3 1675

3249 4 1674

Range - Moderately Severe Level

Data Valid but Below Normal Operating

Aftertreatment 1 Exhaust Gas Temperature 2

3249 16 1968

3249 17 2742

Range - Moderately Severe Level

Data Valid but Above Normal Operational

Range - Most Severe Level

Data Erratic, Intermittent or Incorrect

Aftertreatment 1 Diesel Particulate Filter

Differential Pressure

Aftertreatment 1 Diesel Particulate Filter

Differential Pressure

3249 18 2743

3251 0 1922

3251 2 1883

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Above Normal Operating

Aftertreatment 1 Diesel Particulate Filter

Differential Pressure

Aftertreatment 1 Diesel Particulate Filter

Differential Pressure

Aftertreatment 1 Diesel Particulate Filter

3251 3 1879

3251 4 1881

Range - Least Severe Level

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Differential Pressure

Aftertreatment 1 Diesel Particulate Filter

Differential Pressure

Aftertreatment 1 Fuel Rate

3251 15 2639

3251 16 1921

3481 16 2778

Voltage Above Normal, or Shorted to High

Source

Sensor supply voltage 1

3509 3 386

Operation & Maintenance Manual Troubleshooting

Range

Moderately Severe Level

Range Moderately Severe Level

Severe

Level

Sensor Supply Voltage #1 Circuit – Voltage Below Normal, or Shorte d t o Low

Source

Sensor Supply Voltage #2 Circuit – Voltage Above Normal, or Short ed to High

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Source

Sensor Supply Voltage #2 Circuit – Voltage Below Normal, or Shorte d t o Low

Source

Sensor Supply Voltage #3 Circuit - Voltage Above Normal, or Shorted to High

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Source

Sensor Supply Voltage #3 Circuit – Voltage Below Normal, or Shorte d t o Low

Source

Voltage Below Normal, or Shorted to Low

Source

Sensor Supply 4 Circuit - Voltage above normal, or shorted to high source

Source

Voltage Above Normal, or Shorted to High

Source

Voltage Above Normal, or Shorted to High

Sensor Supply 5 - Voltage Above Normal, or Shorted to High Source

Source

Sensor Supply 5 - Voltage Below Normal, or Shorted to Low Source

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Sensor Supply 6 Circuit - Voltage above normal, or shorted to high source

Source

mbient Air Density - Data Valid But Below Normal Operating Range - Least Severe

Sensor Supply 6 Circuit - Voltage below normal, or shorted to low sour ce

Level

Voltage Below Normal, or Shorted to Low

Source

Data Valid but Below Normal Operating

Range - Least Severe Level

ECU Power Output Supply Voltage 1 - Voltage Above Normal, or Shorted t o High

Source

Aftertreatment Fuel Injector 1 - Dat a Valid But Above Normal Operating Range -

Data Valid but Above Normal Operating

ECU Power Output Supply Voltage 1 - Voltage Below Normal, or Shorted t o Low

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

ftertreatment Diesel Particulate Filter Outlet Pressure - Data Erratic, Intermittent or

Source

ECU Power Output Supply Voltage 1 - Data Valid But Below Normal Operating

Range - Moderately Severe Level

Incorrect

Source

Data Valid but Below Normal Operating

Range - Moderately Severe Level

Aftertreatment Diesel Particulate Filter Outlet Pressure Sensor Circuit - Voltage

Above Normal, or Shorted to High Source

Aftertreatment Diesel Particulate Filter Outlet Pressure Sensor Circuit - Voltage

Below Normal, or Shorted to Low Source

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Engine Air Shutoff Circuit - Voltage above normal, or shor t ed t o high source

Source

Voltage Below Normal, or Shorted to Low

Engine Air Shutoff Circuit - Voltage below normal, or short ed to low source

Source

Particulate Trap Active Regeneration Inhibited Due to I nhibit Swit ch - Condition

Exists

Not Available or Condition Exists

J1939 SPN Description J1939 FMI Description Cummins Description

Sensor supply voltage 1

Sensor supply voltage 2

Sensor supply voltage 3

Sensor supply voltage 4

Sensor supply voltage 5

Sensor supply voltage 6

Ambient Air Density

Aftertreatment 1 Hydrocarbon Doser

ECU Power Output Supply Voltage #1

Diesel Particulate Filter Outlet Pressure 1 Data Erratic, Intermittent or Incorrect

Diesel Particulate Filter Outlet Pressure 1

Engine Air Shutoff Status

Diesel Particulate Filter Active Regeneration

Inhibited Due to Inhibit Switch

Code

Cummins

FMI

J1939

SPN

3509 4 352

3510 3 227

3510 4 187

3511 3 239

3511 4 238

3512 3 2185

3513 3 1695

3513 4 1696

3514 3 515

3514 4 516

3555 17 1943

3556 16 2728

3597 3 1939

3597 4 1941

3597 18 1938

3610 2 3135

3610 3 3133

3610 4 3134

3667 3 3139

J1939

3667 4 3141

3703 31 2777

Troubleshooting Operation & Maintenance Manual

Aftertreatment Diesel Particulate Filter System - Data Valid But Above Normal

Operating Range - Least Severe Level

Aftertreatment Diesel Particulate Filter System - Data Valid But Above Normal

Operating Range - Moderately Severe Level

Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature - Data Valid But

Above Normal Operating Range - Moderately Severe Level

Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature - Data erratic,

intermittent or incorrect

Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature Sensor Circuit -

Voltage above normal, or shorted to high source

Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature Sensor Circuit -

Voltage below normal, or shorted to low source

Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperat ur e Swapped - Out of

Calibration

Aftertreatment SCR Operator Inducement - Data valid but above nor mal oper at ional

range - Most Severe Level

Engine Turbocharger Wastegate Actuator - Current above nor mal or gr ounded

Engine Turbocharger Wastegate Actuator - Mechanical system not responding or

out of adjustment

High Pressure Common Rail Fuel Pressure Relief Valve - Mechanical system not

responding or out of adjustment

Cruise Control (Resistive) Signal Circuit - Voltage Above Nor mal, or Shorted to High

Crankcase Depression Valve - Mechanical System Not Responding or Out of

Cruise Control (Resistive) Signal Circuit - Voltage Below Normal, or Shorted to Low

Adjustment

Source

Data Valid but Above Normal Operating

J1939 SPN Description J1939 FMI Description Cummins Description

Aftertreatment Diesel Particulate Filter

Code

Cummins

FMI

J1939

SPN

3936 15 1981

J1939

Range - Least Severe Level

Data Valid but Above Normal Operating

Range - Moderately Severe Level

Data Valid but Above Normal Operational

Range - Most Severe Level

System

Aftertreatment Diesel Particulate Filter

System

Aftertreatment 1 Diesel Oxidation Catalyst

Intake Gas Temperature

3936 16 3168

4765 0 3251

Data Erratic, Intermittent or Incorrect

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Out of Calibration

Not Available or Condition Exists Aftertreatment Diesel Particulate Filter Missing - Condition Exists

Aftertreatment 1 Diesel Oxidation Catalyst

Intake Gas Temperature

Aftertreatment 1 Diesel Oxidation Catalyst

Intake Gas Temperature

Aftertreatment 1 Diesel Oxidation Catalyst

Intake Gas Temperature

Aftertreatment 1 Diesel Oxidation Catalyst

Intake Gas Temperature

Aftertreatment 1 Diesel Particulate Filter

4765 2 3315

4765 3 3314

4765 4 3313

4765 13 3325

4795 31 1993

Not Available or Condition Exists Aftertreatment Diesel Oxidation Catalyst Missing - Condition Exists

Data Valid but Above Normal Operational

Range - Most Severe Level

Missing

Aftertreatment 1 Diesel Oxidation Catalyst

Missing

Aftertreatment SCR Operator Inducement

Severity

4796 31 1664

5246 0 3712

Mechanical System not Responding or Out

of Adjustment

Engine Turbocharger Wastegate Actuator 1 Current Below Normal or Open Circuit Engine Turbocharger Wastegate Actuator - Cur r ent below nor mal or open cir cuit

Engine Turbocharger Wastegate Actuator 1 Current Above Normal or Grounded Circuit

Engine Turbocharger Wastegate Actuator 1

Engine Turbocharger Wastegate Actuator 1 Root Cause Not Known Engine Turbocharger Wastegate Actuator - Root Cause Not Known

5421 5 3922

5421 6 3923

5421 7 3921

5421 11 3927

Engine Turbocharger Wastegate Actuator 1 Root Cause Not Known Engine Turbocharger Wastegate Actuator - Condition Exist s

5421 11 3928

Mechanical System not Responding or Out

of Adjustment

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Engine Turbocharger Wastegate Actuator 1 Out of Calibration Engine Turbocharger Wastegate Actuator - Out of Calibr at ion

High Pressure Common Rail Fuel Pressure

Relief Valve

Cruise Control (Resistive) Signal Circuit

3 193

4 194

5421 13 3918

5571 7 3727

520199

Mechanical System not Responding or Out

of Adjustment

Crankcase Depression Valve

Glow Plug Module Bad Intelligent Device or Component Glow Plug Module - Bad intelligent device or component

7 2699

12 3222

520435

520320

Operation & Maintenance Manual Troubleshooting

Engine Exhaust Gas Recirculation (EGR) Outlet Pressure Sensor Circuit - Above

Normal, or Shorted to High Source

Engine Exhaust Gas Recirculation (EGR) Outlet Pressure Sensor Circuit - Voltage

Below Normal, or Shorted to Low Source

Engine Exhaust Gas Recirculation (EGR) Mixer Inlet Temperature Sensor Circuit -

Voltage Above Normal, or Shorted to High Source

Engine Exhaust Gas Recirculation (EGR) Mixer Inlet Temperature Sensor Circuit -

Voltage Below Normal, or Shorted to Low Source

J1939 SPN Description J1939 FMI Description Cummins Description

Code

Cummins

FMI

J1939

SPN

J1939

Voltage Above Normal, or Shorted to High

Source

Voltage Below Normal, or Shorted to Low

Source

Voltage Above Normal, or Shorted to High

Engine Exhaust Gas Recirculation (EGR)

Outlet Pressure Sensor Circuit

Engine Exhaust Gas Recirculation (EGR)

Outlet Pressure Sensor Circuit

Engine Exhaust Gas Recirculation (EGR)

3 3136

4 3137

520441

Source

Voltage Below Normal, or Shorted to Low

Source

Mixer Inlet Temperature Sensor Circuit

Engine Exhaust Gas Recirculation (EGR)

Mixer Inlet Temperature Sensor Circuit

3 3295

4 3296

520442

Not Available or Condition Exists Engine Crankcase Ventilation Hose Disconnected - Condition Exists

Engine Crankcase Ventilation Hose

Disconnected

Utility Reverse kW Fault Root Cause Not Known Utility Reverse kW Fault - Condition Exists

31 3377

11 3924

520448

520553

Reserved for temporary use Not Available or Condition Exists Reserved for temporary use - Condition Exists

31 952

524286

Reserved for temporary use Not Available or Condition Exists Reserved for temporary use - Condition Exists

31 953

524286

Troubleshooting Operation & Maintenance Manual

Operation & Maintenance Manual Troubleshooting

100

Doosan HP450 Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual