Doosan Infracore P250WDO-T4F User manual

OPERATIONandMAINTENANCE
MANUAL
COMPRESSORSMODEL:
DoosanInfracorePortablePower
1293GlenwayDrive
Statesville,N.C.28625
DoosanPortablePower.com
P/N:46720670(2018)RevC
P250/HP210WDO-T4F(G91)

iii

TABLEOFCONTENTS
Operation&MaintenanceManual
TITLEPAGE
........................................................................................................................................................iii
FOREWORD..........................................................................................................................9
Information.....................................................................................................................................10
DRAWBARINSTRUCTIONS...............................................................................................13
InstructionKitForDrawbar............................................................................................................14
SAFETY...............................................................................................................................17
SafetyPrecautions.........................................................................................................................18
CompressedAir..........................................................................................................................19
ExhaustSystem.........................................................................................................................20
Materials....................................................................................................................................20
Battery.......................................................................................................................................21
CoolantSystem..........................................................................................................................22
Transport...................................................................................................................................22
Decals.............................................................................................................................................23
NOISEEMISSION................................................................................................................27
NoiseEmission...............................................................................................................................28
CompressorNoiseEmissionControlInformation..........................................................................28
MaintenanceLog............................................................................................................................29
NoiseEmissionWarranty............................................................................................................29
Introduction................................................................................................................................30
MaintenanceSchedule................................................................................................................30
GENERALDATA.................................................................................................................33
GeneralDataInformation................................................................................................................34
ExpendableServiceParts...........................................................................................................34
OPERATINGINSTRUCTIONS............................................................................................37
ControlPanel..................................................................................................................................38
Control/GaugePanel..................................................................................................................38
QuickViewScreens........................................................................................................................40
5

TABLEOFCONTENTS
Operation&MaintenanceManual
TITLEPAGE
FaultandAlert...........................................................................................................................41
ServiceIntervalSetup.................................................................................................................43
LanguagesandUnits..................................................................................................................45
DisplaySetup.............................................................................................................................46
DisplayCompressorandDisplaySoftwareInformation.................................................................46
DisplayCompressorandDisplaySoftwareInformation.................................................................47
BeforeTowing.................................................................................................................................48
Towing.......................................................................................................................................50
SettingUp..................................................................................................................................50
BeforeStarting...........................................................................................................................51
Starting......................................................................................................................................52
Shutdown...................................................................................................................................53
PressureRegulatorAdjustmentInstructions.................................................................................54
ENGINEOPERATION..........................................................................................................55
EngineOperationandMaintenance................................................................................................56
Safety........................................................................................................................................57
Instructions................................................................................................................................58
GeneralRepair...........................................................................................................................60
EnvironmentalPollution..............................................................................................................61
EngineManagement...................................................................................................................62
PreventionofPollution................................................................................................................63
StartandShutdown........................................................................................................................64
Break-inPeriodofEngine............................................................................................................65
InspectionafterStartingtheEngine.............................................................................................67
OperationinWinter.....................................................................................................................68
RegularInspection.........................................................................................................................69
CheckingtheEngineOil..............................................................................................................70
ReplacementofEngineOil..........................................................................................................72
Coolant...........................................................................................................................................76
CheckingtheCoolant..................................................................................................................77
ReplenishmentofCoolant...........................................................................................................83
ReplacementofCoolant..............................................................................................................84
LUBRICATION.....................................................................................................................87
Lubrication.....................................................................................................................................88
CompressorOilChart.................................................................................................................89
MAINTENANCE...................................................................................................................91
GeneralInformation........................................................................................................................92
6

TABLEOFCONTENTS
Operation&MaintenanceManual
TITLEPAGE
CompressorOilFilters....................................................................................................................95
ReceiverSeparatorSystem.........................................................................................................96
ScavengeLine................................................................................................................................97
ExteriorFinishCare....................................................................................................................97
FieldReplacementofExteriorDecals..........................................................................................98
PreventiveMaintenanceSchedule.................................................................................................100
TROUBLESHOOTING.......................................................................................................103
Introduction...................................................................................................................................104
TroubleshootingChart................................................................................................................105
DiagnosticCodes......................................................................................................................110
CompressorDiagnosticCodes......................................................................................................111
APPENDIXA......................................................................................................................115
Warranty........................................................................................................................................116
................................................................................................................................................116
................................................................................................................................................116
................................................................................................................................................117
RevisionHistory............................................................................................................................119
7

8

Foreword
9

Operation&MaintenanceManualForeword
Information
TheContentsOfThisManualAreConsideredT oBeProprietaryAndCondentialToDoosan
InfracorePortablePower(HereinReferredToAs“PortablePower”),AndShouldNotBe
ReproducedWithoutThePriorWrittenPermissionOfPortablePower.
NothingContainedInThisDocumentIsIntendedT oExtendAnyPromise,WarrantyOr
Representation,ExpressedOrImplied,RegardingThePortablePowerProductsDescribed
Herein.AnySuchWarrantiesOrOtherTermsAndConditionsOfSaleOfProductsShall
BeInAccordanceWithTheStandardT ermsAndConditionsOfSaleForSuchProducts,
WhichAreAvailableUponRequest.
ThisManualContainsInstructionsAndTechnicalDataToCoverAllRoutineOperationAnd
ScheduledMaintenanceTasksByOperationAndMaintenanceStaff.MajorOverhaulsAre
OutsideTheScopeOfThisManualAndShouldBeReferredToAnAuthorizedPortable
PowerServiceDepartment.
AllComponents,Accessories,Pipes,AndConnectorsAddedToTheCompressedAir
SystemShouldBe:
•OfGoodQuality,ProcuredFromAReputableManufacturerAnd,Wherever
Possible,BeOfATypeApprovedByPortablePower.
•ClearlyRatedForAPressureAtLeastEqualToTheCompressorSafetyValve
Setting.
•CompatibleWithTheCompressorOil.
•AccompaniedWithInstructionsForSafeInstallation,Operation,AndMaintenance.
DetailsOfApprovedEquipmentAreAvailableFromThePortablePowerService
Departments.TheUseOfRepairPartsOtherThanThoseIncludedWithinTheApproved
PartsListMayCreateHazardousConditionsOverWhichPortablePowerHasNo
Control.Therefore,PortablePowerCannotBeHeldResponsibleForEquipmentInWhich
Non-ApprovedRepairPartsAreInstalled.
PortablePowerReservesTheRightT oMakeChangesAndImprovementsToProducts
WithoutNoticeAndWithoutIncurringAnyObligationT oMakeSuchChangesOrAddSuch
ImprovementsToProductsSoldPreviously.
TheIntendedUsesOfThisCompressorAreOutlinedBelowAndExamplesOfUnapproved
UsageAreAlsoGiven.However,PortablePowerCannotAnticipateEveryApplicationOr
WorkSituationThatMayArise.IfInDoubt,ConsultSupervision.
ThisCompressorHasBeenDesignedAndSuppliedForAboveGroundOperationT oBe
UsedForCompressionOfNormalAmbientAirContainingNoAdditionalGases,Vapors,Or
ParticlesWithinTheAmbientT emperatureRangeSpeciedInTheGeneralDataSection
OfThisManual.
10

ForewordOperation&MaintenanceManual
ThisCompressorShouldNotBeUsed:
•ForDirectOrIndirectHumanConsumptionOfTheCompressedAir.
•OutsideTheAmbientTemperatureRangeSpeciedInTheGeneralDataSection
OfThisManual.
•WhenAnActualOrForeseeableRiskOfHazardousLevelsOfFlammableGases
OrVaporsExists.
•WithOtherThanPortablePowerApprovedComponents.
•WithGuards,Controls,OrSwitchesMissingOrDisabled.
•ForStorageOrTransportationOfMaterialsInsideOrOnTheEnclosure.
PortablePowerAcceptsNoResponsibilityForErrorsInTranslationOfThisManualFrom
TheOriginalEnglishVersion.
You,AsTheCustomer,AreExpectedToProvideCertainServiceAndMaintenanceItems.
YourPortablePowerDealerWillProvideAllOtherMoreDetailedServiceAndMaintenance
ItemsOnASpecialPreventiveMaintenanceScheduleForEachCompressor.ItIsVery
ImportantThatTheMinimumServiceAndMaintenanceRequirementsExplainedInThis
ManualBePerformedAtTheRequiredIntervals.ExceedingTheseIntervalsMayReduce
TheReliabilityOfTheCompressor.
ThePurposeOfThisManualIsT oTrainTheOperatorWithFunctions,Operation,AndBasic
ServiceAndMaintenanceRequirementsOfTheCompressor.DuringThePreparationOfThis
Manual,EveryEffortWasMadeT oEnsureTheAccuracyAndAdequacyOfTheContents.
YourPortablePowerDealerWillAssistWithSetupAndInitialStartupOfTheCompressor
AndWillAlsoProvideBriefOperatingAndServiceInstructions.BeforeStartingThe
Compressor,ThisManualAndInstructionsShouldBeCarefullyReadT oObtainAThorough
KnowledgeOfTheDutiesToBePerformed.PleaseTakePrideInTheCompressor,KeepIt
CleanAndInGoodMechanicalCondition.
ToEnableProperMaintenanceRecords,PortablePowerProvidesANoiseEmissionControl
MaintenanceLogInTheNoiseEmissionSectionOfThisManual.TheNoiseEmission
SectionContainsARecommendedMaintenanceScheduleAndProvidesSpaceInThe
LogForTheT echnicianToNoteWhatServiceAndMaintenanceWasDone,ByWhom,
Where,AndWhen.
11

12

DrawbarInstructions
13

Operation&MaintenanceManualDrawbarInstructions
InstructionKitForDrawbar
ToConvertfromShippingPositiontoTowingPosition
14

DrawbarInstructionsOperation&MaintenanceManual
TheFollowingToolsareRequired:
Ratchet
13mmSockettotRatchet
TorqueWrenchsetto68footpounds(9.4kg-meters)
16mmSockettotT orqueWrench
5-inchExtensionforTorqueWrench
HardwareIncluded:
(4)12mmBoltswithPre-appliedThreadLock.
(2)8mmT aptiteBolts
(2)Washers
(2)SafetyChainsarezippedtiedtoDrawbar.
1.RemoveHardwareboxfromCompressorToolbox.
2.OpenboxandremovethebagcontainingHardware,andAssemblyinstructions.
3.UsingtheJack,raisethefrontoftheUnitsotheLegsareapproximately1-inch
abovetheground.
4.RemovethetemporaryRetainingBoltsfrombothsidesoftheFrameattheDrawbar
connection(SeeFigure1).
5.CarefullylowertheDrawbartotheLevelposition.
6.InstalltheFourBolts(withPre-appliedThreadLock)tothefourpointsinsidethe
EnclosureandTorqueto68pounds(9.4kg-meters)(SeeFigure1).
7.InstallSafetyChainsbyslidingthesecondlinkofoneChainintotheslotinDrawbar
Plate.FastenChaintoPlateusingT aptiteandWasher.RepeatfortheotherSafety
Chain(SeeFigure2)
SupporttheDrawbaratthePintleEye:
1.PullthePinoutoftheJacklocatedattheFrontoftheEnclosure.RemovetheJack
byslidingifOfftheMountingTube.RelocateandinstalltheJacktotheMounting
TubeonthesideoftheDrawbar.
15

16

Safety
17

Operation&MaintenanceManualSafety
SafetyPrecautions
Neveroperatethecompressorwithoutrstobservingallsafetywarningsandcarefullyreading
theOperationandMaintenanceManualshippedfromthefactorywiththiscompressor.
Ensuretheoperatorreadsandunderstandsthedecalsandconsultsthemanualsbefore
operationorperformingmaintenance.
Ensureallmaintenancepersonnelareadequatelytrained,competent,andhavereadthe
manuals.
Ensureallprotectivecoversareinplaceandthecanopy/doorsareclosedduringoperation.
Thespecicationofthiscompressorissuchthatthecompressorisnotsuitableforusein
ammablegasriskareas.Ifsuchanapplicationisrequired,alllocalregulations,codesof
practice,andsiterulesmustbeobserved.Toensurethecompressorcanoperateinasafe
andreliablemanner,additionalequipmentsuchasgasdetection,exhaustsparkarrestors,
andintake(shut-off)valvesmayberequired,dependentonlocalregulationsorthedegree
ofriskinvolved.
Aweeklyvisualcheckmustbemadeofallfasteners/xingscrewssecuringmechanicalparts.
Inparticular,safety-relatedpartssuchascouplinghitch,drawbarcomponents,wheels,tires,
andliftingbailshouldbecheckedfortotalsecurity.
Allcomponentswhichareloose,damaged,orunserviceablemustberectiedwithoutdelay.
Airdischargedfromthiscompressormaycontaincarbonmonoxideorothercontaminants
whichwillcauseseriousinjuryordeath.Donotbreathedischargedair.
Thiscompressorproducesloudnoisewiththedoorsopenorservicevalvevented.Extended
exposuretoloudnoisecancausehearingloss.Alwayswearhearingprotectionwhendoors
areopenorservicevalveisvented.
Neverinspectorservicethecompressorwithoutrstdisconnectingbatterycable(s)to
preventaccidentalstarting.
Donotusepetroleumproducts(solventsorfuels)underhighpressureasthiscanpenetrate
theskinandresultinseriousillness.Weareyeprotectionwhilecleaningthecompressor
withcompressedairtopreventdebrisfrominjuringeye(s).
Rotatingfanbladecancauseseriousinjury.Donotoperatewithoutfanguardinplace.
Usecaretoavoidcontactinghotsurfaces(engineexhaustmanifoldandpiping,airreceiver,
andairdischargepiping,etc.).
Etherisanextremelyvolatile,highlyammablegas.Whenitisspeciedasastartingaid,
usesparingly.DonotuseEtheriftheenginehasglowplugsorinletheaterstartingaids.
Enginedamagewillresult.
Neveroperatethecompressorwithguards,covers,orscreensremoved.Keephands,hair,
clothing,tools,blowguntips,etc.wellawayfrommovingparts.
18

SafetyOperation&MaintenanceManual
CompressedAir
Compressedaircanbedangerousifincorrectlyhandled.Priortoperformingmaintenance
orserviceonthecompressor,ensureallpressureisventedfromthesystemandthe
compressorcannotbestartedaccidentally.
Ensurethecompressorisoperatingattheratedpressureandtheratedpressureisknown
toallrelevantpersonnel.
Allairpressureequipmentinstalledin,orconnectedto,thecompressormusthavesafe
workingpressureratingsofatleastthecompressorsafetyvalvesetting.
Ifmorethanonecompressorisconnectedtoonecommondownstreamplant,effectivecheck
valvesandisolationvalvesmustbettedandcontrolledbyworkprocedures,toensureone
compressorcannotaccidentallybepressurizedoroverpressurizedbyanother.
Compressedairmustnotbeusedforadirectfeedtoanyformofbreathingapparatusor
mask.
Compressedaircancauseseriousinjuryordeath.Relievepressurebeforeremovingller
plugs/caps,ttings,orcovers.
Airpressurecanremaintrappedinairsupplylinewhichcanresultinseriousinjuryordeath.
Alwayscarefullyventairsupplylineattoolorventvalvebeforeperforminganyserviceor
maintenance.
Dischargedaircontainsaverysmallpercentageofcompressorlubricatingoilandcare
shouldbetakentoensuredownstreamequipmentiscompatible.
Ifdischargedairistobeultimatelyreleasedintoaconnedspace,adequateventilation
mustbeprovided.
Whenusingcompressedair,alwaysuseappropriatepersonalprotectiveequipment.
Allpressurecontainingparts,especiallyexiblehosesandtheircouplings,mustberegularly
inspected,befreefromdefects,andbereplacedaccordingtothemanualinstructions.
Avoidbodilycontactwithcompressedair.
Thesafetyvalvelocatedintheseparatortankmustbecheckedperiodicallyforcorrect
operation.
Wheneverthecompressorisstopped,airwillowbackintothecompressorfromdownstream
devicesorsystemsunlesstheservicevalveisclosed.Installacheckvalveatthecompressor
servicevalvetopreventreverseowintheeventofanunexpectedshutdownwhenthe
servicevalveisopen.
Disconnectedairhoseswhipandcancauseseriousinjuryordeath.Alwaysattachasafety
owrestrictiontoeachhoseatthesourceofsupplyorbranchlineinaccordancewithOSHA
Regulation29CFRSection1926.302(b).
Neverallowthecompressortositstoppedwithpressureintheseparatortankorpiping.
19

Operation&MaintenanceManualSafety
ExhaustSystem
Hotengineexhaustgasandhotexhaustsystemsurfacesareproducedduringandafter
compressoroperation.Avoidcontactwithexhaustgasandhotexhaustsystemsurfaces.
Keepammableandcombustiblematerialsaway.Donotoperatecompressoron,under,or
nearammableorcombustiblematerials.
Thepotentialforhighertemperaturesispresentwhentheexhaustaftertreatmentsystem
undergoesregeneration.Refertoenginemanualforfurthersafetyinstructionsand
informationontheexhaustaftertreatmentsystemandcontrols.
Materials
THefollowingsubstancesmaybeproducedduringtheoperationofthiscompressor:
•BrakeLiningDust
•EngineExhaustFumes
AvoidInhalationOfMaterialSubstances.
Ensurethatadequateventilationofthecoolingsystemandexhaustgasesismaintainedat
alltimes.
Thefollowingsubstancesareusedinthemanufactureofthiscompressorandmaybe
hazardoustohealthifusedincorrectly:
•Antifreeze
•CompressorOil
•EngineOil
•PreservativeGrease,LubricatingGrease
•RustPreventative
•DieselFuel
•BatteryElectrolyte
20