Doosan XHP1000WCAT-T4i User manual

COMPRESSOR MODELS
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
DoosanPortablePower.com
Book: 46604941 (10-2012) Rev A
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.
OPERATION and MAINTENANCE
XHP1000WCAT-T4i (E45)
MANUAL
HP1300WCAT-T4i (E46)

2

3
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Compressor Noise Emission Control Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
A. Compressed Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
B. Safety and Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
C. Acoustic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
D. Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
E. Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
F. Air Intake and Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
G. Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
H. Isolation Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
I. Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
J. Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
General Data Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Service Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

4
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
ViewPort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Before Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Compressor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Service Air Connection(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Air Hose Restraint Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Compressor Oil Cooler, Engine Radiator, and other Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . .72
Air Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Fuel Filter Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Charge Air Cooler Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Running Gear/Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

5
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Pressure Regulation for XHP1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Adjustment Instructions for XHP units with Electronic Control Caterpillar Engines. . . . . . . . . . . . . . . . .77
Pressure Regulation for HP1300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Dual Pressure Regulation Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Compressor Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Portable Compressor Oil Chart for XHP1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Portable Compressor Oil Chart for HP1300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Think Before Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Do the Simplest Things First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Double Check Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Find and Correct Basic Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Compressor Diagnostic Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Caterpillar T4i Engine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
IQ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Low Ambient Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
IQ System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

6

7
Foreword

Operation & Maintenance Manual Foreword
8
Information
1)
ECDeclarationofConformity
2)
3)
We:
4)
RepresentedinECby:
DoosanTradingLimited
1293GlenwayDrive BlockB,SwordsBusinessCampus
Statesville Swords
NorthCarolina28625Ͳ9218 Co.Dublin
USA Ireland
5)
Herebydeclarethat,underoursoleresponsibilitytheproduct(s)
6)
Machinedescription: PortableCompressors
7)
MachineModel:
8)
Commercialname:
9)
Serialnumber:
10)
is(are)inconformitywiththerelevantprovisionsofthefollowingECDirective(s)
11)
2006/42/EC TheMachineryDirective
12)
2004/108/EC TheElectromagneticCompatibilityDirective
13)
2000/14/EC TheNoiseEmissionDirective
16)
97/68/EC TheemissionofenginesfornoͲroadmobilemachinery
17)
andtheiramendments
18)
ConformitywiththeNoiseEmissionDirective2000/14/EC
Machinemodelsnotedaboveutilizeengineswithpowerratings>350kwandaretherefore
RicLunsford
27)
QualityControlManager
28)
IssuedatStatesville,N.C.
29)
30)
Thetechnicaldocumentationforthemachineryisavailablefrom:
CPN46553504RevA
exemptfromNoiseEmissionDirective2000/14/EC.
DoosanInfracorePortablePower,1293GlenwayDrive,Statesville,N.C.28625Ͳ9218USA
Originaldeclaration
Date
XHP1000WCATͲT4i,10/370,10/455,25/300,25/330,10/425,10/375,25/280, HP1600WCU-T4i,
XHP1000WCATͲT4i,10/370,10/455,25/300,25/330,10/425,10/375,25/280
NHP1500,XHP1070WCAT,XHP1170WCAT,HP1300WCU,HP1600WCU,HP1300WCATͲT4i,
NHP1500,XHP1070WCAT,XHP1170WCAT,HP1300WCU,HP1600WCU,HP1300WCATͲT4i,
DoosanInternationalUSA,Inc
Machinemodelsrepresentedinthismanualmay beusedinvariouslocationsworldͲwide.Machinessoldand
shippedintoEuropeanUnionTerritoriesrequirethatthemachinedisplaytheCEMarkandconformtovarious
directives.Insuchcases,thedesignspecificationofthismachinehasbeencertifiedascomplyingwithECdirectives.
AnymodificationtoanypartisabsolutelyprohibitedandwouldresultintheCECertificationandmarkingbeing
renderedinvalid.Adeclarationofthatconformityfollows:
CPN46552201revA

Foreword Operation & Maintenance Manual
9
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 unapproved 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.

Operation & Maintenance Manual Foreword
10
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 foreseeable risk of hazardous levels of flammable gases 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 manualbe 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.

11
Safety

Operation & Maintenance Manual Safety
12
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 regulations 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 cable(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 cleaning 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
13
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 smallpercentage of compressor lubricating oil and care 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 the compressor from downstream
devices or systems unless the service valve is closed. Install a check valve at the compressor
servicevalveto preventreverseflowin the eventofanunexpected shutdownwhenthe 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
14
Exhaust System
Hot engine exhaust gas and hot exhaust system surfaces are produced during and after
compressoroperation.Avoidcontactwithexhaustgasandhotexhaustsystemsurfaces. Keep
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
15
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.
CAUTION
!
Do not attempt to jumpstart a frozen battery since this may cause it to
explode.
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.
Radiator
Hotenginecoolant andsteamcancause injury. EnsuretheRadiatorPressure Cap isremoved
with due care and attention.
Do not remove the pressure cap from a HOT radiator. Allow radiator to cool before removing
pressure cap.

Operation & Maintenance Manual Safety
16
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 speeds
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 aserviceable condition and tires are properly inflated.
• the canopy is secure.
• all ancillary equipment is stored in a safe and secure manner.
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
17
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 stillallowing 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
18
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
19
Free Safety Decals
To promote communication of Safety Warnings on products
manufactured by the Portable Power Division in Statesville, 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
20
attach safety device
(OSHA Valve) at source of
When using air tools
air supply for each tool.
Close service valve and
operate tool to vent
trapped air before
performing any service.
Do not breathe this air.
0
310
3
Hot