Doosan XP825WCU-T4i User manual

XP825WCU-T4i (E47)
COMPRESSOR MODELS
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
DoosanPortablePower.com
Book: 46559964 (2-3-2012) 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
HP750WCU-T4i (E48)
MANUAL

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

4
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
ViewPort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Before Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Compressor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Service Air Connection(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Air Hose Restraint Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Compressor Oil Cooler, Engine Radiator, and other Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . .61
Air Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Fuel Filter Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Charge Air Cooler Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Running Gear/Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Running Gear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

5
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Compressor Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Portable Compressor Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Think Before Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Do the Simplest Things First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Double Check Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Find and Correct Basic Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Engine Diagnostic Codes - Cummins Engine with CM2250 Controller . . . . . . . . . . . . . . . . . . . . . .85
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
IQ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Low Ambient Option Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
IQ System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Dual Pressure Regulation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

6

7
Foreword

Operation & Maintenance Manual Foreword
8
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 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.

Foreword Operation & Maintenance Manual
9
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, or controls or switches missing or disabled.
F. For storage or transportation of materials inside or on the enclosure.
This company 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 adequacy and accuracy of the contents.
Your Portable Power dealer will assist with setup and initial startup of the compressor. He will
also provide brief operating and service instructions and will insure that a copy of this manual
is included with the compressor. 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 within this manual. This section contains a recommended schedule and
space so that the serviceman can note what service and maintenance was done, by whom,
where, and when.

Operation & Maintenance Manual Foreword
10

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 that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
Ensure that maintenance personnel are adequately trained, competent and have read the
manuals.
Make sure that all protective covers are in place and that 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 then all local regulations, codes of
practice and site rules must be observed. To ensure that 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 on 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 this 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 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 inflammable 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 or
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. Before doing any work on the
compressor, ensure that all pressure is vented from the system and that the compressor
cannot be started accidentally.
Ensure that the compressor is operating at the rated pressure and that the rated pressure is
known to all relevant personnel.
Allairpressureequipmentinstalledin or connected tothe compressormusthavesafeworking
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, so that one
compressor cannot accidentally be pressurized or over pressurized by another.
Compressed air must not be used for adirect 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.
The discharged air contains a very small percentage of compressor lubricating oil and care
should be taken to ensure that downstream equipment is compatible.
If the 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
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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
undergoesregeneration.Referto enginemanualforfurthersafety instructionsandinformation
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:
•anti-freeze
• 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
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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 and
service tasks. Contact local authorities for proper disposal of these materials.
Battery
A battery contains sulfuric acid and can give off 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 slave start a frozen battery since this may cause it to
explode.
Exercise extreme caution when using booster battery. To jump battery, connect ends of one
booster cable to the positive (+) terminal of each battery. Connect one end of other cable to
the negative (-) terminal of the booster battery and other end to a ground connection away
from dead battery (to avoid a spark occurring near any explosive gases that may be present).
After starting the compressor, always disconnect cables in reverse order.
Radiator
Hot engine coolant and steam can cause injury. Ensure that the radiator filler cap is removed
with due care and attention.
Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before
removing pressure cap.

Operation & Maintenance Manual Safety
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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 down prior to releasing the radiator filler cap. Using a
cloth to protect the hand, slowly release the filler cap, absorbing any
released fluid with the cloth. Do not remove the filler 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 that:
• the tires and towing hitch are in a serviceable condition, and that tires are properly
inflated.
• 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.
• break-away cables/safety chains are connected to the towing vehicle.
Thecompressormustbe towed in a levelattitudeinordertomaintain 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. Make sure 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
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Safety chains/breakaway cable and their adjustment (where fitted).
Ensure that the breakaway cable is securely coupled to the towed compressor and also to a
substantial point on the towing vehicle.
Ensure that the 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 that the effective chain length is as short as possible while still allowing normal
articulation of the towed compressor and effective operation of the breakaway cable.

Operation & Maintenance Manual Safety
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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
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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 on the bottom 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! Assure that decals are present on the
compressor. Replace decals that are not readable.

Operation & Maintenance Manual Safety
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Hot