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.
TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety Precautions. . . . .
TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE Before Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Compressor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Compressor Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword 7
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.
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 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.
Operation & Maintenance Manual 10 Foreword
Safety 11
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.
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.
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. 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.
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.
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.
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.
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.
Safety Operation & Maintenance Manual 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.
Operation & Maintenance Manual Safety Close service valve and operate tool to vent trapped air before performing any service. When using air tools attach safety device (OSHA Valve) at source of air supply for each tool. Do not breathe this air. 54629902 REV. C 3M 5S 54749163 REV. C Hot 54568795 REV.
Safety Operation & Maintenance Manual 21
Operation & Maintenance Manual 22 Safety
Safety Operation & Maintenance Manual 23
Operation & Maintenance Manual Safety Decals Graphic Form and Meaning of ISO Symbols Prohibition / Mandatory Information / Instructions Warning WARNING: Electrical Shock Risk WARNING: Pressurized Component or System WARNING: Hot Surface WARNING: Pressure Control WARNING: Corrosion Risk WARNING: Air/Gas Flow or Air Discharge WARNING: Pressurized Vessel 24 WARNING: Maintain correct tire pressure (Refer to the GENERAL WARNING: Hot and harmful exhaust INFORMATION section of this manua gas
Safety Operation & Maintenance Manual 0oC WARNING: Flammable Liquid WARNING: Before connecting the tow WARNING: For operating temperature bar or commencing to tow consult the below 0oC, consult the Operation and Operation and Maintenance Manual Maintenance Manual WARNING: Do not undertake any WARNING: Consult the Operation and maintenance on this machine until Maintenance manual before the electrical supply is disconnected commencing any maintenance and the air pressure is totally relieved Do not remo
Operation & Maintenance Manual Do not stand on any service valve or other parts of the pressure system Safety Do not operate with doors or enclosure open Do not use fork lift truck from this side Do not exceed trailer speed limit No open flames Do not open service valve before the air hose is attached Use fork lift truck from this side only Emergency stop Tie down point Lifting point ON (power) OFF (power) Read the Operation and Maintenance manual before operation or maintenance of this machin
Safety Operation & Maintenance Manual Replace any cracked protective shield Oil drain Engine Oil Fuel level / point Pressure control Malfunction Battery charging condition Low pressure High pressure Engine malfunction High Compressor Temperature Compressor malfunction Low engine oil pressure Engine high temperature 27
Operation & Maintenance Manual 28 Safety
Noise Emission 29
Operation & Maintenance Manual Noise Emission Noise Emission This section pertains only to compressors distributed within the United States.
Noise Emission Operation & Maintenance Manual Maintenance Log COMPRESSOR MODEL_________________________ SERIAL NO. __________________________________ USER UNIT NO. _______________________________ UNIT IDENTIFICATION Engine Make & Model:_________________ DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Serial No.
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.
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.
Operation & Maintenance Manual Noise Emission MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO.
General Data 35
Operating & Maintenance Manual General Data General Data Information P600WCUT4i XP525WCUT4i HP450WCUT4i VHP400WC U-T4i Air Delivery - cfm (m3/min) 600 (170) 525 (14.9) 450 (12.7) 400 (11.3) Rated Operating Pressure psi (bar) 100 (6.9) 125 (8.6) 150 (10.3) 200 (13.8) MODEL COMPRESSOR Safety Valve Setting - psi (bar) 250 (17.2) 200 (13.8) ENGINE Manufacturer Cummins Model QSB 6.
General Data Operating & Maintenance Manual MEASUREMENTS/WEIGHTS Overall Length - feet (meters) (incl. bumper) 14.8 (4.5) 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.
Operating & Maintenance Manual 38 General Data
Operating Instructions 39
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.
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.
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.
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. Pressing the ENTER Button after the service channels have been displayed, acknowledges the message and the display unit returns to the default screen.
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 Button.
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).
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
Operating & Maintenance Manual 56 Operating Instructions
Maintenance 57
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 preventative maintenance for the engine, refer to the Engine Manual.
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.
Operation & Maintenance Manual Maintenance Maintenance Schedule Initial 500 miles /850 km 60 Daily 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 *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 Weekly Monthly Every 3 Every 6 Every 12 Months Months Months 500
Maintenance Operation & Maintenance Manual Initial 500 miles /850 km Daily Weekly Monthly Air Cleaner Elements Every 12 Every 48 Every 6Months Months Months 500 hrs. 1000 hrs 5000 hrs R/WI *Fuel/Water Separator Element R Fuel Filter Element R Engine Oil Change R Engine Oil Filter R *Engine Coolant Cond.
Operation & Maintenance Manual Maintenance Initial 500 miles /850 km Daily Weekly Monthly 3 Months 6 Months 500 hrs. 1000 hrs *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.
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.
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.
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).
Operation & Maintenance Manual ! Maintenance 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/or eye contact with the antifreeze solution. 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.
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 loosened. 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.
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.
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.
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 70 Thickener Type Lithium Complex Dropping Point 215°C (419°F) Minimum Consistency NLGI No.
Maintenance Operation & Maintenance Manual Pressure Regulator Adjusting Instructions Low Pressure Regulator High 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.
Operation & Maintenance Manual Maintenance Torque Values TABLE 1 INCH FASTENERS SAEJ249 72 SAEJ249
Maintenance Operation & Maintenance Manual Note: Cooling Fan Drive Bolts (10.9 M8x1.25) should be torqued to 23Nm (17ft-lbF). TABLE 3 TABLE 3 WHEEL TORQUE CHART Wheel Torque Chart - Inch 1/2” lug nuts Torque (Ft-Lbs) 13” Wheel 80-90 15” Wheel 105-115 16” Wheel 16.
Operation & Maintenance Manual 74 Maintenance
Lubrication 75
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 the instructions regarding types of lubricants and the frequency of their application be explicitly followed.
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.
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.
Troubleshooting 79
Operation & Maintenance Manual Troubleshooting Introduction Troubleshooting for a portable air compressor is an organized study of a particular 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.
Troubleshooting Operation & Maintenance Manual Troubleshooting Chart Complaint Cause 1. Compressor has stopped Out of fuel. unexpectedly Compressor oil temperature too high. Engine coolant temperature too high. Engine oil pressure too low. Loose or broken belts. Loose wire connection. Low fuel level fault. Defective sensor. Malfunctioning relay. Blown fuse. Engine malfunctioning. Airend malfunctioning. 2. Compressor won won'tt start or Battery disconnect switch off. run Emergency stop pushed.
Operation & Maintenance Manual Complaint Troubleshooting Cause Defective sensor. (continued) 2. Compressor won't start or run Malfunctioning relay. Engine malfunctioning. 3. High engine Coolant Temperature Airend malfunctioning. Low coolant level. Loose or broken belts. Ambient temperature above rated ambient temperature range. Dirty operating conditions. Dirty cooler(s). Compressor tilted beyond out-of-level operating limit. Operating pressure too high. Recirculation of cooling air.
Troubleshooting Complaint 6. High compressor oil temperature Operation & Maintenance Manual Cause Ambient temperature above rated ambient temperature range. Compressor tilted beyond out-of-level operating limit. Low compressor oil level. Wrong compressor oil. Dirty cooler(s). Dirty operating conditions. Clogged compressor oil filter(s). Loose or broken belts. Operating pressure too high. Recirculation of cooling air. Malfunctioning compressor oil thermostat. 7. Low engine speed Loose or broken belts.
Operation & Maintenance Manual Complaint Troubleshooting Cause 9. Low air delivery / low cfm Clogged air filter element(s). Incorrect pressure regulation adjustment. Malfunctioning inlet unloader / butterfly valve Wrong air filter element(s). Low engine speed 10. Short air filter life 11. Compressor will not unload 12. Safety valve opens 13. Excessive carryover (compressor oil in the compressed air) Correction Clean or replace air filter element(s). Make adjustments per this manual.
Troubleshooting Operation & Maintenance Manual Engine Diagnostic Codes - Cummins Engine with CM2250 Controller LCD Display 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
Operation & Maintenance Manual LCD Display 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 86 Display Name Troubleshooting
4 16 2 10 0 1 2 3 4 9 19 2 16 3 4 15 16 1 2 3 4 27 81 84 84 91 91 91 91 91 91 91 93 95 97 97 97 97 100 100 100 100 141 135 435 415 1852 418 429 428 2372 528 287 3326 132 131 1242 147 148 242 241 2754 2272 J1939 J1939 Cummins SPN FMI Code Engine Oil Pressure Engine Oil Pressure Engine Oil Pressure Engine Oil Pressure Water in Fuel Indicator Water in Fuel Indicator Water in Fuel Indicator Water in Fuel Indicator Fuel Pressure Engine Net
9 19 0 3 4 14 16 18 31 31 1 2 3 4 17 18 0 0 1 3 4 108 108 110 110 110 110 110 110 110 110 111 111 111 111 111 111 157 157 157 157 157 452 451 2249 1911 449 197 2448 196 195 422 235 2659 2646 2789 146 1847 145 144 151 3373 3372 J1939 J1939 Cummins SPN FMI Code Engine Injector Metering Rail 1 Pressure Engine Injector Metering Rail 1 Pressure Engine Injector Metering Rail 1 Pressure Engine Injector Metering Rail 1 Pressure Engine Injector
16 18 2 16 18 9 19 0 0 2 2 9 16 18 2 3 4 3 4 15 16 157 157 166 168 168 171 171 190 190 190 190 191 191 191 411 411 411 412 412 412 412 2962 2961 2376 2375 2274 2273 1866 489 349 3328 2321 689 2468 234 3371 3369 441 442 951 559 553 J1939 J1939 Cummins SPN FMI Code Engine Exhaust Gas Recirculation 1 Differential Pressure Engine Exhaust Gas Recirculation 1 Differential Pressure Engine Exhaust Gas Recirculation 1 Differential Pressure Engine Exhaus
3 4 14 14 2 13 3 4 2 4 16 18 2 4 2 12 12 31 2 9 13 441 441 441 441 558 558 597 597 611 611 611 611 612 623 627 627 629 633 639 639 639 286 285 426 2311 343 351 1117 244 115 2293 2292 2186 523 771 769 432 431 1381 292 294 293 J1939 J1939 Cummins SPN FMI Code Not Available or Condition Exists Bad Intelligent Device or Component Bad Intelligent Device or Component Data Erratic, Intermittent or Incorrect Voltage Below Normal, or Shorted to
14 7 9 12 13 15 31 2 3 4 5 5 5 5 5 5 3 3 4 3 3 640 641 641 641 641 641 641 644 647 647 651 652 653 654 655 656 677 697 697 702 703 529 527 2558 2557 584 325 323 332 324 331 322 245 2377 237 2635 1962 2449 2634 2636 2387 599 J1939 J1939 Cummins SPN FMI Code Auxiliary I/O #03 Auxiliary I/O #02 Auxiliary PWM Driver #1 Auxiliary PWM Driver #1 Engine Starter Motor Relay Engine Injector Cylinder #06 Engine Injector Cylinder #05 Engine Injector
11 14 2 2 7 3 4 3 4 19 3 4 3 4 3 4 3 4 3 2 2 703 703 723 723 723 729 729 974 974 974 1073 1073 1075 1075 1112 1112 1136 1136 1172 1188 1209 2554 3925 691 698 697 2365 2368 2266 2265 2363 2367 288 134 133 2556 2555 731 2322 778 2195 779 J1939 J1939 Cummins SPN FMI Code Engine Exhaust Gas Pressure Engine Turbocharger 1 Compressor Intake Temperature Engine Turbocharger Wastegate Actuator 1 Position Engine ECU Temperature Engine ECU Temperat
3 4 16 2 2 3 4 7 2 31 3 4 14 2 9 14 11 16 18 3 4 1209 1209 1209 1231 1235 1347 1347 1347 1377 1378 1388 1388 1388 1623 1623 1632 1675 1800 1800 2623 2623 1241 1239 2264 2263 3737 2998 3186 3213 296 298 297 649 497 281 271 272 3331 3329 2764 2374 2373 J1939 J1939 Cummins SPN FMI Code Data Erratic, Intermittent or Incorrect Data Erratic, Intermittent or Incorrect Voltage Above Normal, or Shorted to High Source Voltage Below Normal, or Shorted t
3 4 15 4 5 6 7 13 13 11 17 18 31 2 3 4 13 0 2 3 4 2630 2630 2789 2791 2791 2791 2791 2791 2797 3050 3050 3050 3058 3241 3241 3241 3241 3242 3242 3242 3242 3316 3317 3318 3311 1663 1665 1666 1667 2774 1691 2638 2637 2765 1896 2357 2353 2349 2351 2346 2572 2571 J1939 J1939 Cummins SPN FMI Code Aftertreatment Diesel Particulate Filter Intake Gas Temperature – Data valid but above normal operational range – Most Severe Level Aftertreatment 1 Di
15 16 2 3 4 16 0 2 3 4 16 17 18 0 2 3 4 15 16 16 3 3242 3242 3245 3245 3245 3245 3246 3249 3249 3249 3249 3249 3249 3251 3251 3251 3251 3251 3251 3481 3509 386 2778 1921 2639 1881 1879 1883 1922 2743 2742 1968 1674 1675 1676 3312 1972 1877 1876 1878 3253 3254 J1939 J1939 Cummins SPN FMI Code Sensor supply voltage 1 Aftertreatment 1 Fuel Rate Aftertreatment 1 Diesel Particulate Filter Differential Pressure Aftertreatment 1 Diesel Particulate F
4 3 4 3 4 3 3 4 3 4 17 16 3 4 18 2 3 4 3 4 31 3509 3510 3510 3511 3511 3512 3513 3513 3514 3514 3555 3556 3597 3597 3597 3610 3610 3610 3667 3667 3703 2777 3141 3139 3134 3133 3135 1938 1941 1939 2728 1943 516 515 1696 1695 2185 238 239 187 227 352 J1939 J1939 Cummins SPN FMI Code 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 Norma
3727 193 194 2699 3222 0 2 3 4 13 31 31 0 5 6 7 11 11 13 7 3 4 7 12 4765 4765 4765 4765 4765 4795 4796 5246 5421 5421 5421 5421 5421 5421 5571 520199 520199 520320 520435 3918 3928 3927 3921 3923 3922 3712 1664 1993 3325 3313 3314 3315 3251 3168 16 3936 1981 15 3936 J1939 J1939 Cummins SPN FMI Code Glow Plug Module Crankcase Depression Valve Cruise Control (Resistive) Signal Circuit Bad Intelligent Device or Component Mechanical System not
3136 3137 3295 3296 3377 3924 952 953 3 4 3 4 31 11 31 31 520441 520441 520442 520442 520448 520553 524286 524286 J1939 J1939 Cummins SPN FMI Code Reserved for temporary use Reserved for temporary use Utility Reverse kW Fault Engine Exhaust Gas Recirculation (EGR) Outlet Pressure Sensor Circuit Engine Exhaust Gas Recirculation (EGR) Outlet Pressure Sensor Circuit Engine Exhaust Gas Recirculation (EGR) Mixer Inlet Temperature Sensor Circuit Engine Exhaust Gas Recirculation (EG
Troubleshooting Operation & Maintenance Manual 99
Operation & Maintenance Manual 100 Troubleshooting
Options 103
Operation & Maintenance Manual Options IQ System The IQ System is a complete, self-contained system which provides cooler, cleaner air than from a standard portable compressor. The system utilizes an integral aftercooler, high-efficiency filtration, and a patented condensate disposal system to provide the cool, clean air. The condensate disposal system injects all liquid condensed from the moisture separator and filters into the engine exhaust system where it is vaporized by heat.
Options Operation & Maintenance Manual ! CAUTION The compressor regulation system is adjusted to maintain regulated pressure at the Separator Tank. DO NOT adjust regulation to provide full rated pressure at the Service Valve when the IQ System is enabled. This will result in operation at excessive horsepower levels, causing overheating, reduced engine life, and reduced airend life.
Operation & Maintenance Manual Options IQ System Configuration IQ System Active Standard Operation (IQ System Bypassed) (1) Separator Tank (6) Primary IQ Filter (2) Minimum Pressure Valve (7) Secondary IQ FIlter (3) 3 Way Selector Valve (8) Check Valve (4) Aftercooler (9) Service Valve (5) Water Separator 106
Options Operation & Maintenance Manual Maintenance Daily Maintenance Verify, during fullload (maximum compressed air delivery) operation, the IQ System filter restriction is not excessive. Filter restriction can be checked at the control panel. The compressor will shutdown if restriction exceeds recommended values. ! CAUTION Excessively restricted filter elements may cause an increase in the amount of aerosol water and oil carryover which could result in damage to downstream equipment.
Operation & Maintenance Manual Options Filter Replacement • With engine shutdown, ensure pressure is relieved from air system. • Disconnect drains on the bottom of each filter housing. Inspect fittings and hoses for any blockage. Clean if necessary. • Using a chain wrench or similar tool, loosen the housing. The housing should be removed by hand after initial loosening, taking care to prevent the housing from falling. • Remove and replace the filter element being careful not to damage outer wrap.
Revision History Rev.
Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2011 Doosan Infracore Portable Power Printed in the U.S.A.
