Doosan P250/HP210WKUB-EX-T2, Operation And Maintenance Manual

Page 1: ...OPERATION and MAINTENANCE MANUAL COMPRESSORS MODEL Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 DoosanPortablePower com P N 46734785 2018 Rev B P250 HP210WKUB EX T2 G92 ...

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Page 4: ...y 17 Radiator 18 Transport 18 Decals 20 Decal Symbols 25 GENERAL DATA 29 General Data Information 30 Expendable Service Parts 30 OPERATING INSTRUCTIONS 33 Before Towing 34 Setting Up All Units 34 Towing 35 P250 HP210 Control Panel 36 Before Starting 37 Starting 38 Cold Weather Starting 38 Stopping 38 Speed and Pressure Regulator Adjustment Instructions 40 Engine Speed Control 41 MAINTENANCE 43 Mai...

Page 5: ...cavenge Line 50 Exterior Finish Care 50 Field Replacement of Exterior Decals 51 Maintenance Schedule 52 LUBRICATION 53 Lubrication 54 Compressor Oil Chart 55 Engine Oil Standards 56 TROUBLESHOOTING 57 Troubleshooting Introduction 58 Action Plan 58 Troubleshooting Chart 60 WARRANTY 63 64 65 66 Revision History 67 4 ...

Page 6: ...Foreword 5 ...

Page 7: ...le 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 Par...

Page 8: ...uirements Explained In This Manual Be Performed At The Required Intervals Exceeding These Intervals May Reduce The Reliability Of The Compressor The Purpose Of This Manual Is To Train The Operator With Functions Operation And Basic Service And Maintenance Requirements Of The Compressor During The Preparation Of This Manual Every Effort Was Made To Ensure The Accuracy And Adequacy Of The Contents Y...

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Page 10: ...Drawbar Information 9 ...

Page 11: ...Operation Maintenance Manual Drawbar Information Instruction Kit For Drawbar To Convert from Shipping Position to Towing Position 10 ...

Page 12: ...tely 1 inch above the ground 4 Remove the temporary Retaining Bolts from both sides of the Frame at the Drawbar connection See Figure 1 5 Carefully lower the Drawbar to the Level position 6 Install the Four Bolts with Pre applied Thread Lock to the four points inside the Enclosure and Torque to 68 pounds 9 4 kg meters See Figure 1 7 Install Safety Chains by sliding the second link of one Chain int...

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Page 14: ...Safety 13 ...

Page 15: ...ould 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 caus...

Page 16: ...pply line at tool or vent valve before performing any service or maintenance Discharged air contains a very small percentage 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...

Page 17: ...ration 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 Avoid Inhalation Of Material Substances Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times Th...

Page 18: ...ifreeze 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 Do...

Page 19: ...raining 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 the specified lifting and tie down points are used When loading or transporting the compressor ensure the towing vehicle its size weight towing hitch and electrical supply are all suitable to ...

Page 20: ...handbrake and if necessary suitable wheel chocks 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 Att...

Page 21: ...ecals 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 Repla...

Page 22: ...tructions inform your supervisor Red Background Indicates the presence of a hazard which WILL cause serious injury death or property damage if ignored Orange Background Indicates the presence of a hazard which CAN cause serious injury death or property damage if ignored Yellow Background Indicates the presence of a hazard which WILL or CAN cause injury or property damage if ignored Blue Background...

Page 23: ...Operation Maintenance Manual Safety 22 ...

Page 24: ...Safety Operation Maintenance Manual 23 ...

Page 25: ...Operation Maintenance Manual Safety 24 ...

Page 26: ...Safety Operation Maintenance Manual Decal Symbols Graphic Form and Meaning of ISO Symbols 25 ...

Page 27: ...Operation Maintenance Manual Safety 26 ...

Page 28: ...Safety Operation Maintenance Manual 27 ...

Page 29: ...Operation Maintenance Manual Safety 28 ...

Page 30: ...General Data 29 ...

Page 31: ...ressor Lubricant gallon liters 4 5 17 4 5 17 Engine Cooling System gallon liters 3 7 14 3 7 14 Engine Crankcase Lubricant quarts liters 3 5 13 2 3 5 13 2 Fuel Tank gallon litres 34 5 130 6 34 5 130 6 RUNNING GEAR Tire Size ST205 75D15 ST205 75D15 Inflation Pressure Cold psi 50 50 Towing Speed Maximum mph km hr 65 mph 105 65 mph 105 UNIT MEASUREMENTS WEIGHTS Overall Length feet meters 11 5 3 5 11 5...

Page 32: ...r Element Compressor Secondary Optional 46707047 Air Cleaner Element Engine Secondary Optional 46707047 Engine Oil Filter Element 46715766 Fuel Water Separator Element 46709386 In Line Fuel Filter 46708785 PRO TEC Compressor Fluid 1 gal 36899698 PRO TEC Engine Fluid 1 gal 54480918 Fan Belt 46735745 Modification or alteration of this machine Can result in severe injury or death Do not modify or alt...

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Page 34: ...Operating Instructions 33 ...

Page 35: ...rawbar Attach to vehicle Fold jack handle down and forward Swing up jack tube and FULLY insert pin in tube Remove tire chocks Test brakes if so equipped Test lights running stop and turn signals Always raise or remove jack for maximum ground clearance before towing Setting Up All Units Position as level as possible The design of these units permits a 15 degree sidewise limit on out of level operat...

Page 36: ...N cause severe injury or death Disconnect Engage tow vehicle parking brake Chock tires of compressor Set the vehicle parking brake Chock wheels of unit Standing to the side remove pin from tube of jack Disconnect safety chains Crank jack to raise eye or coupler from hitch Tow vehicle can be moved 35 ...

Page 37: ...essure Gauge Indicates pressure in receiver tank normally from 0 psi kPa to the rated pressure of the machine 2 Main Ignition Switch OFF ON PREHEAT START Switch 3 Hourmeter Indicates machine operating hours 4 Service Air Button Push to engage Allows user to load compressor after engine warm up 36 ...

Page 38: ...l Add only CLEAN low or ultra low sulfur diesel fuel for maximum service from the engine Check the compressor lubricating fluid level between bottom and midway of the sight glass on the separator tank This machine produces loud noise with doors open Extended exposure to loud noise can cause hearing loss Wear hearing protection when doors or valve s are open Close all doors to maintain a cooling ai...

Page 39: ...d Weather Starting Move power switch to the Glow Plug position and hold 10 seconds Then turn to start Exercise extreme caution when using a booster battery to start To jump start Connect the ends of one booster cable to the positive terminals of each battery Then connect one end of the other cable to the negative terminal of the booster battery and the other end to the engine block Not to the nega...

Page 40: ...c blow down valve malfunction is suspected open manual blowdown valve Since the service valve is closed air downstream of the valve may be trapped A vent hole in the service valve will slowly bleed air from the hose Do not disconnect hoses until all pressure has been vented Do NOT use ETHER Machine has shutdowns and switches as follows Low Engine oil pressure in the engine High engine coolant temp...

Page 41: ...the closed position turn the adjusting screw on the High pressure regulator clockwise until the pressure gauge indicates 175 180 psi Tighten the pressure regulator jam nut 3 To adjust the low pressure regulation while at idle turn the manual valve to the open position turn the adjusting screw on the Low pressure regulator until the pressure gauge indicated 125 130 psi Tighten the Low pressure regu...

Page 42: ...alled in the hole closest to the flywheel housing as shown below See Figure 1 This speed is compatible with 100 psi functionality Likewise the factory has preset the engine speed control to provide 2200 rpm engine speed when the clevis pin is installed in the hole furthest from the flywheel housing as shown below See Figure 2 This speed is compatible with 150 psi functionality 41 ...

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Page 44: ...Maintenance 43 ...

Page 45: ...these units require periodic servicing to provide maximum output and performance Servicing may consist of pre operation and post operation procedures to be performed by the operating or maintenance personnel The primary function of preventive maintenance is to prevent failure and consequently the need for repair Preventive maintenance is the easiest and the least expensive type of maintenance Main...

Page 46: ...es The instruments or gauges are essential for safety maximum productivity and long service life of the machine Inspect the gauges and test any diagnostic lamps prior to start up During operation observe the gauges and any lamps for proper functioning Refer to Operating Controls for the normal readings Fuel Tank CLEAN fuel in the fuel tanks is vitally important and every precaution should be taken...

Page 47: ...nes to and from the air cleaners the engine cooling system hoses and all of the flexible hoses used for air oil and fuel be inspected To ensure freedom from air leaks all rubber hose joints and the screw type hose clamps must be absolutely tight Regular inspection of these connections for wear or deterioration is necessary Premature wear of both the engine and compressor is ASSURED whenever dust l...

Page 48: ... against the fitting The tubing can be removed and replaced numerous times without losing its sealing ability To install the nylon tubing make a mark with tape or grease pencil approximately 7 8 inch from the end of the tubing Insert the tubing into the sleeve and push in past the first resistance to the bottom The mark should be approximately 1 16 inch from the sleeve for the 3 8 inch O D tubing ...

Page 49: ...en the service air valve s to ensure that system is relieved of all pressure Close the valve s 2 Turn the spin on filter element counterclockwise to remove it from the filter housing Inspect the filter 3 Inspect the oil filter head to be sure the gasket was removed with the oil filter element Clean the gasket seal area on the oil filter head Installing a new oil filter element when the old gasket ...

Page 50: ...erature is likely to occur causing shut down of the unit To correct this situation it will be necessary to clean the cooler using a cleaning compound in accordance with the manufacturer s recommendations Compressor Oil The lubricating and cooling oil must be replaced every 500 hours of operation or six 6 months whichever comes first Refer to warranty section about extended warranty Receiver Separa...

Page 51: ...0 minutes to permit element to clear itself Exterior Finish Care This unit was painted and heat cured at the factory with a high quality thermoset polyester powder coating The following care will ensure the longest possible life from this finish 1 If necessary to remove dust pollen etc from housing wash with water and soap or dish washing liquid detergent Do not scrub with a rough cloth pad etc 2 ...

Page 52: ...uch 10 Apply any Dupont Topcoat Finish such as Imron or Centari according to the label instructions NOTE To re topcoat the textured surfaces when sheet metal repairs are not necessary follow steps 1 2 4 5 6 8 and 10 Field Replacement of Exterior Decals Field Replacement of Enclosure Decals 1 The decal area should be wiped with 70 isopropyl alcohol and a lint free cloth in a well ventilated area 2 ...

Page 53: ...Operation Maintenance Manual Maintenance Maintenance Schedule 52 ...

Page 54: ...Lubrication 53 ...

Page 55: ...n of the moving parts reduces to a minimum the possibility of mechanical failures The Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed A regular service program should be developed to include all items and fluids These intervals are based on average operating conditions In the event of extremely severe hot cold dusty or wet operati...

Page 56: ...eferred PRO TEC Alternate ISO Viscosity Grade 46 with rust and oxidation inhibitors for rotary screw compressor service 350 psi 23 C to 52 C 10 F to 125 F 65 F to 125 F 18C C to 52 C Preferred PRO TEC XHP605 Alternate XHP405 ISO Viscosity Grade 68 Group 3 or 5 with rust and oxidation inhibitors designed for air compressor service Preferred XHP605 XHP1001 Preferred Oil Use of these oils with Doosan...

Page 57: ...engine oil which satisfies the following recommended specifications Engine Model SAE Classification Oil Class V3300DI T SAE 10W30 API Service Quality or Better than CD Class V3300DI T SAE 15W40 API Service Quality or Better than CD Class Note Doosan engine oils are recommended for use in this machine If Doosan engine oil is not available use good quality engine oil that API Service quality is bett...

Page 58: ...Troubleshooting 57 ...

Page 59: ... and ask yourself these questions 1 What were the warning signals that preceded the trouble 2 Has a similar trouble occurred before 3 What previous maintenance work has been done 4 If the compressor will still operate is it safe to continue operating it to make further checks B Do The Simplest Things First Most troubles are simple and easily corrected For example most complaints are low capacity w...

Page 60: ...ilure has been corrected be sure to locate and correct the cause of the trouble so the same failure will not be repeated A complaint of premature breakdown may be corrected by repairing any improper wiring connections but something caused the defective wiring The cause may be excessive vibration 59 ...

Page 61: ...h See Table 4 Engine Water Temp Too High Check coolant level If necessary Add Loose Wire Connection Wiggle wires at switches connector blocks Make repairs Defective Discharge Air Temp Switch Replace switch Defective Engine Oil Pressure Switch Replace switch Broken Engine Fan Belt Replace fan belt Engine Oil Pressure Too Low Check engine oil level and add if necessary Malfunctioning Relay Replace r...

Page 62: ...eck fluid level If necessary Add Malfunctioning Start Switch Replace switch Defective D2 Diode Replace D2 Diode Blown Fuse Replace fuse Check for Short Engine Oil Pressure Too Low Check engine oil level and add if necessary Compressor Oil Temp Too High See Table 4 Defective Discharge Air Temp Switch Replace switch Defective Engine Oil Pressure Switch Replace switch Defective Engine Temp Switch Rep...

Page 63: ...sor Oil Temperature Complaint Corrective Action Dirty Cooler Clean exterior surfaces Low Oil Level Add oil Look for any leaks Clogged Oil Filter Elements Replace elements Change oil Operating Pressure Too High Reduce pressure to spec Dirty Operating Conditions Move unit to cleaner environment Ambient Temp 120 F 49 C Above spec limit Out of Level 15 degrees Relocate or reposition unit Wrong Lube Oi...

Page 64: ...WARRANTY 63 ...

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Page 68: ...Revision History REV DATE DESCRIPTION A 03 21 2018 Original Release 67 B 07 09 2018 Addec P65 Calif Warning Label ...

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Page 71: ...Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 DoosanPortablePower com Doosan Infracore Portable Power Printed in the U S A ...