This document is an Operation and Maintenance Manual for a Doosan Infracore Portable Power Compressor Model 9/235, with serial numbers starting from 814000. It provides essential information for the safe and efficient operation and maintenance of the machine.
Function Description
The Doosan Infracore Portable Power Compressor Model 9/235 is designed to produce compressed air for various applications. It is intended for use only under specified conditions, compressing normal ambient air free of known or detectable additional gases, vapors, or particles. The machine is not approved for direct or indirect human consumption of compressed air without suitable filtration and purity checks. It is also not intended for use in potentially explosive atmospheres. The manual emphasizes that any machine modifications are strictly prohibited and will invalidate EC certification.
Important Technical Specifications
The manual provides detailed technical specifications for both the compressor and the engine.
Compressor:
- Actual Free Air Delivery: 23.4 m³/min (825 CFM)
- Normal Operating Discharge Pressure: 8.6 bar (125 psi)
- Maximum Allowable Pressure: 10.3 bar (150 psi)
- Safety Valve Setting: 14 bar (200 psi)
- Maximum Pressure Ratio (absolute): 9.6:1
- Operating Ambient Temperature: -10°C to +46°C (14°F to 115°F) for Whisperized models
- Cooling System: Oil injection
- Oil Capacity: 64 litres (17 GAL)
- Maximum Oil System Temperature: 120°C (248°F)
Engine:
- Type/Model: 6C8.3
- Number of Cylinders: 6
- Oil Capacity: 31.7 litres (8.4 gal)
- Speed at Full Load: 2000 min⁻¹ (RPM)
- Speed at Idle: 1500 min⁻¹ (RPM)
- Power Available at Full Load: 205 kW (275 hp)
- Electrical System: 24V negative earth
- Fuel Tank Capacity: 462 litres (122 gal)
- Coolant Capacity: 34 litres (9 gal)
- Engine Type: Water-Cooled, four cycle, in-line overhead valve type
- Combustion Type: Direct injection
- Bore x Stroke: 6-114 x 134.9 mm (4.49 x 5.31 in)
- Engine Displacement: 8.3 L (506 cid)
- Compression Ratio: 18:1
- Firing Order: 1-5-3-6-2-4
- Governor: Mechanical type
- Specified Fuel: Diesel fuel (ASTM D975 No. 2-D)
- Starter: 24V - 7.2 kW
- Alternator: 24V - 50 A
- Specified Engine Oil (API grade): CG-4, CH-4, or better
- Engine Dry Weight: 617 kg (1360 lb)
- Overall Dimensions (L x W x H): 1128 mm (44.4 in) x 749 mm (29.5 in) x 1096 mm (43.2 in)
- Valve Clearance (cold): Intake 0.30 mm (.012 in), Exhaust 0.61 mm (.024 in)
Sound Level Data:
- Rated Load (Operator position - 1m from machine): 86 dB(A)
- Sound Power Level (2000/14/EC): 102 Lwa
- Average Sound Pressure Level at 10m to ISO 3744: 74 dB(A)
- EPA Noise: 76 dB(A)
Wheels and Tyres:
- Number of Wheels: 4
- Tyre Size: 7.50-16 LT
- Tyre Pressure: 4.5 bar (65 psi)
- Net Weight (Less Fuel): 3900 kg (8600 lb)
Usage Features
The manual provides detailed operating instructions, including commissioning, compressor mounting, and procedures for starting, stopping, and emergency stopping.
Starting the Machine:
- Place the unit on a level surface (within 15 degrees lengthways and sideways).
- Check engine lubrication oil, compressor oil, and diesel fuel levels.
- Drain the fuel filter water separator.
- Open and then close the service valve to relieve pressure.
- Check radiator coolant level and air restriction indicators.
- For cold starts (below 0°C), open the manual blowdown valve fully, complete the starting sequence, and close the valve once the engine runs freely.
- The machine features a key-operated switch for starting, with positions for "ON" and "CRANK."
- After warm-up, the "Service Air Switch" is pushed to provide full air pressure.
Stopping the Machine:
- Close the service valve.
- Allow the machine to run unloaded for a short period to reduce engine temperature.
- Turn the start switch to the "OFF" position.
- The automatic blowdown valve should relieve system pressure upon stopping. If it fails, pressure must be relieved manually via the service valve(s).
Emergency Stopping:
- Turn the key switch to "OFF" or push the emergency stop switch (if fitted).
Monitoring During Operation:
- The control panel includes an hourmeter, compressor discharge pressure gauge, fuel level gauge, engine speed gauge, discharge air temp gauge, engine oil pressure gauge, engine water temp gauge, and voltmeter.
- A diagnostic display panel indicates auto shutdown conditions such as high compressor temp, low engine oil pressure, high engine coolant temp, low fuel level, low battery voltage, low engine coolant level, and restricted air filter.
Dual Pressure Regulation (when fitted):
- Allows selection between 7 bar (100 psi) and the machine's rated pressure. The pressure gauge indicates the selected setting.
Maintenance Features
The manual outlines a comprehensive maintenance schedule and procedures for various components.
General Maintenance:
- Safety Decals: Available free of charge; orders should be submitted to the Doosan Portable Power EMEA Aftermarket Department.
- Personnel: Maintenance personnel must be adequately trained and competent.
- Pre-Maintenance Checks: Ensure all pressure is vented, electrical supply is disconnected, and guards are in place.
- Regular Inspections: Weekly visual checks of fasteners, safety-related parts (coupling hitch, drawbar, road-wheels, lifting bail).
- Fluid Disposal: Proper disposal of oil, diesel fuel, antifreeze, brake fluid, and batteries is emphasized.
Engine Maintenance:
- Oil and Filter Change: Engine oil and oil filter element must be changed simultaneously according to the maintenance schedule (e.g., every 500 hours or 6 months).
- Coolant Change: Every 1000 hours or 12 months, using a 50/50 Ethylene glycol base antifreeze/water mix.
- Air Cleaner: Element replacement every 500 hours or 6 months, or sooner if the restriction indicator shows red. Dust collector box(es) should be cleaned daily.
- Fan Belt: Check tension and abnormalities.
- Battery: Check cable connections for looseness/corrosion, electrolyte level, and ensure full charge, especially in cold weather.
- Fuel System: Drain water from the fuel filter/separator regularly. Replace fuel filter elements every 500 hours or 6 months.
Compressor Maintenance:
- Oil Filter: Refer to the maintenance chart for servicing intervals.
- Oil Separator Element: Refer to the maintenance chart for servicing intervals.
- Scavenge Line: Check for obstructions when changing compressor lubricant.
- Lubricating Oil: Use Doosan Preferred Fluids (PRO-TEC, XHP 605, XHP 1001, XHP 405) for extended airend warranty.
Running Gear/Wheels:
- Wheel Nut Torque: Check 20 miles (30 km) after refitting wheels.
- Wheel Bearings: Pack with grease every 6 months (MIL-G-10924 specification).
- Tyre Pressure: Maintain correct tyre pressure (4.5 bar / 65 psi).
Troubleshooting:
- A detailed troubleshooting guide is provided for common issues such as engine not starting, engine stops/stalls, engine overheats, engine speed issues, excessive vibration, and oil leaks.
Warranty:
- The standard warranty covers defects in material and workmanship for 3 months or 6 months from shipment, depending on the item.
- Portable compressors, generators (9 Kva-550 Kva), light towers, and air dryers have a 12-month/2,000-hour warranty.
- Portable compressor air ends have a 24-month/4,000-hour warranty, with an optional extended warranty of 60 months/10,000 hours for major components (rotors, housings, bearings, gears) if genuine Doosan parts/fluids are used and maintenance is performed by authorized service engineers.
- Construction tools have a 12-month warranty.
- Engines (Caterpillar, Cummins, John Deere, Kubota) carry their manufacturers' warranties, with some extended warranties available under specific conditions.
- Parts have a 6-month unlimited hour warranty.
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