This document is an Operating & Maintenance Manual for Doosan Infracore Portable Power compressors, specifically covering models HP1600WCU-T3 (E09), HP1600WCU-FX-T3 (E10), HP1600WCU-EU-FX-T3 (E67), HP1600FCU-EX-T3 (E49), and HP1600FCU-T3 (E68), as well as HP1300WCU-T3 (E84), 10/370 (B37), and 10/455 (B38). The manual provides comprehensive information for the safe and efficient operation, maintenance, and troubleshooting of these portable air compressors.
Function Description:
The devices described are portable air compressors designed to deliver compressed air for various applications. They are powered by Cummins QSX15 diesel engines and feature an advanced control system for monitoring and managing operational parameters. The compressors are equipped with an IQ System, a complete, self-contained system that provides cooler, cleaner air than a standard portable compressor. This system utilizes an integral aftercooler, high-efficiency filtration, and a patented condensate disposal system to provide 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, eliminating the need for collecting the condensate.
Important Technical Specifications:
- Compressor Models: HP1600WCU, HP1300WCU, 10/370, 10/455, HP1600WCU-FX-T3, HP1600WCU-EU-FX-T3, HP1600FCU-EX-T3, HP1600FCU-T3.
- Air Delivery: HP1600WCU: 1600 cfm (756 litres/sec); HP1300WCU: 1300 cfm (614 litres/sec).
- Rated Operating Pressure: 80-150 psi (552-1034 kPa).
- Engine (Diesel): Manufacturer: Cummins, Model: QSX15.
- Rated Horsepower at 1800 rpm: QSX15: 560 hp (HP1600WCU), 510 hp (HP1300WCU).
- Electrical System: 24VDC.
- Full Load Speed: 1800 rpm.
- No Load Speed: 1200 rpm.
- Fluid Capacities:
- Compressor Lubricant: 55 (208) litres.
- Engine Lube (including filter): 12 (46) litres.
- Engine Coolant (radiator): 15.2 (57.5) litres.
- Fuel Tank (Clean DIESEL fuel): 230 (870) litres.
- Units Measurements/Weights (HSRG, Wagon RG, LRG):
- Overall Length: 24.2 (7.4) ft, 19.0 (5.79) ft, 19.9 (5.79) ft.
- Overall Height: 8.33 (2.54) ft, 8.33 (2.54) ft, 7.25 (2.21) ft.
- Overall Width: 7.5 (2.29) ft, 7.5 (2.29) ft, 7.5 (2.29) ft.
- Gross Weight (pounds kg): 17,200 (7810), 17,200 (7810), 16,700 (7590).
- (including fluids - no fuel): est, est, est.
- Running Gear: Tire Size: 215/75R17.5H. Towing Speed (maximum) mph: 65 (HSRG), 20 (Wagon RG), NA (LRG). Inflation Pressure: 125 psig.
Usage Features:
- Operating Controls and Instruments: The control panel includes various gauges and indicator lamps for monitoring parameters such as compressor oil level, engine oil level, radiator coolant level, battery, radiator, air cleaner service, fuel tank, fuel/water separator, oil leaks, fuel leaks, drain water from fuel filters, coolant leaks, radiator filter cap, air cleaner precleaner dumps, fan/alternator belts, battery connections/electrolyte, tire pressure, wheel lug nuts, hoses, automatic shutdown system, air cleaner system, compressor oil cooler exterior, engine rad/oil cooler exterior, fasteners, guards, and air cleaner elements.
- Starting: The unit requires a battery disconnect switch to be in the "ON" position. The keyswitch is turned to "ON" for diagnostic lamps to light and the LED display to flash. In freezing weather, heaters switch "ON" and wait 60 seconds. The engine starter motor should not be operated for more than 10 seconds without allowing at least one minute cooling time between start attempts. Ether injection is used for cold weather starting.
- Normal Operation: The compressor operates in either loaded or unloaded states. In the unloaded state, the inlet valve is closed, and the unit runs at 1200 RPM with no air delivery. In the loaded state, the inlet valve is open or modulated, and the engine speed varies between 1200 RPM and 1800 RPM to match the required flow.
- Stopping: To stop, close air service valve(s), allow the unit to run at "IDLE" for 3 to 5 minutes to reduce engine temperatures, and then turn the keyswitch to the "OFF" position.
- IQ System: Provides cooler, cleaner air and automatically disposes of condensate. The system monitors ambient temperature and adjusts movable louvers to control airflow through the aftercooler, ensuring optimal performance and preventing freezing in cold conditions.
- Pressure Regulation: The pressure regulator (PR) can be adjusted by loosening the locknut (G) and turning the adjustment screw (H). The service valve (US) holds pressure in the inlet unloader (IU) after shutdown.
Maintenance Features:
- Maintenance Schedule: A detailed maintenance chart outlines daily, weekly, monthly, 3-month/500-hour, 6-month/1000-hour, 12-month/2000-hour, 18-month/3000-hour, 2-year, 4-year, and 6-year maintenance tasks. These tasks include checking/adjusting (C), draining (D), greasing (G), replacing (R), testing (T), checking before towing (CBT), and checking/reporting (CR) various components.
- Routine Maintenance: Emphasizes safety precautions before any maintenance work, such as ensuring the machine is stopped, depressurized, and battery cables are disconnected.
- Protective Shutdown System: The manual describes how to test the low engine fuel level switch.
- Scavenge Line: Regular checks are required to ensure the scavenge line is clear of any obstructions to prevent oil carryover.
- Compressor Oil Filter: Instructions for removal, inspection, and reassembly are provided. It is crucial to use a new oil filter element and ensure proper sealing to prevent leaks.
- Compressor Oil Separator Element: Details on removal, inspection, and reassembly, including precautions to avoid static build-up.
- Compressor Oil Cooler and Engine Radiator: Maintenance involves ensuring cleanliness and proper airflow. Warnings are given regarding hot engine coolant and antifreeze.
- Air Filter Elements: Instructions for removal and reassembly, with a caution against removing elements while the machine is running.
- Ventilation and Cooling Fan Drive: Checks for clear air inlets and outlets, and proper tensioning of fan belts.
- Fuel System: Daily draining of sediment/condensate from the fuel tank and regular replacement of the fuel filter water separator element.
- Hoses: Periodic inspection for cracks, leaks, and damage.
- Electrical System and Battery: Checks for loose connections, corrosion, and proper battery restraint.
- Pressure System: Regular inspection for damage, corrosion, and proper functioning of components.
- Tire Pressure and Running Gear/wheels: Checks for correct tire pressure and proper tightening of wheel nuts.
- Lubrication: General information on lubricants, compressor oil change procedures, and a Portable Compressor Fluid Chart specifying preferred fluids based on ambient temperature and rated operating pressure.
- Running Gear Wheel Bearings: Greasing every 12 months with MIL-G-10924 grease.
Troubleshooting:
The manual includes a comprehensive troubleshooting section with an action plan, double-check procedures, and identification of basic causes. It provides a list of WEDGEDiagnostic Display Codes and ALERT/SHUTDOWN CONDITIONS with corresponding fault codes, light indications, and delay times. A detailed Troubleshooting Chart outlines common complaints (e.g., Unit Shutdown, Won't Start/Run, High Engine Temperature, Low Engine Oil Pressure, Alternator Low Voltage, High Compressor Discharge Temperature, Engine RPM Down, Excessive Vibration, Low CFM, Short Air Cleaner Life, Will Not Unload, Safety Valve Relieves) and their corrective actions.
Safety:
The manual includes extensive safety information, including general precautions, warnings regarding compressed air, materials (brake lining dust, engine exhaust fumes, anti-freeze, compressor lubricant, engine lubricant, preservative grease, rust preventative, diesel fuel, battery electrolyte), battery handling, radiator care, transport procedures, safety chains, and decals. It also addresses noise emission control and tampering with noise control systems, emphasizing compliance with U.S. Environmental Protection Agency regulations. Free safety decals are available from Doosan Infracore Portable Power.
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