This document is an Operation and Maintenance Manual for a Doosan Infracore Portable Power compressor. It covers the functions, operation, and basic service and maintenance requirements for the P600/XP535WCU-T4i (E90) and HP450/VHP400WCU-T4i (E91) compressor models.
Function Description:
The device is a portable air compressor designed for above-ground operation, compressing normal ambient air without additional gases, vapors, or particles. It is not intended for direct or indirect human consumption of compressed air, use outside specified ambient temperature ranges, or in areas with a foreseeable risk of flammable gases or vapors. The compressor features two pressure modes: Low Pressure Mode and High Pressure Mode, allowing it to regulate air delivery based on demand. An optional IQ System provides cooler, cleaner air through an integral aftercooler, high-efficiency filtration, and a condensate disposal system that vaporizes liquid condensate into the engine exhaust, eliminating the need for collection.
Important Technical Specifications:
The manual provides general data for four models: P600WCU-T4i, XP525WCU-T4i, HP450WCU-T4i, and VHP400WCU-T4i.
- Compressor:
- Air Delivery (cfm / m³/min):
- P600WCU-T4i: 600 (17.0)
- XP525WCU-T4i: 525 (14.9)
- HP450WCU-T4i: 450 (12.7)
- VHP400WCU-T4i: 400 (11.3)
- Rated Operating Pressure (psi / bar):
- P600WCU-T4i: 100 (6.9)
- XP525WCU-T4i: 125 (8.6)
- HP450WCU-T4i: 150 (10.3)
- VHP400WCU-T4i: 200 (13.8)
- Safety Valve Setting (psi / bar):
- P600WCU-T4i & XP525WCU-T4i: 200 (13.8)
- HP450WCU-T4i & VHP400WCU-T4i: 250 (17.2)
- Engine:
- Manufacturer: Cummins
- Model: QSB 6.7
- Rated Power at Full Load Speed (hp / kW): 173 (129) @ 2200 RPM
- Full Load Speed (rpm): 2200 (P600WCU-T4i, HP450WCU-T4i), 1950 (XP525WCU-T4i, VHP400WCU-T4i)
- Idle Speed (rpm): 1500
- Idle Speed (warm-up) (rpm): 1600
- Electrical System: 24V
- Fluid Capacities (U.S. Gallons / liters):
- Compressor Oil: 9.5 (36)
- Engine Oil (including filter): 4.6 (17.5)
- Engine Coolant: 7.0 (26.5)
- Fuel Tank: 73 (276)
- Ambient Temperature Range:
- Standard Features: 10°F (-12°C) to 120°F (49°C)
- Required Options: -10°F (-23°C) to 120°F (49°C)
- Aftercooler or IQ System: 32°F (0°C) to 110°F (43°C)
- Out-Of-Level Operating Limit: 15°
- Measurements/Weights:
- Overall Length (incl. bumper): 14.8 feet (4.5 meters)
- Overall Height: 6.7 feet (2.0 meters)
- Overall Width: 6.5 feet (1.98 meters)
- Operating Weight (with fuel): 4700 lb (2132 kg)
- Shipping Weight (less fuel): 4178 lb (1895 kg)
- Running Gear:
- Tire Size: ST235/80R16
- Tire Inflation Pressure: 65 psi (4.5 bar)
- Maximum Towing Speed: 65 mph (105 km/hr)
Usage Features:
The compressor is equipped with a control panel featuring a MidPort display for operating parameters and diagnostic codes, along with gauges for air pressure, engine tachometer, compressor temperature, engine coolant temperature, fuel level, and engine oil pressure. A keypad allows for starting and shutting down the compressor, switching between high and low pressure modes, and loading the compressor after warm-up. The MidPort display is user-configurable for language (English, Spanish, French) and units (English or Metric). Quick View Screens provide easy access to up to 18 common parameters. An AUTO POWER OFF feature conserves battery power when the engine is not running. The unit has a central lifting bail for single-point lifting and is designed for towing with appropriate towing vehicles and safety precautions.
Maintenance Features:
The manual outlines a comprehensive maintenance schedule with intervals for daily, weekly, monthly, and every 3, 6, 12, 24, 48, and 72 months/hours/miles. Key maintenance tasks include:
- Daily: Checking compressor oil level, engine oil level, radiator coolant level, gauges/lamps, air cleaner service indicators, fuel tank fill, fuel/water separator drain, oil leaks, fuel leaks, drain water from fuel filters, coolant leaks, and radiator filler cap.
- 100 hours: Inspecting fasteners, enclosure panels, air intake and engine exhaust systems.
- 250 hours: Inspecting cooling systems and isolation mounts.
- 500 hours / 3 months: Checking fan/alternator belts, battery connections/electrolyte, hoses, automatic shutdown system, air cleaner system, compressor oil cooler exterior, engine radiator/oil cooler exterior, engine charge air cooler exterior, and aftercooler exterior.
- 500 hours / 6 months: Replacing air cleaner elements, fuel/water separator element, fuel filter element, engine oil, engine oil filter, engine coolant conditioning element, compressor oil filter element, and compressor oil.
- 1000 hours / 12 months: Replacing oil separator element, checking separator tank exterior, engine coolant, engine crankcase breather element, water pump grease, shutdown switch settings, scavenge orifice & related parts, scavenge line, valve clearance, feed pump strainer, and injection nozzle.
- 2 years: Checking safety valve.
- 4 years: Replacing hoses.
- 6 years: Checking separator tank interior.
- Lubrication: Specific instructions for engine oil and compressor oil changes, including recommendations for Doosan Tier 4 Premium Engine Oil for Tier 4 engines and Portable Power formulated compressor oil for extended airend warranty. The manual also provides specifications for running gear wheel bearing grease.
- Troubleshooting: A detailed chart lists common complaints, potential causes, and corrections, including diagnostic codes displayed on the MidPort for both compressor and engine issues. Engine diagnostic codes are also available via the J1939 network for advanced troubleshooting.
- IQ System Maintenance: Daily checks for filter restriction, weekly cleaning of Y-strainer screens and orifices, and yearly replacement of primary and secondary IQ System filter elements.
- Safety Decals: The manual emphasizes the importance of safety decals, providing a guide to their meaning and encouraging replacement of unreadable decals.
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