Doosan XHP1000WCAT-T4i Operation And Maintenance Manual
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Doosan XHP1000WCAT-T4i Operation And Maintenance Manual

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OPERATION and MAINTENANCE
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.com
Book: 46604941 (10-2012) Rev A
MANUAL
COMPRESSOR MODELS
XHP1000WCAT-T4i (E45)
HP1300WCAT-T4i (E46)

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Summary of Contents for Doosan XHP1000WCAT-T4i

  • Page 1 HP1300WCAT-T4i (E46) 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.com Book: 46604941 (10-2012) Rev A...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE FOREWORD ............. . 7 Information .
  • Page 4 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE OPERATING INSTRUCTIONS ..........41 Control Panel .
  • Page 5 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE Compressor Oil..............76 Pressure Regulation for XHP1000 .

  • Page 7: Foreword

    Foreword...

  • Page 8: Information

    Noise Emission Directive 2000/14/EC. Ric Lunsford Quality Control Manager Issued at Statesville, N.C. Date The technical documentation for the machinery is available from: Doosan Infracore Portable Power, 1293 Glenway Drive, Statesville, N.C. 28625 9218 USA CPN 46553504 Rev A CPN 46552201 rev A...
  • Page 9 Foreword Operation & Maintenance Manual 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.
  • Page 10 Operation & Maintenance Manual Foreword 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.

  • Page 11: Safety

    Safety...

  • Page 12: Safety Precautions

    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.

  • Page 13: Compressed Air

    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.

  • Page 14: Exhaust System

    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.

  • Page 15: Battery

    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.

  • Page 16: Transport

    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.
  • Page 17 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.

  • Page 18: Decals

    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.
  • Page 19 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.
  • Page 20 Operation & Maintenance Manual Safety Close service valve and When using air tools operate tool to vent attach safety device trapped air before (OSHA Valve) at source of performing any service. air supply for each tool. Do not breathe this air.
  • Page 21 Safety Operation & Maintenance Manual km/h...
  • Page 22 Operation & Maintenance Manual Safety Do NOT drain while tank is under pressure, first relieve pressure. Use both hands to open door when machine is running. Access lifting bail from inside machine.
  • Page 23 Safety Operation & Maintenance Manual this machine before operation or servicing. Do not alter or modify this machine without the express written consent of the manufacturer. For transporting this machine in Canada the Fuel Crossover Valves located on the crossover line between fuel tanks must be closed to minimize fuel spillage and to meet Canadian TDG regulations.
  • Page 24 At reservoir, add coolant as necessary to reach "Cold" level. Identify and repair any leaks. Dispose of waste in accordance with federal, state and local laws and regulations. RESERVOIR Factory Filled With Doosan Factory Filled With Doosan Protective Lubricants Protective Lubricants ENGINE ENGINE...
  • Page 25 Safety Operation & Maintenance Manual EQUIPMENT DAMAGE WILL OCCUR. Use forklift points provided to lift equipment.

  • Page 26: Decals

    Operation & Maintenance Manual Safety Decals Graphic Form and Meaning of ISO Symbols Prohibition / Mandatory Information / Instructions Warning WARNING: Electrical Shock Risk WARNING: Pressurized Component WARNING: Hot Surface or System WARNING: Pressure Control WARNING: Corrosion Risk WARNING: Air/Gas Flow or Air Discharge WARNING: Maintain correct tire pressure (Refer to the GENERAL...
  • Page 27 Safety Operation & Maintenance Manual WARNING: Flammable Liquid WARNING: Before connecting the tow WARNING: For operating temperature bar or commencing to tow consult the below 0 C, consult the Operation and Operation and Maintenance Manual Maintenance Manual WARNING: Do not undertake any WARNING: Consult the Operation and Do not Breathe the compressed air maintenance on this machine until...
  • Page 28 Operation & Maintenance Manual Safety Do not stand on any service valve Do not operate with doors or Do not use fork lift truck or other parts of the pressure system enclosure open from this side km/h Do not open service valve before Do not exceed trailer speed limit No naked lights the air hose is attached...
  • Page 29 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...
  • Page 30 Operation & Maintenance Manual Safety...

  • Page 31: Noise Emission

    Noise Emission...

  • Page 32: Noise Emission

    Operation & Maintenance Manual Noise Emission Noise Emission This section pertains only to compressors distributed within the United States. WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...

  • Page 33: Maintenance Log

    Noise Emission Operation & Maintenance Manual Maintenance Log COMPRESSOR MODEL_________________________ SERIAL NO. __________________________________ USER UNIT NO. _______________________________ UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Engine Make & Model:_________________ Serial No.:__________________________ __________________________________ Purchaser or Owner:__________________ __________________________________ Address: ___________________________ Date Purchased:_____________________ The Noise Control Act of 1972 (86 Stat.

  • Page 34: Introduction

    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.

  • Page 35: Fasteners

    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.
  • Page 36 Operation & Maintenance Manual Noise Emission MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY DESCRIPTION OF WORK HOURMETER MAINT/ INSPECT LOCATION WORK DONE ITEM NO. READING DATE CITY/ STATE BY (NAME)

  • Page 37: General Data

    General Data...

  • Page 38: General Data Information

    Operating & Maintenance Manual General Data General Data Information MODELS XHP1000WCAT-T4i HP1300WCAT-T4i COMPRESSOR 1000 (28.3) 1300 (36.8) Air Delivery - cfm (m /min) Rated Operating Pressure - psi (bar) 140-365 (9.7-25.2) 75-150 (5.2-10.3) Safety Valve Setting - psi (bar) 440 psi (30.3) 200 psi (13.8)

  • Page 39: Service Parts

    General Data Operating & Maintenance Manual MEASUREMENTS/WEIGHTS HSRG Overall Length - feet (meters) 16.9 (5.2) 16.0 (4.9) Overall Height - feet (meters) 8.4 (2.6) 7.1 (2.2) Overall Width - feet (meters) 7.0 (2.1) 7.0 (2.1) Operating Weight, with fuel - lb (kg) 17,021 (7721) 16,074 (7291) Shipping Weight, less fuel - lb (kg)
  • Page 40 Operating & Maintenance Manual General Data Maintenance Interval Kits - HP1300 46613781 ......500 hours 46613782 ......1000 hours 46572086 ......2000 hours Part Number Description Where Used Quantity 36864361 ......Filter Element, Air Inlet Primary ..Airend ......1 36864379 ......Filter Element, Air Inlet Secondary ..Airend ......1 36867786 ......

  • Page 41: Operating Instructions

    Operating Instructions...

  • Page 42: Control Panel

    Operating & Maintenance Manual Operating Instructions Control Panel...
  • Page 43 Operating Instructions Operating & Maintenance Manual Gauge Panel 1. Air Pressure Gauge: Indicates pressure 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.

  • Page 44: Viewport

    Operating & Maintenance Manual Operating Instructions ViewPort Navigation Button The Navigation Button is located under the LCD display and is used to select display screens and make selections on the display screens. The Navigation Button functions are shown below. The available display screens are shown in the menu bar along the bottom of the LCD display. Pressing the Right or Left side of the Navigation Button will scroll to the next available screen.
  • Page 45 Operating Instructions Operating & Maintenance Manual Initial Screen The initial screen of the ViewPort displays digital gauges indicating current values of key operating parameters. Pressing the center of the Navigation Button (ENTER) activates the screen. Use the Up or Down functions to scroll the small gauges to view all available gauges. The gauges displayed will vary with optional equipment installed on compressor.
  • Page 46 Operating & Maintenance Manual Operating Instructions...
  • Page 47 Operating Instructions Operating & Maintenance Manual Options Screen Use the Right or Left function on the Navigation Button to highlight the Option Screen in the menu bar on the LCD display. The Option Screen icon is a computer display monitor located on the bottom left hand side of the LCD display.
  • Page 48 Operating & Maintenance Manual Operating Instructions Press the center of the Navigation Button (ENTER) to make selection. Option will become yellow. Continue to set all options using the same sequence of steps. Press the Down function until no options are highlighted. Press the Right function to select the gauges screen on the Menu Bar.
  • Page 49 Operating Instructions Operating & Maintenance Manual Use the Right or Left function of the Navigation Button to highlight the Info Screen on the Menu Bar. Press the center of the Navigation Button (ENTER) to activate Info Screen. Use the Up function to highlight preferred resource.
  • Page 50 Operating & Maintenance Manual Operating Instructions Using Up or Down function of Navigation Button highlights features of selected resource. The Green circle icon indicates addition information available by pressing center of Navigation Button (ENTER). Additional scrolling may be available by using Up or Down functions.
  • Page 51 Operating Instructions Operating & Maintenance Manual Use Left function of Navigation Button to back out of currently selected resource. At main menu of info screen, another resource may be selected. Continue to use the Left function to exit the Info Screen. Use the Up or Down function of the Navigation Button to highlight the CAN Devices screen.
  • Page 52 Operating & Maintenance Manual Operating Instructions Events Screen The Events Screen will appear automatically upon the occurrence of any Engine or Equipment Fault Code, and will display all current Events in an automatically cycling loop. The number of current Faultcode Events will be displayed in the Status Bar at the top of the ViewPort screen.
  • Page 53 Operating Instructions Operating & Maintenance Manual...

  • Page 54: Lifting

    Operating & Maintenance Manual Operating Instructions Lifting The central lifting bail allows the compressor to be lifted from a single point. Use hoist or crane capable of lifting compressor weight (See General Data). WARNING Falling off the compressor can cause serious injury or death. Use ladder and handholds to access lifting bail.

  • Page 55: Compressor Mounting

    Operating Instructions Operating & Maintenance Manual Compressor Mounting Portable compressors, which are modified to remove the running gear and mount the compressor directly to trailers, truck beds, or frames, etc. may experience failure of the enclosure, frame, and/or other components. It is necessary to isolate the compressor package from the carrier base with a flexible mounting system.

  • Page 56: Air Hose Restraint Installation

    Operating & Maintenance Manual Operating Instructions Air Hose Restraint Installation Safety devices such as hose restraints (whipchecks) must be used to prevent hose whipping if a connection fails. Whipchecks are to be constructed of woven stainless steel, galvanized steel wire rope, or chain with a minimum strength adequate for the supplied pressure and hose diameter.
  • Page 57 Operating Instructions Operating & Maintenance Manual CAUTION Do not attempt to jumpstart a frozen battery since this may cause it to explode. Exercise extreme caution when using an external method to jumpstart a unit. Verify the electrical systems on the weak battery system and the external jump system are the same voltage type system, 12VDC or 24VDC.
  • Page 58 Operating & Maintenance Manual Operating Instructions 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. If ultra-low sulfur diesel is not used, the engine could possibly not meet emissions regulations and the engine or aftertreatment system may be damaged.

  • Page 59: Starting

    Operating Instructions Operating & Maintenance Manual Starting NOTICE This compressor is equipped with a Battery Disconnect Switch which disconnects power for long term storage. The switch is located near the battery. This switch must be in the ON position to provide power to the Control Panel for starting the compressor.

  • Page 60: Normal Operation

    Operating & Maintenance Manual Operating Instructions Normal Operation The Operator may observe and monitor operating parameters using the ViewPort and gauge(s). 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. In the event the compressor controller detects a parameter at a dangerously high or low level, the compressor will automatically shutdown with the cause of the shutdown shown on the ViewPort.
  • Page 61 Operating Instructions Operating & Maintenance Manual NOTICE Failure to allow turbocharger cool down prior to shutdown can cause turbocharger damage. CAUTION Use the Emergency Stop only for emergency conditions. Do not use for normal shutdown. Emergency Stop must be reset before starting can be accomplished.

  • Page 62: Decommissioning

    Operating & Maintenance Manual Operating Instructions Decommissioning When the compressor is to be permanently decommissioned or dismantled, it is important to ensure that all hazard risk are either eliminated or recipient of the compressor notified. In particular: • Do not destroy batteries or components containing asbestos without containing the materials safely.

  • Page 63: Maintenance

    Maintenance...

  • Page 64: General Information

    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.
  • Page 65 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.

  • Page 66: Maintenance Schedule

    Operation & Maintenance Manual Maintenance Maintenance Schedule Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months 500 hrs. 1000 hrs. /850 km 2000 hrs. Compressor Oil Level Engine Oil Level *Radiator Coolant Level Gauges/Lamps *Air Cleaner Service Indicators Fuel Tank (Fill at end of day) *Fuel/Water Separator Drain Oil Leaks...
  • Page 67 Maintenance Operation & Maintenance Manual Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months Months 500 hrs. 1000 hrs /850 km 2000 hrs 3000 hrs Air Cleaner Elements R/WI Fuel Tank Vent Filter *Fuel/Water Separator Element (change with air filters) Fuel Filter Element Engine Oil Change Engine Oil Filter...
  • Page 68 Operation & Maintenance Manual Maintenance Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months 500 hrs. 1000 hrs /850 km 2000 hrs *Brake linkage *Brakes *Pintle Eye Bolts *Tire Pressure and Condition *Wheel Lug Nuts *Running gear bolts(1) 2 Yrs 4 Yrs 6 Yrs...

  • Page 69: Scavenge Line

    Maintenance Operation & Maintenance Manual Scavenge Line The scavenge line runs from the combined orifice/check valve at scavenge tube in the separator tank to the fitting located in the airend. Ensure the scavenge line and scavenge tube are clear of any obstruction. Refer to the Maintenance Schedule for recommended servicing intervals.

  • Page 70: Compressor Oil Separator Element

    Operation & Maintenance Manual Maintenance CAUTION Start the compressor (refer to Before Starting and Starting in the Operating Section in this manual) and check for leakage before the compressor is returned to service. Compressor Oil Separator Element Refer to the Maintenance Schedule in this section for the recommended servicing intervals. If element has to be replaced, proceed as follows: Removal WARNING...

  • Page 71: Reassembly

    Maintenance Operation & Maintenance Manual CAUTION In severe applications such as sandblasting, quarry drilling, well drilling, and gas drilling, more frequent service intervals will be required to ensure long component life. If there is any indication of the formation of varnishes, shellacs or lacquers on the filter element, it is a warning the compressor lubricating and cooling oil has deteriorated and should be changed immediately.

  • Page 72: Compressor Oil Cooler, Engine Radiator, And Other Heat Exchangers

    Operation & Maintenance Manual Maintenance Compressor Oil Cooler, Engine Radiator, and other Heat Exchangers When grease, oil, and dirt accumulate on the exterior surfaces of the heat exchangers, the efficiency is impaired. It is recommended the heat exchangers be cleaned per the Maintenance Schedule in this manual.

  • Page 73: Inspection

    Maintenance Operation & Maintenance Manual Inspection Check for cracks, holes, or any other damage to the element by holding the element up to a light source or by passing a lamp inside. CAUTION If inspection reveals damage to the main element, the safety element must also be replaced.

  • Page 74: Charge Air Cooler Pipework

    If electrical grease is not present or very minimal, then add a small amount of Doosan Part No. 22409114 electrical grease to the terminals. Dirty and/or corroded electrical terminals can be cleaned using electrical contact cleaner.

  • Page 75: Pressure System

    Refer to the Engine Operator Manual. The Tier 4 engine in this compressor requires proper engine lubricating oil to ensure proper aftertreatment system operation and engine durability. Consider Doosan Tier 4 Premium Engine Oil. Refer to Engine Operator Manual for engine oil specifications.

  • Page 76: Compressor Oil

    Operation & Maintenance Manual Maintenance Compressor Oil Refer to the Maintenance Schedule in this section for service intervals. NOTE: If the compressor has been operating under adverse conditions, or has suffered long shutdown periods, then more frequent service intervals will be required. WARNING Do NOT, under any circumstances, remove any drain plugs or the oil filler plug from the compressor lubricating and cooling system without first...

  • Page 77: Pressure Regulation For Xhp1000

    Maintenance Operation & Maintenance Manual Pressure Regulation for XHP1000 Normally, regulation requires no adjusting, but if proper adjustment is lost, proceed as follows: Adjustment Instructions for XHP units with Electronic Control Caterpillar Engines. The operating pressure of this unit was set at the factory to the maximum rating (at full speed). See General Data.
  • Page 78 Operation & Maintenance Manual Maintenance 12. If the pressure exceeds 80 psi: Loosen jam nut (H), turn rod (L) 1/8 to 1/4 turn CCW (as viewed from rod end) to lightly close butterfly. Secure jam nut (H). Use the Manual Blowdown Valve to bleed pressure down to 60 psi (close M BVD).

  • Page 79: Pressure Regulation For Hp1300

    Maintenance Operation & Maintenance Manual Pressure Regulation for HP1300 This machine is equipped with a Dual Pressure Regulation system which allows the unloaded operating pressure to be changed between two levels. These levels are selectable by a two- position valve located on the left side of the Separator Tank. The settings labeled High and Low are factory set at 150 psig for the High pressure and 100 psig for the Low setting.
  • Page 80 Operation & Maintenance Manual Maintenance 8. Ensure Unloader Solenoid acts to hold pressure in Inlet Unloader after shutdown. After startup, the compressor controller will open Unloader Solenoid. 9. Repeat all steps above to select and adjust the Low Pressure Regulator to maintain 100 psig rated pressure at full load engine RPM.

  • Page 81: Dual Pressure Regulation Control

    Maintenance Operation & Maintenance Manual Dual Pressure Regulation Control The compressor is fitted with a dual pressure control valve. The valve selects between 125 psi and the rated operating pressure on HP models. The valve selects between 200 psi and the rated operating pressure on XHP models.

  • Page 82: Torque Values

    Operation & Maintenance Manual Maintenance Torque Values TABLE 1 INCH FASTENERS SAEJ249 SAEJ249...
  • Page 83 Maintenance Operation & Maintenance Manual TABLE 3 WHEEL TORQUE CHART Wheel Torque Chart - Inch Wheel Torque Chart - Metric 1/2” lug nuts Torque (Ft-Lbs) Torque (N-m) Torque (ft-Lbs) 13” Wheel 80-90 15” Wheel 105-115 M12 Bolts 85-95 62-70 16” Wheel 105-115 M14 Bolts 145-155...
  • Page 84 Operation & Maintenance Manual Maintenance...

  • Page 85: Lubrication

    Lubrication...

  • Page 86: General Information

    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.
  • Page 87 Lubrication Operation & Maintenance Manual WARNING High pressure air can cause severe injury or death from hot oil and flying debris. Always relieve pressure before removing caps, plugs, covers, or other parts from pressurized air system. Ensure the Air Pressure Gauge reads zero (0) pressure and ensure there is no air discharge when opening the manual blowdown valve.

  • Page 88: Portable Compressor Oil Chart For Xhp1000

    XHP1001 Below -10°F Consult Factory (Below -23°C) Preferred Oils - Use of these oils with Doosan branded filters can extend airend warranty. Refer to the Warranty Policy for details or contact your representative. Table 1: Preferred Oils 1 gal. (3.8 Liter) 5 gal.

  • Page 89: Portable Compressor Oil Chart For Hp1300

    (6.9 to 13.8 bar) Below -10°F Consult Factory (Below -23°C) Preferred Oils - Use of these oils with Doosan branded filters can extend airend warranty. Refer to the Warranty Policy for details or contact your representative. Table 2: Preferred Oils 1 gal.
  • Page 90 Operation & Maintenance Manual Lubrication...

  • Page 91: Troubleshooting

    Troubleshooting...

  • Page 92: Introduction

    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.

  • Page 93: Troubleshooting Chart

    Troubleshooting Operation & Maintenance Manual Troubleshooting Chart Complaint Cause Correction 1. Compressor has stopped Out of fuel. Add clean fuel. unexpectedly Compressor oil temperature too high. See Complaint #6. Engine coolant temperature too high. Check coolant level. If low, add coolant.
  • Page 94 Operation & Maintenance Manual Troubleshooting Complaint Cause Correction Defective sensor. Identify and check sensor. Replace if (continued) necessary. See Electronic Service 2. Compressor won't start or Manual. Malfunctioning relay. Identify and check relay. Replace if necessary. See Electronic Service Manual. Engine malfunctioning.
  • Page 95 Troubleshooting Operation & Maintenance Manual Complaint Cause Correction 6. High compressor oil Ambient temperature above rated Operate in cooler environment. ambient temperature range. temperature Compressor tilted beyond out-of-level Reposition or relocate compressor to operating limit. be more level. Low compressor oil level. Add compressor oil.
  • Page 96 Operation & Maintenance Manual Troubleshooting Complaint Cause Correction 9. Low air delivery / low cfm Clogged air filter element(s). Clean or replace air filter element(s). Incorrect pressure regulation Make adjustments per this manual. adjustment. Malfunctioning inlet unloader / butterfly Inspect valve. Make adjustments per valve.

  • Page 97: Diagnostic Codes

    Troubleshooting Operation & Maintenance Manual Diagnostic Codes The ViewPort displays diagnostic codes for the compressor system and the engine. Listings of these codes are provided in this section. The engine diagnostic codes can also be read with the engine manufacturer's service tool. A service tool connector is provided in the electrical harness, providing access to the J1939 CAN network.

  • Page 98: Compressor Diagnostic Codes

    Operation & Maintenance Manual Troubleshooting Compressor Diagnostic Codes Code Code Display Name Description Type Engine speed less than 900 RPM for Low Engine Speed FAULT 30 seconds. Engine speed greater than 1900 RPM High Engine Speed FAULT for 30 seconds. Engine crank attempt longer than 15 Engine Crank Timeout ALERT...
  • Page 99 Troubleshooting Operation & Maintenance Manual Code Code Display Name Description Type Airend Oil Pressure Airend oil pressure sensor reading out FAULT Sensor of range. (HP Model only) Fuel level sensor reading out of Fuel Level Sensor ALERT range. Low Separator Tank Separator tank pressure below 40 psi FAULT Pressure...
  • Page 100 Operation & Maintenance Manual Troubleshooting Code Code Display Name Description Type Communication between Titan AutoStart Controller controller and AutoStart controller not ALERT Communication functional. Communication between Titan IQ TCU Controller controller and IQ TCU controller not ALERT Communication functional. Titan Controller Communication between Titan ALERT Communication...

  • Page 101: Caterpillar T4I Engine Diagnostic Codes

    Troubleshooting Operation & Maintenance Manual Caterpillar T4i Engine Diagnostic Codes...
  • Page 102 Operation & Maintenance Manual Troubleshooting...
  • Page 103 Troubleshooting Operation & Maintenance Manual...
  • Page 104 Operation & Maintenance Manual Troubleshooting...
  • Page 105 Troubleshooting Operation & Maintenance Manual...
  • Page 106 Operation & Maintenance Manual Troubleshooting...
  • Page 107 Troubleshooting Operation & Maintenance Manual...
  • Page 108 Operation & Maintenance Manual Troubleshooting...

  • Page 109: Options

    Options...

  • Page 110: Iq System

    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.

  • Page 111: Low Ambient Operation

    Options Operation & Maintenance Manual The condensate lines are then piped together and the condensate is injected at a single point into the engine exhaust piping. The compressed air then travels through the check valve, and out through the service air valve.

  • Page 112: Iq System Configuration

    Operation & Maintenance Manual Options IQ System Configuration...

  • Page 113: Maintenance

    Options Operation & Maintenance Manual Maintenance Daily Maintenance Verify, during full load (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...

  • Page 114: Filter Replacement

    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 loosening, taking care to prevent the housing from falling.
  • Page 115 Revision History   Rev. EC Number Comments Original release CN 025041...
  • Page 116 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.

This manual is also suitable for:

Hp1300wcat-t4iE45E46

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