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HP1600FCU-T3 (E68) 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: 22523815 (9/2013) Rev F...
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Operating & Maintenance Manual Foreword Add in PDF Page for CE Mark...
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Foreword Operating & 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.
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Operating & Maintenance Manual Foreword D. With other than Portable Power approved components. E. With guards, or controls or switches missing or disabled. F. For storage or transportation of materials inside or on the enclosure. This company accepts no responsibility for errors in translation of this manual from the original English version.
Operating & Maintenance Manual Safety Safety Safety Precautions General Information Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.
Safety Operating & Maintenance Manual Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, blow gun tips, etc. well away from moving parts. Compressed Air Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.
Operating & Maintenance Manual Safety Materials The following substances may be produced during the operation of this machine: • brake lining dust • engine exhaust fumes WARNING Avoid inhalation Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times.
Safety Operating & Maintenance Manual This machine may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authorities for proper disposal of these materials. Battery A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive.
Operating & Maintenance Manual Safety Transport When loading or transporting machines, ensure that the specified lifting and tie down points are used. When loading or transporting machines, ensure that the towing vehicle, its size, weight, towing hitch and electrical supply are all suitable to provide safe and stable towing at speeds either, up to the legal maximum for the country in which it is being towed or, as specified for the machine model if lower than the legal maximum.
Safety Operating & Maintenance Manual Decals Decals are located on the machine to point out potential safety hazards. Read and follow these instructions. If you do not understand the instructions, inform your supervisor. Note that there are different decal headings: DANGER (Red Background) Indicates the presence of a hazard which WILL cause serious injury,...
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Operating & Maintenance Manual Safety DECALS Look for these signs on machines manufactured in Europe, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor. GRAPHIC FORM AND MEANING OF ISO SYMBOLS...
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Operating & Maintenance Manual Safety Look for these signs on machines manufactured in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor...
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Operating & Maintenance Manual Safety This section pertains only to machines 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;...
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Safety Operating & 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 or CAUTION. Decal part numbers are on the bottom of each decal and are also listed in the compressor’s parts manual.
Operating & Maintenance Manual Noise Emission Noise Emission This section pertains only to machines 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;...
Noise Emission Operating & Maintenance Manual NOISE EMISSION CONTROL 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.
Operating & Maintenance Manual Noise Emission Introduction The unit 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.
Noise Emission Operating & 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.
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Operating & 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)
Operating & Maintenance Manual Operating Instructions Operating Instructions Operating Controls and Instruments The operating controls and instruments are arranged on the control panel as shown above. A description of each panel device is as follows: 1. Panel Light: Illuminates instrument and control panel. Controlled by Switch 14. 2.
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Operating Instructions Operating & Maintenance Manual 7. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to dirty IQ air filters (if equipped). 8. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to low fuel level. Lamp blinks at low fuel warning. 9.
Operating & Maintenance Manual Operating Instructions Lifting Unit The central lifting bail can be reached through the roof door only from inside the machine. Use hoist or crane capable of lifting machine gross weight (see General Data). Before Towing Ensure that the tires, wheels and running gear are in good condition and secure. Wagon Style Running Gear •...
Operating Instructions Operating & Maintenance Manual This unit is equipped with on-board fuel tanks with a total capacity of 230 gallons which provides 10 hours of full load operation. Compressor Mounting Portable compressors, which are modified to remove the running gear and mount the machine direct to trailers, truck beds or frames, etc.
Operating & Maintenance Manual Operating Instructions Before Starting Open manual blowdown valve to ensure the separator has been vented of all pressure. Close the valve before starting. Inspect the complete installation including remote fuel lines (if any) and air hose routing and connections.
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Operating Instructions Operating & Maintenance Manual NOTE: This machine will not allow engine starting if engine coolant is low. NOTICE If the appropriate mixture of antifreeze is not used during freezing temperatures, failure to drain the engine may cause costly engine damage.
Operating & Maintenance Manual Operating Instructions Starting NOTICE This unit is equipped with a battery disconnect switch which removes power from the machine controller for long term storage. The switch is located on the side of the engine near the battery. This switch must be turned ON to provide power to the control panel for starting this unit.
Operating Instructions Operating & Maintenance Manual Normal Operation The Operator may observe and monitor operating parameters using the gages on the panel. In the event the machine controller detects a parameter outside normal operating limits, the unit will shutdown. In the event the machine controller detects a parameter at a dangerously high or low level, the machine will be automatically be stopped with the cause of the SHUTDOWN shown on the diagnostic lights and display.
Operating & Maintenance Manual Operating Instructions CAUTION Machines with EMERGENCY STOP BUTTON - Use the Emergency Stop Button only for emergency conditions. Do not use for normal machine stopping. Button must be reset before starting can be accomplished. NOTICE Once the engine stops, the automatic blowdown valve will relieve pressure from the separator tank.
Operating Instructions Operating & Maintenance Manual Theory of Operation The compressed air exits the separator tank through the top cover piping, and can then travel along one of two paths, selectable via manual valving. One path allows Standard Operation, which bypasses the IQ System, and delivers air quality equivalent to a standard oil-flooded portable compressor.If the IQ System is enabled by proper setting of the selector valve, the compressed air first enters the aftercooler.
Operating & Maintenance Manual Operating Instructions If the IQ System is bypassed (Standard Operation selected), the delivered air pressure will be approximately equal to the separator tank pressure. If the IQ System operation is selected, the delivered air pressure will be slightly less, depending on the restriction of the filters. CAUTION The compressor regulation system is adjusted to maintain regulated pressure at the separator tank.
Operating Instructions Operating & Maintenance Manual • Verify that the piping from the orifice purge points to the exhaust system is not clogged. CAUTION Blockage of the Y-strainers, orifices, or piping can result in flooding of the vessels with condensate. If flooding occurs, excessive condensate may enter the air stream and could result in damage to downstream equipment.
Operating & Maintenance Manual Operating Instructions Pressure Regulation Normally, regulation requires no adjusting; but if proper adjustment is lost, proceed as follows: Before Starting Unit 1. Atop separator cover at pressure regulator (PR) loosen locknut (G) counterclockwise. Turn adjustment screw counter clockwise one full turn. After Starting Unit 2.
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Operating Instructions Operating & Maintenance Manual 4. Insure that pressure is maintained at rated pressure, then turn regulator adjustment screw (H) counter clockwise until engine speed just begins to be reduced. NOTE: Turning regulator adjustment screw (H) clockwise will raise pressure at full speed.
Maintenance Operating & Maintenance Manual Prior to attempting any maintenance work, ensure that:- • all air pressure is fully discharged and isolated from the system. If the automatic blowdown valve is used for this purpose, then allow enough time for it to complete the operation.
Operating & Maintenance Manual Maintenance Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:- • the machine is suitably tested. • all guards and safety protection devices are refitted. • all panels are replaced, canopy and doors closed. •...
Maintenance Operating & Maintenance Manual Compressor Oil Filter Refer to the MAINTENANCE CHART in this section for the recommended servicing intervals. Removal WARNING Do not remove the filter(s) without first making sure that the machine is stopped and the system has been completely relieved of all air pressure. (Refer to STOPPING THE MACHINE in the OPERATING INSTRUCTIONS section of this manual) Clean the exterior of the filter housing and remove the spin-on element.
Operating & Maintenance Manual Maintenance Reassembly Clean the filter gasket contact area and install the new element.Tighten until the gasket makes contact with the filter housing. Tighten an additional 1/2 to 3/4 of a revolution. CAUTION Start the machine (refer to PRIOR TO STARTING and STARTING THE MACHINE in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the machine is put back into service.
Maintenance Operating & Maintenance Manual Reassembly Thoroughly clean the orifice/drop tube and filter gasket contact area before reassembly. Install the new element. WARNING DO not remove the staple from the anti-static gasket on the separator element since it serves to ground any possible static build-up. Do not use gasket sealant since this will affect electrical conductance.
Operating & Maintenance Manual Maintenance WARNING Follow the instructions provided by the antifreeze supplier when adding or draining the antifreeze solution. It is advisable to wear personal protective equipment to prevent skin and eye contact with the antifreeze solution. Air Filter Elements The air filter element should be replaced regularly (refer to the MAINTENANCE CHART) or when the restriction indicator shows red, whichever comes first.
Maintenance Operating & Maintenance Manual Fuel System The fuel tank should be filled daily or every eight hours. To minimize condensation in the fuel tank(s), it is advisable to top up after the machine is shut down or at the end of each working day.
Operating & Maintenance Manual Maintenance Pressure System Regularly, it is necessary to inspect the external surfaces of the system (from the airend through to the discharge valve(s)) including hoses, tubes, tube fittings and the separator tank, for visible signs of impact damage, excessive corrosion, abrasion, tightness and chafing. Any suspect parts should be replaced before the machine is put back into service.
Maintenance Operating & Maintenance Manual Compressor Lubricating Oil Refer to the MAINTENANCE CHART in this section for service intervals. NOTE: If the machine has been operating under adverse conditions, or has suffered long shutdown periods, then more frequent service intervals will be required.
Operating & Maintenance Manual Lubrication Lubrication General Information Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit 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.
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Lubrication Operating & Maintenance Manual WARNING High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. Ensure the following conditions are met: —...
Operating & Maintenance Manual Lubrication Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change. NOTE: Fluids listed as “preferred”...
Operating & Maintenance Manual Troubleshooting Trouble Shooting 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.
Troubleshooting Operating & Maintenance Manual C. Double Check Before Disassembly The source of most compressor troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a compressor can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly.
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Operating & Maintenance Manual Troubleshooting Fault Code Description (QSX15 Engine Fault Codes) Engine Oil Pressure Low - Warning Engine Coolant Temperature Sensor Circuit - Shorted High Engine Coolant temperature Sensor Circuit - Shorted Low Engine Coolant temperature High - Critical lntake Manifold Temperature Sensor #1 Circuit Shorted Low lntake Manifold Temperature Sensor #1 Circuit Shorted High Intake Manifold Temperature #1 High - Critical...
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Troubleshooting Operating & Maintenance Manual Fault Code Description (QSX15 Engine Fault Codes) Injector Solenoid Valve Cylinder #5 Circuit Grounded Circuit Injector Solenoid Valve Cylinder #3 Circuit Grounded Circuit Injector Solenoid Valve Cylinder #6 Circuit Grounded Circuit Injector Solenoid Valve Cylinder #2 Circuit Grounded Circuit Real Time Clock - Power Interrupt Engine Control Module - Data Lost Engine Control Module - Warning Internal Hardware Failure...
Troubleshooting Operating & Maintenance Manual Wedge Diagnostic Display Codes If the fault indicator lamp is illuminated, refer to the Alert/Shutdown List fault indicator lamp is illuminated, refer to the Engine Diagnostic List If the ALERT/SHUTDOWN CONDITIONS Alert Shutdown Condition Code Light (Blinks) Code Delay...
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Operating & Maintenance Manual Troubleshooting ALERT/SHUTDOWN CONDITIONS Serial Comm. Problem CPRSR Malf. CAN Bus Problem CPRSR Malf. Condition Code Light (Blinks) Code Delay LIght (Steady) (sec). Auto Start/Stop Module Failure - no CPRSR Malf. comm for 17 sec. Low Fuel Level fuel level fuel level Air Filter Restriction...
Troubleshooting Operating & Maintenance Manual Troubleshooting Chart Bold Headings depict the COMPLAINT - Subheadings suggest the CAUSE NOTE: Subheadings suggest sequence to follow troubleshooting. 1. Unit Shutdown: Corrective Action Out of Fuel Add CLEAN diesel Fuel Compressor Oil Temp. too High See Complaint 6 Engine Water Temp.
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Operating & Maintenance Manual Troubleshooting 4. Low Engine Oil Pressure Corrective Action Low Oil Level Add oil. Out of Level > 15 degrees Relocate or reposition. Wrong Lube Oil See Engine Oil Spec. Change oil. Clogged Oil Filter Element(s) Replace element(s). Engine Malfunctioning See Troubleshooting in Engine Manual.
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Troubleshooting Operating & Maintenance Manual 8. Excessive Vibration: Rubber Mounts, Loose or Damaged Tighten or replace. Defective Fan Replace fan. Drive Coupling Defective Replace coupling. Engine Malfunctioning See Troubleshooting in Engine Manual. Airend Malfunctioning See Complaint 7, 11, 12 Engine idle speed too low. See Engine Manual.
Operating & Maintenance Manual Electrical Electrical General Information and Operational Theory General The machine has an electronic monitor and control system to provide discharge air pressure control and engine and package monitor functions. The system uses the WEDGE controller to perform these functions.
Electrical Operating & Maintenance Manual Sensors and Transducers The electronics system contains sensors and transducers that are used to collect process data from the compressor. The temperature is measured by a thermistor. This device exhibits a change in resistance as the temperature changes. The resistance causes an input voltage change to the WEDGE controller input and is interpreted as a temperature change.
Operating & Maintenance Manual Electrical Electronic Engine The HP1300/1600 machine contains an emissions certified diesel engine. In order to meet the emissions requirements, the engine has an electronic control system. The control system handles all the monitor, alarm and control functions for the engine. The WEDGE controller communicates with the engine controller over the J1939 CAN network.
Electrical Operating & Maintenance Manual Troubleshooting Flow Chart PROBLEM CHECK LIST Control panel key is turned to “ON’ Check F1 fuse position, WEDGE controller Check operation of switch S1 annuciator lamps and 4 digit LED Check wiring from S1 to WEDGE display do not come on controller Checking battery voltage, ensure...
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Revision History Rev. EC Number Comments Original release General Data Update Maintenance Section Update Added containment notice to Safety Section STA10011 Doosan reference updates CN026601 Added Flex Models to Front Cover CN034865...
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