Doosan P425WCU-EX-T2 User manual

OPERATION and MAINTENANCE
MANUAL
COMPRESSOR MODEL
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
DoosanPortablePower.com
P/N: 46673128 (03-2015) Rev A
P425WCU-EX-T2 (F66)
XP375WCU-EX-T2 (F65)
HP375WCU-EX-T2 (F67)
A PDF version of the Electronic Service
Manual is available for free download
on Doosan Passport>Doosan Portable
Power>Smart Equip Order Management
and Manuals

TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
FOREWORD........................................................................................................................5
Information..................................................................................................................................... 6
SAFETY ............................................................................................................................... 9
Safety Precautions ......................................................................................................................... 10
Compressed Air.......................................................................................................................... 10
Exhaust System ......................................................................................................................... 11
Materials.................................................................................................................................... 12
Battery....................................................................................................................................... 13
Radiator..................................................................................................................................... 13
Transport ................................................................................................................................... 15
Decals ....................................................................................................................................... 16
GENERAL DATA .................................................................................................................19
General Data Information................................................................................................................ 20
Expendable Service Parts........................................................................................................... 21
OPERATING INSTRUCTIONS ............................................................................................23
Control Panel.................................................................................................................................. 24
Quick View Screens........................................................................................................................ 26
Fault and Alert................................................................................................................................ 26
Service Interval............................................................................................................................... 30
Display Setup ................................................................................................................................. 32
Display Compressor and Display Software Information ID............................................................. 34
Display Compressor and Display Software Information................................................................. 34
Languages and Units Set Up .......................................................................................................... 36
Before Towing................................................................................................................................. 36
Setting Up....................................................................................................................................... 37
Towing............................................................................................................................................ 38
Before Starting ............................................................................................................................... 38
Starting........................................................................................................................................... 39
3

TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
Shutdown ....................................................................................................................................... 41
Pressure Regulator Adjustment Instructions ................................................................................. 42
LUBRICATION.....................................................................................................................43
Compressor Oil Chart..................................................................................................................... 44
MAINTENANCE...................................................................................................................47
General Information........................................................................................................................ 48
Compressor Oil Filters.................................................................................................................... 51
Receiver Separator System ............................................................................................................ 52
Scavenge Line................................................................................................................................ 53
Exterior Finish Care........................................................................................................................ 53
Field Replacement of Canopy Decals............................................................................................. 55
....................................................................................................................................................... 57
................................................................................................................................................. 57
TROUBLESHOOTING.........................................................................................................57
Introduction.................................................................................................................................... 59
Troubleshooting Chart.................................................................................................................... 60
Diagnostic Codes ........................................................................................................................... 66
Revision History............................................................................................................................. 69
4

FOREWORD
5

Operation & Maintenance Manual FOREWORD
Information
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.
Nothing contained in this document is intended to extend any promise, warranty or
representation, expressed or implied, regarding the Portable Power products described
herein. Any such warranties or other terms and conditions of sale of products shall be in
accordance with the standard terms and conditions of sale for such products, which are
available upon request.
This manual contains instructions and technical data to cover all routine operation and
scheduled maintenance tasks by operation and maintenance staff. Major overhauls are
outside the scope of this manual and should be referred to an authorized Portable Power
Service department.
All components, accessories, pipes, and connectors added to the compressed air system
should be:
• of good quality, procured from a reputable manufacturer and, wherever possible,
be of a type approved by Portable Power.
• clearly rated for a pressure at least equal to the compressor safety valve setting.
• compatible with the compressor oil.
•accom
panied with instructions for safe installation, operation, and maintenance.
Details of approved equipment are available from the Portable Power Service departments.
The use of repair parts other than those included within the approved parts list may create
hazardous conditions over which Portable Power has no control. Therefore, Portable Power
cannot be held responsible for equipment in which non-approved repair parts are installed.
Portable Power reserves the right to make changes and improvements to products without
notice and without incurring any obligation to make such changes or add such improvements
to products sold previously.
The intended uses of this compressor are outlined below and examples of unapproved
usage are also given. However, Portable Power cannot anticipate every application or work
situation that may arise. If in doubt, consult supervision.
This compressor has been designed and supplied for above ground operation to be used for
compression of normal ambient air containing no additional gases, vapors, or particles within
the ambient temperature range specified in the General Data Section of this manual.
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FOREWORD Operation & Maintenance Manual
This compressor should not be used:
• For direct or indirect human consumption of the compressed air.
• Outside the ambient temperature range specified in the General Data Section of
this manual.
• When an actual or foreseeable risk of hazardous levels of flammable gases or
vapors exists.
• With other than Portable Power approved components.
• With guards, controls, or switches missing or disabled.
• For storage or transportation of materials inside or on the enclosure.
Portable Power accepts no responsibility for errors in translation of this manual from the
original English version.
You, as the customer, are expected to provide certain service and maintenance items. Your
Portable Power dealer will provide all other more detailed service and maintenance items on
a special preventive maintenance schedule for each compressor. It is very important that the
minimum service and maintenance requirements explained in this manual be performed at
the required intervals. Exceeding these intervals may reduce the reliability of the compressor.
The purpose of this manual is to train the operator with functions, operation, and basic
service and maintenance requirements of the compressor. During the preparation of this
manual, every effort was made to ensure the accuracy and adequacy of the contents.
Your Portable Power dealer will assist with setup and initial startup of the compressor and
will also provide brief operating and service instructions. Before starting the compressor,
this manual and instructions should be carefully read to obtain a thorough knowledge of the
duties to be performed. Please take pride in the compressor, keep it clean and in good
mechanical condition.
To enable proper maintenance records, Portable Power provides a Noise Emission Control
Maintenance Log in the Noise Emission Section of this manual. The Noise Emission Section
contains a recommended Maintenance schedule and provides space in the log for the
technician to note what service and maintenance was done, by whom, where, and when.
7

8

SAFETY
9

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.
Ensure all maintenance personnel are adequately trained, competent, and have read the
manuals.
Ensure all protective covers are in place and the canopy/doors are closed during operation.
The specification of this compressor is such that the compressor is not suitable for use in
flammable gas risk areas. If such an application is required, all local regulations, codes of
practice, and site rules must be observed. To ensure the compressor can operate in a safe
and reliable manner, additional equipment such as gas detection, exhaust spark arrestors,
and intake (shut-off) valves may be required, dependent on local regulations or the degree
of risk involved.
A weekly visual check must be made of all fasteners/fixing screws securing mechanical parts.
In particular, safety-related parts such as coupling hitch, drawbar components, wheels, tires,
and lifting bail should be checked for total security.
All components which are loose, damaged, or unserviceable must be rectified without delay.
Air discharged from this compressor may contain carbon monoxide or other contaminants
which will cause serious injury or death. Do not breathe discharged air.
This compressor produces loud noise with the doors open or service valve vented. Extended
exposure to loud noise can cause hearing loss. Always wear hearing protection when doors
are open or service valve is vented.
Never inspect or service the compressor without first disconnecting battery cable(s) to
prevent accidental starting.
Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate
the skin and result in serious illness. Wear eye protection while cleaning the compressor
with compressed air to prevent debris from injuring eye(s).
Rotating fan blade can cause serious injury. Do not operate without fan guard in place.
Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver,
and air discharge piping, etc.).
Never operate the compressor 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. 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.
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SAFETY Operation & Maintenance Manual
All air pressure equipment installed in, or connected to, the compressor must have safe
working pressure ratings of at least the compressor safety valve setting.
If more than one compressor is connected to one common downstream plant, effective check
valves and isolation valves must be fitted and controlled by work procedures, to ensure one
compressor cannot accidentally be pressurized or over pressurized by another.
Compressed air must NOT be used for a direct feed to any form of breathing apparatus
or mask.
Compressed air can cause serious injury or death. Relieve pressure before removing filler
plugs/caps,fittings, or covers.
Air pressure can remain trapped in air supply line which can result in serious injury or death.
Always carefully vent air supply line at tool or vent valve before performing any service or
maintenance.
Discharged air contains a very small percentage of compressor lubricating oil and care
should be taken to ensure downstream equipment is compatible.
If discharged air is to be ultimately released into a confined space, adequate ventilation
must be provided.
When using compressed air, always use appropriate personal protective equipment.
All pressure containing parts, especially flexible hoses and their couplings, must be regularly
inspected, be free from defects, and be replaced according to the manual instructions.
Avoid bodily contact with compressed air.
The safety valve located in the separator tank must be checked periodically for correct
operation.
Whenever the compressor is stopped, air will flow back into the compressor from downstream
devices or systems unless the service valve is closed. Install a check valve at the compressor
service valve to prevent reverse flow in the event of an unexpected shutdown when the
service valve is open.
Disconnected air hoses whip and can cause serious injury or death. Always attach a safety
flow restrictor to each hose at the source of supply or branch line in accordance with OSHA
Regulation 29CFR Section 1926.302(b).
Never allow the compressor to sit stopped with pressure in the separator tank or piping.
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.
11

Operation & Maintenance Manual SAFETY
Materials
The following substances may be produced during the operation of this compressor:
• brake lining dust
• engine exhaust fumes
Avoid inhalation of material substances.
Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at
all times.
The following substances are used in the manufacture of this compressor and may be
hazardous to health if used incorrectly:
• compressor oil
• preservative grease, lubricating grease
•rustpr
eventative
• battery electrolyte
Avoid ingestion, skin contact, and inhalation of fumes.
12

SAFETY Operation & Maintenance Manual
Should compressor oil come into contact with the eyes, irrigate with water for at least 5
minutes.
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.
Do NOT start or operate this compressor in a confined area. Avoid breathing exhaust fumes
when working on or near the compressor.
This compressor may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air
filters, and batteries which may require proper disposal when performing maintenance or
service tasks. Contact local authorities for proper disposal of these materials.
Battery
A battery contains sulfuric acid and can produce gases which are corrosive and potentially
explosive. Avoid contact with skin, eyes, and clothing. In case of contact, flush area
immediately with water.
Do not attempt to jump start a frozen battery since this may cause the
battery to explode.
Exercise extreme caution when using an external method to jump start
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. Connect the Positive (+) terminal of the external system to
the Positive (+) terminal on the weak system. Connect the Negative (-)
terminal of the external system to the Negative (-) terminal of the weak
system. Always disconnect the two systems in reverse order.
Radiator
Hot engine coolant and steam can cause injury. Ensure the Radiator Pressure Cap is
removed with due care and attention.
Do not remove the pressure cap from a HOT radiator. Allow radiator to cool before removing
pressure cap.
13

Operation & Maintenance Manual SAFETY
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 pressure cap, absorbing
any released fluid with the cloth. Do not remove the pressure cap
until all excess fluid is released and the engine cooling system fully
depressurized.
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.
The potential for higher temperatures is present when the exhaust
aftertreatment system undergoes regeneration. Refer to Engine
Manual for further safety instructions and information on the exhaust
aftertreatment system and controls.
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SAFETY Operation & Maintenance Manual
Transport
When loading or transporting the compressor, ensure the specified lifting and tie down points
are used.
When loading or transporting the compressor, ensure 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 compressor model if lower than the legal maximum. Do not exceed gross vehicle
weight rating.
Before towing the compressor, ensure:
•thetiresa
nd towing hitch are in a serviceable condition and tires are properly
inflated.
• the canopy is secure.
• all ancillary equipment is stored in a safe and secure manner.
• the brakes and lights are functioning correctly and meet necessary road traffic
requirements.
• breakaway cables/safety chains are connected to the towing vehicle.
The compressor must be towed in a level attitude in order to maintain correct handling,
braking, and lighting functions. This can be achieved by correct selection and adjustment of
the vehicle towing hitch and, on variable height running gear, adjustment of the drawbar.
1. Ensure wheels, tires, and drawbar connectors are in safe operating condition and
drawbar is properly connected before towing.
2. When parking, always use the handbrake and, if necessary, suitable wheel chocks.
15

Operation & Maintenance Manual SAFETY
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.
Attach safety chains to the towing vehicle at substantial anchorage points of suitable strength.
Ensure effective chain length is as short as possible while still allowing normal articulation of
the towed compressor and proper operation of the breakaway cable.
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.
(Red Background)
Indicates the presence of a hazard which WILL cause serious injury,
death, or property damage, if ignored.
(Orange Background)
Indicates the presence of a hazard which CAN cause serious injury,
death, or property damage, if ignored.
(Yellow Background)
Indicates the presence of a hazard which WILL or CAN cause injury or
property damage, if ignored.
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SAFETY Operation & Maintenance Manual
(Blue Background)
Indicates important set-up, operating, or maintenance information.
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. Submit orders
for Safety Decals to the Statesville Parts Service Dept. The no charge
order should contain only Safety Decals.
Help promote product safety! Ensure decals are present on the
compressor. Replace decals that are not readable.
17

18

GENERAL DATA
19

Operation & Maintenance Manual GENERAL DATA
General Data Information
MODEL P425 XP375 HP375
COMPRESSOR
Air Delivery CFM (m³/min) 425 (12.0) 375 (10.6) 375 (10.6)
Rated Operating Pressure
— psi (bar) 100 (6.9) 125 (8.6) 150 (10.3)
Safety Valve Setting — psi
(kPa) 200 (13.8) 200 (13.8) 200 (13.8)
ENGINE (Diesel)
Manufacturer Cummins Cummins Cummins
Model B3.9 B3.9 B3.9
Rated Power at Full Load
Speed — hp(kw) 125 (96.0) @2200
RPM 125 (96.0) @2200 RPM 125 (96.0) @2200 RPM
Full Load Speed — rpm 2200 2200 2200
Idle Speed — rpm 1400 1400 1400
Idle Speed — (warm-up) —
rpm 1500 1500 1500
Electrical System 12V 12V 12V
FLUID CAPACITIES
Compressor Lubricant —
gallon (litres) 9.5 (36) 9.5 (36) 9.5 (36)
Engine Oil, including filter —
gallon (litres) 3.8 (14.4) 3.8 (14.4) 3.8 (14.4)
Engine Coolant — gallon
(litres) 4.5 (17.0) 4.5 (17.0) 4.5 (17.0)
Fuel Tank — gallon (litres) 64.6 (244.5) 64.6 (244.5) 64.6 (144.5)
AMBIENT TEMPERATURE RANGE
With Standard Features 10°F (-12°C) to 120°F (49°C)
With Required Options –10°F (-23°C) to 120°F (49°C)
With Aftercooler or IQ
System 32°F (0°C) to 110°F (43°C)
OUT-OF-LEVEL
Out-Of-Level Operating Limit 15°
UNIT MEASUREMENTS & WEIGHTS
Overall Length — feet
(meters) 13.1 (4.02)
Overall Height — feet
(meters) 5.7 (1.74)
20