Ingersoll-Rand DOOSAN P425WCU Operation & Maintenance Manual
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Ingersoll-Rand DOOSAN P425WCU Operation & Maintenance Manual

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OPERATION, 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 machine.
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 22592083 (1-07) Rev A
Revised (10-12)
MANUAL
P425WCU
XP375WCU
HP375WCU
COMPRESSOR MODELS
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.

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Summary of Contents for Ingersoll-Rand DOOSAN P425WCU

  • Page 1 This manual must be available to the personnel who operate and maintain this machine. Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, Doosan Infracore Portable Power service marks, logos, or other proprietary identifying marks belonging...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE FOREWORD ............. . 7 Foreword.
  • Page 4 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE GENERAL DATA ............37 General Data.
  • Page 5 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE Reassembly ..............61 VENTILATION.
  • Page 6 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 7: Foreword

    Foreword 22592086...

  • Page 8: Foreword

    Details of approved equipment are available from Ingersoll-Rand Service departments. The use of repair parts / lubricants / fluids other than those included within the Ingersoll-Rand approved parts list may create hazardous conditions over which Ingersoll-Rand has no control.
  • Page 9 Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or vapours. Use of the machine fitted with non Ingersoll-Rand approved components / lubricants / fluids. Use of the machine with safety or control components missing or disabled.
  • Page 10 **Always use Ingersoll-Rand Replacement parts!** 22592086...

  • Page 11: Safety

    Section A - Safety 22592086...

  • Page 12: Safety

    Operation & 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.

  • Page 13: Compressed Air

    Safety Operation & Maintenance Manual 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. Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel.

  • Page 14: Materials

    Operation & 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.

  • Page 15: Battery

    Safety Operation & 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.

  • Page 16: Transport

    Operation & 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.

  • Page 17: Decals

    Safety Operation & Maintenance Manual Decals Graphic Form and Meaning of ISO Symbols 22592086...
  • Page 18 Operation & Maintenance Manual Safety 22592086...
  • Page 19 Safety Operation & Maintenance Manual 22592086...
  • Page 20 Operation & Maintenance Manual Safety 22592086...
  • Page 21 Safety Operation & Maintenance Manual Look for these signs 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. Indicates the presence of a hazard which WILL cause DANGER serious injury, death or property damage, if ignored.
  • Page 22 Operation & Maintenance Manual Safety 22592086...
  • Page 23 Safety Operation & Maintenance Manual 22592086...
  • Page 24 **Always use Ingersoll-Rand Replacement parts!** 22592086...

  • Page 25: Warranty

    Section B - Warranty 22592086...

  • Page 26: Warranty

    Oil-Free airends are fee-based and may require a maintenance agreement. Formal enrollment is required. Ingersoll-Rand will provide a new part or repaired part, at its election, in place of any part, which is found upon its inspection to be defective in material and workmanship during the period prescribed above.

  • Page 27: General Warranty Information

    2 yrs/4000 hrs using IR fluids and filters DEUTZ 2000 Available at dealer INGERSOLL-RAND 4000 5 yrs/10,000 hrs when using genuine Ingersoll-Rand fluids and parts. Refer to operator’s manual. KUBOTA (North America only) 2000 Major components 36 mo/3000 hrs (parts only) (Western Europe & Oceania)

  • Page 28: Warranty Registration

    Machines shipped outside the United States require notification be made to initiate the machine warranty. Fill out the Warranty Registration Form in this section, keep a copy for your records and mail form to: Ingersoll-Rand Company Utility Equipment Division P.O. Box 868 Mocksville, North Carolina 27028 Attn: Warranty Department NOTE: Completion of this form validates the warranty.
  • Page 29 The warranty and limitation of liability has been reviewed and understood by the owner/user. In the event that this unit is to be used within a nuclear facility, the owner/user shall notify Ingersoll-Rand of such use so that Ingersoll-Rand may arrange for appropriate nuclear liability protection from the owner-licensee of the facility.
  • Page 30 Operation & Maintenance Manual Warranty 22592086...

  • Page 31: Noise Emission

    Section C - Noise Emission 22592086...

  • Page 32: Noise Emission

    NOTE: the above information applies only to units that are built in compliance with the U.S. Environmental Protection Agency. Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.

  • Page 33: Noise Emission Control

    Noise Emission Operation & 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.

  • Page 34: Introduction

    Operation & 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.

  • Page 35: Fasteners

    Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer. J. Fuels and Lubricates Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand Company and Engine Manufacturer’s Operator and Maintenance Manuals. 22592086...
  • 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) 22592086...

  • Page 37: General Data

    Section D - General Data 22592086...

  • Page 38: General Data

    Operation & Maintenance Manual General Data General Data Actual free air delivery P425WCU 12,0m (425 CFM) XP375WCU 10,6m (375 CFM) HP375WCU 10,6m (375 CFM) Normal operating discharge pressure P425WCU 6,9 bar (100 psi) XP375WCU 8,6 bar (125 psi) HP375WCU 10,3 bar (150 psi) Maximum Allowable Pressure P425WCU 8,6 bar (125 psi)
  • Page 39 General Data Operation & Maintenance Manual Engine (P425WCU, XP375WCU, HP375WCU) Type/Model Cummins/4B3.9TAA Number of Cylinders Oil Capacity 31.7 litres (8.4 gal) Speed at Full Load min -1 (RPM) 2200 revs Speed at Idle min -1 (RPM) 1500 revs Power Available at Full Load 93kW(125hp) Electrical System 12 V neg.
  • Page 40 **Always use Ingersoll-Rand Replacement parts!** 22592086...

  • Page 41: Operating Instructions

    Section E - Operating Instructions 22592086...

  • Page 42: Operating Instructions

    It is necessary to isolate the compressor package from the carrier base with a flexible mounting system. Such a system must also prevent detachment of the package from the carrier base in the event the isolators fail. Contact Ingersoll-Rand representative for flexible mounting kits.
  • Page 43 Operating Instructions Operation & Maintenance Manual WARNING All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine safety valve setting, and materials compatible with the compressor lubricant (refer to the GENERAL DATA SECTION).

  • Page 44: Prior To Starting

    Operation & Maintenance Manual Operating Instructions Prior to Starting 1. Place the unit in a position that is as level as possible. The design of the unit permits a 15 degree lengthways and sideways limit on out of level operation. When the unit has to be operated out of level, it is important to keep the engine oil level near the high level mark (with the unit level).
  • Page 45 Operating Instructions Operation & Maintenance Manual 6. Open the service valve(s) to ensure that all pressure is relieved from the system. Close the service valve(s). CAUTION Do not operate the machine with the canopy/doors in the open position as this may cause overheating and operators to be exposed to high noise levels.

  • Page 46: Control Panel

    Operation & Maintenance Manual Operating Instructions Control Panel Diagnostic/Auto Shutdown (Optional) 1. High Engine Temperature - Coolant above 220°F (104°C) or more. 2. Low Engine Oil Pressure - 12 psi or less. 3. High Compressor Temperature - 248°F (120°C). 4. Air Filters Restricted - Needs servicing. 5.
  • Page 47 Operating Instructions Operation & Maintenance Manual Controls (Standard) 12. Power Switch - Rotate “ON” to activate systems prior to Starting. Rotate “OFF” to stop engine. 18. Service Air Button - PUSH, after warm-up. Provides full air pressure at the service outlet. Optional Controls 13.

  • Page 48: Starting The Machine

    Operation & Maintenance Manual Operating Instructions Starting The Machine All normal starting functions are incorporated in the key operated switch. • Turn the key switch to position 1. • Turn the key switch to crank position (3) (engine start position) NOTE: Position (2) is used only when grid heater option is installed.

  • Page 49: Push After Warm Up

    Operating Instructions Operation & Maintenance Manual Push After Warm Up NOTE: In order to allow the machine to start at a reduced load, a valve, which is operated by a button located on the instrument panel, is incorporated in the regulation system. (The valve automatically returns to the start position when the machine is switched off and air pressure relieved from the system).

  • Page 50: Re-Starting After An Emergency

    Operation & Maintenance Manual Operating Instructions Re-Starting After an Emergency If the machine has been switched off because of a machine malfunction, then identify and correct the fault before attempting to re-start. If the machine has been switched off for reasons of safety, then ensure that the machine can be operated safely before re-starting.

  • Page 51: Maintenance

    Section F - Maintenance 22592086...

  • Page 52: Maintenance

    Operation & Maintenance Manual Maintenance Maintenance 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 Fuel Leaks...
  • Page 53 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 *Fue/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease.

  • Page 54: Routine Maintenance

    Operation & Maintenance Manual Maintenance Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months 500 hrs. 1000 hrs /850 km 2000 hrs Scavenge line * Engine breather element Separator tank (2) exterior *Lubricator (Fill) 2 Yrs 4 Yrs 6 Yrs Safety valve Hoses...

  • Page 55: Prior To Attempting Any Maintenance Work, Ensure That

    Maintenance Operation & 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.

  • Page 56: Upon Completion Of Maintenance Tasks And Prior To Returning The Machine Into Service, Ensure That

    Operation & 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. •...

  • Page 57: Compressor Oil Filter

    Maintenance Operation & 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.

  • Page 58: Compressor Oil Separator Element

    Operation & Maintenance Manual Maintenance COMPRESSOR OIL SEPARATOR ELEMENT Refer to the MAINTENANCE CHART in this section for the recommended servicing intervals. If, however, the element has to be replaced, then proceed as follows: 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.

  • Page 59: Compressor Oil Cooler And Engine Radiator

    Maintenance Operation & Maintenance Manual 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. COMPRESSOR OIL COOLER AND ENGINE RADIATOR When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator, the efficiency is impaired.

  • Page 60: Drain And Flush Radiator (2000 Hour Intervals)

    Operation & Maintenance Manual Maintenance DRAIN and FLUSH RADIATOR (2000 hour intervals) 1. Level the unit and shut off the engine. WARNING DO NOT attempt this procedure when the engine is hot. Wait for the engine, muffler and tailpipes to cool down before proceeding. Failure to do so could result in severe burns.

  • Page 61: Air Filter Elements

    Maintenance Operation & Maintenance Manual 12. Allow the engine to cool. Check the coolant level in the radiator again, top off the radiator with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap. 13. The overflow bottle should be 1/4 to 1/2 full. If not, fill to this level with a 50/50 mixture of ethylene glycol and water.

  • Page 62: Fuel Filter Water Separator

    Operation & Maintenance Manual Maintenance FUEL FILTER WATER SEPARATOR The fuel filter water separator contains a filter element which should be replaced at regular intervals (see the SERVICE/MAINTENANCE CHART). CHARGE AIR COOLER PIPEWORK Inspect all hoses and clamps on the charge cooler pipe work. Engine damage will occur if the charge cooling system leaks.

  • Page 63: Tire Pressure

    Maintenance Operation & Maintenance Manual TIRE PRESSURE See the GENERAL DATA SECTION of this manual. RUNNING GEAR/WHEELS Check the wheel nut torque 20 miles (30 kilometres) after refitting the wheels. Refer to the Torque Setting Chart below. M12 Bolts Torque (Ft-Lbs) 13”...

  • Page 64: Compressor Lubricating Oil

    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. WARNING DO NOT, under any circumstances, remove any drain plugs or the oil filler-plug from the compressor lubricating and cooling system 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...

  • Page 65: Lubrication

    Section G - Lubrication 22592086...

  • Page 66: Lubrication

    -10°F to 125°F Preferred: (-23°C to 52°C) IR XHP 605 Alternate: Preferred Ingersoll-Rand Fluids - Use of these IR XHP405 ISO Viscosity Grade 68 fluids with original I-R filters can extend airend Group 3 or 5 with rust and warranty. Refer to operator’s manual warranty...

  • Page 67: Speed And Pressure Regulation Adjustment

    Lubrication Operation & Maintenance Manual Speed and Pressure Regulation Adjustment Normally, regulation requires no adjusting, but if correct adjustment is lost, proceed as follows: Refer to the diagram above. A. Throttle Arm B. Adjusting Screw C. Engine Governor D. Separator Tank E.

  • Page 68: Torque Setting Table

    Operation & Maintenance Manual Lubrication Torque Setting Table 22592086...

  • Page 69: Torque Setting Table

    Lubrication Operation & Maintenance Manual Torque Setting Table 22592086...

  • Page 70: Fault Finding

    Operation & Maintenance Manual Lubrication Fault Finding FAULT CAUSE REMEDY Batteries not connect batteries. No reaction from connected. instrument panel when key turned Fuse at starter motor Replace fuse. to (I) position. ‘blown’. Low battery charge. Check the fan belt tension, battery and cable connections.
  • Page 71 Lubrication Operation & Maintenance Manual FAULT CAUSE REMEDY Electrical fault. Test the electrical circuits. Low engine oil Check the oil level and oil filter(s). pressure. Safety shut-down Check the safety shut-down switches. system in operation. Engine starts but Fuel starvation. Check the fuel level and fuel system components.
  • Page 72 **Always use Ingersoll-Rand Replacement parts!** 22592086...
  • Page 73 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2009 Doosan Infracore International, Inc. Printed in the USA...

This manual is also suitable for:

Doosan xp375wcuDoosan hp375wcu

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