Doosan XP375WCU-T2 Operation And Maintenance Manual
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Doosan XP375WCU-T2 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
P/N: 22592083 (5-2014) Rev C
MANUAL
COMPRESSOR MODELS
HP375WCU (B11)
XP375WCU (B12)
P425WCU (B13)
HP375WCU-T2 (D46)
XP375WCU-T2 (D44)
P425WCU-T2 (D45)

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  • Page 1 P425WCU-T2 (D45) 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 P/N: 22592083 (5-2014) Rev C...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE FOREWORD ............. . 7 Information .
  • Page 4 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE Dual Pressure Regulation When Fitted ..........41 Stopping The Machine .
  • Page 5 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE LUBRICATION ............57 Lubrication .

  • Page 7: Foreword

    Foreword...

  • Page 8: Information

    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.
  • Page 9 Foreword Operation & Maintenance Manual 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 10 Operation & Maintenance Manual Foreword...

  • 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...
  • Page 18 Operation & Maintenance Manual Safety...
  • Page 19 Safety Operation & Maintenance Manual...
  • Page 20 Operation & Maintenance Manual Safety...
  • Page 21 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 on the bottom of each decal and are also listed in the compressor parts manual.

  • Page 23: Noise Emission

    Noise Emission...

  • Page 24: Noise Emission Control Maintenance Log

    Operating & Maintenance Manual Noise Emission 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 25: Introduction

    Noise Emission Operating & Maintenance Manual 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 below 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 26: Fasteners

    Operating & Maintenance Manual Noise Emission 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 27 Noise Emission Operating & Maintenance Manual MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK OR COMMENTS HOURMETER MAINT/ INSPECT LOCATION CITY/ WORK DONE READING DATE STATE BY (NAME)

  • Page 29: General Data

    Section C - General Data...

  • Page 30: 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)
  • Page 31 Refer to engine manual Coolant Capacity 17 liters (4.5 gal) Sound Level Data A) "W” Model, EPA Noise 76 dB (A) Wheels and Tires (P425WCU, XP375WCU, HP375WCU) Number of Wheels 2 x 5.5 Tire Size ST225/75R15 (D) Tire Pressure 4.5 bar (65 psi)

  • Page 33: Operating Instructions

    Section D - Operating Instructions...

  • Page 34: 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 Doosan Portable Power representative for flexible mounting kits.
  • Page 35 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 36: 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 37 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 38: 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 39 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 40: 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 41: 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 42: 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 43: Maintenance

    Section E - Maintenance...

  • Page 44: 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 45 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 *Fuel/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease.

  • Page 46: 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 47: 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 48: Protective Shutdown System

    Operation & Maintenance Manual Maintenance position that can be clearly seen. 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. •...

  • Page 49: 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 50: Compressor Oil Separator Element

    Operation & Maintenance Manual Maintenance MACHINE in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the machine is put back into service. 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...

  • Page 51: 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 52: 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 53: 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 54: 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 55: 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 56: 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 57: Lubrication

    Section F - Lubrication...

  • Page 58: Lubrication

    Operation & Maintenance Manual Lubrication 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”...
  • Page 59 Lubrication Operation & Maintenance Manual Preferred Fluids - Use of these fluids with original filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your Portable Power representative. Preferred 1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Llitre) Fluids Preferred: Pro-Tec™...

  • Page 60: Speed And Pressure Regulation Adjustment

    Operation & Maintenance Manual Lubrication 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 61: Torque Setting Table

    Lubrication Operation & Maintenance Manual Torque Setting Table...

  • Page 62: Torque Setting Table

    Operation & Maintenance Manual Lubrication Torque Setting Table...

  • Page 63: Fault Finding

    Lubrication Operation & Maintenance Manual 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 64 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 65 Revision History Rev. EC Number Comments Original release Updated with Doosan references CN026142 Flex Models Added to Front Cover CN034866...
  • Page 66 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2012 Doosan Infracore Portable Power Printed in the U.S.A.

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