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OPERATION and MAINTENANCE
A PDF version of the Electronic Service
Manual is available for free download
on Doosan Passport>Doosan Portable
Power>Smart Equip Order Management
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
DoosanPortablePower.com
P/N: 46673128 (03-2015) Rev A
MANUAL
COMPRESSOR MODEL
P425WCU-EX-T2 (F66)
XP375WCU-EX-T2 (F65)
HP375WCU-EX-T2 (F67)
and Manuals
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Table of Contents
Troubleshooting
Related Manuals for Doosan P425WCU-EX-T2
Summary of Contents for Doosan P425WCU-EX-T2
- Page 1 COMPRESSOR MODEL 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 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 DoosanPortablePower.com...
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Page 3: Table Of Contents
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 ............................ - Page 4 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 ..........................
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Page 5: Foreword
FOREWORD... -
Page 6: 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 7 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.
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Page 9: Safety
SAFETY... -
Page 10: 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 11: Exhaust System
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. -
Page 12: Materials
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. -
Page 13: Battery
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. - Page 14 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.
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Page 15: Transport
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. -
Page 16: Decals
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. - Page 17 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.
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Page 19: General Data
GENERAL DATA... -
Page 20: General Data Information
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 100 (6.9) 125 (8.6) 150 (10.3) — psi (bar) Safety Valve Setting — psi 200 (13.8) 200 (13.8) 200 (13.8) - Page 21 GENERAL DATA Operation & Maintenance Manual Overall Width — feet 6.5 (1.98) (meters) Overall Weight (with fuel) — 4410 (2000) lbs (kg) Shipping Weight (less fuel) 3950 (1792) — lbs (kg)
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Page 22: Expendable Service Parts
22586010 PRO-TEC® Compressor Fluid (5 gal) 36899706 Engine Fluid (5 gal) 36875938 Modification or alteration of this machine. Can result in severe injury or death. Do not modify or alter without the express written consent of Doosan Infracore Portable Power. -
Page 23: Operating Instructions
OPERATING INSTRUCTIONS... -
Page 24: Control Panel
Operation & Maintenance Manual OPERATING INSTRUCTIONS Control Panel 1. Micro-Port Display: Displays compressor, engine operating parameters, and diagnostic codes. 2. Air Pressure Gauge: Indicates pressure in the Separator Tank. 3. Inlet Heater Indicator: Indicates when Engine Air Inlet Heater is active. 4. - Page 25 QUICK VIEW SCREENS...
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Page 26: Quick View Screens
Operation & Maintenance Manual OPERATING INSTRUCTIONS Quick View Screens Engine and Compressor Parameters The Quick View Screens allow for easy viewing of up to 8 commonly used parameters by pressing the UP and DOWN buttons. Pressing the UP and DOWN buttons continuously loops through the Quick View Screens such that when the last screen is reached pressing the Down button displays the first screen and vice versa. -
Page 27: Fault And Alert
OPERATING INSTRUCTIONS Operation & Maintenance Manual Fault and Alert If a FAULT occurs, the display unit will display CPR Code and Description for Compressor Error. An Engine Fault will be displayed only when the engine is shutdown. The FAULT has to be acknowledged by the user by pressing the Enter button. - Page 28 Operation & Maintenance Manual OPERATING INSTRUCTIONS When present an ALERT with the number of alert conditions will popup on the screen, the user will press the UP or DOWN button to display the warning or press the ENTER button to acknowledge a warning has occurred.
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Page 30: Service Interval
Operation & Maintenance Manual OPERATING INSTRUCTIONS Service Interval SERVICE will popup on the screen after one of the two hour service channels has decremented to 5 hours. The user will press the UP or DOWN button to display the service channels or press the enter button to acknowledge a service has occurred. - Page 31 OPERATING INSTRUCTIONS Operation & Maintenance Manual The service intervals can be changed by pressing the ENTER button while on the default screen. Using the UP or DOWN buttons to highlight the desired interval and press the ENTER button to select. Use the UP and DOWN buttons to increase or decrease the number of hours.
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Page 32: Display Setup
Operation & Maintenance Manual OPERATING INSTRUCTIONS Display Setup The Display Menu functions give users the ability to configure the LCD. Options for configuring the display include intensity, contrast, and viewing mode. To access the Display Menu, press and hold the ENTER button while the Default Screen is displayed until the Main Menu appears. - Page 33 OPERATING INSTRUCTIONS Operation & Maintenance Manual WAIT TO START When the Key Switch is switched to the ON position the display will initialize and then the Wait To Start message will be displayed. Wait to Start offers a chance to check for Faults/Alerts prior to crank as well as allowing the starting aids to function.
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Page 34: Display Compressor And Display Software Information Id
Operation & Maintenance Manual OPERATING INSTRUCTIONS Display Compressor and Display Software Information ID Change Compressor ID The Compressor ID is a unique 3 digit code that identifies the model of machine in the software. Normally this should not be changed or unexpected results may occur. The Compressor ID can be changed by accessing the Setup Menu. - Page 35 OPERATING INSTRUCTIONS Operation & Maintenance Manual Figure 9...
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Page 36: Languages And Units Set Up
Operation & Maintenance Manual OPERATING INSTRUCTIONS Languages and Units Set Up The DISPLAY is user configurable to display in English, Spanish, or French languages and in either English or Metric units. These can be changed by accessing the Setup Menu. To access the Setup Menu, press and hold the ENTER button while the Default Screen is displayed until the Main Menu appears. -
Page 37: Before Towing
OPERATING INSTRUCTIONS Operation & Maintenance Manual Before Towing Failure to follow these instructions CAN cause severe injury or death. • Ensure tow vehicle has towing capacity for weight of this unit as stated on general data decal.Use jack to raise or lower drawbar. •... -
Page 38: Towing
Operation & Maintenance Manual OPERATING INSTRUCTIONS Towing Failure to follow these instructions CAN cause severe injury or death. Disconnect • Engage tow vehicle parking brake. • Chock tires of compressor. • Set the vehicle parking brake. Chock wheels of unit. •... -
Page 39: Starting
OPERATING INSTRUCTIONS Operation & Maintenance Manual • Check the compressor lubricating fluid level between bottom and midway of the sight glass on the separator tank. This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve (s) are open. - Page 40 Operation & Maintenance Manual OPERATING INSTRUCTIONS • Complete starting sequence above. • Close manual blowdown valve as soon as engine runs freely. • Do not allow machine to run for long periods with manual blowdown valve open. • Allow the engine to reach operating temperature. •...
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Page 41: Shutdown
OPERATING INSTRUCTIONS Operation & Maintenance Manual If there is no air demand at idle speed (pressure rises above the unload point pressure), the compressor will unload by closing the inlet valve. The compressor then runs at idle speed unloaded with no air delivery. If air demand increases (pressure falls below the load point pressure), the compressor reloads to meet the required air demand. -
Page 42: Pressure Regulator Adjustment Instructions
Operation & Maintenance Manual OPERATING INSTRUCTIONS Pressure Regulator Adjustment Instructions Before Starting 1. On the Pressure Regulator, loosen the jam nut and turn screw counterclockwise until tension is no longer felt at the screw. Then, turn screw clockwise one full turn. 2. -
Page 43: Lubrication
LUBRICATION... -
Page 44: Compressor Oil Chart
Operation & Maintenance Manual LUBRICATION 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 45 LUBRICATION Operation & Maintenance Manual Preferred Oil - Use of these oils with Doosan branded filters can extend airend warranty. Refer to the warranty policy for details or contact your representative. Preferred Oil 1 gal. (3.8 Liter) 5 gal. (19.0 55 gal.
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Page 47: Maintenance
MAINTENANCE... -
Page 48: General Information
Operation & Maintenance Manual MAINTENANCE General Information Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty. If performing more than visual inspections, disconnect battery cables and open manual blowdown valve. Use extreme care to avoid contacting hot surfaces (engine exhaust manifold, piping, air receiver, and air discharge piping, etc.). - Page 49 MAINTENANCE Operation & Maintenance Manual 4. Pull out safety element. 5. Install new filters in air cleaner body. 6. Re-install cover on air cleaner body. 7. Close the 4 latches after securing to air cleaner body. Make sure that all clamps and flange joints are tight. Make sure the pre-cleaner dirt dump is pointed within 30°...
- Page 50 Operation & Maintenance Manual MAINTENANCE Radiator The use of water alone in this engine can result in major engine failure. Refer to engine section for coolant recommendation. Hoses Each month it is recommended that all of the intake lines to and from the air cleaners, the engine cooling system hoses and all of the flexible hoses used for air, oil, and fuel be inspected.
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Page 51: Compressor Oil Filters
MAINTENANCE Operation & Maintenance Manual Compressor Oil Filters The oil filter must be replaced every 500 hours of operation or six (6) months, whichever comes first. To service oil filters it will first be necessary to shut the unit down. Wipe off any external dirt and oil from the exterior of the filter to minimize any contamination from entering the lubrication system. -
Page 52: Receiver Separator System
Operation & Maintenance Manual MAINTENANCE oil cooler core so that the entire cooling area can transmit the heat of the lubricating and cooling oil to air stream. In the event foreign deposits, such as sludge and lacquer, accumulate in the oil cooler to the extent that its cooling efficiency is impaired, a resulting high discharge air temperature is likely to occur, causing shut down of the unit. -
Page 53: Scavenge Line
MAINTENANCE Operation & Maintenance Manual Scavenge Line 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. The scavenge line originates at the manifold and terminates at the compressor airend near the oil filter element. - Page 54 Operation & Maintenance Manual MAINTENANCE 6. Blow and tack the area to be painted. 7. Apply a smooth coat of Duponts 1854S Tuffcoat Primer to all bare metal areas and allow to dry. 8. Apply 2 medium - wet coats of Duponts 222S Adhesion Promoter over the entire area to be painted, with a 5 minute flash in between coats.
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Page 55: Field Replacement Of Canopy Decals
MAINTENANCE Operation & Maintenance Manual Field Replacement of Canopy Decals Field Replacement of Enclosure Decals 1. The decal area should be wiped with 70% isopropyl alcohol and a lint free cloth, in a well ventilated area. 2. Allow sufficient time for drying, but not enough time for dust to resettle on surface. 3. - Page 60 ...
- Page 61 TROUBLESHOOTING...
- Page 62 Operation & Maintenance Manual TROUBLESHOOTING 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.
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Page 63: Introduction
TROUBLESHOOTING Operation & Maintenance Manual 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 64: Troubleshooting Chart
Operation & Maintenance Manual TROUBLESHOOTING Troubleshooting Chart Complaint Cause Correction 1. Compressor has Out of Fuel. Add clean fuel. stopped unexpectedly Compressor Oil Temp. too See Complaint #6. high. Engine Coolant Temp. too Check coolant level. If low, high. add coolant. See Complaint Engine Oil Pressure too low. - Page 65 TROUBLESHOOTING Operation & Maintenance Manual 2. Compressor won’t start Low battery voltage. Check battery condition, or run recharge if necessary. Check electrolyte level, add if necessary. Check cable connections, clean and tighten as needed. Blown fuse. Identify and replace fuse. See Electronic Service Manual.
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Page 66: Diagnostic Codes
Operation & Maintenance Manual TROUBLESHOOTING 3. High Engine Coolant Low coolant level. Check coolant level. If low, Temperature add coolant. Loose or broken belts. Tighten or replace belt set. Ambient temperature above Operate in cooler rated ambient temp. range. environment. Dirty operating conditions. - Page 67 TROUBLESHOOTING Operation & Maintenance Manual 5. Low electrical system Loose or broken belts. Tighten or replace belt set. voltage Loose wire connection. Check wires at switches and connectors to find loose connection. Make repairs. See Electronic Service Manual. Low battery voltage. Check battery condition, recharge if necessary.
- Page 68 Operation & Maintenance Manual TROUBLESHOOTING Blocked or restricted oil lines. Clean by flushing, or replace lines. Airend malfunctioning. See Complaints #11, #12. 7. Low engine speed Clogged fuel filters. Service fuel filters. See Engine Manual. Drain and clean fuel tanks. Add clean fuel.
- Page 69 TROUBLESHOOTING Operation & Maintenance Manual 10. Short air filter life Dirty operating conditions. Move compressor to cleaner environment. Wrong air filter element(s). Install correct air filter element(s). Inadequate air filter element Install new air filter cleaning. element(s). Incorrect stopping Comply with procedure in procedure.
- Page 70 Operation & Maintenance Manual TROUBLESHOOTING Diagnostic Codes The Micro-Port displays Diagnostic Codes for the compressor system and the engine. Listings of these codes are provided in this section. A service tool connector is provided in the electrical harness, providing access to the J1939 CAN network.
- Page 71 TROUBLESHOOTING Operation & Maintenance Manual CPR CODE 30 High Airend Airend discharge temperature FAULT HIGH AIREND Discharge greater than or equal to 248˚F. TEMP Temperature Airend Discharge Airend discharge temperature FAULT CPR CODE 32 AIREND DISC Temperature sensor reading out of range. TEMP SENSOR Sensor CPR CODE 33...
- Page 72 Operation & Maintenance Manual TROUBLESHOOTING CPR CODE 54 Regulation Regulation system pressure FAULT REG SYSTEM System Pressure sensor reading out of range. PRES SENSOR Sensor Emergency Stop button has been FAULT CPR CODE Emergency Stop 55 E-STOP Activated activated. ACTIVATED CPR CODE 58 Ambient Ambient temperature sensor...
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Page 73: Revision History
TROUBLESHOOTING Operation & Maintenance Manual Revision History REV. CN Number Comments Original Release... - Page 76 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 DoosanPortablePower.com © Doosan Infracore Portable Power Printed in the U.S.A.
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