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Doosan HP375WCU, Operation And Maintenance Manual

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TABLE OF CONTENTS

Operating & Maintenance Manual

TITLE

PAGE

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SAFETY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11

Safety  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety Precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

General Information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compressed Air  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Radiator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transport  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety chains/connections and their adjustment where fitted: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Graphic Form and Meaning of ISO Symbols  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 17

NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

NOISE EMISSION CONTROL MAINTENANCE LOG  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. Compressed Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
B. Safety and Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
C. Acoustic Materials  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
D. Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
E. Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F. Air Intake and Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
G. Cooling Systems  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
H. Isolation Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
I. Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
J. Fuels and Lubricants  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  29

General Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  33

Operating Instructions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Compressor Mounting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Prior to Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control Panel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starting The Machine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Push After Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Summary of Contents for HP375WCU

Page 1: ...nfracore Portable Power 1293 Glenway Drive Statesville N C 28625 DoosanPortablePower com P N 22592083 5 2014 Rev C 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 OPERATION and MAINTENANCE MANUAL ...

Page 2: ...2 ...

Page 3: ...E EMISSION CONTROL MAINTENANCE LOG 24 Noise Emission Warranty 24 Introduction 25 Maintenance Schedule 25 A Compressed Air Leaks 25 B Safety and Control Systems 25 C Acoustic Materials 25 D Fasteners 26 E Enclosure Panels 26 F Air Intake and Engine Exhaust 26 G Cooling Systems 26 H Isolation Mounts 26 I Engine Operation 26 J Fuels and Lubricants 26 GENERAL DATA 29 General Data 30 OPERATING INSTRUCT...

Page 4: ...ks and prior to returning the machine into service ensure that 48 PROTECTIVE SHUTDOWN SYSTEM 48 Low engine fuel level switch 48 SCAVENGE LINE 48 COMPRESSOR OIL FILTER 49 Removal 49 lnspection 49 Reassembly 49 COMPRESSOR OIL SEPARATOR ELEMENT 50 Removal 50 lnspection 50 Reassembly 50 COMPRESSOR OIL COOLER AND ENGINE RADIATOR 51 DRAIN and FLUSH RADIATOR 2000 hour intervals 52 AIR FILTER ELEMENTS 53 ...

Page 5: ...NTS Operating Maintenance Manual TITLE PAGE LUBRICATION 57 Lubrication 58 Portable Compressor Fluid Chart 58 Speed and Pressure Regulation Adjustment 60 Torque Setting Table 61 Torque Setting Table 62 Fault Finding 63 ...

Page 6: ...6 ...

Page 7: ...7 Foreword ...

Page 8: ...ible 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 accompanied 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 p...

Page 9: ...e 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 adequacy and accuracy of the conte...

Page 10: ...Operation Maintenance Manual Foreword 10 ...

Page 11: ...22592086 11 Section A Safety ...

Page 12: ...mponents road wheels 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 machine may contain carbon monoxide or other contaminants which will cause serious injury or death Do not breathe this air This machine produces loud noise with the doors open or service valve vented Extended exp...

Page 13: ...at tool or vent valve before performing any service The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible If the 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 A...

Page 14: ...ttery electrolyte WARNING Avoid ingestion skin contact and inhalation of fumes Should compressor lubricant come into contact with the eyes then irrigate with water for at least 5 minutes Should compressor lubricant come into contact with the skin then wash off immediately Consult a physician if large amounts of compressor lubricant are ingested Consult a physician if compressor lubricant is inhale...

Page 15: ...pt to slave start a frozen battery since this may cause it to explode Exercise extreme caution when using booster battery To jump battery connect ends of one booster cable to the positive terminal of each battery Connect one end of other cable to the negative terminal of the booster battery and other end to a ground connection away from dead battery to avoid a spark occurring near any explosive ga...

Page 16: ...ed 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 Make sure wheels tires and tow bar connectors are in safe operating condition and tow bar is properly connected before towing 2 When parking always use the han...

Page 17: ...Safety Operation Maintenance Manual 17 Decals Graphic Form and Meaning of ISO Symbols ...

Page 18: ...Operation Maintenance Manual Safety 18 ...

Page 19: ...Safety Operation Maintenance Manual 19 ...

Page 20: ...Operation Maintenance Manual Safety 20 ...

Page 21: ... 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 Submit orders for Safety Decals to the Statesville Parts Service Dept The no charge order should contain only Safety Decals Help promote product safety Assure that decals are present on the compressor Replace decals t...

Page 22: ...22 ...

Page 23: ...23 Noise Emission ...

Page 24: ... ultimate purchaser and each subsequent purchaser that this air compressor was designed built and equipped to conform at the time of sale to the first retail purchaser with all applicable U S EPA Noise Control Regulations This warranty is not limited to any particular part component or system of the air compressor Defects in the design assembly or in any part component or system of the compressor ...

Page 25: ...and correct the leak s B Safety and Control Systems Repair or replace all safety and control systems or circuits as malfunction occurs No compressor should be operated with either system bypassed disabled or nonfunctional C Acoustic Materials In daily inspections observe these materials Maintain all acoustic material as nearly as possible in its original condition Repair or replace all sections th...

Page 26: ... should be inspected after each 100 hours of operation for loose damaged or deteriorated components Repairs or replacements should be made before the next period of use G Cooling Systems All components of the cooling system for engine water and compressor oil should be inspected every 250 hours of use Any discrepancies found should be corrected before placing the unit back in operation Unrestricte...

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

Page 28: ...28 ...

Page 29: ...29 Section C General Data ...

Page 30: ...bar 150 psi Maximum Allowable Pressure P425WCU 8 6 bar 125 psi XP375WCU 10 3 bar 150 psi HP375WCU 12 1 bar 175 psi Safety Valve Setting P425WCU 10 bar 150 psi XP375WCU 14 bar 200 psi HP375WCU 14 bar 200 psi Maximum Pressure Ratio absolute P425WCU 7 9 1 XP375WCU 9 6 1 HP375WCU 11 3 1 Operating ambient temperature Whisperized 12 C to 48 C 10 F to 118 F Cooling system Oil injection Oil capacity 36 li...

Page 31: ...le min 1 RPM 1500 revs Power Available at Full Load 93kW 125hp Electrical System 12 V neg ground Fuel Tank Capacity 219 liters 58 gal Oil Specification 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 Net Weight Less Fuel 198...

Page 32: ...32 ...

Page 33: ...33 Section D Operating Instructions ...

Page 34: ...hat there is sufficient clearance for ventilation and exhaust requirements Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks Ensure that the machine is positioned securely and on a stable foundation Any risk of movement should be removed by suitable means especially to avoid strain on any rigid discharge piping Compressor Moun...

Page 35: ...compatible with the compressor lubricant refer to the GENERAL DATA SECTION WARNING 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 so that one machine cannot accidently be pressurized over pressurized by another WARNING When flexible discharge hoses are used it is recommended that s...

Page 36: ...instructions in the Engine Operator s Manual or section 3 Check the compressor oil level in the sight glass located on the separator tank 4 Check the diesel fuel level A good rule is to top up at the end of each working day This prevents condensation from occurring in the tank Refer to the engine operator s manual section for diesel fuel specification CAUTION When refuelling switch off the engine ...

Page 37: ...rators to be exposed to high noise levels 7 Check the radiator coolant level with the unit level Check the air filter restriction indicator s Refer to the MAINTENANCE section of this manual When starting or operating the machine in temperatures below or approaching 0 C 32 F ensure that the operation of the regulation system the unloader valve the safety valve and the engine are not impaired by ice...

Page 38: ...s 3 High Compressor Temperature 248 F 120 C 4 Air Filters Restricted Needs servicing 5 Spare 6 Spare Diagnostic Auto Shutdown Standard 7 Alternator Not Charging Needs attention 8 Low Fuel Level Must add fuel to operate 9 Hourmeter Records running time for maintenance 10 Compressor Discharge Pressure Gauge lndicates pressure in receiver tank psi kPa 11 Fuel Level Gauge Indicates amount of fuel in t...

Page 39: ...l air pressure at the service outlet Optional Controls 13 Engine Speed Gauge Indicates engine speed 14 Discharge Air Temp Gauge Indicates in F and C Normal operating range 185 F 85 to 248 F 104 C 15 Engine Oil Pressure Gauge Indicates engine oil pressure psi kPa 16 Engine Water Temp Gauge Indicates coolant temperature with normal operating range from 180 F 82 C to 210 F 99 C 17 Voltmeter Indicates...

Page 40: ...peed At temperatures below 32 F 0 C or if there is difficulty starting first time Open the manual blowdown valve fully 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 At this point in the operation of the machine it is safe to apply...

Page 41: ...ted by the selection and during normal running the selector switch may be safely operated Precaution must be taken to ensure that downstream equipment is rated to suit the available pressure The pressure gauge indicates which setting has been selected Stopping The Machine Close the service valve Allow the machine to run unloaded for a short period of time to reduce the engine temperature Turn the ...

Page 42: ...or a listing of shutdown conditions CAUTION To ensure an adequate flow of oil to the compressor at low temperature never allow the discharge pressure to fall below 3 5 bar 50 psi Decommissioning When the machine is to be permanently decommissioned or dismantled it is important to ensure that all hazard risks are either eliminated or notified to the recipient of the machine In particular Do not des...

Page 43: ...43 Section E Maintenance ...

Page 44: ...Precleaner Dumps C Fan Alternator Belts C Battery Connections Electrolyte C Tire Pressure and Surface C Wheel Lug Nuts C Hoses Oil Air Intake etc C Automatic Shutdown System C Air Cleaner System C Compressor Oil Cooler Exterior C Engine Rad Oil Cooler Exterior C Fasteners Guards C Air Cleaner Elements R WI Disregard if not appropriate for this particular machine D Drain 1 or 3000 miles 5000km whic...

Page 45: ...rifice Related Parts C Oil Separator Element R Feed Pump Strainer Cleaning C Valve Clearance Check C Lights running brake turn CBT Pintle Eye Bolts CBT Brakes C C Brake linkage C Emergency stop T Running gear linkage G Safety valve C Running gear bolts 1 C Disregard if not appropriate for this particular machine D Drain 1 or 3000 miles 5000km whichever is the sooner G Grease 2 or as defined by loc...

Page 46: ...ils to operate then pressure must be gradually relieved by operating the manual blowdown valve Suitable personal protective equipment should be worn Ensure that maintenance personnel are adequately trained competent and have read the Maintenance Manuals Initial 500miles 850 km Daily Weekly Monthly 3 Months 500 hrs 6 Months 1000 hrs 12 Months 2000 hrs Scavenge line C Engine breather element C Separ...

Page 47: ...r removing panels or covers to work inside a machine ensure that anyone entering the machine is aware of the reduced level of protection and the additional hazards including hot surfaces and intermittently moving parts The machine cannot be started Prior to attempting any maintenance work on a running machine ensure that the work carried out is limited to only those tasks which require the machine...

Page 48: ...ow engine fuel level switch Test the low engine fuel level switch circuit as follows Start the machine NOTE Do not press the load button Disconnect the switch the machine should shutdown Re connect the switch Test the low engine fuel level switch by removing and operating the float manually WARNING Never remove or replace switches when the machine is running SCAVENGE LINE The scavenge line runs fr...

Page 49: ... the oil filter element Clean the gasket seal area on the oil filter head CAUTION If there is any indication of the formation of varnishes shellacs or lacquers on the filter element it is a warning that the compressor lubricating and cooling oil has deteriorated and that it should be changed immediately Refer to LUBRICATION later in this section NOTICE Installing a new oil filter element when the ...

Page 50: ...op tube from the separator tank cover plate and then remove the cover plate Remove the separator element lnspection Examine the filter element Examine all hoses and tubes and replace if necessary 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 ele...

Page 51: ...ccumulation of oil grease and dirt from the exterior core of the cooler so that the entire cooling area can radiate the heat of the lubricating and cooling oil water into the air stream WARNING Hot engine coolant and steam can cause injury When adding coolant or antifreeze solution to the engine radiator stop the engine at least one minute prior to releasing the radiator filler cap Using a cloth t...

Page 52: ...or Place a hose onto the petcock and channel the coolant into a container Open the petcock and allow the coolant to drain 5 Flush the radiator with clean water and allow to drain After radiator is drained close the petcock and remove the hose 6 Transfer used coolant to a properly labeled container and dispose of properly 7 Drain the contents of the overflow bottle by removing the overflow hose fro...

Page 53: ...eassembly Assemble the new element into the filter housing ensuring that the seal seats properly Secure element by tightening nut Before restarting the machine check that all clamps are tight VENTILATION Always check that the air inlets and outlets are clear of debris etc COOLING FAN DRIVE Periodically check that the fan mounting bolts in the fan hub have not loosened If for any reason it becomes ...

Page 54: ...ECTRICAL SYSTEM WARNING Disconnect the battery cables before performing any maintenance or service Check the security of electrical terminals on the switches and relays i e nuts or screws loose which may cause local hot spot oxidation Inspect the components and wiring for signs of overheating i e discolouration charring of cables deformation of parts acrid smells and blistered paint BATTERY Keep t...

Page 55: ...ighten where necessary LUBRICATION CAUTION Always check the oil levels before a new machine is put into service If for any reason the unit has been drained it must be re filled with new oil before it is put into operation ENGINE LUBRICATING OIL The engine oil and oil filter element should be changed at the engine manufacturer s recommended intervals Refer to the Engine operator manual section Refe...

Page 56: ...ERATING INSTRUCTIONS section of this manual Completely drain the receiver separator system including the piping and oil cooler by removing the drain plug s and collecting the used oil in a suitable container Replace the drain plug s ensuring that each one is secure NOTE If the oil is drained immediately after the machine has been running then most of the sediment will be in suspension and will the...

Page 57: ...57 Section F Lubrication ...

Page 58: ...ed for extended warranty Compressor oil carryover oil consumption may be greater with the use of alternative fluids DesignOperating Pressure Ambient Temperature Specification 100 psi to 300 psi 10 F to 125 F 23 C to 52 C Preferred Pro Tec Alternate ISO Viscosity Grade 46 with rust and oxidation inhibitors designed for air compressor service 350 psi 10 Fto125 F 23 C to 52 C 65 Fto125 F 18 C to 52 C...

Page 59: ...er to operator s manual warranty section for details or contact your Portable Power representative Preferred Fluids 1 gal 3 8 Litre 5 gal 19 0 Litre 55 gal 208 2 Litre 220 gal 836 Llitre Preferred Pro Tec 36899698 36899706 36899714 36899722 XHP605 22252076 22252050 22252068 XHP1001 35612738 35300516 XHP405 22252126 22252100 22252118 ...

Page 60: ...oad speed and the service valve is fully open Refer to the GENERAL INFORMATION section of this manual Adjust the service valve on the outside of the machine to maintain normal operating discharge pressure without the throttle arm moving from the full speed position before normal operating discharge pressure is attained Turn the adjusting screw clockwise to increase the pressure Optimum adjustment ...

Page 61: ...Lubrication Operation Maintenance Manual 61 Torque Setting Table ...

Page 62: ...Operation Maintenance Manual Lubrication 62 Torque Setting Table ...

Page 63: ...starvation Check the fuel level and fuel system components Replace the fuel filter if necessary Relay failed Replace the relay Faulty stop solenoid Check the stop solenoid Engine stops while in service or is reluctant to start Low fuel level Fill fuel tank and bleed air from fuel system if necessary Refer to MAINTENANCE SECTION Safety shut down system in operation Check the safety shut down switch...

Page 64: ...p the machine and clean the cooling fins with compressed air or steam Use reduced pressure for cleaning the fins Reduced cooling air from fan Check the fan and the drive belts Check for any obstruction inside the cowl Faulty thermostat Check the thermostat and replace if necessary Engine speed too high lncorrect throttle arm setting Check the engine speed setting Engine speed too low lncorrect thr...

Page 65: ...Revision History Rev EC Number Comments A Original release B C CN026142 Updated with Doosan references D CN034866 Flex Models Added to Front Cover ...

Page 66: ... 2012 Doosan Infracore Portable Power Printed in the U S A Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 www doosanportablepower com ...

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