Doosan P185WDOU-T4F, P185WDO-T4F Operation And Maintenance Manual
OPERATION and MAINTENANCE
PDF versions of the Parts Manual and the Electronic Service Manual
are available for download at:
http://www.doosanportablepower.com/en/aftermarket/parts/online-parts-manuals
MANUAL
COMPRESSOR MODEL
P185WDOU-T4F (F89)
Doosan Infracore Portable Power
1293 Glenway Drive
tesville, N.C. 28625
Sta
DoosanPortablePower.com
P/N: 46680186 (10-2015) Rev A
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE
PAGE
FOREWORD ..........................................................................................................................9
Information..................................................................................................................................... 10
SAFETY ...............................................................................................................................13
Safety Precautions ......................................................................................................................... 14
Compressed Air..........................................................................................................................14
ExhaustSystem......................................................................................................................... 15
Materials.................................................................................................................................... 16
Battery....................................................................................................................................... 17
Radiator ..................................................................................................................................... 17
Decals....................................................................................................................................... 19
Decals................................................................................................................................. 21
NOISE EMISSION................................................................................................................25
Noise Emission............................................................................................................................... 26
Introduction .................................................................................................................................... 26
Maintenance Schedule.................................................................................................................... 27
Noise Emission Warranty ............................................................................................................... 29
Maintenance Log ............................................................................................................................ 30
GENERAL DATA .................................................................................................................33
General Data Information................................................................................................................ 34
OPERATING INSTRUCTIONS ............................................................................................37
Control/Gauge Panel ...................................................................................................................... 38
Auto Power Off ............................................................................................................................... 40
Quick View Screens........................................................................................................................ 41
Fault and Alert ............................................................................................................................... 41
Service Interval Set Up ................................................................................................................... 44
Display Setup ................................................................................................................................. 46
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE
Language and Units........................................................................................................................ 47
Compressor ID................................................................................................................................ 48
Utility Package Set-Up (no running gear)........................................................................................ 48
Before Starting ............................................................................................................................... 48
Starting........................................................................................................................................... 50
Shutdown ....................................................................................................................................... 51
Pressure Regulator Adjustment Instructions ................................................................................. 52
PAGE
ENGINE OPERATION..........................................................................................................53
Engine Operation and Maintenance................................................................................................ 54
SAFETY..................................................................................................................................... 54
Instructions ................................................................................................................................ 55
GeneralRepair........................................................................................................................... 57
Environmental Pollution .............................................................................................................. 58
Engine Management................................................................................................................... 59
Preventionof Pollution................................................................................................................ 60
Start and Shutdown.................................................................................................................... 61
Break-in Period of Engine............................................................................................................ 62
Inspectionafter Starting the Engine ............................................................................................. 63
Operation in Winter..................................................................................................................... 64
RegularInspection...................................................................................................................... 65
Checking the Engine Oil........................................................................................................ 66
Replacementof EngineOil.................................................................................................... 68
Coolant ................................................................................................................................ 70
Checking the Coolant...................................................................................................... 71
Replenishment of Coolant............................................................................................... 74
Replacementof Coolant.................................................................................................. 75
FuelSystem ................................................................................................................... 76
LUBRICATION .....................................................................................................................79
Compressor Oil Chart..................................................................................................................... 80
MAINTENANCE ...................................................................................................................83
General Information........................................................................................................................ 84
Compressor Oil Filters.................................................................................................................... 87
Receiver Separator System ............................................................................................................ 88
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE
Scavenge Line ................................................................................................................................ 89
Exterior Finish Care........................................................................................................................ 89
Field Replacement of Exterior Decals............................................................................................. 91
PAGE
TROUBLESHOOTING .........................................................................................................95
Introduction .................................................................................................................................... 97
Troubleshooting Chart.................................................................................................................... 98
Diagnostic Codes ..........................................................................................................................105
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE
PAGE
FOREWORD
9
Operation & Maintenance Manual FOREWORD
Information
The contents o
Infracore Portable Power (herein referred to as “Portable Power”), and should not be
reproduced without the prior written permission of Portable Power.
Nothing con
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
accordanc
available upon request.
This manual contains instructions and technical data to cover all routine operation and
schedule
outside the scope of this manual and should be referred to an authorized Portable Power
Service department.
All comp
should be:
onents, accessories, pipes, and connectors added to the compressed air system
• of good quality, procured from a reputable manufacturer and, wherever possible,
• clearly rated for a pressure at least equal to the compressor safety valve setting.
• compatible with the compressor oil.
•accom
f this manual are considered to be proprietary and confidential to Doosan
tained in this document is intended to extend any promise, warranty or
e with the standard terms and conditions of sale for such products, which are
d maintenance tasks by operation and maintenance staff. Major overhauls are
be of a t
ype approved by Portable Power.
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 c reate
rdous conditions over which Portable Power has no control. Therefore, Portable Power
haza
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
ice and without incurring any obligation to make such changes or add such improvements
not
to products sold previously.
The intended uses of this compressor are outlined below and examples of unapproved
age are also given. However, Portable Power cannot anticipate every application or work
us
situation that may arise. If in doubt, consult supervision.
This compressor has been designed and supplied for above ground operation to be used for
ompression of normal ambient air containing no additional gases, vapors, or particles within
c
the ambient temperature range specified in the General Data Section of this manual.
10
FOREWORD Operation & Maintenance Manual
This compressor should not be used:
• For direct or indirect human consumption of the compressed air.
• Outside the am
bient 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 exist
s.
• With other than Portable Power approved components.
• With guards, controls, or switches missing or disabled.
• For storag
e 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 th
e 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
e and maintenance requirements of the compressor. During the preparation of this
servic
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
lso provide brief operating and service instructions. Before starting the compressor,
will a
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
anical condition.
mech
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
tains a recommended Maintenance schedule and provides space in the log for the
con
technician to note what service and maintenance was done, by whom, where, and when.
11
12
SAFETY
13
Operation & Maintenance Manual SAFETY
Safety Precautions
Never operate
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 o
Ensure all maintenance personnel are adequately trained, competent, and have read the
manuals.
Ensure all
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 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 i
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 lif
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
, and site rules must be observed. To ensure the compressor can operate in a safe
nvolved.
ting bail should be checked for total security.
will cause serious injury or death. Do not breathe discharged air.
the compressor without first observing all safety warnings and carefully reading
r performing maintenance.
protective covers are in place and the canopy/doors are closed during operation.
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
pen or service valve is vented.
are o
Never inspect or service the compressor without first disconnecting battery cable(s) to
prevent accidental starting.
not use petroleum products (solvents or fuels) under high pressure as this can penetrate
Do
the skin and result in serious illness. Wear eye protection while cleaning the compressor
with compressed air to prevent debris from injuring eye(s).
otating fan blade can cause serious injury. Do not operate without fan guard in place.
R
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.
14
Ensure the compressor is operating at the rated pressure and the rated pressure is known
to all relevant personnel.
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 on
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 a
or mask.
Compressed air can cause serious injury or death. Relieve pressure before removing filler
plugs/caps
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
maintena
Discharged air contains a very small percentage of compressor lubricating oil and care
should be taken to ensure downstream equipment is compatible.
If disch
must be provided.
When using compressed air, always use appropriate personal protective equipment.
All pre
inspected, be free from defects, and be replaced according to the manual instructions.
Avoid bodily contact with compressed air.
arged air is to be ultimately released into a confined space, adequate ventilation
ssure containing parts, especially flexible hoses and their couplings, must be regularly
e c ompressor is connected to one common downstream plant, effective check
ir must NOT be used for a direct feed to any form of breathing apparatus
, fittings, or covers.
nce.
The sa
operation.
Whenever the compressor is stopped, air will flow back into the compressor from downstream
devi
service valve to prevent reverse flow in the event of an unexpected shutdown when the
service valve is open.
Dis
flow restrictor to each hose at the s ource of supply or branch line in accordance with OSHA
Regulation 29CFR Section 1926.302(b).
Ne
fety valve located in the separator tank must be checked periodically for correct
ces or systems unless the service valve is closed. Install a check valve at the compressor
connected air hoses whip and can cause serious injury or death. A lways attach a safety
ver 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.
15
Operation & Maintenance Manual SAFETY
Materials
The following substances may be produced during the operation of this compressor:
• brake lining dust
• engine exhau
Ensure tha
all times.
The following substances are used in the manufacture of this compressor and may be
hazardou
t adequate ventilation of the cooling system and exhaust gases is maintained at
s to health if used incorrectly:
• compressor oil
• preservative grease, lubricating grease
•rustpr
• battery electrolyte
eventative
st fumes
Avoid inhalation of material substances.
Avoid
ingestion, skin contact, and inhalation of fumes.
16
SAFETY Operation & Maintenance Manual
Should compressor oil come into contact with the eyes, irrigate with water for at least 5
minutes.
Should compre
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 s
Do NOT start or operate this compressor in a confined area. Avoid breathing exhaust fumes
when working on or near the compressor.
This compre
filters, and batteries which may require proper disposal when performing maintenance or
service tasks. Contact local authorities for proper disposal of these materials.
ssor oil come into contact with the skin, wash off immediately. Consult a
heets for compressor and engine oils should be obtained from the oil supplier.
ssor may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air
Battery
A batter
explosive. Avoid contact with skin, eyes, and clothing. In case of contact, flush area
immediately with water.
y contains sulfuric acid and can produce gases which are corrosive and potentially
Do not attempt to jump start a frozen battery since this may cause the
battery to explode.
cise extreme caution when using an external method to jump start
Exer
a unit. Verify the electrical systems on the weak battery system and
the external jump system are the same voltage type system, 12VDC
4VDC. Connect the Positive (+) terminal of the external system to
or 2
the Positive (+) terminal on the weak system. Connect the Negative (-)
terminal of the external system to the Negative (-) terminal of the weak
tem. Always disconnect the two systems in reverse order.
sys
Radiator
Hot engine coolant and steam can cause injury. Ensure the Radiator Pressure Cap is
removed with due care and attention.
o not remove the pressure cap from a HOT radiator. Allow radiator to cool before removing
D
pressure cap.
17
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 f uid with the cloth. Do not remove the pressure cap
until all excess f uid is released and the engine cooling system fully
depressurized.
Follow th
e 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
solutio
n.
The potential for higher temperatures is present when the exhaust
treatment system undergoes regeneration. Refer to Engine
after
Manual for further safety instructions and information on the exhaust
aftertreatment system and controls.
18
SAFETY Operation & Maintenance Manual
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 p
Indicates the presence of a hazard which CAN cause serious injury,
death, o
roperty damage, if ignored.
(Orange Background)
r property damage, if ignored.
(Yellow Background)
Indicates the presence of a hazard which WILL or CAN cause injury or
prope
rty damage, if ignored.
19
Operation & Maintenance Manual SAFETY
(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 identif ed 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.
20
SAFETY Operation & Maintenance Manual
Decals
21
Operation & Maintenance Manual SAFETY
22
SAFETY Operation & Maintenance Manual
23
24
NOISE EMISSION
25
Operation & Maintenance Manual NOISE EMISSION
Noise Emission
This section p
Compressor Noise Emission Control Information
Note: The a
with the U.S. Environmental Protection Agency.
Portable Power reserves the right to make changes or add improvements without notice
and witho
products sold previously.
The Purchaser is urged to include the above provisions in any agreement for any resale
of this c
Federal law prohibits the following acts or the causing thereof:
(1) The removal or rendering inoperative by any persons, other than for purposes of
mainte
any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use; or (2) the use of the compressor after such device or element
of des
ompressor.
nance, repair, or replacement, of any device or element of design incorporated into
ign has been removed or rendered inoperative by any person.
ertains only to compressors distributed within the United States.
Tampering with noise control system prohibited.
bove information applices only to compressors that are built in compliance
ut incurring any obligation to make s uch changes or add such improvements to
Among those acts included in the prohibition against tampering are these:
1. Removal or rendering inoperative any of the following:
he engine exhaust system or parts thereof
a. t
b. the air intake system or parts thereof
c. enclosure or parts thereof
2. Re
3. Operation of the compressor with any of the enclosure doors open.
moval of any of the following:
a. fan shroud
b. vibration mounts
. sound absorption material
c
Introduction
The compressor for which this Maintenance Log is provided conforms to U.S. E.P.A.
Regulations for Noise Emissions, applicable to Portable Air Compressors.
26
NOISE EMISSION Operation & Maintenance Manual
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 maintena
detailed instructions on the maintenance items are given on following page.
nce was done, by whom, where and when. The Maintenance Schedule and
27
Operation & Maintenance Manual NOISE EMISSION
Maintenance Schedule
PERIOD DESCRIPTION
As Detected
As Detecte
Daily
100 HOURS FASTENERS
d
COMPRESSED AIR LEAKS
Correct all compressed air leaks during the first shutdown period
after disco
and efficiency loss, shut down immediately and correct the leak(s).
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.
ACOUSTIC MATERIALS
In daily inspections, observe these materials. Maintain all acoustic
materi
replace all sections that have: 1) sustained damage, 2) have
partially separated from panels to which they were attached, 3) are
missi
storage conditions.
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.
very. If severe enough to cause serious noise problems
al as nearly as possible in its original condition. Repair or
ng, or have otherwise deteriorated due to severe operating or
0HOURS
10
100 HOURS AIR INTAKE AND ENGINE EXHAUST
250 HOURS COOLING SYSTEMS
CLOSURE PANELS
EN
Enclosure panels should be inspected at 100 hour operational
intervals. All panels that are warped, punctured, torn, or otherwise
eformed, such that their noise containment function is reduced,
d
should be repaired or replaced before the next operation interval.
Doors, access panels, and hatch closures especially, should be
checked and adjusted at this time to ensure continuous seating
between gasket or acoustic material and the mating frame.
Engine and compressor air intake and engine exhaust systems
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.
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
compressor back in operation. Unrestricted airflow over the radiator
and oil cooler must be maintained at all times during operation.
28
NOISE EMISSION Operation & Maintenance Manual
PERIOD DESCRIPTION
250 HOURS ISOLATION MOUNTS
Engine/airend isolation mounts should be inspected after each
250 hours of o
the molded rubber or with bent or broken bolts due to operation
or storage in severe environments should be replaced with
equivalent
See Operator Manual ENGINE OPERATION
Inspect and maintain engine condition and operation as
recommended in the manuals supplied by the engine
manufacturer.
peration. Those mounts with cracks or splits in
parts.
See Oper
ator Manual
FUELS AN
D LUBRICANTS
Use only the types and grades of fuels and lubricants
recommended in the Operator and Maintenance Manual and
Engine
Manual.
29
Operation & Maintenance Manual NOISE EMISSION
Noise Emission Warranty
The manufactu
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 w arrant
compressor. Defects in the design, assembly or in any part, component, or system of
the compressor which, at the time of sale to the first retail purchaser, caused noise
emissions t
compressor.(40CFR204.58-1)
rer warrants to the ultimate purchaser and each subsequent purchaser that
y is not limited to any particular part, component, or system of the air
o exceed Federal Standards are covered by this warranty for the life of air
30
NOISE EMISSION Operation & Maintenance Manual
Maintenance Log
COMPRESSOR MODEL:
SERIAL NO:
USER UNIT NO:
UNIT IDENTIFICATION DEALER / DISTRIBUTOR INFORMATION
Engine Make & Model:
Serial No:
Purchaser or Owner:
Address: Date Purchased:
The Noise Co
system of any compressor manufactured and sold under the above regulations, specifically
the following acts or the causing thereof:
(1) the rem
maintenance, repair, or replacement, of any device or element of design incorporated into
new compressor for the purpose of noise control prior to its sale or delivery to the ultimate
purchase
of design has been removed or rendered inoperative by any person.
ntrol Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control
oval or rendering inoperative by any persons, other than for purposes of
r or while it is in use; or (2) the use of the compressor after such device or element
Purchased From:
31
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