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Doosan P185WDOU-T4F, Operation And Maintenance Manual

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TABLE OF CONTENTS

Operation & Maintenance Manual

TITLE

PAGE

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

ENGINE OPERATION..........................................................................................................53

Engine Operation and Maintenance................................................................................................ 54

SAFETY..................................................................................................................................... 54
Instructions ................................................................................................................................ 55
General Repair ........................................................................................................................... 57
Environmental Pollution .............................................................................................................. 58
Engine Management................................................................................................................... 59
Prevention of Pollution ................................................................................................................ 60
Start and Shutdown .................................................................................................................... 61
Break-in Period of Engine............................................................................................................ 62
Inspection after Starting the Engine ............................................................................................. 63
Operation in Winter..................................................................................................................... 64
Regular Inspection...................................................................................................................... 65

Checking the Engine Oil........................................................................................................ 66
Replacement of Engine Oil .................................................................................................... 68
Coolant ................................................................................................................................ 70

Checking the Coolant...................................................................................................... 71
Replenishment of Coolant ............................................................................................... 74
Replacement of Coolant.................................................................................................. 75
Fuel System ................................................................................................................... 76

LUBRICATION .....................................................................................................................79

Compressor Oil Chart..................................................................................................................... 80

MAINTENANCE...................................................................................................................83

General Information........................................................................................................................ 84

Compressor Oil Filters.................................................................................................................... 87

Receiver Separator System ............................................................................................................ 88

Summary of Contents for P185WDOU-T4F

Page 1: ...1293 Glenway Drive Statesville N C 28625 DoosanPortablePower com P N 46680186 10 2015 Rev A P185WDOU T4F F89 PDF versions of the Parts Manual and the Electronic Service Manual are available for downl...

Page 2: ......

Page 3: ...6 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 Info...

Page 4: ...al Repair 57 Environmental Pollution 58 Engine Management 59 Prevention of Pollution 60 Start and Shutdown 61 Break in Period of Engine 62 Inspection after Starting the Engine 63 Operation in Winter 6...

Page 5: ...ONTENTS Operation Maintenance Manual TITLE PAGE Scavenge Line 89 Exterior Finish Care 89 Field Replacement of Exterior Decals 91 TROUBLESHOOTING 95 Introduction 97 Troubleshooting Chart 98 Diagnostic...

Page 6: ...TABLE OF CONTENTS Operation Maintenance Manual TITLE PAGE...

Page 7: ...FOREWORD 9...

Page 8: ...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 in...

Page 9: ...rements 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...

Page 10: ...12...

Page 11: ...SAFETY 13...

Page 12: ...aged or unserviceable must be rectified without delay Air discharged from this compressor may contain carbon monoxide or other contaminants which will cause serious injury or death Do not breathe disc...

Page 13: ...ovided When using compressed air always use appropriate personal protective equipment All pressure containing parts especially flexible hoses and their couplings must be regularly inspected be free fr...

Page 14: ...terial substances Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times The following substances are used in the manufacture of this compressor and may be...

Page 15: ...orities for proper disposal of these materials Battery A battery contains sulfuric acid and can produce gases which are corrosive and potentially explosive Avoid contact with skin eyes and clothing In...

Page 16: ...the pressure cap until all excess f uid is released and the engine cooling system fully depressurized Follow the instructions provided by the antifreeze supplier when adding or draining the antifreeze...

Page 17: ...tructions inform your supervisor Red Background Indicates the presence of a hazard which WILL cause serious injury death or property damage if ignored Orange Background Indicates the presence of a haz...

Page 18: ...e 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 list...

Page 19: ...SAFETY Operation Maintenance Manual Decals 21...

Page 20: ...Operation Maintenance Manual SAFETY 22...

Page 21: ...SAFETY Operation Maintenance Manual 23...

Page 22: ...24...

Page 23: ...NOISE EMISSION 25...

Page 24: ...tive by any persons other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its s...

Page 25: ...he Maintenance Performance Schedule for all required noise emission controls and 2 space so that the purchaser or owner can record what maintenance was done by whom where and when The Maintenance Sche...

Page 26: ...ch 100 hours of operation They should be retightened repaired or if missing replaced immediately to prevent subsequent damage and noise emission increase 100 HOURS ENCLOSURE PANELS Enclosure panels sh...

Page 27: ...h bent or broken bolts due to operation or storage in severe environments should be replaced with equivalent parts See Operator Manual ENGINE OPERATION Inspect and maintain engine condition and operat...

Page 28: ...he 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 asse...

Page 29: ...ompressor manufactured and sold under the above regulations specifically the following acts or the causing thereof 1 the removal or rendering inoperative by any persons other than for purposes of main...

Page 30: ...32...

Page 31: ...GENERAL DATA 33...

Page 32: ...an Doosan Model D24 49 HP D24 73 HP Electrical System 12VDC 12VDC FLUID CAPACITIES Compressor Lubricant quarts litres 12 11 4 Engine Crankcase Lubricant quarts litres 9 6 9 2 Engine Lubricant gallon q...

Page 33: ...tion 1 An Auxiliary Drive such as a hydraulic pump can be mounted to the auxiliary drive location on the right hand side of the front of the engine 2 The maximum auxiliary drive power from the engine...

Page 34: ...36...

Page 35: ...OPERATING INSTRUCTIONS 37...

Page 36: ...2 Tachometer Display Displays compressor operating parameters and diagnostic codes 3 Hourmeter Displays cumulative hours of machine operation 4 Keypad Used for Start and Shut Down Service Air accessi...

Page 37: ...r list menu choices or maximum parameter value is reached DOWN The DOWN button functions identical to the UP button with the exception that its direction for all displays menu choices and values is do...

Page 38: ...inutes the control system will automatically power OFF Power can be restored by simply pressing the Power Button In the event of a Fault this feature is not active and the power will remain ON until t...

Page 39: ...the first screen and vice versa See Figure 1 Note 1 Only the parameters that are available from the engine or compressor will be displayed Note 2 Unit times out after 3 minutes of inactivity and retur...

Page 40: ...rror 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 The unit does not time out in the Fault Display After...

Page 41: ...utton to acknowledge a warning has occurred If there are multiple alerts pressing the DOWN button will scroll through the various alerts All faults and warnings will be displayed until the engine shut...

Page 42: ...n If service is between 5 and 0 hours or it remains at 0 hours the SERVICE DUE display will appear every hour To disable the user can reset the hours to the OFF position by decreasing the value to OFF...

Page 43: ...OPERATING INSTRUCTIONS Operation Maintenance Manual 45...

Page 44: ...WN button then press the ENTER button Scroll to the Display option using the DOWN button then press the ENTER button Use the DOWN or UP buttons to highlight and the ENTER button to select the desired...

Page 45: ...h 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 displa...

Page 46: ...degrees C over the ambient temperature The inlet and outlet grilles must not be restricted See Figure Y for recommended clearance around the compressor The cross sectional area of any ductwork must be...

Page 47: ...pped with option 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 l...

Page 48: ...l below 50 psi Normal Operation The operator may observe and monitor operating parameters using the Mini Port and gauges In the event the compressor controller detects a parameter outside normal opera...

Page 49: ...s not needed Note Until Main Power Button is pressed the gauges can be read and the Mini Port can be navigated using the UP DOWN and ENTER Buttons 5 If the Main Power Button is not pressed within 3 mi...

Page 50: ...2 Close service valve s After Starting 1 Push the Service Air button on the Control Panel The unit should speed up and then unload and drop back to IDLE With the unit unloaded turn the adjusting scre...

Page 51: ...ENGINE OPERATION 53...

Page 52: ...ot be held liable for any critical damage or faults which may be caused by the use of unauthorized or non factory remanufactured parts The maintenance methods stated in this Operation and Maintenance...

Page 53: ...s skin contact with corrosive acids or fuel burns with hot oil exposure of eyes to fuel or antifreeze occurs while starting inspecting or repairing an engine see a doctor immediately Cautions for Star...

Page 54: ...ay occur Do not exchange or disassemble a pipe or hose from the engine fuel circuit engine oil circuit coolant circuit or compressed air circuit while the engine is operating The leaked liquid may cau...

Page 55: ...he power supply to the engine and remove the wire harness connector connected to the engine control unit ECU 13 Do NOT give any electric or mechanical shocks or perform welding work on the electrical...

Page 56: ...while performing engine repairs 1 Good ventilation and low humidity should be maintained in the work space 2 The workspace should be clean and in good order No flammables are allowed in the workshop 3...

Page 57: ...NOT adjust convert or change the ECU without our authorization If a problem is found in an engine research and solve the cause to prevent the critical faults in advance Use of genuine Doosan parts is...

Page 58: ...ion Consider the following to manage engine without causing environmental pollution 1 Discharge oil and coolant using collection containers 2 Discard oil and coolant according to the regulations of th...

Page 59: ...rting the engine for the first time after purchase 1 Before starting an engine check the levels of fuel coolant and oil Replenish those fluids if required 2 Ensure engine oil level is between the uppe...

Page 60: ...re the provision of high quality engines before being shipped However engines are not operated for a long period of time in this test Therefore new engines require a break in period during the initial...

Page 61: ...lant is circulating properly If the coolant level in the supplementary tank is too low the coolant gauge may be inaccurate 4 Replace engine oil and oil filter after the break in period If engine oil a...

Page 62: ...lay and blocking of fuel and ignition Operation in Winter Preventing Coolant from Freezing When only water used as coolant without mixing with antifreeze corrosion in the engine degradation of cooling...

Page 63: ...the engine and wait for 5 10 minutes to allow the engine oil to flow back into the oil pan The engine oil level should indicate between the upper limit and the lower limit of the oil level gauge Engi...

Page 64: ...0 6 liter in the engine Checking the Engine Oil 1 Move the unit to a flat surface to maintain the engine level 2 Start the engine and then shut down when it reaches the normal temperature 3 Wait for...

Page 65: ...ults 1 Insert the oil level gauge again by using the ring 2 If the dipstick doesn t slide in rotate it 180 and try again 3 Pull the oil level dipstick upward to remove 1 Check if the oil is smeared be...

Page 66: ...d with engine oil immediately wash with water soap or hand cleaners Do not clean skin with gasoline fuel thinner or solvent Apply a skin protective cream after cleaning Do not put oil stained gloves o...

Page 67: ...other parts by using a cloth when detaching the f lter After replacing the oil f lter wipe clean any other parts which the oil has touched 2 Cleanly wipe the surface on which the oil filter is mounted...

Page 68: ...ge may cause engine faults If you have injected engine oil far over the upper limit of the oil level gauge drain it until the engine oil level indicates somewhere between the upper and lower limit of...

Page 69: ...ly necessary to open the radiator cap while the engine is overheated wrap the radiator cap with a cloth and slowly open the cap in two steps until the steam pressure has been released from the inside...

Page 70: ...55 C drain the coolant When taking out a sample of coolant from the supplementary tank it is diff cult to measure the precise concentration Always take out sample by opening the drain plug of coolant...

Page 71: ...where the color of MOLYBDATE Middle pad on the standard color table which is identical with the Middle B of the test sheet is crossed with the color of NITRITE on the standard color table which is ide...

Page 72: ...ne and radiator are cold 2 Replenish coolant up to the inlet of the radiator 3 After starting the engine let the coolant circulate sufficiently and check the coolant level If there is insufficient coo...

Page 73: ...t drain plug of the radiator and drain coolant 5 After completing coolant drain connect the coolant drain plug 6 Drain the coolant from the coolant supplementary tank and cleanse the tank 7 Fill the r...

Page 74: ...entary tank and then install radiator cap 16 Operate the engine at idle until the cooling fan rotates 2 3 times 17 Shut down the engine and wait until the engine and radiator are cooled 18 After check...

Page 75: ...use corrosion and plugging of fuel system components Use of biodiesel blend fuel may result in premature failure of fuel system components i e plugged fuel filters and deteriorated fuel lines Shorter...

Page 76: ...78...

Page 77: ...LUBRICATION 79...

Page 78: ...may be necessary All filters and filter elements for air and compressor oil must be obtained through Portable Power to assure the proper size and filtration for the compressor Compressor Oil Chart Re...

Page 79: ...airend warranty Refer to the warranty policy for details or contact your representative Preferred Oil 1 gal 3 8 Liter 5 gal 19 0 Liter 55 gal 208 Liter 220 gal 836 Liter Pro Tec 36899698 36899706 368...

Page 80: ...82...

Page 81: ...MAINTENANCE 83...

Page 82: ...ist of pre operation and post operation procedures to be performed by the operating or maintenance personnel The primary function of preventive maintenance is to prevent failure and consequently the n...

Page 83: ...ng Refer to Operating Controls for the normal readings Fuel Tank CLEAN fuel in the fuel tanks is vitally important and every precaution should be taken to ensure that only clean fuel is poured or pump...

Page 84: ...te relative movement between components It is important they be periodically inspected for wear and deterioration It is also important the operator does not use the hoses as convenient hand hold or st...

Page 85: ...ead Installing a new oil f lter element when the old gasket remains on the f lter head will cause an oil leak and can cause property damage 4 Lubricate the new filter gasket with the same oil being us...

Page 86: ...to warranty section about extended warranty Receiver Separator System High pressure air can cause severe injury or death from hot oil and f ying parts Always relieve pressure before removing caps plu...

Page 87: ...essure for 30 to 40 minutes to permit element to clear itself Exterior Finish Care This unit was painted and heat cured at the factory with a high quality thermoset polyester powder coating The follow...

Page 88: ...to do this is to spray the Tuffcoat Primer using a pressure pot and use about 2 5 pounds of air pressure This will allow the primer to splatter causing the textured look NOTE You must be careful not t...

Page 89: ...e for dust to resettle on surface 3 Align decals prior to removing the backing 4 Peel one section of backing from decal while still aligned and squeegee decal from center of the edges to remove air 5...

Page 90: ......

Page 91: ......

Page 92: ...94...

Page 93: ...TROUBLESHOOTING 95...

Page 94: ...ation 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...

Page 95: ...intenance work has been done 4 If the compressor will still operate is it safe to continue operating it to make further checks Do the Simplest Things First Most troubles are simple and easily correcte...

Page 96: ...to find loose connection Make repairs See Electronic Service Manual Low fuel level fault If adequate fuel in the tank check fuel level sender device Replace if determined faulty See Electronic Servic...

Page 97: ...Add clean fuel Compressor oil temp too high See Complaint 6 Engine coolant temp too high Check coolant level If low add coolant See Complaint 3 Engine oil pressure too low See Complaint 4 Loose wire c...

Page 98: ...r loose or missing belly pans Fan not working Check wires at switches and connectors to find loose connection Make repairs See Electronic Service Manual 3 High Engine Coolant Temperature Loose wire co...

Page 99: ...Low compressor oil Add compressor oil Look for and repair any leaks Wrong compressor oil Change compressor oil Review compressor oil specification Dirty cooler s Clean exterior of cooler s Dirty oper...

Page 100: ...ints 11 12 Rubber mounting isolators loose or damaged Tighten or replace Defective or imbalanced fan Replace fan Defective airend drive coupling Replace coupling Engine malfunctioning See troubleshoot...

Page 101: ...ped 11 Compressor will not unload Plugged vent leak Clean and or replace Operating pressure too high Reduce pressure to rated operating pressure Malfunctioning inlet unloader Inspect valve Make adjust...

Page 102: ...104...

Page 103: ...CODE 10 ENG SPEED RESPONSE Engine Speed Response Engine target idle speed not met within 10 seconds after loading compressor ALERT CPR CODE 11 A A SATTEMPT EXCEEDED AutoStart Attempts Exceeded Compres...

Page 104: ...out of range FAULT CPR CODE 34 HIGH PRES AT START High Separator Tank Pressure At Start Separator tank pressure greater than 20 psi at crank attempt ALERT CPR CODE 35 HIGH SEPT TANK PRES High Separato...

Page 105: ...CODE 53 SEP TANK TEMP SENSOR Separator Tank Temperature Sensor Separator Tank Temperature Sensor reading out of range FAULT CPR CODE 54 REG SYSTEM PRES SENSOR Regulation System Pressure Sensor Regula...

Page 106: ...rt Controller Communication Communication between Titan controller and AutoStart controller not functional ALERT CPR CODE 75 IQ TCU CTRL COMMS IQ TCU Controller Communication Communication between Tit...

Page 107: ...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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