Doosan P185WDOU-T4F (F89) User manual

COMPRESSORSMODEL:
DoosanInfracorePortablePower
1293GlenwayDrive
Statesville,N.C.28625
DoosanPortablePower.com
P/N:46680186(2015)RevC
P185WDOU-T4F(F89)
P185WDOU-T4F(H28)
XP185WDOUA-T4F(F91)
XP185WDOUA-T4F(H29)

iii

TABLEOFCONTENTS
TITLEPAGE
........................................................................................................................................................iii
FOREWORD........................................................................................................................11
Information.....................................................................................................................................12
SAFETY...............................................................................................................................15
SafetyPrecautions.........................................................................................................................16
CompressedAir..........................................................................................................................17
SafetyInformation..........................................................................................................................18
CompressorDescriptionandIntendedUse..............................................................................18
OperatingSafety.......................................................................................................................20
ServiceSafety...........................................................................................................................22
VisualWalkAroundandInspection..........................................................................................23
OperatorSafetywhileusingInternalCombustionEngines......................................................24
OperatingSafety.......................................................................................................................24
Battery.................................................................................................................................25
ExhaustSystem...................................................................................................................25
CoolantSystem....................................................................................................................26
Materials..............................................................................................................................27
ServiceAirConnection(s)......................................................................................................28
AirHoseRestraintInstallation................................................................................................29
FuelSafety..........................................................................................................................29
SafetyDecals..................................................................................................................................30
SafetyDecalsSummary..............................................................................................................31
SafetyDecals(continued)...........................................................................................................32
SafetyDecals(continued)...........................................................................................................33
SafetyDecals(continued)...........................................................................................................34
SafetySymbols..........................................................................................................................35
SafetySymbols(continued).........................................................................................................36
LIFTING,TRANSPORTINGANDPREPARATION.............................................................37
Lifting,TransportingandPreparation.............................................................................................38
Introduction................................................................................................................................38
LiftingtheCompressor................................................................................................................38
LiftingtheCompressor................................................................................................................39
CompressorMounting.................................................................................................................39
UtilityPackageSet-Up(NoRunningGear)...................................................................................40
PreparingforFirstUse................................................................................................................41
SettingUptheCompressor.........................................................................................................41
Fueling(Refueling)theFuelTank................................................................................................42
Lubrication.................................................................................................................................44
EngineOil..................................................................................................................................44
CompressorOil..........................................................................................................................45
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TABLEOFCONTENTS
TITLEPAGE
PreparationforStorage...............................................................................................................45
NOISEEMISSION................................................................................................................47
NoiseEmission...............................................................................................................................48
CompressorNoiseEmissionControlInformation..........................................................................48
NoiseIntroduction..........................................................................................................................49
MaintenanceSchedule................................................................................................................49
NoiseEmissionWarranty............................................................................................................51
MaintenanceLog........................................................................................................................51
MaintenanceRecord.......................................................................................................................52
GENERALDATA.................................................................................................................53
GeneralDataforP185WDOU-T4F...................................................................................................54
GeneralDataforXP185WDOUA-T4F...............................................................................................55
HPAvailableforAuxiliaryPowerUse.............................................................................................56
XP185WDOUA-T4FModel..........................................................................................................56
OPERATINGINSTRUCTIONS............................................................................................57
ControlPanel..................................................................................................................................58
InstrumentControlPanel.............................................................................................................58
InstrumentControlPanelIndicators.............................................................................................59
AutoPowerOff...........................................................................................................................60
QuickViewScreens........................................................................................................................61
FaultandAlert...........................................................................................................................62
ServiceIntervalSetup.................................................................................................................64
DisplaySetup.............................................................................................................................66
LanguagesandUnits..................................................................................................................67
BeforeStartup................................................................................................................................68
BeforeStartingtheCompressor...................................................................................................68
StartingProcedure......................................................................................................................71
NormalOperation.......................................................................................................................73
Operation-Loaded.................................................................................................................73
Operation-Unloaded.............................................................................................................73
Shutdown...................................................................................................................................74
PressureRegulatorAdjustmentInstructions.................................................................................76
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TABLEOFCONTENTS
TITLEPAGE
ENGINEOPERATION..........................................................................................................77
EngineOperationandMaintenance................................................................................................78
EngineManagement...................................................................................................................78
Safety........................................................................................................................................80
Instructions................................................................................................................................81
Instructions(continued).........................................................................................................82
GeneralRepair...........................................................................................................................84
EnvironmentalPollution..............................................................................................................85
PreventionofPollution................................................................................................................86
StartupandShutdown....................................................................................................................87
InspectionafterStartingtheEngine.............................................................................................89
Break-inPeriodofEngine............................................................................................................90
OperationinWinter.....................................................................................................................93
RegularInspection.........................................................................................................................94
ReplacementofEngineOil..........................................................................................................95
ProcedureforChangingOilandOilFilter.....................................................................................96
Step1ComponentLocations.................................................................................................96
Step2CheckingOilLevel.....................................................................................................98
Step3:CheckOilLevelA-BLimits.......................................................................................100
Step4DrainEngineOil.......................................................................................................102
Step5:ReplacingOilFilter...................................................................................................104
Step6:FinalInspectionforLeaks.........................................................................................106
Coolant..........................................................................................................................................108
CheckingtheCoolant.................................................................................................................109
ReplenishmentofCoolant..........................................................................................................112
ReplacementofCoolant.............................................................................................................113
LUBRICATION...................................................................................................................115
GeneralLubricationInformation....................................................................................................116
CompressorOilChange.............................................................................................................116
CompressorOilChart................................................................................................................118
MAINTENANCE.................................................................................................................121
GeneralMaintenanceInformation..................................................................................................122
MaintenancePrecautions...........................................................................................................123
ScheduledMaintenance.............................................................................................................125
CompressorOilLevel................................................................................................................125
ScavengeLine..........................................................................................................................126
CompressorOilFilter.................................................................................................................127
CompressorOilSeparatorElement.............................................................................................128
CompressorOilCooler,EngineRadiator,andotherHeatExchangers...........................................130
AirFilterElements.....................................................................................................................131
Gauges.....................................................................................................................................133
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TABLEOFCONTENTS
TITLEPAGE
CoolingFanDrive......................................................................................................................133
FuelSystem..............................................................................................................................133
DieselExhaustFluid..................................................................................................................133
FuelFilterWaterSeparator........................................................................................................133
ChargeAirCoolerPipework.......................................................................................................133
Radiator....................................................................................................................................134
Hoses.......................................................................................................................................134
Ventilation.................................................................................................................................134
ElectricalSystem.......................................................................................................................135
Battery......................................................................................................................................135
PressureSystem.......................................................................................................................135
TirePressure.............................................................................................................................135
Fasteners..................................................................................................................................136
RunningGear/Wheels................................................................................................................136
Lubrication................................................................................................................................136
EngineOil.................................................................................................................................136
CompressorOil.........................................................................................................................137
BearingLubrication....................................................................................................................138
ExteriorFinishCare...................................................................................................................139
FieldReplacementofExteriorDecals.........................................................................................140
TROUBLESHOOTING.......................................................................................................141
Introduction...................................................................................................................................142
TroubleshootingChart................................................................................................................143
DiagnosticCodes......................................................................................................................149
COMPRESSORDIAGNOSTICCODES............................................................................151
CompressorDiagnosticCodes......................................................................................................152
ENGINEFAULTCODES....................................................................................................157
EngineFaultCodeList..................................................................................................................158
EngineFaultCodeList...............................................................................................................159
EngineFaultCodeList...............................................................................................................160
EngineFaultCodeList...............................................................................................................161
EngineFaultCodeList...............................................................................................................162
EngineFaultCodeList...............................................................................................................163
EngineFaultCodeList...............................................................................................................164
EngineFaultCodeList...............................................................................................................165
EngineFaultCodeList...............................................................................................................166
EngineFaultCodeList...............................................................................................................167
EngineFaultCodeList...............................................................................................................168
PREVENTIVEMAINTENANCESCHEDULE(PMS).........................................................169
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TABLEOFCONTENTS
TITLEPAGE
PreventiveMaintenanceSchedule(PMS)......................................................................................170
TORQUEVALUES.............................................................................................................171
TorqueValues................................................................................................................................172
TorqueValues(Continued).........................................................................................................173
WIRINGDIAGRAMS..........................................................................................................175
CompressorandEngineHarness..................................................................................................176
......................................................................................................................................................177
......................................................................................................................................................178
......................................................................................................................................................179
......................................................................................................................................................180
CompressorandEngineControlSystem......................................................................................181
......................................................................................................................................................182
......................................................................................................................................................183
P185WDOUGeneratorOption........................................................................................................184
......................................................................................................................................................185
ElectricalPartsList........................................................................................................................186
......................................................................................................................................................187
WARRANTY.......................................................................................................................189
Warranty........................................................................................................................................190
DoosanPortablePowerGeneralWarrantyInformation.................................................................190
TruckMountedEquipment.........................................................................................................191
DoosanInfracoreFederal&CaliforniaEmissionControlSystemsLimitedWarrantyforNon-Road
Engines(CI)..............................................................................................................................192
RevisionHistory............................................................................................................................193
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10

Foreword
11

Foreword
Information
SAVETHESEINSTRUCTIONS—Thismanualcontainsimportantinstructionsforthe
compressormodelsstatedinthismanual.Theseinstructionshavebeenwrittenexpresslyby
DoosanInfracorePortablePowerandmustbefollowedduringinstallation,operation,and
maintenanceofthesemachines.
ThecontentsofthismanualareconsideredtobeproprietaryandcondentialtoDoosan
InfracorePortablePower(hereinreferredtoas“PortablePower”),andshouldnotbe
reproducedwithoutthepriorwrittenpermissionofPortablePower.
Nothingcontainedinthisdocumentisintendedtoextendanypromise,warrantyor
representation,expressedorimplied,regardingthePortablePowerproductsdescribed
herein.Anysuchwarrantiesorothertermsandconditionsofsaleofproductsshallbein
accordancewiththestandardtermsandconditionsofsaleforsuchproducts,whichare
availableuponrequest.
Thismanualcontainsinstructionsandtechnicaldatatocoverallroutineoperationand
scheduledmaintenancetasksbyoperationandmaintenancestaff.Majoroverhaulsare
outsidethescopeofthismanualandshouldbereferredtoanauthorizedPortablePower
servicedepartment.
Allcomponents,accessories,pipes,andconnectorsaddedtothecompressedairsystem
shouldbe:
•Ofgoodquality,procuredfromareputablemanufacturerand,whereverpossible,
beofatypeapprovedbyPortablePower.
•Clearlyratedforapressureatleastequaltothecompressorsafetyvalvesetting.
•Compatiblewiththecompressoroil.
•Accompaniedwithinstructionsforsafeinstallation,operation,andmaintenance.
DetailsofapprovedequipmentareavailablefromthePortablePowerservicedepartment.
Theuseofrepairpartsotherthanthoseincludedwithintheapprovedpartslistmaycreate
hazardousconditionsoverwhichPortablePowerhasnocontrol.Therefore,PortablePower
cannotbeheldresponsibleforequipmentinwhichnon-approvedrepairpartsareinstalled.
UsetheQRCodeonthecompressortoorderthePartsBookfororderingreplacementparts.
Whenorderingpartsorrequestingserviceinformation,bepreparedtoprovidethe
compressormodelnumber,itemnumber,revisionnumber,andserialnumber.
PortablePowerreservestherighttomakechangesandimprovementstoproductswithout
noticeandwithoutincurringanyobligationtomakesuchchangesoraddsuchimprovements
toproductssoldpreviously.
Theintendeduseofthiscompressorareoutlinedbelowandexamplesofunapproved
usagearealsogiven.However,PortablePowercannotanticipateeveryapplicationorwork
situationthatmayarise.Ifindoubt,consultsupervision.
Thiscompressorhasbeendesignedandsuppliedforabovegroundoperationtobeusedfor
compressionofnormalambientaircontainingnoadditionalgases,vapors,orparticleswithin
theambienttemperaturerangespeciedinthegeneraldatasectionofthismanual.
12

Foreword
ThiscompressorshouldNOTbeused:
•Fordirectorindirecthumanconsumptionofthecompressedair.
•Outsidetheambienttemperaturerangespeciedinthegeneraldatasectionof
thismanual.
•Whenanactualorforeseeableriskofhazardouslevelsofammablegasesor
vaporsexists.
•WithotherthanPortablePowerapprovedcomponents.
•Withguards,controls,orswitchesmissingordisabled.
•Forstorageortransportationofmaterialsinsideorontheenclosure.
PortablePoweracceptsnoresponsibilityforerrorsintranslationofthismanualfromthe
originalEnglishversion.
You,asthecustomer,areexpectedtoprovidecertainserviceandmaintenanceitems.Your
PortablePowerdealerwillprovideallothermoredetailedserviceandmaintenanceitemson
aspecialpreventivemaintenancescheduleforeachcompressor.Itisveryimportantthatthe
minimumserviceandmaintenancerequirementsexplainedinthismanualbeperformedat
therequiredintervals.Exceedingtheseintervalsmayreducethereliabilityofthecompressor.
Thismanualprovidesinformationandprocedurestosafelyoperateandmaintaintheabove
PortablePowermodel(s).Foryourownsafetyandtoreducetheriskofinjury,carefullyread,
understand,andobserveallinstructionsdescribedinthismanual.
PortablePowerexpresslyreservestherighttomaketechnicalmodications,evenwithout
notice,whichimprovetheperformanceorsafetystandardsofitsmachines.
Theinformationduringthepreparationofthismanual,everyeffortwasmadetoensurethe
accuracyandadequacyofthecontents.containedinthismanualisbasedonmachines
manufacturedupuntilthetimeofpublication.PortablePowerreservestherighttochange
anyportionofthisinformationwithoutnotice.
YourPortablePowerdealerwillassistwithsetupandinitialstartupofthecompressorand
willalsoprovidebriefoperatingandserviceinstructions.Beforestartingthecompressor,
thismanualandinstructionsshouldbecarefullyreadtoobtainathoroughknowledgeofthe
dutiestobeperformed.Pleasetakeprideinthecompressor,keepitcleanandingood
mechanicalcondition.
Toenablepropermaintenancerecords,PortablePowerprovidesanoiseemissioncontrol
maintenanceloginthenoiseemissionsectionofthismanual.Thenoiseemissionsection
containsarecommendedmaintenancescheduleandprovidesspaceinthelogforthe
techniciantonotewhatserviceandmaintenancewasdone,bywhom,where,andwhen.
13

14

Safety
15

Safety
SafetyPrecautions
Neveroperatethecompressorwithoutrstobservingallsafetywarningsandcarefullyreading
theOperationandMaintenanceManualshippedfromthefactorywiththiscompressor.
Ensuretheoperatorreadsandunderstandsthedecalsandconsultsthemanualsbefore
operationorperformingmaintenance.
Ensureallmaintenancepersonnelareadequatelytrained,competent,andhavereadthe
manuals.
Ensureallprotectivecoversareinplaceandthecanopy/doorsareclosedduringoperation.
Thespecicationofthiscompressorissuchthatthecompressorisnotsuitableforusein
ammablegasriskareas.Ifsuchanapplicationisrequired,alllocalregulations,codesof
practice,andsiterulesmustbeobserved.Toensurethecompressorcanoperateinasafe
andreliablemanner,additionalequipmentsuchasgasdetection,exhaustsparkarrestors,
andintake(shut-off)valvesmayberequired,dependentonlocalregulationsorthedegree
ofriskinvolved.
Aweeklyvisualcheckmustbemadeofallfasteners/xingscrewssecuringmechanicalparts.
Inparticular,safety-relatedpartssuchascouplinghitch,drawbarcomponents,wheels,tires,
andliftingbailshouldbecheckedfortotalsecurity.
Allcomponentswhichareloose,damaged,orunserviceablemustberectiedwithoutdelay.
Airdischargedfromthiscompressormaycontaincarbonmonoxideorothercontaminants
whichwillcauseseriousinjuryordeath.Donotbreathedischargedair.
Thiscompressorproducesloudnoisewiththedoorsopenorservicevalvevented.Extended
exposuretoloudnoisecancausehearingloss.Alwayswearhearingprotectionwhendoors
areopenorservicevalveisvented.
Neverinspectorservicethecompressorwithoutrstdisconnectingbatterycable(s)to
preventaccidentalstarting.
Donotusepetroleumproducts(solventsorfuels)underhighpressureasthiscanpenetrate
theskinandresultinseriousillness.Weareyeprotectionwhilecleaningthecompressor
withcompressedairtopreventdebrisfrominjuringeye(s).
Rotatingfanbladecancauseseriousinjury.Donotoperatewithoutfanguardinplace.
Usecaretoavoidcontactinghotsurfaces(engineexhaustmanifoldandpiping,airreceiver,
andairdischargepiping,etc.).
Etherisanextremelyvolatile,highlyammablegas.Whenitisspeciedasastartingaid,
usesparingly.DonotuseEtheriftheenginehasglowplugsorinletheaterstartingaids.
Enginedamagewillresult.
Neveroperatethecompressorwithguards,covers,orscreensremoved.Keephands,hair,
clothing,tools,blowguntips,etc.wellawayfrommovingparts.
16

Safety
CompressedAir
Compressedaircanbedangerousifincorrectlyhandled.Priortoperformingmaintenance
orserviceonthecompressor,ensureallpressureisventedfromthesystemandthe
compressorcannotbestartedaccidentally.
Ensurethecompressorisoperatingattheratedpressureandtheratedpressureisknown
toallrelevantpersonnel.
Allairpressureequipmentinstalledin,orconnectedto,thecompressormusthavesafe
workingpressureratingsofatleastthecompressorsafetyvalvesetting.
Ifmorethanonecompressorisconnectedtoonecommondownstreamplant,effectivecheck
valvesandisolationvalvesmustbettedandcontrolledbyworkprocedures,toensureone
compressorcannotaccidentallybepressurizedoroverpressurizedbyanother.
CompressedairmustNOTbeusedforadirectfeedtoanyformofbreathingapparatus
ormask.
Compressedaircancauseseriousinjuryordeath.Relievepressurebeforeremovingller
plugs/caps,ttings,orcovers.
Airpressurecanremaintrappedinairsupplylinewhichcanresultinseriousinjuryordeath.
Alwayscarefullyventairsupplylineattoolorventvalvebeforeperforminganyserviceor
maintenance.
Dischargedaircontainsaverysmallpercentageofcompressorlubricatingoilandcare
shouldbetakentoensuredownstreamequipmentiscompatible.
Ifdischargedairistobeultimatelyreleasedintoaconnedspace,adequateventilation
mustbeprovided.
Whenusingcompressedair,alwaysuseappropriatepersonalprotectiveequipment.
Allpressurecontainingparts,especiallyexiblehosesandtheircouplings,mustberegularly
inspected,befreefromdefects,andbereplacedaccordingtothemanualinstructions.
Avoidbodilycontactwithcompressedair.
Thesafetyvalvelocatedintheseparatortankmustbecheckedperiodicallyforcorrect
operation.
Wheneverthecompressorisstopped,airwillowbackintothecompressorfromdownstream
devicesorsystemsunlesstheservicevalveisclosed.Installacheckvalveatthecompressor
servicevalvetopreventreverseowintheeventofanunexpectedshutdownwhenthe
servicevalveisopen.
Disconnectedairhoseswhipandcancauseseriousinjuryordeath.Alwaysattachasafety
owrestrictiontoeachhoseatthesourceofsupplyorbranchlineinaccordancewithOSHA
Regulation29CFRSection1926.302(b).
Neverallowthecompressortositorstoppedwithpressureintheseparatortankorpiping.
17

Safety
SafetyInformation
CompressorDescriptionandIntendedUse
Thiscompressorisamobilecompressedairsource.TheDoosancompressorconsistsof
atrailer-mountedcabinetcontainingafueltank,dieselengine,compressorinletsystem,
compressorcoolingandlubricationsystem,compressordischargesystem,controlsystem,
instrumentandelectricalsystem.Astheengineruns,thecompressorconvertsmechanical
energyintoairpower.
Whenairisconsumedbythecompressor,theinletunloadervalveopens,andairisdrawn
intothecompressorthroughadrytypeairlter.Airentersthehousingofthecompressor
whereitispartiallycompressed.Airthenpassesalongtheutesfromthewideendtothe
narrowendwhereitiscompressedtothedesireddischargepressure.
Theoilisremovedbyair/oilseparatorlter.Thisoilisreturnedtothesystemtoaidin
compressorlubrication.
Airpassesthroughanaircooledaftercooler,whereitiscooled.Theowandservice
pressureforcompressedairiscontrolledbytheoperatorfromtheinstrument/controlpanel.
Refertotheproductspecicationsgeneraldatasectioninthismanualfortheoutputair
deliveryandoperatingpressureofthiscompressor,andforthemaximumoutputairpower
limitofthiscompressor.
Thiscompressorhasbeendesignedandbuiltstrictlyfortheintendedusedescribedabove.
Usingthecompressorforanyotherpurposecouldpermanentlydamagethecompressoror
seriouslyinjuretheoperatororotherpersonsinthearea.Compressordamagecaused
bymisuseisnotcoveredunderwarranty.
Thefollowingaresomeexamplesofmisuse:
•Operatingthecompressorinamannerthatisinconsistentwithallfederal,state
andlocalcodesandregulations.
•Usingthecompressorasaladder,support,orworksurface.
•Usingthecompressortocarryortransportpassengersorequipment.
•Usingthecompressortotowothercompressors.
•Operatingthecompressoroutsideoffactoryspecications.
•Operatingcompressorinamannerinconsistentwithallwarningsfoundonthe
compressorandintheOperator’sManual.
18

Safety
Thiscompressorhasbeendesignedandbuiltinaccordancewiththelatestglobalsafety
standards.Ithasbeencarefullyengineeredtoeliminatehazardsasfaraspracticableandto
increaseoperatorsafetythroughprotectiveguardsandlabeling.However,somerisksmay
remainevenafterprotectivemeasureshavebeentaken.Theyarecalledresidualrisks.On
thiscompressor,theymayincludeexposureto:
•Heat,noise,exhaust,andcarbonmonoxidefromtheengine.
•Firehazardsfromimproperrefuelingtechniques.
•Fuelanditsfumes.
•Electricshockand/orarcash.
•Personalinjuryfromimproperlyrelievingpressurebeforeremovingllerplugs/caps,
ttingsorcovers.
Electrocutionorsevereelectricalshockhazardsarepresentthroughout
thecompressoranytimetheengineisrunning!
Toprotectyourselfandothers,makesureyouthoroughlyreadandunderstandthesafety
informationpresentedinthismanualbeforeoperatingthecompressor.
Thiscompressorisbuiltwithusersafetyinmind;however,likeanydeviceitcanpresent
serioushazardsifimproperlyoperatedandserviced.Followinstructionscarefully!Should
questionsariseduringoperationorserviceofthisequipment,contactDoosanInfracore
PortablePower.
19

Safety
OperatingSafety
Familiarityandpropertrainingarerequiredforthesafeoperationof
thecompressor.Compressoroperatedimproperlyorbyuntrained
personnelcanbedangerous.Readtheoperatinginstructionscontained
inboththismanualandtheenginemanualandfamiliarizeyourselfwith
thelocationandproperuseofallcontrols.Inexperiencedoperators
shouldreceiveinstructionfromsomeonefamiliarwiththecompressor
beforebeingallowedtooperateit.
Operatorqualications
Onlytrainedpersonnelarepermittedtostart,operate,andshutdownthecompressor.They
alsomustmeetthefollowingqualications:
•Havereceivedinstructiononhowtoproperlyusethecompressor.
•Arefamiliarwithrequiredsafetydevices.
Thecompressormustnotbeaccessedoroperatedby:
•Children
•Peopleimpairedbyalcoholordrugs
PersonalProtectiveEquipment(PPE)
WearthefollowingPersonalProtectiveEquipment(PPE)whileoperatingthiscompressor:
•Close-ttingworkclothesthatdonothindermovement.
•Safetyglasseswithsideshields.
•Hearingprotection.
•Safety-toedfootwear.
20