Doosan P185WDO-T4F User manual

Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
DoosanPortablePower.com
P/N: 46670941 (2014) Rev B
OPERATION and MAINTENANCE
MANUAL
COMPRESSOR MODEL
P185WDO-T4F (F63)

TABLEOFCONTENTS
Operation&MaintenanceManual
TITLEPAGE
FOREWORD..........................................................................................................................9
Information.....................................................................................................................................10
DRAWBARINFORMATION.................................................................................................13
InstructionKit.................................................................................................................................14
SAFETY...............................................................................................................................15
SafetyPrecautions.........................................................................................................................16
CompressedAir..........................................................................................................................16
ExhaustSystem.........................................................................................................................17
Materials....................................................................................................................................18
Battery.......................................................................................................................................19
Radiator.....................................................................................................................................19
Transport...................................................................................................................................21
Decals.......................................................................................................................................22
NOISEEMISSION................................................................................................................25
NoiseEmission...............................................................................................................................26
CompressorNoiseEmissionControlInformation..........................................................................26
Introduction....................................................................................................................................27
MaintenanceSchedule....................................................................................................................27
NoiseEmissionWarranty...............................................................................................................29
MaintenanceLog............................................................................................................................30
GENERALDATA.................................................................................................................33
GeneralDataInformation................................................................................................................34
ExpendableServiceParts...........................................................................................................34
OPERATINGINSTRUCTIONS............................................................................................37
ControlPanel..................................................................................................................................38
Control/GaugePanel.......................................................................................................................39
AutoPowerOff...............................................................................................................................40

TABLEOFCONTENTS
Operation&MaintenanceManual
TITLEPAGE
QuickViewScreens........................................................................................................................41
FaultandAlert................................................................................................................................41
ServiceIntervalSetUp...................................................................................................................44
LanguagesandUnitsSetUp..........................................................................................................46
DisplaySetup.................................................................................................................................47
CompressorIDSetUp....................................................................................................................48
BeforeTowing.................................................................................................................................50
SettingUp.......................................................................................................................................51
Towing............................................................................................................................................52
BeforeStarting...............................................................................................................................52
Starting...........................................................................................................................................53
Shutdown.......................................................................................................................................54
PressureRegulatorAdjustmentInstructions.................................................................................55
ENGINEOPERATION..........................................................................................................57
EngineOperationandMaintenance................................................................................................58
SAFETY.....................................................................................................................................58
Instructions................................................................................................................................59
GeneralRepair...........................................................................................................................61
EnvironmentalPollution..............................................................................................................62
EngineManagement...................................................................................................................63
PreventionofPollution................................................................................................................64
StartandShutdown....................................................................................................................65
Break-inPeriodofEngine............................................................................................................66
InspectionafterStartingtheEngine.............................................................................................67
OperationinWinter.....................................................................................................................68
RegularInspection......................................................................................................................69
CheckingtheEngineOil........................................................................................................70
ReplacementofEngineOil....................................................................................................72
Coolant................................................................................................................................75
CheckingtheCoolant......................................................................................................76
ReplenishmentofCoolant...............................................................................................78
ReplacementofCoolant..................................................................................................79

TABLEOFCONTENTS
Operation&MaintenanceManual
TITLEPAGE
Compressor Oil Chart..................................................................................................................... 84
MAINTENANCE...................................................................................................................87
General Information........................................................................................................................ 88
Compressor Oil Filters.................................................................................................................... 91
ReceiverSeparatorSystem............................................................................................................92
ScavengeLine................................................................................................................................93
Exterior Finish Care........................................................................................................................ 93
FieldReplacementofCanopyDecals.............................................................................................95
LUBRICATION .....................................................................................................................83
TROUBLESHOOTING.........................................................................................................99
Introduction ...................................................................................................................................101
TroubleshootingChart...................................................................................................................102
DiagnosticCodes..........................................................................................................................108
EngineDiagnosticCodes..............................................................................................................111
RevisionHistory............................................................................................................................111



FOREWORD
9

Operation&MaintenanceManualFOREWORD
Information
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.
DetailsofapprovedequipmentareavailablefromthePortablePowerServicedepartments.
Theuseofrepairpartsotherthanthoseincludedwithintheapprovedpartslistmaycreate
hazardousconditionsoverwhichPortablePowerhasnocontrol.Therefore,PortablePower
cannotbeheldresponsibleforequipmentinwhichnon-approvedrepairpartsareinstalled.
PortablePowerreservestherighttomakechangesandimprovementstoproductswithout
noticeandwithoutincurringanyobligationtomakesuchchangesoraddsuchimprovements
toproductssoldpreviously.
Theintendedusesofthiscompressorareoutlinedbelowandexamplesofunapproved
usagearealsogiven.However,PortablePowercannotanticipateeveryapplicationorwork
situationthatmayarise.Ifindoubt,consultsupervision.
Thiscompressorhasbeendesignedandsuppliedforabovegroundoperationtobeusedfor
compressionofnormalambientaircontainingnoadditionalgases,vapors,orparticleswithin
theambienttemperaturerangespeciedintheGeneralDataSectionofthismanual.
10

FOREWORDOperation&MaintenanceManual
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.
Thepurposeofthismanualistotraintheoperatorwithfunctions,operation,andbasic
serviceandmaintenancerequirementsofthecompressor.Duringthepreparationofthis
manual,everyeffortwasmadetoensuretheaccuracyandadequacyofthecontents.
YourPortablePowerdealerwillassistwithsetupandinitialstartupofthecompressorand
willalsoprovidebriefoperatingandserviceinstructions.Beforestartingthecompressor,
thismanualandinstructionsshouldbecarefullyreadtoobtainathoroughknowledgeofthe
dutiestobeperformed.Pleasetakeprideinthecompressor,keepitcleanandingood
mechanicalcondition.
Toenablepropermaintenancerecords,PortablePowerprovidesaNoiseEmissionControl
MaintenanceLogintheNoiseEmissionSectionofthismanual.TheNoiseEmissionSection
containsarecommendedMaintenancescheduleandprovidesspaceinthelogforthe
techniciantonotewhatserviceandmaintenancewasdone,bywhom,where,andwhen.
11

12

DRAWBARINFORMATION
13

Operation&MaintenanceManualDRAWBARINFORMATION
InstructionKit
14

SAFETY
15

Operation&MaintenanceManualSAFETY
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.).
Neveroperatethecompressorwithguards,covers,orscreensremoved.Keephands,hair,
clothing,tools,blowguntips,etc.wellawayfrommovingparts.
CompressedAir
Compressedaircanbedangerousifincorrectlyhandled.Priortoperformingmaintenance
orserviceonthecompressor,ensureallpressureisventedfromthesystemandthe
compressorcannotbestartedaccidentally.
Ensurethecompressorisoperatingattheratedpressureandtheratedpressureisknown
toallrelevantpersonnel.
16

SAFETYOperation&MaintenanceManual
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
owrestrictortoeachhoseatthesourceofsupplyorbranchlineinaccordancewithOSHA
Regulation29CFRSection1926.302(b).
Neverallowthecompressortositstoppedwithpressureintheseparatortankorpiping.
ExhaustSystem
Hotengineexhaustgasandhotexhaustsystemsurfacesareproducedduringandafter
compressoroperation.Avoidcontactwithexhaustgasandhotexhaustsystemsurfaces.
Keepammableandcombustiblematerialsaway.Donotoperatecompressoron,under,or
nearammableorcombustiblematerials.
17

Operation&MaintenanceManualSAFETY
Materials
Thefollowingsubstancesmaybeproducedduringtheoperationofthiscompressor:
•brakeliningdust
•engineexhaustfumes
Avoidinhalationofmaterialsubstances.
Ensurethatadequateventilationofthecoolingsystemandexhaustgasesismaintainedat
alltimes.
Thefollowingsubstancesareusedinthemanufactureofthiscompressorandmaybe
hazardoustohealthifusedincorrectly:
•compressoroil
•preservativegrease,lubricatinggrease
•rustpreventative
•batteryelectrolyte
Avoidingestion,skincontact,andinhalationoffumes.
18

SAFETYOperation&MaintenanceManual
Shouldcompressoroilcomeintocontactwiththeeyes,irrigatewithwaterforatleast5
minutes.
Shouldcompressoroilcomeintocontactwiththeskin,washoffimmediately.Consulta
physicianiflargeamountsofcompressoroilareingestedorifcompressoroilisinhaled.
Nevergiveuidsorinducevomitingifthepatientisunconsciousorhavingconvulsions.
Safetydatasheetsforcompressorandengineoilsshouldbeobtainedfromtheoilsupplier.
DoNOTstartoroperatethiscompressorinaconnedarea.Avoidbreathingexhaustfumes
whenworkingonornearthecompressor.
Thiscompressormayincludesuchmaterialsasoil,dieselfuel,antifreeze,brakeuid,oil/air
lters,andbatterieswhichmayrequireproperdisposalwhenperformingmaintenanceor
servicetasks.Contactlocalauthoritiesforproperdisposalofthesematerials.
Battery
Abatterycontainssulfuricacidandcanproducegaseswhicharecorrosiveandpotentially
explosive.Avoidcontactwithskin,eyes,andclothing.Incaseofcontact,usharea
immediatelywithwater.
Donotattempttojumpstartafrozenbatterysincethismaycausethe
batterytoexplode.
Exerciseextremecautionwhenusinganexternalmethodtojumpstart
aunit.Verifytheelectricalsystemsontheweakbatterysystemand
theexternaljumpsystemarethesamevoltagetypesystem,12VDC
or24VDC.ConnectthePositive(+)terminaloftheexternalsystemto
thePositive(+)terminalontheweaksystem.ConnecttheNegative(-)
terminaloftheexternalsystemtotheNegative(-)terminaloftheweak
system.Alwaysdisconnectthetwosystemsinreverseorder.
Radiator
Hotenginecoolantandsteamcancauseinjury.EnsuretheRadiatorPressureCapis
removedwithduecareandattention.
DonotremovethepressurecapfromaHOTradiator.Allowradiatortocoolbeforeremoving
pressurecap.
19

Operation&MaintenanceManualSAFETY
Hotenginecoolantandsteamcancauseinjury.Whenaddingcoolant
orantifreezesolutiontotheengineradiator,stoptheengineandallow
radiatortocoolpriortoreleasingtheRadiatorPressureCap.Usinga
clothtoprotectthehand,slowlyreleasethepressurecap,absorbing
anyreleaseduidwiththecloth.Donotremovethepressurecap
untilallexcessuidisreleasedandtheenginecoolingsystemfully
depressurized.
Followtheinstructionsprovidedbytheantifreezesupplierwhenadding
ordrainingtheantifreezesolution.Itisadvisabletowearpersonal
protectiveequipmenttopreventskinandeyecontactwiththeantifreeze
solution.
Thepotentialforhighertemperaturesispresentwhentheexhaust
aftertreatmentsystemundergoesregeneration.RefertoEngine
Manualforfurthersafetyinstructionsandinformationontheexhaust
aftertreatmentsystemandcontrols.
20

SAFETYOperation&MaintenanceManual
Transport
Whenloadingortransportingthecompressor,ensurethespeciedliftingandtiedownpoints
areused.
Whenloadingortransportingthecompressor,ensurethetowingvehicle,itssize,weight,
towinghitch,andelectricalsupplyareallsuitabletoprovidesafeandstabletowingatspeeds
either,uptothelegalmaximumforthecountryinwhichitisbeingtowed,orasspecied
forthecompressormodeliflowerthanthelegalmaximum.Donotexceedgrossvehicle
weightrating.
Beforetowingthecompressor,ensure:
•thetiresandtowinghitchareinaserviceableconditionandtiresareproperly
inated.
•thecanopyissecure.
•allancillaryequipmentisstoredinasafeandsecuremanner.
•thebrakesandlightsarefunctioningcorrectlyandmeetnecessaryroadtrafc
requirements.
•breakawaycables/safetychainsareconnectedtothetowingvehicle.
Thecompressormustbetowedinalevelattitudeinordertomaintaincorrecthandling,
braking,andlightingfunctions.Thiscanbeachievedbycorrectselectionandadjustmentof
thevehicletowinghitchand,onvariableheightrunninggear,adjustmentofthedrawbar.
1.Ensurewheels,tires,anddrawbarconnectorsareinsafeoperatingconditionand
drawbarisproperlyconnectedbeforetowing.
2.Whenparking,alwaysusethehandbrakeand,ifnecessary,suitablewheelchocks.
21