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OPERATION, MAINTENANCE,
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 46490694 (3-2010) Rev A
Revised (10-12)
MANUAL
P185WJD-T4I (D75)
COMPRESSOR MODEL
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
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Table of Contents
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Summary of Contents for Doosan P185WJD-T4I
- Page 1 Ingersoll-Rand Company in this manual is historical or nominative 1293 Glenway Drive in nature, and is not meant to suggest a current affiliation between Statesville, N.C. 28625 Ingersoll-Rand Company and Doosan Company or the products of either. www.doosanportablepower.com Book: 46490694 (3-2010) Rev A...
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Page 3: Table Of Contents
TABLE OF CONTENTS Manual-Name TITLE PAGE FOREWORD ............1-3 Foreword. - Page 4 TABLE OF CONTENTS Manual-Name TITLE PAGE MAINTENANCE ............6-39 Maintenance .
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Page 5: Foreword
Foreword Book: 46490694 (03-2010) Rev A... - Page 6 Operating & Maintenance Manual Foreword Foreword The contents of this manual are considered to be proprietary and confidential to Doosan Infracore Portable Power (herein referred to as “Portable Power”), and should not be reproduced without the prior written permission of Portable Power.
- Page 7 Foreword Operating & Maintenance Manual This machine should not be used: A. For direct or indirect human consumption of the compressed air. B. Outside the ambient temperature range specified in the general data section of this manual. C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists.
- Page 8 Operating & Maintenance Manual Foreword Book: 46490694 (03-2010) Rev A...
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Page 9: Drawbar Notice
DRAWBAR NOTICE Book: 46490694 (03-2010) Rev A... - Page 10 Operating & Maintenance Manual DRAWBAR NOTICE Sketch). DRAWBAR NOTICE (Important) 8. Temporarily support drawbar and move jack from front of compressor to side of This machine may have been shipped from drawbar. the factory with the drawbar positioned upright. To Convert From Shipping Position to Towing Position The following tools are required: Ratchet...
- Page 11 DRAWBAR NOTICE Operating & Maintenance Manual Book: 46490694 (03-2010) Rev A...
- Page 12 Operating & Maintenance Manual DRAWBAR NOTICE Book: 46490694 (03-2010) Rev A...
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Page 13: Safety
Safety Book: 46490694 (03-2010) Rev A... -
Page 14: Safety Precautions
Operating & Maintenance Manual Safety Safety Precautions General check valves and isolation valves must be fitted and controlled by work procedures, so Ensure that the operator reads and that one machine cannot accidentally be understands the decals and consults the pressurized or over pressurized by another. - Page 15 Safety Operating & Maintenance Manual other cable to the negative (-) terminal of the flammable gas. USE SPARINGLY! DO NOT booster battery and other end to a ground use ETHER if unit has GLOW Plug starting connection away from dead battery (to avoid aid.
- Page 16 Operating & Maintenance Manual Safety Book: 46490694 (03-2010) Rev A...
- Page 17 Safety Operating & Maintenance Manual Book: 46490694 (03-2010) Rev A...
- Page 18 Operating & Maintenance Manual Safety Book: 46490694 (03-2010) Rev A...
- Page 19 Safety Operating & Maintenance Manual Look for these signs on machines shipped to markets in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor. DANGER DANGER (Red Background) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
- Page 20 Operating & Maintenance Manual Safety Book: 46490694 (03-2010) Rev A...
- Page 21 Safety Operating & Maintenance Manual Table 1: FREE SAFETY DECALS Safety Decals are available free of charge. Safety Decals are identified by the decal heading: DANGER, WARNING, or CAUTION. Decal part numbers are on the bottom of each decal and are also listed in the compressor’s parts manual.
- Page 22 Operating & Maintenance Manual Safety Book: 46490694 (03-2010) Rev A...
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Page 23: Noise Emission
Noise Emission Book: 46490694 (03-2010) Rev A... -
Page 24: This Section Pertains Only To Machines Distributed Within The United States
Operating & Maintenance Manual Noise Emission Noise Emission This section pertains only to machines distributed within the United States. WARNING Tampering with Noise Control System Prohibited Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative 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 sale or delivery to the ultimate purchaser or while it is in use;... -
Page 25: Noise Emission Warranty
Noise Emission Operating & Maintenance Manual Noise Emission Control Maintenance Log COMPRESSOR MODEL __________________________ SERIAL NO. ___________________________________ USER UNIT NO. ________________________________ UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Engine Make & Model: ________________ __________________________________ Serial No.: _________________________ __________________________________ Purchaser or Owner: _________________ __________________________________ Address: __________________________ Date Purchased: ____________________... - Page 26 Operating & Maintenance Manual Noise Emission deformed, such that their noise containment function is reduced, should be repaired or Maintenance Schedule replaced before the next operation interval. Item Area Period Doors, access panels, and hatch closures Compressed Air Leaks As Detected especially, should be checked and adjusted Safety and Control Systems As Detected...
- Page 27 Noise Emission Operating & Maintenance Manual Maintenance Record For Noise Emission Control And Extended Warranty Item Hourmeter Maint/inspect Location Work Done Description Of Work Reading Date City/state By (Name) Book: 46490694 (03-2010) Rev A...
- Page 28 Operating & Maintenance Manual Noise Emission Book: 46490694 (03-2010) Rev A...
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Page 29: General Data
GENERAL DATA Book: 46490694 (03-2010) Rev A... -
Page 30: Unit Model
Operating & Maintenance Manual GENERAL DATA General Data Unit Model: UNIT MODEL P185WJD Air Delivery CFM (litres/sec) 185 (87) Engine Speed - RPM (Full Load) 2600 Engine Speed - RPM (No Load) 1500 COMPRESSOR Rated Operating Pressure - psi (kPa) 100 psi (689) Safety Valve Setting - psi (kPa) 200 psi (1379) -
Page 31: Expendable Service Parts
36899698 PRO-TEC Compressor Fluid (1 gal) WARNING Modification or alteration of this machine. Can result in severe injury or death. Do not modify or alter without the express written consent of Doosan Infracore Portable Power. Book: 46490694 (03-2010) Rev A... - Page 32 Operating & Maintenance Manual GENERAL DATA Book: 46490694 (03-2010) Rev A...
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Page 33: Operation
OPERATION Book: 46490694 (03-2010) Rev A... -
Page 34: Before Towing
Operating & Maintenance Manual OPERATION BEFORE TOWING WARNING Failure to follow these instructions CAN cause severe injury or death. • Assure tow vehicle has towing capacity for weight of this unit as stated on general data decal. • Position the tow vehicle to align its hitch with the pintle eye or coupler of the compressor. -
Page 35: Towing
OPERATION Operating & Maintenance Manual TOWING DISCONNECT • Engage tow vehicle parking brake. • Chock tires of compressor. • Set the vehicle parking brake. Chock wheels of unit. • Standing to the side, remove pin from tube of jack. • Disconnect safety chains. Crank jack to raise eye or coupler from hitch. Tow vehicle can be moved. - Page 36 Operating & Maintenance Manual OPERATION Before Starting • Open service valve(s) to ensure pressure is relieved in receiver-separator system. • Close valve(s) in order to build up full air pressure and ensure proper oil circulation. • Check battery for proper connections and condition. •...
- Page 37 OPERATION Operating & Maintenance Manual Starting • Turn the POWER switch to “ON”. • Turn Power switch to “START” position to crank engine. Hold switch in “START” position for approximately 5 seconds after engine starts. NOTICE Do not operate the starter motor for more than 30 seconds without allowing at least 30 seconds cooling time between start attempts.
- Page 38 Operating & Maintenance Manual OPERATION Stopping NOTICE Whenever the machine is stopped, air will flow back into the compressor system from devices or systems downstream of the machine unless the service valve is closed. Install a check valve at the machine service valve to prevent reverse flow in the event of an unexpected shutdown when the service valve is open.
- Page 39 OPERATION Operating & Maintenance Manual • Before Starting 1. On the Pressure Regulator, loosen the jam nut and turn screw counterclockwise until tension is no longer felt at the screw. Then, turn screw clockwise one full turn. 2. Close service valve(s). 3.
- Page 40 Operating & Maintenance Manual OPERATION Compressor Diagnostic Display Codes Small Electronic Control Unit (SECU) During SECU Controller power-up, the number 8 flashes to check the display operation. Next, the display will step through the 3 digit software revision number. Center Bar Blinking Compressor is ready to start (no faults) Engine Model Not Compressor will start and operate with a 1700-2300 rpm range.
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Page 41: Maintenance
MAINTENANCE Book: 46490694 (03-2010) Rev A... -
Page 42: General
Operating & Maintenance Manual MAINTENANCE Maintenance CAUTION Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty. If performing more than visual inspections, disconnect battery cables and open manual blowdown valve. Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). -
Page 43: Air Cleaner
MAINTENANCE Operating & Maintenance Manual Air Cleaner If this unit is equipped with the Optional Full Instrumentation, the SECU Module, located inside front panel near instrument panel, will Display #9 when either engine or compressor air filter is restricted. Weekly squeeze the rubber valve (precleaner dirt dump) on each air cleaner housing to ensure that they are not clogged. -
Page 44: Fasteners
Operating & Maintenance Manual MAINTENANCE Tires A weekly inspection is recommended. Tires that have cuts or cracks or little tread should be repaired or replaced. Monthly check the wheel lug nuts for tightness. Fasteners Visually check entire unit in regard to bolts, nuts and screws being properly secured. Spot check several capscrews and nuts for proper torque. - Page 45 MAINTENANCE Operating & Maintenance Manual Premature wear of both the engine and compressor is ASSURED whenever dust-laden air is permitted to enter the engine’s combustion chamber or compressor intake. The flexible hoses used in the fuel, oil and air lines on these units are primarily used for their ability to accommodate relative movement between components.
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Page 46: Compressor Oil Cooler
Operating & Maintenance Manual MAINTENANCE NOTICE Installing a new oil filter element when the old gasket remains on the filter head, will cause an oil leak and can cause property damage. 4. Lubricate the new filter gasket with the same oil being used in the machine. 5. -
Page 47: Receiver-Separator Systems
MAINTENANCE Operating & Maintenance Manual Receiver-Separator Systems WARNING High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. • Open service valve at end of machine. •... -
Page 48: Scavenge Line
Operating & Maintenance Manual MAINTENANCE Scavenge Line WARNING High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. The scavenge line originates at the manifold and terminates at the compressor airend near the oil filter element. - Page 49 MAINTENANCE Operating & Maintenance Manual Field Repair of Texture Paint 1. The sheet metal should be washed and clean of foreign material and then thoroughly dried. 2. Clean and remove all grease and wax from the area to be painted using Duponts 3900S Cleaner prior to sanding.
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Page 50: Maintenance Schedule
Operating & Maintenance Manual MAINTENANCE MAINTENANCE SCHEDULE Daily Weekly Monthly 3 MOS. 6 MOS. 12 MOS. 250 hours 500 hours 1000 hours Compressor Oil Level Engine Oil Level Radiator Coolant Level Gauges/Lamps Air Cleaner Service Indicators Fuel Tank (fill at end of day) DRAIN Fuel Water Separator (Drain) Oil Leaks... -
Page 51: Lubrication
LUBRICATION Book: 46490694 (03-2010) Rev A... -
Page 52: Portable Compressor Fluid Chart
C to 52 Alternate: ISO Viscosity Grade 46 with rust Preferred Fluids - Use of these fluids with and oxidation inhibitors, designed original Doosan/Ingersoll Rand branded for air compressor service. filters can extend airend warranty. Refer to 350 psi Preferred:... -
Page 53: Troubleshooting
Troubleshooting Book: 46490694 (03-2010) Rev A... -
Page 54: Introduction
Operating & Maintenance Manual Troubleshooting Troubleshooting B. Do The Simplest Things First Most troubles are simple and easily corrected. For example, most complaints are Introduction “low capacity” which may be caused by too low an engine speed or “compressor over- Troubleshooting for a portable air heats”... -
Page 55: Trouble Shooting Chart
Troubleshooting Operating & Maintenance Manual Trouble Shooting Chart Bold Headings depict the COMPLAINT - Subheadings indicate CAUSES NOTE: Subheadings suggest sequence to follow troubleshooting. Table 1: Machine Shutdown Cause Corrective Action Out of fuel Add CLEAN diesel fuel. Low fuel shutdown (option) Add CLEAN diesel fuel. - Page 56 Operating & Maintenance Manual Troubleshooting Table 3: Machine Will Not Run Cause Corrective Action Out of fuel Add clean diesel fuel. Low fuel shutdown (option) Add clean diesel fuel. See table 11. Airend discharge temperature too high See table 4. Separator temperature to high See table 5.
- Page 57 Troubleshooting Operating & Maintenance Manual Table 5: High Separator Temperature Shutdown SECU CODE 2 Cause Corrective Action Dirty cooler Clean cooler. Low compressor oil level Add oil. Check for leaks. Clogged compressor oil filter elements Replace elements. Change oil. Operating pressure too high Reduce pressure setting to within spec.
- Page 58 Operating & Maintenance Manual Troubleshooting Table 7: High Engine Coolant Temperature Shutdown SECU CODE 4 Cause Corrective Action Dirty cooler Clean cooler. Dirty operating conditions Relocate machine to cleaner environment. Machine out of level>15 degrees Relocate or level machine. Ambient temperature>120°F (49°C) Above spec.
- Page 59 Troubleshooting Operating & Maintenance Manual Table 11: Low Fuel Shutdown (Option) SECU CODE 8 Cause Corrective Action Out of fuel Add clean diesel fuel. Jumper disconnected (standard Reinstall jumper. Refer to wiring decal. machine) Low fuel shutdown/gauge sensor Check harness connections. Replace sensor. malfunction SECU controller malfunction Check harness connections.
- Page 60 Operating & Maintenance Manual Troubleshooting Table 16: Generator Switch on SECU CODE H (Electronic Engine Models Only) Cause Corrective Action Machine will not start Switch generator to the air only position. Generator switch malfunction Check harness connections. Replace switch. SECU controller malfunction Check harness connections.
- Page 61 Troubleshooting Operating & Maintenance Manual Table 21: Oil Seal Leak Cause Corrective Action Contaminated Lube Oil Drain and flush system. Add new CLEAN oil. Replace seal. Malfunctioning Seal Consult dealer. Replace seal. Scored Shaft See instructions in new seal kit. Table 22: Will Not Unload Cause Corrective Action...
- Page 62 Operating & Maintenance Manual Troubleshooting Book: 46490694 (03-2010) Rev A...
- Page 63 Revision History Rev Level EC Number Comments SVC31192 Original Release...
- Page 64 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2009 Doosan Infracore International, Inc. Printed in the USA...