Page 1 COMPRESSORS MODEL: P185WDOU-T4F (F89) P185WDOU-T4F (H28) XP185WDOUA-T4F (F91) XP185WDOUA-T4F (H29) Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 DoosanPortablePower.com P/N: 46680186 (2015) Rev C...
Page 5: Table Of Contents
TABLE OF CONTENTS TITLE PAGE ................................ iii FOREWORD ........................11 Information ............................. 12 SAFETY ..........................15 Safety Precautions ......................... 16 Compressed Air.......................... 17 Safety Information .......................... 18 Compressor Description and Intended Use ................18 Operating Safety........................20 Service Safety........................... 22 Visual Walk Around and Inspection ..................23 Operator Safety while using Internal Combustion Engines ............
Page 6 TABLE OF CONTENTS TITLE PAGE Preparation for Storage ....................... 45 NOISE EMISSION........................47 Noise Emission..........................48 Compressor Noise Emission Control Information ................48 Noise Introduction .......................... 49 Maintenance Schedule........................ 49 Noise Emission Warranty ......................51 Maintenance Log ........................51 Maintenance Record ........................52 GENERAL DATA .........................53 General Data for P185WDOU-T4F ....................
Page 7 TABLE OF CONTENTS TITLE PAGE ENGINE OPERATION......................77 Engine Operation and Maintenance....................78 Engine Management........................78 Safety ............................80 Instructions ..........................81 Instructions (continued) ......................82 General Repair ........................... 84 Environmental Pollution ......................85 Prevention of Pollution ........................ 86 Startup and Shutdown ........................87 Inspection after Starting the Engine .....................
Page 8 TABLE OF CONTENTS TITLE PAGE Cooling Fan Drive........................133 Fuel System ..........................133 Diesel Exhaust Fluid ........................133 Fuel Filter Water Separator ......................133 Charge Air Cooler Pipework .......................133 Radiator ............................134 Hoses ............................134 Ventilation ..........................134 Electrical System ........................135 Battery ............................135 Pressure System ........................135 Tire Pressure..........................135 Fasteners..........................136 Running Gear/Wheels........................136 Lubrication ..........................136...
Page 9 ..............................183 P185WDOU Generator Option......................184 ..............................185 Electrical Parts List........................186 ..............................187 WARRANTY........................189 Warranty ............................190 Doosan Portable Power General Warranty Information..............190 Truck Mounted Equipment ......................191 Doosan Infracore Federal & California Emission Control Systems Limited Warranty for Non-Road Engines (CI) ..........................192 Revision History ..........................193...
Page 11: Foreword
Foreword...
Page 12: Information
Doosan Infracore Portable Power and must be followed during installation, operation, and maintenance of these machines. 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 13 Foreword This compressor should NOT be used: • For direct or indirect human consumption of the compressed air. • Outside the ambient temperature range specified in the general data section of this manual. • When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists.
Page 15: Safety
Safety...
Page 16: Safety Precautions
Safety Safety Precautions Never operate the compressor without first observing all safety warnings and carefully reading the Operation and Maintenance Manual shipped from the factory with this compressor. Ensure the operator reads and understands the decals and consults the manuals before operation or performing maintenance.
Page 17: Compressed Air
Safety Compressed Air Compressed air can be dangerous if incorrectly handled. Prior to performing maintenance or service on the compressor, ensure all pressure is vented from the system and the compressor cannot be started accidentally. Ensure the compressor is operating at the rated pressure and the rated pressure is known to all relevant personnel.
Page 18: Safety Information
Safety Information Compressor Description and Intended Use This compressor is a mobile compressed air source. The Doosan compressor consists of a trailer-mounted cabinet containing a fuel tank, diesel engine, compressor inlet system, compressor cooling and lubrication system, compressor discharge system, control system, instrument and electrical system.
Page 19 This compressor is built with user safety in mind; however, like any device it can present serious hazards if improperly operated and serviced. Follow instructions carefully! Should questions arise during operation or service of this equipment, contact Doosan Infracore Portable Power.
Page 20: Operating Safety
Safety Operating Safety Familiarity and proper training are required for the safe operation of the compressor. Compressor operated improperly or by untrained personnel can be dangerous. Read the operating instructions contained in both this manual and the engine manual and familiarize yourself with the location and proper use of all controls.
Page 21 Safety Only trained personnel are permitted to start, operate, and shut down the compressor. They also must meet the following guidelines below for operating the compressor safety: 1. Do not operate the compressor when open containers of fuel, paint, or other flammable liquids are near.
Page 22: Service Safety
Safety Service Safety A poorly maintained compressor can become a safety hazard! In order for the compressor to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. Personal Protective Equipment (PPE) Wear the following Personal Protective Equipment (PPE) while servicing or maintaining this compressor: •...
Page 23: Visual Walk Around And Inspection
Safety 7. Do not modify the compressor without the express written approval of the manufacturer. 8. Do not pressure wash the control panel, compressor end, or any other electrical components when cleaning the unit. Never allow water to accumulate around the base of the compressor set.
Page 24: Operator Safety While Using Internal Combustion Engines
Safety Operator Safety while using Internal Combustion Engines Exhaust gas from the engine contains carbon monoxide, a deadly poison. Exposure carbon monoxide can kill you in minutes. • NEVER operate the compressor inside an enclosed area, such as a tunnel, unless adequate ventilation is provided through such items as exhaust fans or hoses.
Page 25: Battery
Safety Battery Do not attempt to jump start a frozen battery since this may cause it to explode. A battery contains sulfuric acid and can produce gases which are corrosive and potentially explosive. Avoid contact with skin, eyes, and clothing. In case of contact, flush area immediately with water.
Page 26: Coolant System
Safety Coolant System Hot engine coolant and steam can cause injury. When adding coolant or antifreeze solution to the engine radiator, stop the engine and allow radiator to cool prior to releasing the reservoir cap. Using a cloth to protect the hand, slowly release the reservoir cap, absorbing any released fluid with the cloth.
Page 27: Materials
Safety Materials Avoid inhalation of material substances. The following substances may be produced during the operation of this compressor: • Brake Lining Dust • Engine Exhaust Fumes Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times.
Page 28: Service Air Connection(S)
Safety Service Air Connection(s) All Air Pressure Equipment Installed In Or Connected To The Compressor Must Have Safe Working Pressure Ratings Of At Least The Safety Valve Setting, And Materials Compatible With The Compressor Oil (Refer To The General Data). Do Not Connect The Air Discharge On This Compressor Onto A Common Header With Any Other Unit Of Any Description, Or Any Other Source Of Compressed Air, Without First Making Sure A Check-Valve Is Used...
Page 29: Air Hose Restraint Installation
Safety Air Hose Restraint Installation Safety devices such as hose restraints (whipchecks) must be used to prevent hose whipping if a connection fails. Whipchecks are to be constructed of woven stainless steel, galvanized steel wire rope, or chain with a minimum strength adequate for the supplied pressure and hose diameter.
Page 30: Safety Decals
Safety Safety Decals Free Safety Decals To promote communication of Safety Warnings on products manufactured by the Portable Power Division in Statesville, N.C., Safety Decals are available FREE of charge. Safety Decals are identified by the decal heading: DANGER, WARNING, CAUTION, NOTICE. Decal part numbers are located in the lower right hand corner of each decal and are also listed in the Parts Manual.
Page 31: Safety Decals Summary
Safety Safety Decals Summary Look for these safety decals on machines manufactured 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. Decals are located on the compressor to point out potential safety hazards.
Page 32: Safety Decals (Continued)
Safety Safety Decals (continued) Below is a summary of safety decals which may be included on your compressor.
Page 33: Safety Decals (Continued)
Safety Safety Decals (continued) Below is a summary of safety decals which may be included on your compressor.
Page 34: Safety Decals (Continued)
Safety Safety Decals (continued) Below is a summary of safety decals which may be included on your compressor.
Page 35: Safety Symbols
Safety Safety Symbols Below is summary of the intended meanings for the symbols used on safety compressor.
Page 36: Safety Symbols (Continued)
Safety Safety Symbols (continued) Below is summary of the intended meanings for the symbols used on safety compressor.
Page 37: Lifting, Transporting And Preparation
Lifting, Transporting and Preparation...
Page 38: Lifting, Transporting And Preparation
Lifting, Transporting and Preparation Lifting, Transporting and Preparation Introduction Failure to follow these instructions could result in serious personal injury or death. Personal injury or damage to equipment can result if material is stored or transported in or on the compressor. Personal injury or damage to vehicle can result if vehicle is rated below 1000 lb load capacity.
Page 39: Lifting The Compressor
Lifting, Transporting and Preparation Lifting the Compressor Crushing/compressor damage hazard. Use approved lifting devices as necessary within sufficient capacity to lift the compressor safely. Refer to General Data for the proper operating weight of the compressor. Severe injury or death can result if compressor shifts or falls suddenly during installation procedures.
Page 40: Utility Package Set-Up (No Running Gear)
Lifting, Transporting and Preparation Utility Package Set-Up (No Running Gear) FIGURE 2-2: UTILITY PACKAGE SET-UP (NO RUNNING GEAR) The unit must be secured while operating or transporting. The compressor must be located on vehicle bed to allow access of normal servicing and maintenance. See Figure X (See Figure 2-2) for mounting base holes provided in base.
Page 41: Preparing For First Use
Lifting, Transporting and Preparation Preparing for First Use Failure to follow these instructions could result in serious personal injury or death. Personal injury or damage to equipment can result if material is stored or transported in or on the compressor. To prepare compressor for first use: 1.
Page 42: Fueling (Refueling) The Fuel Tank
Lifting, Transporting and Preparation Fueling (Refueling) the Fuel Tank Do not permit smoking, open flame, or sparks to occur near the battery, fuel leaking solvents, or other flammable substances and explosive gases. Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns.
Page 43 Lifting, Transporting and Preparation Procedure for fueling (refueling) the fuel tank: Diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes. Always place compressor on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the fuel tank.
Page 44: Lubrication
Refer to the Engine Operator Manual. The Tier 4 engine in this compressor requires engine lubricating oil to ensure proper Aftertreatment System operation and engine durability. Doosan Tier 4 Premium Engine Oil is recommended. Refer to the Engine Operator Manual for engine oil specifications.
Page 45: Compressor Oil
Lifting, Transporting and Preparation Compressor Oil DO NOT, under any circumstances, remove any drain plugs or the oil filler plug from the compressor lubricating and cooling system without first ensuring the compressor is stopped and the system has been completely relieved of all air pressure (refer to STOPPING in the Operating Instructions Section of this manual).
Page 47: Noise Emission
Noise Emission...
Page 48: Noise Emission
Noise Emission Noise Emission This Section Pertains Only To Compressors Distributed Within The United States. 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 49: Noise Introduction
Noise Emission Noise Introduction The Compressor for which this Maintenance Log is provided conforms To U.S. EPA Regulations for Noise Emissions, applicable to Portable Compressors. The purpose of this book is to provide (1) The Maintenance Performance Schedule for all Required Noise Emission Controls and (2) Space so that the Purchaser or Owner can record what Maintenance was done, by whom, where and when.
Page 50 Noise Emission PERIOD DESCRIPTION 100 HOURS AIR INTAKE AND ENGINE EXHAUST Engine and compressor air intake and engine exhaust systems should be inspected after each 100 hours of operation for loose, damaged, or deteriorated components. Repairs or replacements should be made before the next period of use. 250 HOURS COOLING SYSTEMS All components of the cooling system for engine water and...
Page 51: Noise Emission Warranty
Noise Emission Noise Emission Warranty The Manufacturer Warrants to the Ultimate Purchaser and each Subsequent Purchaser that this Compressor was Designed, Built and Equipped to conform at the time of Sale to the First Retail Purchaser, with all applicable U.S. EPA Noise Control Regulations. This Warranty is not Limited to any Particular Part, Component, or System of the Compressor.
Page 52: Maintenance Record
Noise Emission Maintenance Record MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM HOURMETER MAINT/INSP LOCATION WORK DONE BY DESCRIPTION OF WORK READING DATE CITY/STATE (NAME)
Page 53: General Data
General Data...
Page 54: General Data For P185Wdou-T4F
Rated Operating Pressure - psi (bar) 100 (6.9) Safety Valve Setting - psi (bar) 200 (13.78) ENGINE (Diesel) Manufacturer Doosan Model D24 (49 HP) Rated Power @ Full Load Speed - hp (kw) 49 (36.4) @ 2600 rpm Full Load Speed - rpm...
Page 55: General Data For Xp185Wdoua-T4F
Rated Operating Pressure - psi (bar) 125 (8.6) Safety Valve Setting - psi (bar) 200 (13.78) ENGINE (Diesel) Manufacturer Doosan Model D24 (73 HP) Rated Power @ Full Load Speed - hp (kw) 73 @ 2600 rpm Full Load Speed - rpm...
Page 56: Hp Available For Auxiliary Power Use
General Data HP Available for Auxiliary Power Use XP185WDOUA-T4F Model NOTE The XP185WDOU model is designed to have excess power available to allow power to be drawn from the engine to drive auxiliary equipment the customer may desire to use. The application of this power is the responsibility of the customer.
Page 57: Operating Instructions
Operating Instructions...
Page 58: Control Panel
Operating Instructions Control Panel FIGURE 3-1: INSTRUMENT CONTROL PANEL Instrument Control Panel The following definitions describe the controls and functions of the Control Operator Panel (See Figure 3-1). 1. Air Pressure Gauge: Indicates Pressure in the Separator Tank. 2. Mini-Port Display: Displays Compressor Operating Parameters, and Diagnostic Codes.
Page 59: Instrument Control Panel Indicators
Operating Instructions Instrument Control Panel Indicators The following table definitions describe the controls and functions of the Control Operator Panel (See Figure 3-1). STOP: Stops the Compressor. START: Initiates Engine Cranking. SERVICE AIR: Allows Operator to Load Compressor after Warm-Up. Pressing and Releasing the UP Button scrolls up through Parameter lists and Menu choices or Increases a value one Item/Unit at a time.
Page 60: Auto Power Off
Operating Instructions Auto Power Off The compressor control system has a power save feature that is designed to prevent drain on the batteries when the compressor engine is not running. If the Control Panel is powered ON and the engine has not ran for 15 minutes the control system will automatically power OFF.
Page 61: Quick View Screens
Operating Instructions Quick View Screens Engine and Compressor Parameters The Quick View Screens allow for easy viewing of up to 14 commonly used parameters by pressing the UP and DOWN buttons. Pressing the UP and DOWN buttons continuously loops through the Quick View Screens (i.e., when the last screen is reached pressing the DOWN button displays the first screen and vice versa).
Page 62: Fault And Alert
Operating Instructions Fault and Alert If a Fault occurs, the Display unit will Display The SPN, FMI, OC, and description for Engine Fault or the CPR Code and description for Compressor Error. 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.
Page 63 Operating Instructions Fault and Alert (continued) When present, an Alert with the number of Alert conditions will popup on the screen, the User will press the UP or DOWN button to display the Alert, or press the Enter button to acknowledge an Alert has occurred.
Page 64: Service Interval Setup
Operating Instructions Service Interval Setup Service will popup on the screen after one of the two hour service channels has decremented to 5 hours. The user will press the UP or DOWN button to display the service channels or press the ENTER button to acknowledge a service has occurred. Pressing the ENTER button after the service channels have been displayed, acknowledges The message and the display unit returns to the Default Screen.
Page 65 Operating Instructions Service Interval Setup (Continued) The service intervals can be changed by pressing the ENTER button while on the Default Screen that Displays The Engine Hours. Using the UP or DOWN buttons To highlight the desired interval and press the ENTER button to select. Use the UP and DOWN buttons to Increase or Decrease the number of hours.
Page 66: Display Setup
Operating Instructions Display Setup The Display Menu functions give users the ability to configure the LCD. Options for configuring the Display include Intensity, Contrast, and Viewing Mode. To access the Display Menu, press and hold the ENTER button while the Default Screen of Engine Hours is Displayed until the Main Menu appears.
Page 67: Languages And Units
Operating Instructions Languages and Units The Display is User configured to Display in English, Spanish, Or French languages and in either English or Metric units. The Language and Display units can be changed by accessing the Setup Menu. to access the Setup Menu, press and hold the ENTER button while the Default Screen of Engine Hours is Displayed until the Main Menu appears.
Page 68: Before Startup
Operating Instructions Before Startup Before Starting the Compressor Do not remove reservoir cap from a hot radiator. Allow radiator to cool down before removing reservoir cap. Use extreme care when removing a reservoir cap from a liquid cooling system for the engine. The sudden release of pressure from a heated cooling system can result in a loss of coolant and possible severe personal injury.
Page 69 Operating Instructions Unrestricted air flow from a hose will result in a whipping motion of the hose which can cause severe injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure in case of hose failure or other sudden pressure release.
Page 70 Operating Instructions Check the following before starting the compressor: • 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 71: Starting Procedure
Operating Instructions Starting Procedure Do not use ether or any other starting fluid. Starting fluids can cause An explosion, fire, and severe engine damage. The engine is equipped with an electric heater starting aid. To ensure an adequate flow of oil to the Airend, never allow the discharge pressure to fall below 50 psi.
Page 72 Operating Instructions Starting Procedure (continued) Do the following for starting the compressor by following the decal instruction (See Figure 3-10) for startup procedure: FIGURE 3-10: STARTING INSTRUCTION 1. Press the main power button 2. When the wait to start message on the mini-port changes to total fuel% DEF %hours=, press and release green start button 3.
Page 73: Normal Operation
Operating Instructions 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 operating limits, the compressor will alert and/or shutdown, and display a diagnostic code. In the event the compressor controller detects a parameter at a dangerously high or low level, the compressor will be automatically shut down with the cause of the shutdown shown on the Mini-Port.
Page 74: Shutdown
Operating Instructions Shutdown Pressure will remain in the system between the Minimum Pressure Valve and the Service Valve after shutdown and operation of the Automatic Blowdown Valve. This pressure must be relieved by disconnecting any downstream equipment and opening the Discharge Valve to atmosphere. Since the service valve is closed, air downstream of the valve may be trapped.
Page 75 Operating Instructions Once the engine stops, the Automatic Blowdown Valve will relieve pressure from the separator tank. If the Automatic Blowdown Valve fails to operate, pressure must be relieved from the system by means of the Manual Blowdown Valve. This compressor is equipped with a battery disconnect switch which disconnects power for long term storage.
Page 76: Pressure Regulator Adjustment Instructions
Operating Instructions Pressure Regulator Adjustment Instructions FIGURE 3-11 PRESSURE REGULATOR ADJUSTMENTS Always adjust High Pressure first. 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.
Page 77: Engine Operation
Engine Operation...
Page 78: Engine Operation And Maintenance
In the event that a part must be replaced, only genuine Doosan parts, as defined by the parts list (Parts Manual) should be used. Doosan shall not be held liable for any critical damage or faults which may be caused by the use of unauthorized or non-factory remanufactured parts.
Page 79 Using an engine for any purposes other than the designed purpose may cause critical faults to the engine for which Doosan shall not be held liable. For details concerning the usage and purpose of the engine, please direct questions to our Sales Team. Do NOT adjust, convert, or change the ECU without our authorization.
Page 80: Safety
Engine Operation Safety This Operation & Maintenance Section divides maintenance operations such as performing engine checks, troubleshooting, or diagnosing faults into three categories, Danger, Warning, and Caution. In addition, Note is used to provide additional descriptions and information required for maintenance technicians to successfully operate our engines. The recommended repair methods and Danger, Warning, and Caution can enhance the degree of completion of engine maintenance and prevent bodily injury which may occur to workers.
Page 81: Instructions
Engine Operation Instructions When accessories such as necklaces, rings, watches, or gloves become stuck in rotating parts while the engine is operating, serious bodily injury may occur. When a safety accident, such as 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.
Page 82: Instructions (Continued)
Engine Operation Instructions (continued) Read and Observe the following instructions below: 1. In order to maintain the best long term performance and safety, please read and understand this manual and perform routine inspections and regular inspections. 2. We have divided the content of this section into causes of bodily injury and damage to assets and causes of pollution.
Page 83 Engine Operation Instructions (continued) Cautions for Inspection and Repair 1. Inspection and repair of engine should be performed only when the engine is shut down, otherwise, burns or safety accidents may occur. Do not perform inspection or repair while the engine is operating. 2.
Page 84: General Repair
4. Store the disassembled parts in a specified space to avoid damage or contamination. 5. Use specified and special tools for efficient and safe repair. 6. If parts need to be replaced, use only genuine Doosan parts for replacement. Using unauthorized or non-factory remanufactured parts may cause critical damage and faults in engine performance.
Page 85: Environmental Pollution
An engine consists of many parts which are mechanically harmonized. To prevent future engine faults and ensure best performance for a long period, maintenance and replacement of expendable parts should be conducted regularly. Use of Doosan genuine parts is recommended. Using unauthorized or non-factory remanufactured parts may cause critical...
Page 86: Prevention Of Pollution
Engine Operation Prevention of Pollution Consider the following to manage engine without causing environmental pollution. Discard oil according to the regulations set forth by the relevant authorities. Disposing of discharged oil into the ground, sewers, drains, rivers, or the sea will cause serious environmental pollution. Violation of regulations regarding discard of engine oil without observing the handling regulations may result in legal action.
Page 87: Startup And Shutdown
Keep the fluid clean while it is not in use. Use fuel, oil, and coolant recommended by Doosan. Otherwise, critical damage to the engine may occur. 4. Fill the fuel tank (describe in Lifting, Transporting and Preparation), and drain water...
Page 88 Engine Operation Initial Startup and Shutdown Procedure (continued). Starting the Engine Observe the following when starting the engine. 1. For a cold start, start the engine after preheating it sufficiently through the glow plug. After Starting the Engine 1. Operate engine at light load until engine has reached normal operating temperature. 2.
Page 89: Inspection After Starting The Engine
Engine Operation Inspection after Starting the Engine Check the pressure of the engine lubrication system by using the engine oil pressure gauge mounted on the apparatus while the engine is in operation. If pressure decreases on oil pressure gauge, immediately shutdown the engine. In addition, make sure that the recharge alarm indicator lamp of the alternator is off while the engine is operating.
Page 90: Break-In Period Of Engine
Engine Operation Break-in Period of Engine Doosan engines are subjected to a final approval test to ensure 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 50 hours after delivery.
Page 91 In addition, the pressure of cold oil may be higher at a specific rpm than of warm oil. This phenomenon may even occur when the engine operates properly. If engine oil and oil filter need to be replaced, use only genuine engine oil and parts recommended by Doosan.
Page 92 Engine Operation Check the following during the break-in period of a new engine. 1. Periodically check to verify the engine oil level is between the minimum and maximum limit of the oil level gauge. 2. If the oil indicator lamp on the apparatus is lighted or blinks, the oil pressure may be insufficient.
Page 93: Operation In Winter
To prevent this, replace oil to engine oil for cold weather or areas with cold climate. When replacing engine oil, use only genuine engine oil recommended by Doosan. Cold Weather - The manual blowdown valve is closed for normal operation.
Page 94: Regular Inspection
SAE 15W40 API CJ-4 or Better Note: Doosan engine oils are recommended for use in this machine. If Doosan engine oil is not available, use a good quality engine oil that meets API service classification of CJ-4 or Better (See Table 4-1).
Page 95: Replacement Of Engine Oil
Engine Operation Replacement of Engine Oil Prolonged and repeated contact of skin with engine oil may lead to shrinking, dryness of skin and even cause dermatitis. Do not expose skin with exchanged engine oil for a long period. Always wear work clothes and gloves. When skin is stained with engine oil, immediately wash with water, soap or hand cleaners.
Page 96: Procedure For Changing Oil And Oil Filter
Engine Operation Procedure for Changing Oil and Oil Filter Step 1 Component Locations Showing oil fill, oil filter, dipstick and drain locations FIGURE 4-1: SHOWING OIL FILL, OIL FILTER , DIPSTICK and DRAIN LOCATIONS...
Page 97 Engine Operation Refer to the Preventive Maintenance Schedule in this manual for recommended servicing intervals. Perform the following procedure below as follows: Before proceeding do the following: 1. Move the unit to a flat surface to maintain the engine level. 2.
Page 98: Step 2 Checking Oil Level
Engine Operation Step 2 Checking Oil Level Showing oil fill, oil filter , dipstick and drain locations FIGURE 4-2: ENGINE OIL LEVEL GAUGE (DIPSTICK)
Page 99 Engine Operation Refer to the Preventive Maintenance Schedule in this manual for recommended servicing intervals. Perform the following procedure below as follows: Procedure: 1. Locate the engine oil level gauge (dipstick). 2. Twist the oil level gauge (dipstick) handle. 3. Pull the handle of the oil level gauge (dipstick) forward and out (See Figure 4-2). 4.
Page 100: Step 3: Check Oil Level A-B Limits
Engine Operation Step 3: Check Oil Level A-B Limits Showing oil levels between A-B limits FIGURE 4-3: CHECK OIL LEVELS A-B LIMITS...
Page 101 Engine Operation Refer to the Preventive Maintenance Schedule in this manual for recommended servicing intervals. Perform the following procedure below as follows: Procedure: 1. Check if the oil is smeared between the upper limit (a) and the lower limit (b) (See Figure 4-3) of the oil level gauge (dipstick) .
Page 102: Step 4 Drain Engine Oil
Engine Operation Step 4 Drain Engine Oil Showing engine drain location. FIGURE 4-4: SHOWING ENGINE OIL DRAIN...
Page 103 Engine Operation Refer to the Preventive Maintenance Schedule in this manual for recommended servicing intervals. Perform the following procedure below as follows: Oil in the filter may run down while detaching the oil filter. Be careful not to contaminate the other parts by using a cloth when detaching the filter.
Page 104: Step 5: Replacing Oil Filter
Engine Operation Step 5: Replacing Oil Filter Showing oil filter location. FIGURE 4-5: REPLACING OIL FILTER...
Page 105 3. Assemble the oil filter with the filter wrench at a torque of 16 ~ 20 Nm. 4. Add the engine oil. Inject genuine oil recommended by Doosan. 5. Reinsert the oil level gauge (dipstick). 6. Reinstall the oil cap.
Page 106: Step 6: Final Inspection For Leaks
Engine Operation Step 6: Final Inspection for Leaks Performing final inspection for leaks. FIGURE 4-6: FINAL INSPECTION FOR LEAKS...
Page 107 Engine Operation Refer to the Preventive Maintenance Schedule in this manual for recommended servicing intervals. Perform the following procedure below as follows: Procedure: 1. Start the engine and then stop it when it reaches a normal temperature. 2. Check if engine oil leaks after starting the engine. 3.
Page 108: Coolant
Engine Operation Coolant The recommended mixing ratio allows coolant to prevent corrosion of the engine efficiently and to maintain the best engine performance for a long period. Using contaminated water or unspecified antifreeze or additives may cause critical faults in the cooler. General Information The coolant plays an important role in the prevention of overheating and freezing of the engine.
Page 109: Checking The Coolant
Engine Operation Checking the Coolant If the reservoir cap is opened to exchange or replenish coolant while the engine is overheated, hot water will spurt out and may cause serious burns. If it is absolutely necessary to open the reservoir cap while the engine is overheated, wrap the reservoir cap with a cloth and slowly open the reservoir cap in two steps until the steam pressure has been released from the inside.
Page 110 Engine Operation Procedure for checking coolant. 1. Make sure that the engine and radiator are cooled. 2. Check the level in the supplementary tank. 3. If the coolant level indicates between the upper limit and the lower limit on the supplementary tank, it means that the coolant volume is normal.
Page 111 Engine Operation TABLE 5-2: GLYCOL-ANTIFREEZE TEST SHEET 1. Compare the color of part A (See Table 5-2) on the test sheet to the color of GLYCOL/FREEZEPOINT (End pad) of the standard color table. 2. Compare the color of the test sheet (B) (See Table 5-2) to the color of MOLYBDATE (Middle pad) of the standard color table.
Page 112: Replenishment Of Coolant
Engine Operation Replenishment of Coolant Do NOT let foreign substances flow into the engine when replenishing coolant. If the reservoir cap is opened while the engine is hot, hot water will spurt out and may cause serious burns. Open the reservoir cap after making sure that the engine has been fully cooled.
Page 113: Replacement Of Coolant
Engine Operation Replacement of Coolant Never open the reservoir cap while the engine is overheated. If the reservoir cap is opened while the engine is overheated, hot water will spurt out and may cause serious burns. Open the reservoir cap after ensuring that the engine has been cooled sufficiently.
Page 114 Engine Operation After replenishing coolant, check the coolant level of the supplementary tank for at least two or three days. 1. Make sure that engine and radiator are cooled. 2. Place an appropriate size container in front of the coolant drain plug. 3.
Page 115: Lubrication
Lubrication...
Page 116: General Lubrication Information
Lubrication General Lubrication Information Lubrication is an essential part of Preventive Maintenance, affecting to a great extent the useful life of the compressor. Different Lubricants are needed and some components require more frequent Lubrication than others. Therefore, it is important that the instructions regarding types of Lubricants and the frequency of their application be explicitly followed.
Page 117 Lubrication Some Oil Types Are Incompatible When Mixed And Result In The Formation Of Varnishes, Shellacs, Or Lacquers Which May Be Insoluble. Such Deposits Can Cause Serious Troubles Including Clogging Of The Filters. Do Not Mix Oils Of Different Types And Avoid Mixing Different Brands.
Page 118: Compressor Oil Chart
Lubrication Compressor Oil Chart Refer to this chart (See Chart 6-1) for the Correct compressor Oil required. Note that the selection of oil is dependent on the rated operating pressure of the compressor and the ambient temperature expected to be encountered before the next oil change. Note: Oils Listed As “Preferred”...
Page 119 Compressor Oil Carryover (Oil Consumption) May Be Greater With The Use Of Alternative Oils. Preferred Oil - use of these Oils with Doosan (See Table 6-1) branded Filters can extend Airend Warranty. Refer to the Warranty Policy for details or contact your Representative.
Page 121: Maintenance
Maintenance...
Page 122: General Maintenance Information
Maintenance General Maintenance Information Any unauthorized modify cation or failure to maintain this equipment may make it unsafe and out of factory warranty. If performing more than visual inspections, disconnect Negative (-) battery cable and open manual blowdown valve. Use extreme care to avoid contacting hot surfaces (engine exhaust manifold, piping, air receiver, and air discharge piping, etc.).
Page 123: Maintenance Precautions
Maintenance Maintenance Precautions Pressure will remain in the system between the minimum pressure valve and the service valve after shutdown and operation of the automatic blowdown valve. This pressure must be relieved by disconnecting any downstream equipment and opening the discharge valve to atmosphere. Refer to the Preventive Maintenance Schedule (PMS) in this manual that describes the service intervals that should be followed For “Normal”...
Page 124 Maintenance Prior to attempting any maintenance work, ensure: 1. All pressure is vented from the system and the compressor cannot be started accidentally. 2. If the automatic blowdown valve fails to operate, then pressure must be gradually relieved by operating the manual blowdown valve. 3.
Page 125: Scheduled Maintenance
Maintenance Scheduled Maintenance The maintenance schedule is based on normal operation of the unit. This section can be reproduced and used as a checklist by the service personnel. In the event unusual environmental operation conditions exist, the schedule should be adjusted accordingly. Refer to the Preventive Maintenance Schedule in this manual for recommended servicing intervals.
Page 126: Scavenge Line
Maintenance Scavenge Line 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 127: Compressor Oil Filter
Maintenance Compressor Oil Filter Refer to the Preventive Maintenance Schedule in this manual for recommended servicing intervals. Do not remove the filter(s) without first ensuring the compressor is shut off and the system has been completely relieved of all air pressure. (Refer to STOPPING in the OPERATING INSTRUCTIONS section of this manual).
Page 128: Compressor Oil Separator Element
Maintenance Compressor Oil Separator Element Refer to the Preventive Maintenance Schedule in this manual for recommended servicing intervals. Do not remove the filter(s) without first ensuring the compressor is shut off and the system has been completely relieved of all air pressure. (Refer to STOPPING in the OPERATING INSTRUCTIONS section of this manual).
Page 129 Maintenance Compressor Oil Separator Element (continued) If the element has to be replaced, then proceed as follows: Removal Disconnect all hoses and tubes from the separator tank cover plate. Remove the drop tube from the separator tank cover plate and remove the cover plate. Remove the separator element.
Page 130: Compressor Oil Cooler, Engine Radiator, And Other Heat Exchangers
Maintenance Compressor Oil Cooler, Engine Radiator, and other Heat Exchangers Ensure the heat exchanger access doors are closed and secure before starting the engine. Hot engine coolant and steam can cause injury. When adding coolant or antifreeze solution to the engine radiator, stop the engine and allow radiator to cool prior to releasing the radiator pressure cap.
Page 131: Air Filter Elements
Maintenance Air Filter Elements Refer to the Preventive Maintenance Schedule in this manual for recommended servicing intervals. Never remove and replace element(s) when the compressor is running. If inspection reveals damage to the main element, the safety element must be replaced. 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.
Page 132 Maintenance Removal 1. Loosen the two (2) latches item 1, on the sides of the air filter body item 2 and cover item 4. 2. Remove the primary element filter item 3, from air filter body item 2. If equipped, remove the optional safety element filter item 5, from the inside of primary filter item 3.
Page 133: Gauges
Every 3 months check to ensure fan drive mounting bolts to the engine have not loosened. If, for any reason, it becomes necessary to remove or re-tighten the mounting bolts. Replace bolts with Doosan approved bolts and torqued to 25 ft lbs. 35Nm. The fan belt(s) should be checked monthly for wear and correct tensioning.
Page 134: Radiator
Maintenance Check for damaged or deteriorated components. Pay careful attention to keep the internal surfaces clean, particularly when parts are removed for inspection or service. Radiator The use of water alone in this engine can result in major engine failure. Refer to engine section for coolant recommendation.
Page 135: Electrical System
If electrical grease is not present or very minimal, add a small amount of Doosan Part No. 22409114 Electrical Grease to the terminals. Dirty and/or corroded electrical terminals can be cleaned using electrical contact cleaner.
Page 136: Fasteners
Refer to the Engine Operator Manual. The Tier 4 engine in this compressor requires engine lubricating oil to ensure proper Aftertreatment System operation and engine durability. Doosan Tier 4 Premium Engine Oil is recommended. Refer to the Engine Operator Manual for engine oil specifications.
Page 137: Compressor Oil
Maintenance Compressor Oil DO NOT, under any circumstances, remove any drain plugs or the oil filler plug from the compressor lubricating and cooling system without first ensuring the compressor is stopped and the system has been completely relieved of all air pressure (refer to STOPPING in the Operating Instructions Section of this manual).
Page 138: Bearing Lubrication
Maintenance Bearing Lubrication Proper lubrication of the portable compressor’s bearing axle is critical to its proper function and reduction of wear on parts. Wheel bearing should be lubricated at least every 12 months, or more, to ensure proper performance and minimize wear. Use a wheel bearing grease per the Maintenance Schedule in this manual that conforms to the table below (Refer to Table 7-1): TABLE 7-1: GREASE SPECIFICATIONS...
Page 139: Exterior Finish Care
Maintenance Exterior Finish Care This unit was painted, and heat cured at the factory with a high quality, thermoset polyester powder coating. The following care will ensure the longest possible life from this finish. 1. If necessary to remove dust, pollen, etc. from housing, wash with water and soap or dish washing liquid detergent.
Page 140: Field Replacement Of Exterior Decals
Maintenance Field Replacement of Exterior Decals Field Replacement of Enclosure Decals 1. The decal area should be wiped with 70% isopropyl alcohol and a lint free cloth, in a well-ventilated area. 2. Allow enough time for drying, but not enough time for dust to resettle on surface. 3.
Page 141: Troubleshooting
Troubleshooting...
Page 142: Introduction
Troubleshooting Introduction Troubleshooting for a Portable Air Compressor is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The Troubleshooting Chart that follows includes some of the problems that an operator may encounter during the operation of a Portable Compressor.
Page 143: Troubleshooting Chart
Troubleshooting Troubleshooting Chart Complaint Cause Correction 1. Compressor has Out of Fuel. Add Clean Fuel. stopped unexpectedly Compressor Oil Temp. too See Complaint #6. High. Engine Coolant Temp. too Check Coolant level. If low, High. add Coolant. See Complaint Engine Oil Pressure too Low. See Complaint #4. Loose or Broken Belts.
Page 144 Troubleshooting Complaint Cause Correction 2. Compressor won’t Start Blown fuse. Identify and replace fuse. or Run (continued) See Electronic Service Manual. Malfunctioning main power Check switch. Replace if switch. necessary. See Electronic Service Manual. Clogged fuel filters. Service fuel filters. See Engine Manual.
Page 145 Troubleshooting Complaint Cause Correction 3. High Engine Coolant Compressor tilted beyond Reposition or relocate Temperature (continued) out-of-level operating limit. compressor to be more level. Operating pressure too High. Reduce pressure to rated operating pressure. Recirculation of cooling air. Close enclosure doors. Close and secure access panels.
Page 146 Troubleshooting Complaint Cause Correction 6. High Compressor Oil Ambient temperature above Operate in cooler Temperature rated ambient temperature environment. range. Compressor tilted beyond Reposition or relocate out-of-level operating limit. compressor to be more level. Low compressor oil. Add compressor oil. Look for and repair any leaks.
Page 147 Troubleshooting Complaint Cause Correction 7. Low Engine Speed Clogged fuel filters. Service fuel filters. See Engine Manual. Drain and clean fuel tanks. Add clean fuel. Operating pressure too high. Reduce pressure to rated operating pressure. Clogged air filter element(s). Clean or replace air filter element(s).
Page 148 Troubleshooting Complaint Cause Correction 11. Compressor will not Malfunctioning inlet unloader. Inspect valve. Make unload adjustments per this manual. Malfunctioning pressure Check pressure regulator. regulator. Check regulation lines for leaks. Ice in regulation lines and/or Apply heat to lines and or regulation orifice.
Page 149: Diagnostic Codes
Troubleshooting Diagnostic Codes The Miniport Displays Diagnostic Codes For The Compressor System And The Engine. Listings Of These Codes Are Provided In This Section. The Engine Diagnostic Codes Can Also Be Read With The Engine Manufacturer’S Service Tool (Refer to Engine Fault Codes section in this manual). A Service Tool Connector Is Provided In The Electrical Harness, Providing Access To The J1939 Can Network.
Page 151: Compressor Diagnostic Codes
Compressor Diagnostic Codes...
Page 152: Compressor Diagnostic Codes
Compressor Diagnostic Codes Compressor Diagnostic Codes LCD Display Display Name Description Type FAULT CPR CODE 1 Low Engine Speed Engine speed less than 1300 RPM for 30 LOW ENGINE seconds. SPEED CPR CODE 2 High Engine Speed Engine speed greater than 2720 RPM for FAULT HIGH ENGINE 30 seconds.
Page 153 Compressor Diagnostic Codes LCD Display Display Name Description Type CPR CODE 26 Load Inhibit Delay The operator has attempted to load the ALERT LOAD INHIBIT machine before the warm up timer has DELAY expired. CPR CODE 28 Incorrect Engine ECU Engine ECU has a different calibration ALERT Calibration...
Page 154 Compressor Diagnostic Codes LCD Display Display Name Description Type CPR CODE High IQ Filter IQ filters restricting air flow. ALERT 44 HIGH Restriction IQ FILTERS RESTR CPR CODE High Separator Tank Separator tank temperature greater than FAULT 50 HIGH SEP Temperature or equal to 251°...
Page 155 Compressor Diagnostic Codes LCD Display Display Name Description Type CPR CODE 75 IQ TCU Controller Communication between Compressor ALERT IQ TCU CTRL Communication Controller and engine IQ TCU controller COMMS not functional. CPR CODE Low Def Level 0% DEF level initiate engine shutdown FAULT 141 LOW DEF after 1 minute.
Page 157: Engine Fault Codes
Engine Fault Codes...
Page 158: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 159: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 160: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 161: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 162: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 163: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 164: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 165: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 166: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 167: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 168: Engine Fault Code List
Engine Fault Codes Engine Fault Code List...
Page 169: Preventive Maintenance Schedule (Pms)
Preventive Maintenance Schedule (PMS)
Page 170: Preventive Maintenance Schedule (Pms)
Preventive Maintenance Schedule (PMS) Preventive Maintenance Schedule (PMS) Preventive Maintenance Schedule...
Page 171: Torque Values
Torque Values...
Page 172: Torque Values
Torque Values Torque Values Fasteners See the following pages for inch torque chart, metric torque chart and wheel torque chart. All fasteners should be torqued in accordance to size and grade. TABLE 1: INCH FASTENERS...
Page 173: Torque Values (Continued)
Torque Values Torque Values (Continued) TABLE 2: METRIC FASTENERS Note: Cooling Fan Drive Bolts (10.9 M8 x 1.25) should be torqued to 23Nm (17ft-lbF). Separator Lid Max Bolt torque: 166 (ft-lb).
Page 174 Torque Values TABLE 3: WHEEL TORQUE CHART Wheel Torque Chart - Inch Wheel Torque Chart - Metric M12 Bolts Torque (Ft-Lbs) 13” Wheel 60-70 Torque 1/2” Lug Nuts Torque (Ft-Lbs) Torque (N-m) (Ft-Lbs) 13” Wheel 80-90 M12 Bolts 85-95 62-70 15”...
Page 175: Wiring Diagrams
Wiring Diagrams...
Page 176: Compressor And Engine Harness
Compressor and Engine Harness...
Page 181: Compressor And Engine Control System
Compressor and Engine Control System...
Page 184: P185Wdou Generator Option
P185WDOU Generator Option...
Page 186: Electrical Parts List
Electrical Parts List...
Page 188 INTENTIONALLY LEFT BLANK...
Page 189: Warranty
Warranty...
Page 190: Warranty
Warranty Warranty Doosan Portable Power General Warranty Information...
Page 191: Truck Mounted Equipment
Warranty Truck Mounted Equipment...
Page 192: Doosan Infracore Federal & California Emission Control Systems Limited Warranty For Non-Road Engines (Ci)
Warranty Doosan Infracore Federal & California Emission Control Systems Limited Warranty for Non-Road Engines (CI)
Page 193: Revision History
Revision History Rev. Date Description 11/02/2015 Original Release 02/16/2017 Added Content in Manual 03/12/2019 Updated Content in Manual...
Page 196 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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Doosan P185WDOU-T4F (F89) Operation And Maintenance Manual

Foreword

Safety

Lifting, Transporting and Preparation

Noise Emission

General Data

Operating Instructions

Engine Operation

Lubrication

Maintenance

Troubleshooting

Compressor Diagnostic Codes

Engine Fault Codes

Preventive Maintenance Schedule (Pms)

Torque Values

Wiring Diagrams

Warranty

Quick Links

Troubleshooting

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Summary of Contents for Doosan P185WDOU-T4F (F89)