Doosan P185WJD Operation & Maintenance Manual
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Doosan P185WJD Operation & Maintenance Manual

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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: 22610380 (4-09) Rev A
MANUAL
P185WJD (E)
XP185WJD-T1 (222)
COMPRESSOR MODELS

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  • Page 1 COMPRESSOR MODELS 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: 22610380 (4-09) Rev A...

  • 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 ............6-47 Maintenance .

  • Page 5: Foreword

    Foreword Book: 22610380 (4-09) 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 has been designed and supplied for use only in the following specified conditions and applications: • Compression of normal ambient air containing no known or detectable additional gases, vapors or particles. • Operation within the ambient temperature range specified in the GENERAL INFORMATION section of this manual.
  • Page 8 Book: 22610380 (4-09) Rev A...

  • Page 9: Drawbar Notice

    Drawbar Notice Book: 22610380 (4-09) Rev A...

  • Page 10: Drawbar Notice - This Machine May Have Been Shipped From The Factory With The Drawbar Positioned Upright. To Convert From Shipping Position To Towing Position

    Drawbar Notice Drawbar Notice - This machine may have been shipped from the factory with the drawbar positioned upright. To convert from Shipping Position to Towing Position. The following tools are required: Ratchet and 13mm socket to fit ratchet Torque wrench set to 68 foot pounds (9.4 kg-meters) 16mm socket to fit torque wrench 5 inch extension for torque wrench Hardware included: (4) 12mm bolts with pre-applied thread lock, (2) 8mm Taptite...

  • Page 11: Safety

    Safety Book: 22610380 (4-09) Rev A...

  • Page 12: 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 13 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 14 Operating & Maintenance Manual Safety Book: 22610380 (4-09) Rev A...
  • Page 15 Safety Operating & Maintenance Manual Book: 22610380 (4-09) Rev A...
  • Page 16 Operating & Maintenance Manual Safety Book: 22610380 (4-09) Rev A...
  • Page 17 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 18 Operating & Maintenance Manual Safety maintenance information. Book: 22610380 (4-09) Rev A...
  • Page 19 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 20 Operating & Maintenance Manual Safety Book: 22610380 (4-09) Rev A...

  • Page 21: Noise Emission

    Section 3 - Noise Emission Book: 22610380 (4-09) Rev A...

  • Page 22: 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 23: Noise Emission Control Maintenance Log

    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 24 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 25 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: 22610380 (4-09) Rev A...
  • Page 26 Operating & Maintenance Manual Noise Emission Book: 22610380 (4-09) Rev A...

  • Page 27: General Data

    Section 4 - General Data Book: 22610380 (4-09) Rev A...

  • Page 28: Models

    Operating & Maintenance Manual General Data General Data Models: Unit Model P185 XP185 Air Delivery (cfm (litres/sec) 185 (87) 185 (87) Engine Speed - RPM (Full Load) 2500 2500 Engine Speed - RPM (No Load) 1700 1700 COMPRESSOR Rated Operating Pressure - psi (kPa).......100 psi (689) Safety Valve Setting - psi (kPa) ........150 psi (1034) Net Weight (less fuel) pounds........2265 ENGINE (DIESEL)

  • Page 29: Tire Size

    General Data Operating & Maintenance Manual Tire Size ....Tire Size..............P215/75RX15 Inflation Pressure (cold) ..........35 psi Towing Speed (maximum) ........65 mph (105 km/hr) EXPENDABLE SERVICE PARTS Compressor Oil Filter Element........36897353 Compressor Oil Separator Element ......54625942 Air Cleaner Element Primary (Compressor) .....35393685...
  • Page 30 Operating & Maintenance Manual General Data Book: 22610380 (4-09) Rev A...

  • Page 31: Section 5 - Operation

    OPERATION...

  • Page 32: Before Towing

    Operating & Maintenance Manual OPERATION BEFORE TOWING towing. SETTING UP (ALL UNITS) WARNING • Position as level as possible. The design of these units permits a 15 Failure to follow these instructions degree sidewise limit on out-of-level CAN cause severe injury or death. operation.
  • Page 33 OPERATION Operating & Maintenance Manual 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.
  • Page 34 Operating & Maintenance Manual OPERATION 12. Power Switch - Rotate “ON” to activate system prior to starting. CONTROL PANEL - Diagnostics/Auto Rotate “OFF” to stop engine. Shutdown (Standard and Optional) (Standard) 13. Engine Speed Gauge - Indicates engine speed. 14. Discharge Air Temp. Gauge - Indicates in °F (82°C) to 210°F (99°C).
  • Page 35 OPERATION Operating & Maintenance Manual WARNING Before Starting • Open service valve(s) to ensure pressure This machine produces loud noise is relieved in receiver-separator system. with doors open. Extended exposure Close valve(s) in order to build up full air to loud noise can cause hearing loss. pressure and ensure proper oil Wear hearing protection when doors circulation.
  • Page 36 Operating & Maintenance Manual OPERATION to the negative (-) terminal of the booster battery and NOTICE the other end to the engine block. NEGATIVE (-) TERMINAL OF THE WEAK BATTERY. Do not operate the starter motor for more than 10 Units With Optional Diagnostics seconds without allowing Lamps...
  • Page 37 OPERATION Operating & Maintenance Manual the engine. Close air service valves. • Allow the unit to run at idle for 3 to 5 Compressor Air/Oil Temperature: minutes reduce engine temperatures. • At the airend outlet. • Turn Power Switch to “OFF” position. •...
  • Page 38 Operating & Maintenance Manual OPERATION Speed and Pressure Regulator Adjusting Instructions The engine idle and full speed settings are After Starting Unit set and sealed at the factory, and should not be adjusted. Serious injury may result if the 4. If equipped, push the SERVICE AIR full speed is increased.
  • Page 39 OPERATION Operating & Maintenance Manual...

  • Page 40: Maintenance

    Section 6 - MAINTENANCE...

  • Page 41: General

    Operating & Maintenance Manual MAINTENANCE Maintenance for repair. Preventive maintenance is the easiest and the least expensive type of CAUTION maintenance. Maintaining your unit and keeping it clean at all times will facilitate servicing. Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory Scheduled Maintenance warranty.

  • Page 42: Gauges

    MAINTENANCE Operating & Maintenance Manual cover. Remove Element. Battery 2. Inspect air cleaner housing for any Keep the battery posts-to-cable connections condition that might cause a leak and clean, tight and lightly coated with a grease. correct as necessary. Also the electrolyte level in each cell should 3.

  • Page 43: Radiator

    Operating & Maintenance Manual MAINTENANCE Radiator design. Features are as follows: Pulling on the tubing will cause the inner sleeve to withdraw and compress, thus NOTICE tightening the connection. The tubing can be withdrawn only while holding the sleeve against the fitting. The tubing can be The use of water alone in this engine removed and replaced numerous times can result in major engine failure.

  • Page 44: Compressor Oil Cooler

    MAINTENANCE Operating & Maintenance Manual 3. Inspect the oil filter head to be sure the In the event foreign deposits, such as sludge gasket was removed with the oil filter and lacquer, accumulate in the oil cooler to element. Clean the gasket seal area on the extent that its cooling efficiency is the oil filter head.

  • Page 45: Scavenge Line

    Operating & Maintenance Manual MAINTENANCE Additional separation takes place in the oil 4. Run unit at rated operating pressure for separator element which is located in the top 30 to 40 minutes to permit element to of the tank. clear itself. Any oil accumulation in this separator element is continuously drained off by means Exterior Finish Care...
  • Page 46 MAINTENANCE Operating & Maintenance Manual 8. Apply 2 medium - wet coats of Duponts NOTE: You must be careful not to put too 222S Adhesion Promoter over the entire much primer on at one time, this will effect area to be painted, with a 5 minute flash the amount of texture that you are trying to in between coats.
  • Page 47 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 48: Lubrication

    Section 7 - LUBRICATION...

  • Page 49: Portable Compressor Fluid Chart

    Operating & Maintenance Manual LUBRICATION Lubrication Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change.
  • Page 50 LUBRICATION Operating & Maintenance Manual...

  • Page 51: Trouble Shooting

    Trouble Shooting...

  • Page 52: Introduction

    Operating & Maintenance Manual Trouble Shooting Trouble Shooting 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- Trouble shooting for a portable air heats”...

  • Page 53: Trouble Shooting Chart

    Trouble Shooting Operating & Maintenance Manual Trouble Shooting Chart Bold Headings depict the COMPLAINT - Subheadings indicate CAUSES NOTE: Subheadings suggest sequence to follow troubleshooting. Table 1: Unit Shutdown Cause Corrective Action Out of Fuel Add CLEAN diesel Fuel Compressor Oil Level Too Low Add correct oil Compressor Oil Temp.
  • Page 54 Operating & Maintenance Manual Trouble Shooting Defective Shutdown Solenoid Replace solenoid. Defective Engine Temp. Switch Replace Switch Defective Separator Tank Temp Switch Replace Switch Defective Low Fuel Shutdown Switch Replace Switch Malfunctioning Relay Replace relay. Engine Malfunctioning See Trouble Shooting in Engine Section. Airend Malfunctioning See Table 10.
  • Page 55 Trouble Shooting Operating & Maintenance Manual Table 7: Alternator Lamp Stays On: Complaint Corrective Action Low Battery Voltage Check electrolyte level. Add if necessary. Loose or Broken Belts Tighten or replace belt set. Check connectors. Clean & tighten. Recharge battery. Malfunctioning Alternator Repair or replace alternator.
  • Page 56 Operating & Maintenance Manual Trouble Shooting Defective Minimum Pressure Valve Repair or replace valve. Malfunctioning Fan Check fan belt tension. Tighten or replace belt set. Blocked or Restricted Oil Lines Clean by flushing or replace. Airend Malfunctioning See Tables 11, 12, 13, 15, 16 or 18. Table 11: Engine RPM Down Complaint Corrective Action...
  • Page 57 Trouble Shooting Operating & Maintenance Manual Table 14: Short Air Cleaner Life Complaint Corrective Action Inadequate Element Cleaning Install new element. Dirty Operating Conditions Move unit to cleaner environment. Incorrect Stopping Procedure Read procedure in this manual. Wrong Air Filter Element Install proper element.
  • Page 58 Operating & Maintenance Manual Trouble Shooting Table 19: Safety Valve Relieves Complaint Corrective Action Operating Pressure Too High Reduce pressure to spec limit. Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual. Malfunctioning Pressure Regulator Replace regulator. Leak In Regulator Piping Repair leak(s).
  • Page 59 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2009 Doosan Infracore International, Inc. Printed in the USA...

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