Doosan P185WJD-D75, Operating & Maintenance Manual

Page 1: ...chine OPERATION MAINTENANCE COMPRESSOR MODEL P185WJD T4I D75 MANUAL Revised 10 12 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of...

Page 2: ...2...

Page 3: ...sion 2 22 This section pertains only to machines distributed within the United States 2 22 Noise Emission Warranty 2 23 Introduction 2 23 GENERAL DATA 4 27 General Data 4 28 Unit Model 4 28 FLUID CAPA...

Page 4: ...6 41 Battery 6 41 Fasteners 6 42 Radiator 6 42 Hoses 6 42 Compressor Oil Cooler 6 44 Compressor Oil 6 44 Receiver Separator Systems 6 45 Scavenge Line 6 46 Exterior Finish Care 6 46 MAINTENANCE SCHEDU...

Page 5: ...Book 46490694 03 2010 Rev A 3 Foreword...

Page 6: ...ssible be of a type approved by Portable Power clearly rated for a pressure at least equal to the machine maximum allowable working pressure compatible with the compressor lubricant coolant accompanie...

Page 7: ...ce and maintenance items on a special preventive maintenance schedule for each machine It is very important that the minimum service and maintenance requirements explained in this manual be performed...

Page 8: ...Operating Maintenance Manual Foreword 6 Book 46490694 03 2010 Rev A...

Page 9: ...Book 46490694 03 2010 Rev A 7 DRAWBAR NOTICE...

Page 10: ...essor toolbox 2 Open box and remove the bag containing hardware safety chains and assembly instructions 3 Using the jack raise the front of the unit so that the legs are approximately 1 above the grou...

Page 11: ...DRAWBAR NOTICE Operating Maintenance Manual Book 46490694 03 2010 Rev A 9...

Page 12: ...Operating Maintenance Manual DRAWBAR NOTICE 10 Book 46490694 03 2010 Rev A...

Page 13: ...Book 46490694 03 2010 Rev A 11 Safety...

Page 14: ...of at least the machine safety valve rating If more than one compressor is connected to one common downstream plant effective check valves and isolation valves must be fitted and controlled by work p...

Page 15: ...y Do not operate without guard in place Use care to avoid contacting hot surfaces engine exhaust manifold and piping air receiver and air discharge piping etc Ether is an extremely volatile highly fla...

Page 16: ...Operating Maintenance Manual Safety 14 Book 46490694 03 2010 Rev A...

Page 17: ...Safety Operating Maintenance Manual Book 46490694 03 2010 Rev A 15...

Page 18: ...Operating Maintenance Manual Safety 16 Book 46490694 03 2010 Rev A...

Page 19: ...ervisor DANGER DANGER Red Background indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING Orange Background indicates a potentially h...

Page 20: ...Operating Maintenance Manual Safety 18 Book 46490694 03 2010 Rev A...

Page 21: ...l 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 Submit orders for Safety Decals to the Portable Power Parts...

Page 22: ...Operating Maintenance Manual Safety 20 Book 46490694 03 2010 Rev A...

Page 23: ...Book 46490694 03 2010 Rev A 21 Noise Emission...

Page 24: ...system or parts thereof b the air intake system or parts thereof c enclosure or parts thereof 4 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 5 Operation...

Page 25: ...ar part component or system of the air compressor Defects in the design assembly or in any part component or system of the compressor which at the time of sale to the first retail purchaser caused noi...

Page 26: ...e checked and adjusted at this time to insure continuous seating between gasket or acoustic material and the mating frame F Air Intake and Engine Exhaust Engine and compressor air intake and engine ex...

Page 27: ...g Maintenance Manual Book 46490694 03 2010 Rev A 25 Maintenance Record For Noise Emission Control And Extended Warranty Item No Description Of Work Hourmeter Reading Maint inspect Date Location City s...

Page 28: ...Operating Maintenance Manual Noise Emission 26 Book 46490694 03 2010 Rev A...

Page 29: ...Book 46490694 03 2010 Rev A 27 GENERAL DATA...

Page 30: ...UNITS MEASUREMENTS WEIGHTS Overall Length 11 5 3 5 meters Overall Height 5 2 feet 1 56 meters Overall Width 5 7 feet 1 74 meters Track Width 4 9 feet 1 49 meters Weight with fuel 2360 pounds Weight le...

Page 31: ...Infracore Portable Power Description P185WJD Part No Compressor Oil Filter Element 23279078 Compressor Oil Separator Element 22436331 Air Cleaner Element Compressor 35393685 Air Cleaner Element Engine...

Page 32: ...Operating Maintenance Manual GENERAL DATA 30 Book 46490694 03 2010 Rev A...

Page 33: ...Book 46490694 03 2010 Rev A 31 OPERATION...

Page 34: ...pad off the ground Pull pin from tube of jack Fold jack handle down and forward Swing up jack tube and FULLY insert pin in tube Remove tire chocks Test brakes if so equipped Test lights running stop...

Page 35: ...st be relatively free of oil dirt soot and other debris It must be no more than 10 F 5 C over the ambient temperature CONTROL PANEL 1 Discharge Air Pressure Gauge Indicates pressure in receiver tank n...

Page 36: ...level Add only CLEAN low or ultra low sulfur diesel fuel for maximum service from the engine Check the compressor lubricating fluid level between bottom and midway of the sight glass on the separator...

Page 37: ...o the ON position when the engine starts and sustains running Allow engine to warm up 5 to 10 minutes Press the Service Air Button Open air service valve s Cold Weather Starting Turn power switch to t...

Page 38: ...Switch to OFF position When the engine stops automatic blowdown valve should relieve system air pressure If automatic blow down valve malfunction is suspected open manual blowdown valve Never allow u...

Page 39: ...does not pop back out The unit should speed up and then unload and drop back to IDLE With the unit unloaded turn the adjusting screw on the pressure regulator clockwise until the discharge pressure g...

Page 40: ...120 C 3 Low Battery Voltage ALERT condition indicating battery or charging system needs service 11 6 VDC 4 High Eng Temp SHUTDOWN condition due to high engine coolant temperature 248 F 120 C 5 Low Eng...

Page 41: ...Book 46490694 03 2010 Rev A 39 MAINTENANCE...

Page 42: ...to provide maximum output and performance Servicing may consist of pre operation and post operation procedures to be performed by the operating or maintenance personnel The primary function of preven...

Page 43: ...inlet obstructions Make sure the air cleaner mounting bolts and clamps are tight Check the air cleaner housing for dents or damage which could lead to a leak Inspect the air transfer tubing from the...

Page 44: ...The use of water alone in this engine can result in major engine failure Refer to engine section for coolant recommendation Hoses Each month it is recommended that all of the intake lines to and from...

Page 45: ...ape or grease pencil approximately 7 8 inch from the end of the tubing Insert the tubing into the sleeve and push in past the first resistance to the bottom The mark should be approximately 1 16 inch...

Page 46: ...e oil and dirt accumulate on the exterior surfaces of the oil cooler its efficiency is impaired Each month it is recommended that the oil cooler be cleaned by directing compressed air which contains a...

Page 47: ...ing and cooling system separation of the oil from the compressed air takes place in the receiver separator tank As the compressed air enters the tank the change in velocity and direction drop out most...

Page 48: ...maintenance procedure 1 Check oil level Maintain as indicated earlier in this section 2 Thoroughly clean scavenge line any orifice and check valve 3 Assure minimum pressure valve orifice is operation...

Page 49: ...to dry 8 Apply 2 medium wet coats of Duponts 222S Adhesion Promoter over the entire area to be painted with a 5 minute flash in between coats 9 To apply the texture coat use Duponts 1854S Tuffcoat Pri...

Page 50: ...ections Electrolyte C Tire Pressure and Surface C Wheel Lug Nuts C Hoses oil air intake etc C Automatic Shutdown System Test C Air Cleaner System Visual C Compressor Oil Cooler Exterior C CLEAN Engine...

Page 51: ...Book 46490694 03 2010 Rev A 49 LUBRICATION...

Page 52: ...efer to operator s manual warranty section for details or contact your Portable Power representative Design Operating Pressure Ambient Temperature Specification 100 psi to 300 psi 100F to 1250F 230 C...

Page 53: ...Book 46490694 03 2010 Rev A 51 Troubleshooting...

Page 54: ...has been done 4 If the compressor will still operate is it safe to continue operating it to make further checks B Do The Simplest Things First Most troubles are simple and easily corrected For example...

Page 55: ...tions Cause Corrective Action Out of fuel Add CLEAN diesel fuel Low fuel shutdown option Add CLEAN diesel fuel See Table 11 Low battery voltage See Table 6 Airend discharge temperature too high See Ta...

Page 56: ...rrective 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 pressur...

Page 57: ...alve thermostat malfunction Replace thermostat Loose or broken belts Tighten belts Replace belt set Minimum pressure valve malfunction optional Repair or replace valve Engine fan malfunction Inspect f...

Page 58: ...n Check harness connections Replace SECU controller Cause Corrective Action Engine oil level low Add engine oil Clogged engine oil filter element Replace element Machine out of level 15 degrees Reloca...

Page 59: ...end air filter Replace filter s Dirty operating conditions Relocate machine to cleaner environment High air filter pressure drop switch malfunction Check harness connections Replace switch SECU contro...

Page 60: ...ts Loose or Damaged Tighten or replace Anti rumble valve not working Repair or Replace Drive Coupling Defective Replace coupling Defective Fan Replace fan Engine Malfunctioning Consult Dealer Airend M...

Page 61: ...ctioning Inlet Valve Unloader Inspect valve Repair Replace Defective Separator Element Remove element Install new Ice in Regulation Lines Orifice Apply heat to line s and or orifice Cause Corrective A...

Page 62: ...Operating Maintenance Manual Troubleshooting 60 Book 46490694 03 2010 Rev A...

Page 63: ...Revision History Rev Level EC Number Comments A B C D E SVC31192 Original Release...

Page 64: ...2009 Doosan Infracore International Inc Printed in the USA Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 www doosanportablepower com...