Doosan 7/73-10/53 Operation And Maintenance Manual
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Doosan 7/73-10/53 Operation And Maintenance Manual

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7/73 - 10/53
OPERATION AND MAINTENANCE MANUAL
Original Instruction
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
46674184_en_C_09/18
SERIAL No :
543500 -> 543999

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  • Page 1 7/73 - 10/53 OPERATION AND MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to personnel who operate and maintain this machine. SERIAL No : 543500 -> 543999 46674184_en_C_09/18...
  • Page 3 Directive, has been excluded from the scope of this Directive. It may carry "CE" marking in compliance with other applicable EC directives. Jan Moravec Engineering Director Issued at Dobris, Czech Republic Date The technical documentation for the machinery is available from: Doosan Bobcat EMEA s.r.o. (DBEM), U Kodetky 1810, 263 12 Dobris, Czech Republic CPN 46552199 rev P...
  • Page 5 CONTENTS & ABBREVIATIONS CONTENTS FAULT FINDING FOREWORD OPTIONS Lubricator DECALS Safety SAFETY General Information Operating Instructions GENERAL INFORMATION Maintenance Dimensions Fault Finding Data Chalwyn Valve OPERATING INSTRUCTIONS Adjustment Commissioning Maintenance Prior to starting Aftercooler and Water Separator Air hose restraint installation Operating Instructions Starting Maintenance...
  • Page 6 © COPYRIGHT 2018 DOOSAN COMPANY The intended uses of this machine are outlined below and examples of unapproved usage are also given, however the company cannot anticipate every application or work situation that may arise.
  • Page 7 DECALS GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition / Mandatory Information / Instructions Warning WARNING: Electrical shock risk WARNING - Pressurised component or WARNING - Hot surface. system. WARNING - Pressure control. WARNING - Corrosion risk. WARNING - Air/gas flow or Air discharge. WARNING - Pressurised vessel.
  • Page 8 DECALS WARNING - Maintenance work in progress. WARNING - Do not undertake any WARNING - Consult the operation and maintenance on this machine until the maintenance manual before commencing electrical supply is disconnected and the air any maintenance. pressure is totally relieved. Do not breathe the compressed air from this Do not remove the Operating and Maintenance Do not stack.
  • Page 9 DECALS Lashing point (Tie down). Lifting point. On (power). Off (power). Read the Operation and Maintenance manual When parking use prop stand, handbrake and before operation or maintenance of this wheel chocks. machine is undertaken. Compressor oil filling. Diesel fuel. Parking brake.
  • Page 10 DECALS Engine oil drain. Compressor oil drain. 7/73 - 10/53...
  • Page 11 DECALS 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 CAUTION Red background...
  • Page 12 DECALS WARNING WARNING Improper operation of this equipment. Trapped pressure. CAN cause serious injury or death. Can cause serious injury or death. Read Operator's Manual supplied with this machine before operation or servicing. Close service valve and operate tool to vent trapped Modification or alteration of this machine.
  • Page 13 DECALS WARNING WARNING Collapsing propstand. Can cause serious injury.. WARNINGExcessive Towing Speed. CAN cause Clamp propstand securely serious injury or death. Excessive towing speed. Do NOT Tow on Highway. Can cause serious injury or Do NOT exceed 20 mph (32 km/h) death.
  • Page 14 SAFETY Compressed air WARNINGS Warnings call attention to instructions which must be followed Compressed air can be dangerous if incorrectly handled. Before doing precisely to avoid injury or death. any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.
  • Page 15 SAFETY AVOID INGESTION, SKIN CONTACT AND INHALATION OF Transport FUMES. When loading or transporting machines ensure that the specified lifting Should compressor lubricant come into contact with the eyes, then and tie down points are used and cables or chains are in safe limits. irrigate with water for at least 5 minutes.
  • Page 16 SAFETY When parking always use the handbrake and, if necessary, suitable Where brakes and safety chains are fitted: wheel chocks. a) Loop the chains onto the towing vehicle using the towing vehicle Make sure wheels, tyres and tow bar connectors are in safe operating hitch as an anchorage point, or any other point of similar strength.

  • Page 17: General Information

    GENERAL INFORMATION 7/73 - 10/53 FIXED HEIGHT RUNNING GEAR Braked version 7/73 - 10/53 VARIABLE HEIGHT RUNNING GEAR Braked version 7/73 - 10/53...
  • Page 18 GENERAL INFORMATION 7/73 - 10/53 PERMANENT SKID MOUNTED (2434 **) 1200 * 1. * 10mm 2300 * 2. ** 40mm 1019 * 1238 * (1429 **) 378 * 191 * 150 * 70 (2X) 127.0 127.0 223.0 36.0 659.3 195.5 551.2 64.0 406.5...
  • Page 19 GENERAL INFORMATION 7/73 - 10/53 TRUCK SKID MOUNTED (2434 **) 1200 * 1. * 10mm 2300 * 1019 * 2. ** 40mm 1274 * (1464 **) 414 * 191 * 150 * 70 (2X) 127.0 127.0 36.0 659.3 195.5 551.2 223.0 64.0 406.5...
  • Page 20 / receiver, cooler and pipework must be flushed clear of the first fill fluid and new Doosan oil filters installed. When this has been completed, the following oils are approved: for ambient temperatures above -23°C (-9°F),...

  • Page 21: Operating Instructions

    OPERATING INSTRUCTIONS COMMISSIONING Ensure that the correct fork lift truck slots or marked lifting / tie down points are used whenever the machine is lifted or transported. Upon receipt of the unit, and prior to putting it into service, it is When selecting the working position of the machine ensure that there important to adhere strictly to the instructions given below in PRIOR is sufficient clearance for ventilation and exhaust requirements,...
  • Page 22 OPERATING INSTRUCTIONS PRIOR TO STARTING CAUTION: When refueling:- • switch off the engine. 1. Place the unit in a position that is as level as possible. The design • do not smoke. of the unit permits a 15 degree lengthways and sideways limit on •...
  • Page 23 OPERATING INSTRUCTIONS AIR HOSE RESTRAINT INSTALLATION Hoses can fail in areas other than at connecting points and require daily inspection of the hoses for: Safety devices such as hose restraints (whipchecks)must be used to • Cuts, cracks or kinks prevent hose whipping if a connection fails. Whipchecks are to be constructed of woven stainless steel, galvanized steel wire rope or •...
  • Page 24 OPERATING INSTRUCTIONS Warning lamp, low engine oil pressure Main switch Warning lamp, high airend oil temperature High / Low pressure mode switch Warning lamp, dirty IQ filters (IQ filters option) Service air button Warning lamp, high engine coolant temperature Air pressure gauge Warning lamp, low engine fuel level Hourmeter Warning lamp, low battery voltage...
  • Page 25 OPERATING INSTRUCTIONS STARTING THE MACHINE STOPPING THE MACHINE • Close the service valve. WARNING: Under no circumstances should volatile liquids such as Ether be used for starting this machine. • Allow the machine to run unloaded for a short period of time to reduce the engine temperature.
  • Page 26 OPERATING INSTRUCTIONS COMPRESSOR MOUNTING Flash out of fault codes: Fault flash out mode can be entered through the use of a diagnostic switch located next to the fault lights. To enter the flash fault out mode, the keyswitch must be ON, with the engine not Portable compressors, which are modified to remove the running gear running.

  • Page 27: Maintenance Schedule

    R/WI = Replace or when indicated earlier CBT = Check before towing Contact your Doosan Infracore Portable Power dealer for more information or assistance in determining the optimum intervals for your G/C = Grease and check application.
  • Page 28 R/WI = Replace or when indicated earlier decrease in maintenance intervals. CBT = Check before towing Contact your Doosan Infracore Portable Power dealer for more information or assistance in determining the optimum intervals for your G/C = Grease and check application.
  • Page 29 MAINTENANCE ROUTINE MAINTENANCE • warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen. This section refers to the various components which require periodic Upon completion of maintenance tasks and prior to returning the maintenance and replacement.
  • Page 30 MAINTENANCE Alternator/drive belt failure circuit. Reassembly Clean the filter gasket contact area and install the new element by At twelve month intervals test the alternator drive belt failure circuit as screwing in a clockwise direction until the gasket makes contact with follows: the filter housing.
  • Page 31 MAINTENANCE Clean the exterior of the filter housing and remove the filter element by 1. Primary fuel filter / water separator (30 microns) releasing the nut. 2. Secondary fuel filter (10 microns) Inspection Check for cracks, holes or any other damage to the element by holding General Information it up to a light source, or by passing a lamp inside.
  • Page 32 MAINTENANCE Removal CAUTION: Mechanical over-tightening can distort the threads as well Loosen and remove the fuel filter. as damage the filter element seal or filter body. Make sure the o-ring does not stick to the fuel filter head. Remove the Install the filter on the filter head: o-ring with an o ring pick, if necessary.
  • Page 33 MAINTENANCE PRESSURE SYSTEM CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals. At 500 hour intervals it is necessary to inspect the external surfaces of NOTE: To prevent damage to the hand pump priming seals, clean the system (from the airend through to the discharge valve(s)) the fuel pump head and priming pump with Quick Dry Spray Cleaner, including hoses, tubes, tube fittings and the separator tank, for visible...
  • Page 34 MAINTENANCE The brake actuators must not be pre-tensioned - if necessary loosen When the brake has been adjusted accurately the actuating distance the brake linkage [7] on the brake equalisation assembly [8]. is approximately 5-8mm on the cable [11] Check that brake actuators and cables [11] operate smoothly. 3.
  • Page 35 MAINTENANCE Excessive operation of the handbrake lever, which may have been LUBRICATING OIL FILTER (SPIN-ON) caused by worn brake linings, must not be corrected by re-adjusting (shortening) the brake linkage [7] Removal Re-adjustment The handbrake lever [1] should be engaged forcefully several times to set the braking system.
  • Page 36 MAINTENANCE Make sure that the o-ring and two gasket seals are installed on the All filters and filter elements for air and compressor oil must be filter, that they are clean and free of debris. Use clean lubricating oil to obtained through Portable Power to assure the proper size and lightly lubricate the o-ring seal (1) and primary gasket seal (2) only.
  • Page 37 MAINTENANCE • Install the drain plugs. WARNING: Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental CAUTION: Before starting another Internal Preservation of the Fuel regulations. System procedure again (after passing a storage period) it is required CAUTION: After 24 months in storage, the engine cooling system to fill the engine oil pan sump to the high mark using TectylTM 910 or must be drained and flushed with a suitable solvent or a hot,...
  • Page 38 Specifications procedure in Section V of the corresponding owners • Airend – Remove the intake connection and pour the airend intake and/or operation and maintenance manual for antifreeze, water, full with Doosan compressor fluid PRO-TEC, XHP605 or XHP405. and SCA specifications. Reconnect the intake connection. •...
  • Page 39 MAINTENANCE It is necessary to isolate the compressor package from the carrier base Before Starting with a flexible mounting system. Such a system must also prevent 1. Select Low Pressure Mode by turning HI/LO Pressure Switch on detachment of the package from the carrier base in the event the control panel.
  • Page 40 MAINTENANCE TORQUE VALUES Part ft. lbf Part ft. lbf Airend (main body) to engine 29-34 39-47 Discharge hose to Airend- 158-167 214-226 Separator (-24 JIC) Coupling element to engine 35-38 48-52 flywheel Fan clutch to adapter on engine 1033-1047 1400-1420 Air filters to brackets 18-21 24-28...
  • Page 41 (-10°F to 125°F) XHP 605 Alternate: XHP 405 Doosan preferred fluids - the use of these fluids with original Doosan ISO Viscosity Grade branded filters can extend airend warranty. Refer to operator’s manual 68 Group 3 or 5 with warranty section for details or contact your Portable Power representative.
  • Page 42 ELECTRICAL SYSTEM elec 7/73 - 10/53...

  • Page 43: Electrical System

    ELECTRICAL SYSTEM Fan, Full Speed Switch, Oil Pressure Switch, Water Temperature Switch, Water Temperature Valve, Start / Run Solenoid Valve, Hi / Lo Pressure Solenoid IQ Filter Restriction Sensor, Regulation System Pressure (0-30 PSI) Sensor, Discharge Oil Temperature Keyswitch Button, Warm-Up Switch, Hi / Lo Switch, Airend Temperature Switch, Airend Temperature...
  • Page 44 ELECTRICAL SYSTEM 7/73 - 10/53...
  • Page 45 ELECTRICAL SYSTEM BDS1 Switch, Battery Disconnect (Option) Battery System, 12VDC Starter, Engine Sensor, Water-In-Fuel Centre, Fuse / Relay Clutch, Fan Fuse, Alternator Fuse, Engine Intake Air Heater Alternator, Engine Heater, Engine Intake Air Heater, Fuel Connector, Cummins QSF2.8 S3B CM2880B ECM OEM 94 PIN Sensor, Coolant Level Connector, Engine ECM Service Relay, Engine Starter...
  • Page 46 ELECTRICAL SYSTEM Fan, Electric Fan, Electric Cold Start (Option) Connector, TBAP Engine Harness Sensor, TBAP Relay, Electric Fans 7/73 - 10/53...
  • Page 47 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM - 7 PINS IL LH Indicator light - left hand Black IL RH Indicator light - right hand Green Fog light Pink SL LH Stop light - left hand Brown SL RH Stop light - right hand Orange TL LH...
  • Page 48 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM - 13 PINS REVERSE LIGHT IL LH Indicator light - left hand Black IL RH Indicator light - right hand Green Fog light Pink Reverse light Brown SL LH Stop light - left hand Orange SL RH Stop light - right hand...
  • Page 49 PIPING AND INSTRUMENTATION SYSTEM Air discharge Sonic orifice (restricts flow) Pressure gauge Air/oil Separator tank Safety valve Compressor Engine Oil cooler Oil filter Thermostatic valve (when fitted) Separator filter assembly (spin-on) 7/73 - 10/53...

  • Page 50: Fault Finding

    FAULT FINDING FAULT CAUSE REMEDY Engine fails to start. Low battery charge. Check the fan belt tension, battery and cable connections. Bad earth connection. Check the earth cables, clean as required. Loose connection. Locate and make the connection good. Fuel starvation. Check the fuel level and fuel system components.
  • Page 51 Top up the oil level and check for leaks. Dirty or blocked oil cooler. Clean the oil cooler fins Incorrect grade of oil. Use Doosan recommended oil. Recirculation of cooling air. Move the machine to avoid recirculation. Faulty temperature switch.
  • Page 52 FAULT FINDING DIAGNOSTIC CODES Fault Code J1939 SPN J1939 FMI Lamp Colour Cummins Description Stop (Solid) Engine Control Module Critical Internal Failure - Bad intelligent device or component. Stop (Solid) Engine Magnetic Speed/Position Lost Both of Two Signals - Data erratic, intermittent or incorrect.
  • Page 53 FAULT FINDING Fault Code J1939 SPN J1939 FMI Lamp Colour Cummins Description Stop (Solid) Coolant Level - Data valid but below normal operational range - Most Severe Level. 3511 Warning (Solid) Sensor Supply 3 Circuit - Voltage below normal, or shorted to low source. 3511 Warning (Solid) Sensor Supply 3 Circuit - Voltage above normal, or shorted to high...
  • Page 54 FAULT FINDING Fault Code J1939 SPN J1939 FMI Lamp Colour Cummins Description Stop (Solid) Injector Metering Rail 1 Pressure - Data valid but above normal operational range - Most Severe Level. Warning (Solid) Injector Metering Rail 1 Pressure Sensor Circuit - Voltage above normal, or shorted to high source.
  • Page 55 FAULT FINDING Fault Code J1939 SPN J1939 FMI Lamp Colour Cummins Description 1696 3513 Warning (Solid) Sensor Supply 5 - Voltage below normal, or shorted to low source. 1852 Warning (Solid) Water in Fuel Indicator - Data Valid But Above Normal Operating Range - Moderately Severe Level.
  • Page 56 FAULT FINDING Fault Code J1939 SPN J1939 FMI Lamp Colour Cummins Description 2962 Warning (Solid) Exhaust Gas Recirculation Temperature - Data Valid But Above Normal Operating Range - Moderately Severe Level. 2963 None Engine Coolant Temperature - Data Valid But Above Normal Operating Range - Least Severe Level.
  • Page 57 OPTIONS PRIMARY AND SECONDARY FILTER MAINTENANCE OPTION - AFTERCOOLER AND WATER SEPARATOR FIGURE 1. DESCRIPTION The compressed air exits the separator tank through the top cover piping, and will then travel into the aftercooler inlet side. The aftercooler is cooled by the incoming compressor package air. The compressed air and condensate (water with a small amount of compressor lubricant) exits the aftercooler and enters the moisture separator, where most of the condensate is removed.
  • Page 58 OPTIONS WATER SEPARATOR MAINTENANCE FIGURE 4. FIGURE 1. FIGURE 5. FIGURE 2. FIGURE 3. 7/73 - 10/53...
  • Page 59 OPTIONS FIGURE 4. FIGURE 7. FIGURE 5. FIGURE 8. SAFETY CAUTION: The compressor regulation system is adjusted to maintain regulated pressure at the separator tank. DO NOT adjust regulation to provide full regulation pressure at the service valve when the IQ System is enabled. This will result in operation at excessive horsepower levels, causing overheating, reduced engine life, and reduced airend life.
  • Page 60 OPTIONS DRAIN LOCATIONS OPTION - BUNDED BASE DESCRIPTION This machine can be fitted with bund equipment to contain leakages and spillages, which occur within the machine enclosure. The bund will contain all fluids normally installed in the machine, plus an additional 10%. OPERATING INSTRUCTIONS When fitted with bund, the machine must only be operated when level.
  • Page 61 OPTIONS DRAIN LOCATIONS OPTION - CENTRAL DRAINS DESCRIPTION This machine can be fitted with a central drains option. When this option is fitted, all drain ports are routed to one easily accessible point. Each drain port consists of a valve, a safety plug and an identification decal.
  • Page 62 OPTIONS NOTES: OPTION - CHALWYN VALVE (Air intake shutdown valve) Turbocharged Engines - When setting up a valve on a turbocharged engine using the preceding method, it may be found DESCRIPTION that at high power outputs, the engine will shut down at a lower speed than required.
  • Page 63 OPTIONS GENERAL INFORMATION OPTION - LUBRICATOR Oil capacity: 2 litres Oil specification: Refer to the Tool Manufacturer’s Manual. OPERATING INSTRUCTIONS COMMISSIONING Check the lubricator oil level and fill as necessary. PRIOR TO STARTING Check the lubricator oil level and replenish as necessary. MAINTENANCE Check the lubricator oil level and replenish as necessary.
  • Page 64 OPTIONS MAINTENANCE OPTION - SPARK ARRESTOR Daily: Examine the spark arrestor for any sign of gas leakage, cracks or significant areas of damage, i.e. dents of more than a few millimetres in depth. Three Monthly: Remove spark arrestor. Tap with a soft mallet to loosen any internal deposits and shake out.
  • Page 65 NOTICE HOW TO ORDER Doosan can bear no responsibility for injury or damages resulting directly from the use of non-approved repair parts. The satisfactory ordering of parts by a purchaser is greatly dependent Doosan Infracore service facilities and parts are available worldwide.
  • Page 66 The company makes no other warranty or representation of any kind whatsoever, expressed or implied, except that of title, and all implied Doosan offers an airend exchange program to benefit portable warranties, including any warranty of merchantability and fitness for a compressor users.
  • Page 68 Doosan Bobcat EMEA s.r.o U Kodetky 1810 263 12 Dobříš Czech Republic www.doosanportablepower.eu...

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