Doosan 7/72 Operation And Maintenance Manual
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Doosan 7/72 Operation And Maintenance Manual

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7/72
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.
46624235_en_A_09/13
7/72
SERIAL No :
542000
- ->

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  • Page 1 7/72 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. 7/72 SERIAL No : 542000 - -> 46624235_en_A_09/13...
  • Page 2 Machine models represented in this manual may be used in various locations world--wide. Machines sold and shipped into European Union Territories require that the machine display the CE Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid.
  • Page 5 Latvian, Lettish Torque settings table Maltese Compressor lubrication Dutch Norwegian MACHINE SYSTEMS Polish Electrical system Portuguese Piping & instrumentation system Romanian Russian FAULT FINDING Slovak Slovenian Swedish OPTIONS Chinese Lubricator. Chalwyn Valve. Aftercooler and Water Separator. Generator. ENGINE INSTRUCTION MANUAL 7/72...
  • Page 6  COPYRIGHT Details of approved equipment are available from the company service departments. DOOSAN COMPANY The use of repair parts / lubricants / fluids other than those included within the approved parts list may create hazardous conditions over which the company has no control. Therefore the company cannot be held responsible for equipment in which non- -approved repair parts are installed.
  • Page 7 WARNING - - Before connecting the tow bar WARNING - - For operating temperature (Refer to the GENERAL INFORMATION or commencing to tow consult the below 0_C, consult the operation and section of this manual). operation and maintenance manual. maintenance manual. 7/72...
  • Page 8 Do not open the service valve before the Do not exceed the trailer speed limit. No naked lights. airhose is attached. Use fork lift truck from this side only. Emergency stop. Tie down point 7/72...
  • Page 9 When parking use prop stand, handbrake and before operation or maintenance of this Compressor oil filling wheel chocks. machine is undertaken. Diesel fuel Rough Service Designation. Parking brake. No open flame. Wet Location Operation. Replace any cracked protective shield. Oil drain. 7/72...
  • Page 10 Do not breathe this air. WARNING WARNING Rotating Fan Blade. Hot pressurized fluid. CAN cause serious injury. Can cause serious burns. Do NOT operate with guard Do not open radiator while removed. hot. 7/72...
  • Page 11 Access Lifting Bail from inside machine. WARNING WARNING High pressure air. Can cause serious injury or death. Relieve pressure before removing filler plugs/ Door under pressure CAN cause serious caps, fittings or covers. injury. Use both hands to open door when machine is running. 7/72...
  • Page 12 Excessive towing speed. Do NOT Tow on Highway. Can cause serious injury or Do NOT exceed 20 mph (32 km/h) death. Do NOT exceed 65 mph (105 km/hr) For Highway Towable Units. For Non- -Highway Towable Machines 7/72...
  • Page 13 Rotating fan blade can cause serious injury. 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.). 7/72...
  • Page 14 When starting the machine from a slave battery ensure generator set and/or interconnecting cables or conductors with any that the correct polarity is observed and that connections are secure. part of the body or with any non- -insulated conductive object. 7/72...
  • Page 15 S break-away cables/safety chains are connected to the towing enough to prevent the towbar from touching the ground in the event of vehicle. an accidental separation of the towing vehicle from the trailer. 7/72...
  • Page 16 GENERAL INFORMATION 7/72 FIXED HEIGHT RUNNING GEAR Braked version 7/72 VARIABLE HEIGHT RUNNING GEAR Braked version 7/72...
  • Page 17 / receiver, cooler and pipework must be flushed clear of the first fill fluid and new Doosan oil filters installed. Further information may be obtained by request through the When this has been completed, the following oils are approved: customer services department.
  • Page 18 WARNING: If flexible discharge hoses are to carry more than 7 bar the hours of darkness, ensure that the lights are functioning correctly pressure then it is recommended that safety retaining wires are (where fitted). used on the hoses. 7/72...
  • Page 19 5. Drain the fuel filter water separator of water, ensuring that any released fuel is safely contained. 6. Open the service valve(s) to ensure that all pressure is relieved from the system. Close the service valve(s). 7/72...
  • Page 20 Hoses must be selected that are rated for the application as to the maximum pressure and temperature to be encountered as well as compatible with the materials being conveyed inside the hose. Hoses must be compatible with the compressor oil. 7/72...
  • Page 21 S Release to position 2 when the engine starts. S Release to position 1 when the alternator charge light is NOTE: Wear hearing protection at all times when the engine is started extinguished. with the service valve open and air is flowing from the valve. 7/72...
  • Page 22 If the machine has been switched off for reasons of safety, then ensure that the machine can be operated safely before re- -starting. Refer to the PRIOR TO STARTING and STARTING THE UNIT instructions earlier in this section before re- -starting the machine. 7/72...
  • Page 23 S Airend - - Remove the intake connection and pour the airend intake Warranty does not cover failures attributable to mounting of the full with Doosan compressor fluid PRO- -TEC, XHP605 or XHP405. compressor package to the carrier base unless it is a Portable Power Reconnect the intake connection.
  • Page 24 H. Crank Signal Detected: Displayed while start switch is in the pre- -heat or crank position. During SECU/power up, the 8 digit lights to check the display. Next the display will step through the 3 digit software revision number. 7/72...
  • Page 25 ECU failure 4 Long and 1 Short Power supply voltage 2 Long and 3 Short 5V Sensor circuit 2 Long and 4 Short Speed sensor 6 Long Overspeed error 9 Long Oil pressure switch 2 Long and 1 Short 7/72...
  • Page 26 Check and report Contact your Doosan Infracore Portable Power dealer for more information or assistance in determining the optimum intervals for your Drain application.
  • Page 27 Check and report Contact your Doosan Infracore Portable Power dealer for more information or assistance in determining the optimum intervals for your Drain application.
  • Page 28 Check and report Contact your Doosan Infracore Portable Power dealer for more information or assistance in determining the optimum intervals for your Drain application.
  • Page 29 Low engine oil pressure switch. machine, ensure that:- - At three month intervals, test the engine oil pressure switch circuit as follows: the work carried out is limited to only those tasks which require the machine to run. Start the machine. 7/72...
  • Page 30 Start the machine. NOTE: Do not press the load button. Disconnect the switch, the machine should shutdown. Re- -connect the switch. At twelve month intervals, test the low engine fuel level switch by removing and operating the float manually. 7/72...
  • Page 31 CAUTION: Start the machine (refer to PRIOR TO STARTING and STARTING THE UNIT in the OPERATING INSTRUCTIONS section Reset the restriction indicator by depressing the rubber diaphragm. of this manual) and check for leakage before the machine is put back into service. 7/72...
  • Page 32 Check and adjust the brake linkage at 500 miles (850Km) then every 3000 miles (5000Km) or 3 months (whichever is the sooner) to compensate for any stretch of the adjustable cables. Check and adjust the wheel brakes to compensate for wear. 7/72...
  • Page 33 If necessary adjust the brake linkage [7] again without play and without The compression spring [9] must only be lightly pre- - tensioned and pre- -tensioning when operating must never touch the axle tube. Never adjust the brakes at the brake linkage [7]. 7/72...
  • Page 34 Check the brake actuators and cables [11]. The brake actuators must not be pre- -tensioned. Excessive operation of the handbrake lever, which may have been caused by worn brake linings, must not be corrected by re- -adjusting (shortening) the brake linkage [7] 7/72...
  • Page 35 (refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual). 7/72...
  • Page 36 CAUTION: Some oil mixtures are incompatible and result in the formation of varnishes, shellacs or lacquers which may be insoluble. NOTE: Always specify PRO- -TEC oil for use at all ambient temperatures above - -23_C. 7/72...
  • Page 37 SPEED AND PRESSURE REGULATION ADJUSTMENT Open the service valve fully. Check the engine speed up to full RPM, then adjust the service valve to maintain 7 bar (7/72) - - see pressure Normally, regulation requires no adjusting, but if correct adjustment gauge on the control panel.
  • Page 38 58- -67 78- -91 Separator tank to frame 18- -22 24- -30 Exhaust flange to manifold 17- -21 23- -28 Service pipe (- -20jic) 106- -133 143- -180 Sight glass 40- -50 54- -68 Wheel nuts 62- -70 85- -95 7/72...
  • Page 39 Alternate: XHP 405 ISO Viscosity Grade 68 Group 3 or 5 with Preferred Doosan Fluids - - Use of these fluids with original Doosan rust and oxidation branded filters can extend airend warranty. Refer to operator’s manual inhibitors designed warranty section for details or contact your Portable Power for air compressor representative.
  • Page 40 ELECTRICAL SYSTEM 7/72...
  • Page 41 ELECTRICAL SYSTEM 7/72...
  • Page 42 Engine Oil Pressure Switch Rack Actuator Relay Generator Contactor Low Fuel Relay Push After Warm up Solenoid Hourmeter Generator Enable Switch (Option) SECU - - Small Electronic Control Unit Emergency Stop Button (Option) Yanmar Engine ECU Low Fuel Shutdown Switch EGR Valve 7/72...
  • Page 43 SL LH Stop light - - left hand Brown SL RH Stop light - - right hand Orange TL LH Tail light - - left hand Purple TL RH Tail light - - right hand Plug Grey Blue White Yellow 7/72...
  • Page 44 SL LH Stop light - - left hand Orange SL RH Stop light - - right hand Purple TL LH Tail light - - left hand TL RH Tail light - - right hand Grey Plug Blue White Yellow 7/72...
  • Page 45 PIPING AND INSTRUMENTATION SYSTEM Air discharge Oil cooler Sonic orifice (restricts flow) Oil filter Pressure gauge Thermostatic valve (Where fitted) Separator tank Safety valve Compressor Engine Air/oil 7/72...
  • Page 46 Check the regulation system. Premature unloading. Check the regulation and the operation of the pressure transducer. Excessive vibration. Engine speed too low. See ”Engine speed too low” Refer also to the engine section of this manual and the engine diagnostic codes. 7/72...
  • Page 47 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 48 ECU failure 4 Long and 1 Short Power supply voltage 2 Long and 3 Short 5V Sensor circuit 2 Long and 4 Short Speed sensor 6 Long Overspeed error 9 Long Oil pressure switch 2 Long and 1 Short 7/72...
  • Page 49 When using this setting procedure it may be found that the engine occasionally shuts down during the normal operation. If so, turn the adjuster clockwise by a further one half turn. 7. Ensure the adjuster locknut is fully tightened. (Use a thread lock adhesive on the locknut threads.) 7/72...
  • Page 50 Clean the inside of the water separator housing. Water separator maintenance: With engine stopped, ensure pressure is relieved from air system. Remove any hose connected to the water separator housing. Inspect fittings and hoses for any blockage. Clean ifnecessary. Remove and clean the water separator float. 7/72...
  • Page 51 OPTIONS PRIMARY AND SECONDARY FILTER MAINTENANCE FIGURE 4. FIGURE 1. FIGURE 5. FIGURE 2. FIGURE 3. 7/72...
  • Page 52 OPTIONS WATER SEPARATOR MAINTENANCE FIGURE 4. FIGURE 1. FIGURE 5. FIGURE 2. FIGURE 6. FIGURE 3. 7/72...
  • Page 53 CAUTION: Blockage of the condensate will result in flooding of the vessels. If flooding occurs, excessive condensate may enter the air stream and could result in damage to downstream equipment. FIGURE 7. NOTICE: Do not operate at temperatures less that 2C (35F). FIGURE 8. 7/72...
  • Page 54 Ensure compressor / generator mode switch is set to compressor. CAUTION: Do not start stop the machine with the compressor/generator mode switch in the Generator position. Engine starting/cranking is prevented in this mode - - see also “Operating Instructions - - SECU section”. 7/72...
  • Page 55 NOTE: Wear hearing protection at all times when the engine is started Refer to the PRIOR TO STARTING and STARTING THE UNIT with the top open and air is flowing from the valve. instructions earlier in this section before re- -starting the machine. 7/72...
  • Page 56 30 milliamperes on the connected appliance or in the connections to the generator. Do not dispose of a complete machine without documentation relating to instructions for its use. For alternator maintenance refer to Mecc Alte operation and maintenance manual. 7/72...
  • Page 57 Check the appliance and rectify the fault as necessary. A circuit breaker fails to Circuit breaker latching Repair or replace as necessary. re- - set whilst the machine mechanism faulty. running. Refer to Engine Manufacturer’s manual and Mecc Alte manufacturer’s manual 7/72...
  • Page 58 A.C. Electrical Power Schematic Diagram. 115V 1 - - phase. Circuit breaker Resistor Socket outlet 32A Circuit breaker Socket outlet 16A Socket outlet 16A Circuit breaker Switch, generator Circuit breaker Voltmeter Fuse Voltmeter Alternator Contactor Fuse Voltmeter Pushbutton Protective earth conductor 7/72...
  • Page 59 A.C. Electrical Power Schematic Diagram. 230V 1 - - phase. Circuit breaker Resistor Socket outlet 32A Circuit breaker Socket outlet 16A Socket outlet 16A Circuit breaker Switch, generator Alternator Voltmeter Contactor Fuse Voltmeter Pushbutton Fuse Protective earth conductor Voltmeter 7/72...
  • Page 60 A.C. Electrical Power Schematic Diagram. 400/230V 3 - - phase. Circuit breaker Resistor Socket outlet 16A Circuit breaker Socket outlet 16A Socket outlet 16A Circuit breaker Switch, generator Alternator Voltmeter Contactor Fuse Voltmeter Pushbutton Fuse Protective earth conductor Voltmeter Resistor 7/72...

  • Page 61: Table Of Contents

    FUEL, LUBRICANT, AND COOLANT Fuel Lubricant Coolant OPERATION Check before operation Check and operation after start-- up Operation and care of a new engine PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance TROUBLESHOOTING 7/72...

  • Page 62: Foreword

    All information, illustrations, and specifications contained in this Manual are based on the latest product information available at the time of publication. The company reserves the right to make changes in this Manual at any time without prior notice. 7/72...

  • Page 63: External View

    21.Air intake port (From air cleaner) 8. Filler port (engine oil) 22.Flywheel 9. Drain plug (engine oil) 23.Starter motor 10.Fuel injection pump 24.Exhaust manifold 11. Engine oil cooler 25.Alternator 12.Engine oil filter 26.EGR valve 13.Dipstick (engine oil) 27.EGR cooler 14.Eco- -governor 28.EGR pipe 7/72...

  • Page 64: General Information

    The engine serial number is stamped on engine name plate on top of rocker cover. Doosan Genuine Parts Genuine Doosan parts are identical with those used in the engine Confirmation of Engine Number production, and accordingly, they are warranted. It is advisable to quote the engine serial number together with the Genuine Doosan parts are supplied by your branch or distributor.
  • Page 65 Emission control label is attached on the “top of rocker arm cover.” The location of emission control label attached on the engine may vary depending on the engine specification The following is the sample of a label required for engine emission control information, along with location. 7/72...

  • Page 66: Fuel, Lubricant, And Coolant

    Engine failure or malfunction resulting from use of such manufacturer‘s instructions). Biocides are available from your dealer, improper fuel will not be warranted by Doosan. service stations, parts stores and other automotive places. See your authorized dealer for advice on using biocides in your area and for recommendations on which biocides you should use.

  • Page 67: Lubricant

     Be sure to use the mixing ratios specified by the LLC manufacturer for your temperature range. All Doosan portable compressor engines are factory filled with a 50/50 Ethylene glycol base antifreeze/water mix. which provides  Do not mix different types (brand) of LLC, chemical reactions may protection to - -33_C (- -27_F).

  • Page 68: Operation

    The battery cables must be tightened securely. Never reverse “+” and “- -” terminals when reconnecting E. Lower limit cables after disconnection. Even a short period of reverse connection F. Dipstick will damage the electrical parts. 7/72...

  • Page 69: Check And Operation After Start-- Up

    Cover the radiator cap with a thick cloth and loosen the cap slowly to reduce the pressure, then Check the remaining fuel oil level in the fuel tank and re- -fuel if necessary. remove the cap. 7/72...

  • Page 70: Operation And Care Of A New Engine

    If the level is correct, If the engine coolant level in the reserve tank is at the correct level but contact your local Doosan branch or dealer to establish the cause. there is still an indication of an overheat condition and no cause was found, please consult your local Doosan branch or dealer.

  • Page 71: Periodical Inspection And Maintenance

    Doosan fluids) or 500 hour intervals with Doosan PRO- -TEC engine fluid and filters. NOTE: The use of genuine Doosan oil and filters will qualify for extended warranty coverage. Refer to Warranty Section of the manual. PRO- -TEC Engine Fluid Part No. 54480918 (1 gallon).
  • Page 72 CCN 16539462 4) Bleed the fuel system. Refer to Inspection at 50 hours. IMPORTANT: Be sure to use genuine Doosan part (super fine mesh filter). Otherwise, it results in engine damage, uneven engine performance and shorter engine life. Changing oil/water separator element.
  • Page 73 Proper operation of the crankcase breather system is required to maintain the emission requirements of the engine. The EPA/ARB requires that you have the crankcase breather system inspected every 1500 hours. See your authorized Portable Power dealer or distributor for this service. 7/72...

  • Page 74: Cooling System

    (5) Checking and adjusting the EPA emission related parts. adaptor The inspection and servicing require specialized knowledge and techniques. Consult your Portable Power dealer or distributor. EPA allows to apply maintenance schedule for emission related parts as follows: Battery 12V Mating connector (Tool side) 7/72...

  • Page 75: Troubleshooting

    Engine fires but stalls immediately. Air in the fuel system. A connector is provided at an end of the harness of the driven machine so that the diagnosis tool can be loaded with data from the E- -ECU. 7/72...
  • Page 76 Lack of oil Oil leakage Low oil pressure High oil consumption Wrong oil Wrong type and viscosity. High coolant temperature. Over heat. Clogged filter and strainer. Clean and/or replace. Worn bearings and oil pump. Replace. Faulty relief valve. Replace. 7/72...
  • Page 77 Faulty valve stem seal. Damaged seal / Damaged turbocharger seal Oil leakage Loose joints/gaskets. Improper installation of filter and piping. Fuel leakage Damaged seals. Excessive fuel consumption Improper component installation or tightening. Excessive injection volume. Injection pump defective. Excessive mechanical loads 7/72...
  • Page 78 Low coolant temperature. Faulty turbocharger. Battery over discharge Low electrolyte level Crack in battery body. Natural consumption. Charging failure Loose or damaged belt. Faulty alternator. Damaged wiring or contact failure. Excessive electrical loads Insufficient battery capacity for the application. 7/72...

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