Doosan 7/125 Operation & Maintenance Manual
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Doosan 7/125 Operation & Maintenance Manual

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7/125 - 9/115, 7/125 - 10/110, 14/90
OPERATION & MAINTENANCE MANUAL
Original Instruction
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
46641810_en_A_04/14
SERIAL No :
660000 ->

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  • Page 1 7/125 - 9/115, 7/125 - 10/110, 14/90 OPERATION & 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 : 660000 -> 46641810_en_A_04/14...
  • Page 3 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.
  • Page 5 Lubrication Hungarian Speed & pressure regulation Italian Torque settings table Lithuanian Compressor lubrication Latvian, Lettish Maltese MACHINE SYSTEMS Dutch Norwegian FAULT FINDING Polish Portuguese OPTIONS Romanian Russian PARTS ORDERING Slovak Slovenian Swedish Chinese 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 6 The company reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to © COPYRIGHT 2014 products sold previously. DOOSAN COMPANY 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 7 WARNING - For operating temperature (Refer to the GENERAL INFORMATION or commencing to tow consult the below 0° C (32°F), consult the Operation & section of this manual). Operation & Maintenance manual. Maintenance manual. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 8 Do not exceed the trailer speed limit. No naked lights. Do not open the service valve before the airhose is attached. Use fork lift truck from this side only. Emergency stop. Tie down point 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 9 No open flame. Wet Location Operation. Replace any cracked protective shield. Oil drain. Operational status of the engine emission filter. Engine emissions system temperature may be Disable active regeneration of the engine high. emission filter. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 10 All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 11 The compressor must be towed in a level attitude in order to maintain correct handling, braking, and lighting functions. This can be achieved by correct selection and adjustment of the vehicle towing hitch and, on variable height running gear, adjustment of the drawbar. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 12 GENERAL INFORMATION Fixed Height Braked Variable Height Braked 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 13 GENERAL INFORMATION KHD Variable Height LRG (Less Running Gear) 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 14 Maximum oil system temperature 120/ 120/ 120/ 120/ °C/ °F Maximum oil system pressure bar/ 8,6/ 10,3/ 12,1/ 15,5/ LUBRICATING OIL SPECIFICATION (for the specified ambient temperatures). SEE ‘COMPRESSOR LUBRICATION’ IN THE MAINTENANCE SECTION. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 15 100 kgf (220 Lbs) including separator / receiver, cooler and pipework must be flushed clear of the first fill fluid and new Doosan oil filters installed. KHD VARIABLE HEIGHT RUNNING GEAR When this has been completed, the following oils are approved: Braked version for ambient temperatures above -23°C (-9°F),...
  • Page 16 Use ladder and handholds to access lifting bail. Ensure that the machine is positioned securely and on a stable foundation. Any risk of movement should be removed by suitable means, especially to avoid strain on any rigid discharge piping. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 17 CAUTION: When refuelling:- • switch off the engine. • do not smoke. • extinguish all naked lights. • do not allow the fuel to come into contact with hot surfaces. • wear personal protective equipment. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 18 7. KeyPad: Used to start, shutdown and operate the compressor. 2. Engine Tachometer: Indicates engine speed (RPM). 8. Emergency Stop Switch: Used to stop the machine in the event of an emergency. 3. Hourmeter: Indicates machine operating hours. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 19 Screens are displayed brings up the Main Menu. pressure mode. Pressing the ENTER Button after an alert or fault has been displayed acknowledges the message and the display unit returns to the Default Screen. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 20 All Faults and Alerts will be displayed until the engine shuts down and then the most severe Fault will be displayed as a Fault. Pressing the ENTER Button after the Alert has been displayed, acknowledges the message and the display unit returns to the Default Screen of Engine Hours. See Figure 2 Figure 2 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 21 Hours will decrement with every hour on the engine. Use the DOWN Button to highlight the Main Screen menu item and press the ENTER Button to return to the Default Screen of Engine Hours. See Figure 4. Figure 4 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 22 DOWN or UP Buttons to highlight the chosen unit and PRESS the ENTER Button to select. To return to the Default Screen of Engine Hours, use the DOWN Button to highlight the Main Screen menu item and press the ENTER Button. See Figure 5. Figure 5 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 23 Note 2: Unit times out after 3 minutes of inactivity and returns to the Default Screen of Engine Hours. Note 3: Pressing the Enter Button while viewing a Quickview Screen will return to the Default Screen of Engine Hours. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 24 Power can be restored by pressing the Main Power Button. In the event of a fault, this feature is not active and the power will remain on until the fault has been acknowledged or the control system is manually powered off. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 25 Intake Air Filters Restricted - Intake filters restricting air flow. Low System Voltage - 25.5V Electrical system voltage below 25.5 VDC. Airend Oil Pressure Sensor - <0.5V, >4.5V Airend oil pressure sensor reading out of range. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 26 OTC Controller Communication - Communication between Titan controller and OTC controller not functional. IQ TCU Controller Communication - Communication between Titan controller and IQ TCU controller not functional. CAN Keypad Communication Fault - 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 27 Crankcase Pressure - Data Valid But Above Operational Range - Most Normal Operating Range - Moderately Severe Severe Level Level 1942 Engine Crankcase Pressure Data Erratic, Intermittent or Crankcase Pressure - Data Erratic, Intermittent Incorrect or Incorrect 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 28 Voltage Below Normal, or Coolant Temperature Sensor Circuit - Voltage Shorted to Low Source Below Normal, or Shorted to Low Source 1847 Engine Coolant Temperature Special Instructions Engine Coolant Temperature - Special Instructions 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 29 Sensor - Received Network Data In Error Engine Speed Data Valid but Above Normal Engine Speed High - Data Valid but Above Operational Range - Most Normal Operational Range - Most Severe Severe Level Level 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 30 Normal, or Shorted to Low Source 2292 System Diagnostic Code #1 Data Valid but Above Normal Fuel Inlet Meter Device - Data Valid but Above Operating Range - Moderately Normal Operational Range - Moderately Severe Level Severe Level 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 31 Injector Solenoid Cylinder #6 Circuit - Current Open Circuit Below Normal, or Open Circuit Engine Starter Motor Relay Voltage Above Normal, or Starter Relay Driver Circuit - Voltage Above Shorted to High Source Normal, or Shorted to High Source 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 32 Circuit - Voltage Above Normal, or Shorted to Temperature High Source 1188 3925 Engine Turbocharger Data Erratic, Intermittent or Engine Turbocharger Wastegate Actuator 1 Wastegate Actuator 1 Position Incorrect Position - Data erratic, Intermittent or Incorrect 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 33 Engine Turbocharger 1 Data Valid but Above Normal Turbocharger Turbine Inlet Temperature Calculated Turbine Intake Operating Range - Least (Calculated) - Data Valid but Above Normal Temperature Severe Level Operational Range - Least Severe Level 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 34 High Source 3245 1877 Aftertreatment 1 Exhaust Gas Voltage Below Normal, or Aftertreatment Exhaust Gas Temperature 3 Temperature 3 Shorted to Low Source Circuit - Voltage Below Normal, or Shorted to Low Source 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 35 Shorted to High Source Shorted to High Source 3513 1696 Sensor supply voltage 5 Voltage Below Normal, or Sensor Supply 5 - Voltage Below Normal, or Shorted to Low Source Shorted to Low Source 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 36 3712 Aftertreatment SCR Operator Data Valid but Above Normal Aftertreatment SCR Operator Inducement - Inducement Severity Operational Range - Most Data valid but above normal operational range Severe Level - Most Severe Level 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 37 Reserved for temporary use Not Available or Condition Reserved for temporary use - Condition Exists Exists 524286 Reserved for temporary use Not Available or Condition Reserved for temporary use - Condition Exists Exists 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 38 8. To change to the High Pressure Mode, press the High Pressure Button. Three lights on the button will illuminate. CAUTION: To ensure an adequate flow of oil to the airend, never allow the discharge pressure to fall below 3,4 bar. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 39 MidPort. and/or shutdown, and display a diagnostic code. TWO PRESSURE MODES OF OPERATION (7/125 - 9/115 & 7/125 - 10/110) 7/125 - 9/115 & 7/125 - 10/110 The compressor is capable of operating at two pressure modes: 1.
  • Page 40 5. If the Main Power Button is not pressed within 3 minutes (if ambient temperature is above 45°F (7°C)) or 15 minutes if ambient temperature is 45°F (7° C) or below of the keypad use the compressor will automatically shut off. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 41 Portable Power • Airend – Remove the intake connection and pour the airend intake provided system. full with Doosan compressor fluid PRO-TEC, XHP605 or XHP405. Reconnect the intake connection. NOTE: The maintenance schedule in this manual describes the •...
  • Page 42 (1) or 3000 miles/5000km whichever is the sooner G = Grease W I = or when indicated if earlier. C = Check (adjust, clean or replace as necessary) R = Replace CBT = Check before towing. T = Test 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 43 R = Replace C = Check (adjust, clean or replace as necessary) T = Test CBT = Check before towing. W I = or when indicated if earlier. CR = Check and report 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 44 C = Check (adjust, clean or replace as necessary) T = Test CBT = Check before towing. W I = or when indicated if earlier. CR = Check and report Refer to specific sections of the operator's manual for more information. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 45 It is good preventative maintenance to check that the scavenge line of the auto blowdown valve. and tube are clear of any obstruction each time the compressor lubricant is changed as any blockage will result in oil carryover into the discharge air. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 46 CAUTION: Start the machine (refer to PRIOR TO STARTING and STARTING THE UNIT in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the machine is put back into service. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 47 If electrical grease is not present or very minimal, then 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 48 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 Keep the battery terminals and cable clamps clean and lightly to the Engine Operator Manual for engine oil specifications.
  • Page 49 This adjustment procedure must be carried out as described on both wheel brakes. When the brake has been adjusted accurately the actuating distance is approximately 5-8mm on the cable [11] 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 50 Check the handbrake cable [5] for a small amount of play and adjust if Check the compression spring [9] for pre-tensioning. necessary (Variable height only) Check the compression spring [9] for slight pre-tensioning. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 51 Mobility and ease of operation check of the height adjusting • • mechanism Coupling head lubrication • • Drawtube support lubrication – at the housing of the overrun • coupling • Clamping jig bolts tightening 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 52 5Nm). Replace the protection caps (4). Slide the bellows (36) onto the coupling head (1). The rear bolt (2) must be covered by the bellows (36). Secure the bellows (36) with a new cable tie (48). 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 53 MAINTENANCE Replacement of the shock absorber To be carried out ONLY by skilled service personnel. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 54 (36) on the coupling head (1) and the guide bearing (44) using cable ties (48). Replace the grease nipples (38), nipple caps (39) and the shield (15) for the overrun head. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 55 Mount the transmisson lever (17) into the overrun head and secure it with pins (16) and (18). Spread the pin (18) with liquid high strength thread locker and fasten it with a tightening moment of 30 ± 2Nm. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 56 SL-clip (63). Mount the spring pack (61) with the handbrake lever, insert the pin (62) and secure with the SL-clip (63). Set up the whole braking system according to general KNOTT regulation. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 57 OPTIMOL OLISTAMOLY 2 lubricant or equivalent MoS2 based high Adjustement bolt, welded performance grease. Gearing <N3> Using a brush, apply a thin, even layer of SPHEEROL EPL2 or Top spindle equivalent NLGI 2 Grade lubricant. Thread 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 58 OPTIMOL OLISTAMOLY 2 lubricant or equivalent MoS2 based high Adjustement bolt, welded performance grease. Gearing <N3> Using a brush, apply a thin, even layer of SPHEEROL EPL2 or Top spindle equivalent NLGI 2 Grade lubricant. Thread 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 59 3. Adjust the brake system according to details ‘B’ and ‘C’. detail ‘B’ to 0-5mm. Cross-section showing positions of details ‘B’, ‘C’ and ‘R’ c. Hexagonal head nut M16x1,5 DIN936 Torque 30Nm ± 2Nm 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 60 Pressure Regulator except adjust pressure at idle to 12,1-12,4 bar while in High Pressure Mode. 4. Close Service Valves. Note: The High Pressure Regulator must be set at a higher pressure than the Low Pressure Regulator. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 61 TYPICAL SQUARE TORQUE PATTERN (Nm.) (FT-LBF) (Nm.) (FT-LBF) 1/4 - 20 5/16 - 18 3/8 - 16 7/16 - 14 1/2 - 13 9/16 - 12 TYPICAL CIRCULAR TORQUE PATTERN 5/8 - 11 3/4 - 10 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 62 16” Wheel 105-115 M14 Bolts 145-155 107-115 16.5” Wheel 105-115 M16 Bolts 175-185 129-137 5/8” Lug Nuts M18 Bolts 205-215 151-159 16” Wheel 190-210 17” Wheel 190-210 9/16” Clamp nuts/Demountable Wheels 14.5” Wheel 105-115 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 63 Where possible, do NOT mix oils of different types and avoid mixing fluids in order to obtain extended limited airend warranty. different brands. A type or brand change is best made at the time of a complete oil drain and refill. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 64 (-10°F to 125°F) XHP 605 Alternate: XHP 405 Preferred Doosan Fluids - 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 rust and oxidisation representative.
  • Page 65 MACHINE SYSTEMS Compressor and Engine Harness System Schematic 46622240 Rev. B (sheeet 1) 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 66 MACHINE SYSTEMS Compressor and Engine Harness System Schematic 46622240 Rev. B (sheeet 2) 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 67 MACHINE SYSTEMS Compressor and Engine Harness System Schematic 46622240 Rev. B (sheeet 3) 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 68 MACHINE SYSTEMS Compressor and Engine Harness System Schematic 46622240 Rev. B (sheeet 4) 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 69 MACHINE SYSTEMS IQ Option Harness Schematic 46636749 Rev. A (sheeet 1) 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 70 MACHINE SYSTEMS Control Panel Haness Schematic 46641699 Rev. A (sheeet 1) 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 71 MACHINE SYSTEMS Control Panel Haness Schematic 46641699 Rev. A (sheeet 2) 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 72 MACHINE SYSTEMS 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 73 Identify and check sensor. Replace if necessary. See Electronic Service Manual. Malfunctioning relay. Identify and check relay. Replace if necessary. See Electronic Service Manual. Engine malfunctioning. See troubleshooting in Engine manual. Airend malfunctioning. See Fault #6. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 74 Malfunctioning oil cooler pressure Replace valve. relief valve. Malfunctioning minimum pressure Repair or replace valve. valve. Blocked or restricted oil lines. Clean by flushing, or replace lines. Airend malfunctioning. See Faults #11, #12. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 75 Check scavenge line, drop tube, and orifice. Clean and replace as needed. carryover (compressor Deteriorated separator element. Replace separator element. oil in the compressed air) Separator tank pressure too low. Check the minimum pressure valve. Repair or replace as necessary. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 76 Standard Non-Louvred configuration not to be operated below is vaporised by heat. This eliminates the need for collecting the freezing. condensate, and the added cost of disposing of the condensate, which is often regulated by local regulations. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 77 Lower the housing to floor panel and lean it against the airend. Remove and replace the filter element, being careful not to damage outer wrap. Verify the part number of new element vs. old element, as the two IQ filters are of different media. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 78 OPTIONS PRIMARY AND SECONDARY FILTER MAINTENANCE FIGURE 1. FIGURE 4. FIGURE 2. FIGURE 5. FIGURE 3. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 79 OPTIONS WATER SEPARATOR MAINTENANCE FIGURE 1. FIGURE 4. FIGURE 2. FIGURE 5. FIGURE 3. FIGURE 6. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 80 If flooding occurs, excessive condensate may enter the air stream and could result in damage to downstream equipment. NOTICE: Do not operate at temperatures less that 2°C (35° F). FIGURE 7. FIGURE 8. 7/125 - 9/115, 7/125 - 10/110, 14/90...
  • Page 81 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 82 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 83 336-751-4325 (Latin America) Statesville 65-860-6863 (Asia Pacific) 336-751-4325 (Asia Pacific) North Carolina 28625-9218 Office hours: Monday to Friday 8:00 a.m. to 5:30 p.m. (EST) or visit our website and dealer locator at www.doosanportablepower.com 7/125 - 9/115, 7/125 - 10/110, 14/90...

This manual is also suitable for:

9/11510/11014/90

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