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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. SERIAL No : 660000 -> 46641810_en_A_04/14...
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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.
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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...
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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...
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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...
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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...
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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...
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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...
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GENERAL INFORMATION Fixed Height Braked Variable Height Braked 7/125 - 9/115, 7/125 - 10/110, 14/90...
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GENERAL INFORMATION KHD Variable Height LRG (Less Running Gear) 7/125 - 9/115, 7/125 - 10/110, 14/90...
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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...
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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),...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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.
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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...
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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 •...
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(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...
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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...
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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...
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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...
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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...
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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.
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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.
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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...
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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...
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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...
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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...
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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...
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(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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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(-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.
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MACHINE SYSTEMS Compressor and Engine Harness System Schematic 46622240 Rev. B (sheeet 1) 7/125 - 9/115, 7/125 - 10/110, 14/90...
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MACHINE SYSTEMS Compressor and Engine Harness System Schematic 46622240 Rev. B (sheeet 2) 7/125 - 9/115, 7/125 - 10/110, 14/90...
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MACHINE SYSTEMS Compressor and Engine Harness System Schematic 46622240 Rev. B (sheeet 3) 7/125 - 9/115, 7/125 - 10/110, 14/90...
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MACHINE SYSTEMS Compressor and Engine Harness System Schematic 46622240 Rev. B (sheeet 4) 7/125 - 9/115, 7/125 - 10/110, 14/90...
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MACHINE SYSTEMS IQ Option Harness Schematic 46636749 Rev. A (sheeet 1) 7/125 - 9/115, 7/125 - 10/110, 14/90...
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MACHINE SYSTEMS Control Panel Haness Schematic 46641699 Rev. A (sheeet 1) 7/125 - 9/115, 7/125 - 10/110, 14/90...
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MACHINE SYSTEMS Control Panel Haness Schematic 46641699 Rev. A (sheeet 2) 7/125 - 9/115, 7/125 - 10/110, 14/90...
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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...
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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...
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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...
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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...
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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...
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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...
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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.
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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.
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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...
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