Doosan 7/20 Operation And Maintenance Manual
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Doosan 7/20 Operation And Maintenance Manual

Doosan 7/20 Operation And Maintenance Manual

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7/20, P65
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.
22311203 _en_K_12/15
SERIAL No : 121000 - 124199
SERIAL No : 124200 - 129999

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Summary of Contents for Doosan 7/20

  • Page 1 7/20, P65 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 : 121000 - 124199 SERIAL No : 124200 - 129999 22311203 _en_K_12/15...
  • 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.

  • Page 3: Table Of Contents

    Brakes Lubrication Engine lubricating oil Engine lubricating oil specification Engine oil filter element Compressor lubricating oil Compressor oil filter element Running gear wheel bearings Speed & pressure regulation adjustment Drive belt replacement / adjustment Torque Values Compressor lubrication 7/20, P65...
  • Page 4 Not illustrated Latvian, Lettish † Option Maltese As required Dutch High ambient machine Norwegian F.H.R.G. Fixed height running gear Polish Portuguese V.H.R.G. Variable height running gear Romanian Russian Bulgarian Slovak Czech Slovenian Danish Swedish German Chinese Greek English 7/20, P65...

  • Page 5: Foreword

    This machine has been designed and supplied for use only in the following specified conditions and applications: • Compression of normal ambient air containing no known or detectable additional gases, vapours. or particles • Operation within the ambient temperature range specified in the GENERAL INFORMATION section of this manual. 7/20, P65...
  • Page 6 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. 7/20, P65...
  • Page 7 Do not use fork lift truck from this side. Do not exceed the trailer speed limit. No naked lights. Do not open the service valve before the Use fork lift truck from this side only. Emergency stop. airhose is attached. 7/20, P65...
  • Page 8 No open flame. Rough Service Designation. Replace any cracked protective shield. Coolant fill. Wet Location Operation. Prohibition: Do not start Start and stop device. Mandatory action: Hearing protection must be worn. Diesel fuel drain. Engine coolant drain. Compressor oil drain. 7/20, P65...
  • Page 9 DECALS Engine oil drain. Cold Start Procedure. 7/20, P65...

  • Page 10: Noise Emission

    Note: the above information applies only to units that are built in compliance with the U.S. Environmental Protection Agency. Doosan reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.
  • Page 11 This warranty is not limited to any particular 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 noise emissions to exceed Federal Standards are covered by this warranty for the life of the air compressor. (40FR204.58-1). 7/20, P65...
  • Page 12 AS DETECTED ACOUSTIC MATERIALS DAILY FASTENERS 100 HOURS ENCLOSURE PANELS 100 HOURS AIR INTAKE & ENGINE EXHAUST 100 HOURS COOLING SYSTEMS 250 HOURS ISOLATION MOUNTS 250 HOURS ENGINE OPERATION SEE OPERATOR’S MANUAL FUELS & LUBRICANTS SEE OPERATOR’S MANUAL 7/20, P65...
  • Page 13 Use only the types and grades of fuels and lubricants recommended in intervals. All panels that are warped, punctured, torn, or otherwise the Doosan and Engine Manufacturer's Operator and Maintenance deformed, such that their noise containment function is reduced, Manuals.

  • Page 14: Maintenance Record For Noise Emission Control And Extended Warranty

    MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK OR HOURMETER MAINT/INSPECT LOCATION WORK DONE BY COMMENTS READING DATE CITY/STATE (NAME) 7/20, P65...

  • Page 15: Safety

    WARNING: Under no circumstances should volatile liquids such • engine exhaust fumes as Ether be used for starting this machine. AVOID INHALATION Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times. 7/20, P65...
  • Page 16 7/20, P65...
  • Page 17 SAFETY Disposal of contaminated fluids from bund Contaminated fluids removed from bund (where fitted), must be disposed of to designated containers only. 7/20, P65...
  • Page 18 GENERAL INFORMATION VARIABLE HEIGHT RUNNING GEAR FIXED HEIGHT RUNNING GEAR 7/20, P65...
  • Page 19 GENERAL INFORMATION 7/20 Fixed Height 1710 2451 1335 1154 1272 1030 Running Gear 1840 2581 7/20 Variable Height 1335 1154 1272 1030 Running Gear 2026 2767 “ “ “ “ “ “ “ “ “ “ “ “ “ “...
  • Page 20 Below -10°C (14°F) SAE10W-30 including separator / receiver, cooler and pipework must be flushed clear of the first fill fluid and new Doosan oil filters installed. Diesel fuel specification When this has been completed, the following oils are approved: DO NOT USE Fuels that have sulfur content greater than 1.0 % Safety data sheets can be obtained on request from your Doosan (10000 ppm).

  • Page 21: General Information

    515kg (1136 lbs) Tyre pressure. 2,4 bar (35 PSI) Maximum horizontal towing force. 725 kgf (1600 lbs) Maximum vertical coupling load Further information may be obtained by request through the 51,5 kgf (114 lbs) (nose weight). customer services department. 7/20, P65...

  • Page 22: Operating Instructions

    Before towing the unit during the hours of darkness, bar (100psi) pressure then it is recommended that safety ensure that the lights are functioning correctly (where fitted). retaining wires are used on the hoses. Ensure that all transport and packing materials are discarded. 7/20, P65...

  • Page 23: Prior To Starting

    CAUTION: Use only specified diesel fuels (see engine section for details). 7/20, P65...

  • Page 24: Emergency Stopping

    (51psi). STOPPING THE MACHINE • Close the service valve. • Allow the machine to run unloaded for a short period of time to reduce the engine temperature. • Turn the start switch to the 0 (off) position. 7/20, P65...

  • Page 25: Decommissioning

    • Do not allow lubricants or coolants to be released into land surfaces or drains. • Do not dispose of a complete machine without documentation relating to instructions for its use. 7/20, P65...

  • Page 26: Maintenance

    (2) or as defined by local or national legislation = Replace = Check (adjust, clean or replace as necessary) = Test = Check before towing = or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 7/20, P65...
  • Page 27 (2) or as defined by local or national legislation = Replace = Check (adjust, clean or replace as necessary) = Test = Check before towing. = or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 7/20, P65...
  • Page 28 (2) or as defined by local or national legislation = Replace = Check (adjust, clean or replace as necessary) = Test = Check before towing. = or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 7/20, P65...

  • Page 29: Routine Maintenance

    • all guards and safety protection devices are refitted. discharge air. • all panels are replaced, canopy and doors closed. • hazardous materials are effectively contained and disposed of. 7/20, P65...

  • Page 30: Compressor Oil Filter

    Reposition the cover plate, taking care not to damage the gasket, and Before restarting the machine, check that all clamps are tight. replace the cover plate screws tightening in a criss-cross pattern to the recommended torque (refer to the TORQUE SETTING TABLE later in this section). 7/20, P65...

  • Page 31: Ventilation

    3. Take out the element, and rinse it with diesel fuel. 4. After cleaning, reinstall the fuel filter, keeping out of dust and dirt. Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion. 5. Air-bleed the injection pump. 7/20, P65...

  • Page 32: Pressure System

    3. Handbrake lever pivot 300x60 SW 22 4. Transmission lever 5. Brake cable Tighten adjusting screw [12] clockwise until the wheel locks. 6. Breakaway Cable Loosen adjusting screw [12] anti-clockwise (approx. ½ turn) until the wheel can be moved freely. Requirements: 7/20, P65...

  • Page 33: Lubrication

    4. If the oil level is too low, remove the oil filler plug, and add new oil Re-adjusting the overrun braking system (KNOTT to the prescribed level. Running Gear) Re-adjustment of the wheel brakes will compensate for brake lining wear. Follow the procedure described in 2: Brake Shoe Adjustment. 7/20, P65...

  • Page 34: Engine Lubricating Oil Specification

    COMPRESSOR OIL FILTER ELEMENT Refer to the MAINTENANCE SHEDULE in this section for service intervals. RUNNING GEAR WHEEL BEARINGS Wheel bearings should be packed with grease every 6 months. The type of grease used should conform to specification MIL-G-10924. 7/20, P65...

  • Page 35: Speed & Pressure Regulation Adjustment

    Inspect the throttle arm on the engine governor to see that it is extended in the full speed position when the engine is running at full- load speed and the service valve is fully open. (Refer to the GENERAL INFORMATION section of this manual). 7/20, P65...

  • Page 36: Drive Belt Replacement / Adjustment

    Tighten securing screw M12 beside and above the Airend. 1. Main pivot bolt. Tighten main pivot bolt M16 and secure by lock nut. 2. Securing screw. Check belt adjustment. 3. Adjusting screw. Install drive belt guard. 4. Airend 7/20, P65...

  • Page 37: Torque Values

    Band clamp on discharge hose 58-67 78-91 Separator tank to frame 18-22 24-30 Exhaust flange to manifold 17-21 23-28 Band clamp on hose 106-133 143-180 Wheel nuts 50-80 67-109 Fan guard 9-11 12-15 Fan to hub 12-15 16-20 7/20, P65...

  • Page 38: Compressor Lubrication

    (-23°C to 52°C) 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 oxidation representative.

  • Page 39: Electrical System

    Node point Battery 12V Engine oil pressure switch Control fuse 5A Relay, temperature switch D1-2 Diode, blocking Key-switch Fuel pump Solenoid, fuel Alternator 12V High air temperature switch (airend) Glow plugs High coolant temperature switch (engine) Hourmeter Starter motor 7/20, P65...
  • Page 40 Fog light Pink 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 7/20, P65...
  • Page 41 Reverse light Brown 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 7/20, P65...

  • Page 42: Piping & Instrumentation System

    PIPING AND INSTRUMENTATION SYSTEM Air/oil Air discharge Sonic orifice (restricts flow) Pressure gauge Separator tank Safety valve Compressor Engine Oil cooler Oil filter 7/20, P65...

  • Page 43: Fault Finding

    Faulty regulator valve. Check the regulation system. Premature unloading. Check the regulation and the operation of the air cylinder. Excessive vibration. Engine speed too low. See ”Engine speed too low” Refer also to the MAINTENANCE section of this manual. 7/20, P65...
  • Page 44 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 45: Options

    During maintenance operations drain machine fluids using the drain ports indicated Remove fuel tank to drain. WARNING: Major leakages or spillages must be drained before the machine is towed. 1. Engine coolant drain. 2. Engine oil drain. 3. Compressor oil drain. 4. Bunded base drain. 7/20, P65...

  • Page 46: Maintenance

    (Refer to STOPPING THE UNIT in the OPERATING INSTRUC- TIONS section of this manual). CAUTION: If the nylon tubes to the lubricator are disconnected then ensure that each tube is re-connected in its original location. 7/20, P65...

  • Page 47: Parts Ordering

    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 48 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 49 PARTS ORDERING For parts, service or information regarding your local distributor (Europe, Middle East, Africa) please contact: Facility: Telephone: Fax: Doosan Portable Power EMEA Aftermarket +32 (2) 404 0811 +32 (2) 371 6915 Drève Richelle 167 B-1410 Waterloo Belgium For Service information contact: service_emea@dii.doosan.com...

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