Doosan 7/26E Operation And Maintenance Manual
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Doosan 7/26E Operation And Maintenance Manual

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7/26E, 7/31E, 7/41
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.
46671281_en_B_06/18
7/26E
SERIAL No : 109600 -109999
7/31E
SERIAL No : 323300 - 324999
7/41
SERIAL No : 433500 - 439000

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  • Page 1 7/26E, 7/31E, 7/41 OPERATION AND MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to personnel who operate and 7/26E SERIAL No : 109600 -109999 maintain this machine. 7/31E SERIAL No : 323300 - 324999...
  • Page 2 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 N...
  • Page 5 Draining of contaminated fluids Norwegian Draining of machine fluids Polish Portuguese Polymer Canopy Romanian General information Russian Generator Slovak Safety Slovenian General Information Swedish Operating Instructions Chinese Maintenance Fault Finding Cold Start Description Safety General information Operating instructions 7/26E, 7/31E, 7/41...
  • Page 6 Having incorrect voltage and/or frequency ratings. b) Containing computer equipment and/or similar electronics. The company accepts no responsibility for errors in translation of this manual from the original English version. © COPYRIGHT 2018 DOOSAN COMPANY 7/26E, 7/31E, 7/41...
  • 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. 7/26E, 7/31E, 7/41...
  • 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 7/26E, 7/31E, 7/41...
  • Page 9 When parking use prop stand, handbrake and Compressor oil filling before operation or maintenance of this wheel chocks. machine is undertaken. Diesel fuel. Parking brake. Rough Service Designation. No open flame. Wet Location Operation. Replace any cracked protective shield. Oil drain. Start sequence 7/26E, 7/31E, 7/41...
  • Page 10 DO NOT USE ETHER IF THE • engine exhaust fumes MACHINE HAS GLOW PLUG STARTING AID OR ENGINE DAMAGE AVOID INHALATION WILL RESULT. Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times. 7/26E, 7/31E, 7/41...
  • Page 11 3 metres from all power lines and buried power cables, other than those connected to the generator set. Attempt repairs only in clean, dry, well lighted and ventilated areas. 7/26E, 7/31E, 7/41...
  • Page 12 When adjusting the safety chains there should be sufficient free length in the chains to allow normal articulation, whilst also being short enough to prevent the towbar from touching the ground in the event of an accidental separation of the towing vehicle from the trailer. 7/26E, 7/31E, 7/41...
  • Page 13 GENERAL INFORMATION 7/26E, 7/31E FIXED HEIGHT RUNNING GEAR 7/26E, 7/31E VARIABLE HEIGHT RUNNING GEAR 7/26E, 7/31E, 7/41...
  • Page 14 GENERAL INFORMATION 7/26E+, 7/31E+ FIXED HEIGHT RUNNING GEAR 7/26E+, 7/31E+ VARIABLE HEIGHT RUNNING GEAR 7/26E, 7/31E, 7/41...
  • Page 15 GENERAL INFORMATION 7/41 FIXED HEIGHT RUNNING GEAR 7/41 VARIABLE HEIGHT RUNNING GEAR 7/26E, 7/31E, 7/41...
  • Page 16 GENERAL INFORMATION 7/41+ FIXED HEIGHT RUNNING GEAR 7/41+ VARIABLE HEIGHT RUNNING GEAR 7/26E, 7/31E, 7/41...
  • Page 17 GENERAL INFORMATION 7/26E, 7/31E SHIPPING SKID 7/41 PERMANENT SKID 7/26E, 7/31E, 7/41...
  • Page 18 / receiver, cooler and pipework must be High ambient temp. -10°C TO +52°C (14°F TO 126°F) flushed clear of the first fill fluid and new Doosan oil filters installed. Maximum discharge temperature. 120°C (248°F) When this has been completed, the following oils are approved: Cooling system.
  • Page 19 FIXED HEIGHT RUNNING GEAR Unbraked version 7/26E, 7/31E Shipping weight. 735 kg (1621 lbs) Maximum weight. 750 kg (1653 lbs) Maximum horizontal towing force. 7,12 kN (1600 lbs) Maximum vertical coupling load (nose weight). 75 kg (165 lbs) 7/26E, 7/31E, 7/41...
  • Page 20 VARIABLE HEIGHT RUNNING GEAR WHEELS AND TYRES Braked version, light 01 Category Number of wheels. 2 x 4 J x 13 7/41 7/26E, 7/31E, 7/41 Shipping weight. 750 kg (1653 lbs) Tyre size. 155 R13 Maximum weight. 750 kg (1653 lbs) 7/26E, 7/31E, 7/41 Maximum horizontal towing force.
  • Page 21 Before towing the unit during the hours of darkness, bar pressure then it is recommended that safety retaining wires ensure that the lights are functioning correctly (where fitted). are used on the hoses. Ensure that all transport and packing materials are discarded. 7/26E, 7/31E, 7/41...
  • Page 22 CAUTION: Use only specified diesel fuels (see engine section for ice and snow. details) 7/26E, 7/31E, 7/41...
  • Page 23 NOTE: Wear hearing protection at all times when the engine is 3. Turn the key switch to position 3 (engine start position). started when the service valve is open and air is flowing from the valve. 4. Release to position 2 when the engine starts. 7/26E, 7/31E, 7/41...
  • Page 24 If the machine has been switched off for reasons of safety, then ensure or drains. that the machine can be operated safely before re-starting. • Do not dispose of a complete machine without documentation relating to instructions for its use. 7/26E, 7/31E, 7/41...
  • Page 25 (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. 7/26E, 7/31E, 7/41...
  • Page 26 (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. 7/26E, 7/31E, 7/41...
  • 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. 7/26E, 7/31E, 7/41...
  • Page 28 At twelve month intervals, test the water temperature switch by removing it from the machine and immersing in a bath of heated oil. • appropriate personal protective equipment is worn. The switch should operate at 105° C. Refit the switch. 7/26E, 7/31E, 7/41...
  • Page 29 Install the new element. Examine the orifice, check valve and hoses at every service or in the For 7/26E and 7/31E models, replace element O-ring in every event of oil carryover into the discharge air. reassembly.
  • Page 30 Jack up the machine All components of the engine cooling air intake system should be checked periodically to keep the engine at peak efficiency. Disengage the handbrake lever [1]. Fully extend the draw bar [2] on the overrun braking system. 7/26E, 7/31E, 7/41...
  • Page 31 Check the alignment of the equalisation assembly [8], this should be at right angles to the pulling direction 2. Brake Shoe Adjustment Check the play in the brake linkage [7] If necessary adjust the brake linkage [7] again without play and without pre-tensioning 7/26E, 7/31E, 7/41...
  • Page 32 Wheel bearings should be packed with grease every 6 months. The Wheel bearings should be packed with grease every 6 months. The type of grease used should conform to specification MIL-G-10924. type of grease used should conform to specification MIL-G-10924. 7/26E, 7/31E, 7/41...
  • Page 33 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). 7/26E, 7/31E, 7/41...
  • Page 34 Running gear rear to chassis 63-69 82-93 Running gear drawbar to axle 29-35 39-47 Separator tank cover 40-50 54-68 Separator tank to frame 18-22 24-30 Service pipe (-20jic) 106-133 143-180 Sight glass 40-50 54-68 Wheel nuts 62-70 85-95 7/26E, 7/31E, 7/41...
  • Page 35 XHP 405 ISO Viscosity Grade 68 Group 3 or 5 with Doosan preferred fluids - the use of these fluids with original Doosan rust and oxidisation branded filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your Portable Power inhibitors, designed representative.
  • Page 36 ELECTRICAL SYSTEM 7/26E, 7/31E, 7/41...
  • Page 37 Low fuel LED5 No charge Starter motor Connector, minicontroller Connector, minicontroller (Option) Engine oil pressure switch Engine heater relay 7/26E 108475-> 7/31E 319789-> Relay, crank Key-switch Solenoid, fuel High air temperature switch (airend) High water temperature switch (engine) 7/26E, 7/31E, 7/41...
  • Page 38 ELECTRICAL SYSTEM 7/26E, 7/31E, 7/41...
  • Page 39 Relay, control / shut–down Relay, crank Relay, air heater Relay, fuel solenoid Key-switch Solenoid, fuel Solenoid, load / unload(Option) High air temperature switch (airend) High air temperature switch (discharge)(Option) High water temperature switch (engine) Link Timer Safety unit Fuel pump 7/26E, 7/31E, 7/41...
  • Page 40 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 7/26E, 7/31E, 7/41...
  • 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 7/26E, 7/31E, 7/41...
  • Page 42 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 Rear view of the connector White Yellow 7/26E, 7/31E, 7/41...
  • Page 43 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 (Where fitted) 7/26E, 7/31E, 7/41...
  • Page 44 Check the restriction indicators and replace the element(s) if necessary. High pressure air escaping. Check for leaks. Incorrectly set regulation system. Reset the regulation system. Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in the MAINTENANCE section of this manual. 7/26E, 7/31E, 7/41...
  • Page 45 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 46 WARNING: Do not replenish the lubricator oil, or service the lu- bricator without first making sure that the machine is stopped and the system has been completely relieved of all air pressure (Refer to STOPPING THE UNIT in the OPERATING INSTRUC- TIONS section of this manual). 7/26E, 7/31E, 7/41...
  • Page 47 WARNING: The rear space of the unit must be drained daily of DESCRIPTION any rainwater. Check and ensure correct tilt angle is attained during draining. This machine can be fitted with bund equipment to contain leakages and spillages, which occur within the machine enclosure. 7/26E, 7/31E, 7/41...
  • Page 48 Removal or failure of this heat protection may cause canopy heat damage. Do not use high pressure water jet cleaning directly at the decals area. It may cause damage or removal of the decals. 7/26E, 7/31E, 7/41...
  • Page 49 Refer to the SAFETY SECTION in this manual. Rated output 6,8 kW @ 0,8 Power factor (PF) lagging GENERAL INFORMATION (6,5 kVA - 7/26E, 7/31E, 7/41) Rated voltage 110V 1ph or 230V 1ph or 230V 3ph or 400V 3ph + 230V 1ph @ 3000 revs...
  • Page 50 • The system has been inspected and earthed. • No persons are in a hazardous position. • Any warnings necessary have been suitably displayed (where applicable). Ensure compressor / generator mode switch is set to compressor. 7/26E, 7/31E, 7/41...
  • Page 51 OPTIONS Key to compressor / generator mode switch Selects operation of compressor only. Selects operation of compressor and generator together. Selects operation of generator only. 7/26E, 7/31E, 7/41...
  • Page 52 For alternator maintenance refer to Mecc Alte operation and maintenance manual. Refer to the PRIOR TO STARTING and STARTING THE UNIT instructions earlier in this section before re-starting the machine. 7/26E, 7/31E, 7/41...
  • Page 53 (Refer to section 4 output. General Information). Drive belt is not Re-tension the drive belt. tensioned correctly. Drive pulley is Check the drive pulley and tighten loose on the as required. drive shaft. 7/26E, 7/31E, 7/41...
  • Page 54 OPTIONS A.C. Electrical Power Schematic Diagram. 7/26E (110V 6kVA) 7/26E, 7/31E, 7/41...
  • Page 55 OPTIONS A.C. Electrical Power Schematic Diagram. 7/31E, 7/41 (110V 8,5kVA) 7/26E, 7/31E, 7/41...
  • Page 56 OPTIONS A.C. Electrical Power Schematic Diagram. 7/26E, 7/31E, 7/41 (230V 6kVA) 7/26E, 7/31E, 7/41...
  • Page 57 OPTIONS A.C. Electrical Power Schematic Diagram. 7/26E, 7/31E, 7/41 (400/230V) 7/26E, 7/31E, 7/41...
  • Page 58 Do not apply full load to the engine at ambient temperatures Operating ambient temperature.-30_C TO +46_C (-22_F TO 115_F) below -10°C before completing the warm up time. Oil capacity (7/26E), (7/31E)7,5 litres (2 US GAL) Coolant heater Oil capacity (7/41)8,5 litres (2,25 US GAL) The heater must not be operated in the following situations: •...
  • Page 59 Warm up before loading engine • Let the engine run at idle speed for at least 5 minutes for -10°C (For ambient temperature -10°C to -30°C (14°F to -22°F)) (14°F) ambient temperature, to 15 minutes for -30°C (-22°F) ambient temperature 7/26E, 7/31E, 7/41...
  • Page 60 Virtually all legislation regarding the operation of a diesel engine in a hazardous area includes a mandatory requirement to fit a tested and approved exhaust spark arrestor. 7/26E, 7/31E, 7/41...
  • Page 61 The outlet locknut should then be treated with a thread 5. Start engine. Slowly accelerate. Note speed at which shutdown lock adhesive and security tightened. Further adjustment to the inlet occurs. adjuster as per above instructions is then continued. 7/26E, 7/31E, 7/41...

  • Page 62: Table Of Contents

    Lubricant Coolant OPERATION Check before operation Check and operation after start- up Operation and care of a new engine MAINTENANCE SCHEDULE PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance TROUBLESHOOTING 7/26E, 7/31E, 7/41...
  • Page 63 The company reserves the right to make changes in this Manual at any time without prior notice. This manual covers both 3 and 4 cylinder naturally aspirated engines. The pictures contained within are for guidance only and might not reflect the physical characteristics of each individual engine covered. 7/26E, 7/31E, 7/41...

  • Page 64: External View

    21. Flywheel housing 9. Engine oil cooler (4TNV88) 22. Starter motor 10. Engine oil filter 23. Exhaust manifold 11. Dipstick (engine oil) 24. Alternator 12. Governor lever 25. Rocker arm cover 13. Intake manifold 26. Filler port (engine oil) 7/26E, 7/31E, 7/41...

  • Page 65: General Information

    See illustration on page 61 Doosan Genuine Parts Confirmation of Engine Number Genuine Doosan parts are identical with those used in the engine production, and accordingly, they are warranted by. It is advisable to quote the engine serial number together with the machine serial number, as it is required when you contact the company Genuine Doosan parts are supplied by your branch or distributor.
  • Page 66 See illustration on page 61 Doosan Genuine Parts Confirmation of Engine Number Genuine Doosan parts are identical with those used in the engine production, and accordingly, they are warranted by. It is advisable to quote the engine serial number together with the machine serial number, as it is required when you contact the company Genuine Doosan parts are supplied by your branch or distributor.
  • Page 67 See illustration on page 61 Doosan Genuine Parts Confirmation of Engine Number Genuine Doosan parts are identical with those used in the engine production, and accordingly, they are warranted by. It is advisable to quote the engine serial number together with the machine serial number, as it is required when you contact the company Genuine Doosan parts are supplied by your branch or distributor.

  • Page 68: Emission Control Label

    The following is the detail of a label required for engine emission control information, along with location. (97/68/EC Directive label) • Label location: Emission control information label (4TNV88) Emission control information label (On rocker arm cover exhaust side) (3TNV82A, 3TNV88A) 7/26E, 7/31E, 7/41...

  • Page 69: Fuel, Lubricant, And Coolant

    The metal content of Na, Mg, Si, and Al should be equal to or lower than 1 mass ppm. (Test analysis method JPI-5S-44-95) • Lubricity: The wear mark of WS1.4 should be Max. 0.018 in (460 m) at HFRR test. 7/26E, 7/31E, 7/41...

  • Page 70: Lubricant

    COOLANT line. Without LLC, cooling water will freeze and expand to break the cooling line All Doosan portable compressor engines are factory filled with a 50/50 • Be sure to use the mixing ratios specified by the LLC manufac- Ethylene glycol base antifreeze/water mix. which provides protection to turer for your temperature range.

  • Page 71: Check Before Operation

    Manually tighten the filler cap. Do not use a tool such as pliers to securely. Never reverse “+” and “-” terminals when reconnecting tighten it. cables after disconnection. Even a short period of reverse connection will damage the electrical parts. 7/26E, 7/31E, 7/41...

  • Page 72: Check And Operation After Start- Up

    If the engine coolant is boiling, wait until it stops before Leakage in the systems - proceeding. The engine coolant level should be between the “MAX Check the following items: COLD” and “MIN” marks on the reserve tank. 7/26E, 7/31E, 7/41...
  • Page 73 LONG TERM STORAGE found, please consult your local Doosan branch or dealer. Overcooling If the equipment is to be out of operation for an extended period, it...
  • Page 74 Cylinder head Adjust intake I exhaust valve clearance Lapping intake I exhaust valve seats Fuel valve Check fuel injection valve pressure & adjust pump * Check & adjust fuel injection pump * The specific emissions related parts for the EPA/ARB regulations 7/26E, 7/31E, 7/41...
  • Page 75 Change element at 500 hrs or sooner if the restriction indicator shows red. replacement Cylinder compression Consult your local dealer or distributor pressure Valve clearance check Check and adjust every 1000 hours. Consult your local dealer or distributor 7/26E, 7/31E, 7/41...

  • Page 76: Periodical Inspection And Maintenance

    1) Press the V-belt down with your thumb [approx. 98N(10kgf)]. at the middle of the V-belt span to check the tension (deflection). Available positions to check and adjust the V-belt tension (deflection) are at the A, B and C showing with the arrow direction as shown illustration right. 7/26E, 7/31E, 7/41...
  • Page 77 C. Adjusting bracket Use of genuine Doosan fan belt D. Radiator fan E. Set bolt Always use genuine Doosan fan belts as they provide high driving F. Alternator ability and long operating durability. Use of non-Doosan fan belts could G. Deflection result in premature belt wear or belt elongation leading to engine H.
  • Page 78 As the governor is precisely adjusted, most of the controls are sealed, please do not break them. Should any adjustment be necessary, contact your local Doosan branch or distributor. NOTE: The company will not accept any warranty claim on an engine with broken governor seals.

  • Page 79: Air Intake System

    Should any adjustment be necessary, Also, a damaged element leads to abrasion of cylinders and valves, contact your local Doosan branch or distributor. resulting in increased oil consumption, reduced output and shortened engine life.
  • Page 80 Regularly check the rubber hoses of the fuel system and engine has fully been cooled. cooling water system. If cracked or degraded, replace them with new one. Replace the rubber hoses at least every 2 years. 7/26E, 7/31E, 7/41...
  • Page 81 As this maintenance requires specialized knowledge and skill, consult Check Fuel Valve Adjust, cleaning and your dealer. Nozzle and clean repair Fuel injection Pump and Fuel Valve Nozzle. kW % 130 1500 hours of use 3000 hours of use 1500-hour 3000-hour intervals thereafter intervals thereafter 7/26E, 7/31E, 7/41...
  • Page 82 Faulty air heater. Incorrect injection timing. Fuel is injected but engine does not fire. Low cylinder compression pressure. Engine stop solenoid not fully returned. Air in the fuel system. Engine fires but stalls immediately. Incorrect low idle speed adjustment. 7/26E, 7/31E, 7/41...

  • Page 83: Troubleshooting

    Restricted coolant flow (high concentration of antifreeze, etc.) Low oil pressure Oil leakage Lack of oil High oil consumption Wrong oil Wrong type and viscosity. High coolant temperature. Over heat. Clogged filter and strainer. Worn bearings and oil pump. Faulty relief valve. 7/26E, 7/31E, 7/41...
  • Page 84 Damaged seal / Damaged turbocharger seal Oil leakage Loose joints/gaskets. Improper installation of filter and piping. Excessive fuel consumption Damaged seals. Fuel leakage Improper component installation or tightening. Excessive injection volume. Injection pump defective. Excessive mechanical loads 7/26E, 7/31E, 7/41...
  • Page 85 Low coolant temperature Faulty turbocharger Battery over discharge Crack in battery body. Low electrolyte level Natural consumption. Loose or damaged belt. Charging failure Faulty alternator. Damaged wiring or contact failure. Excessive electrical loads Insufficient battery capacity for the application. 7/26E, 7/31E, 7/41...
  • Page 86 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 87 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 90 Doosan Bobcat EMEA s.r.o U Kodetky 1810 263 12 Dobříš Czech Republic www.doosanportablepower.eu...

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