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Summary of Contents for Doosan 7/53
- Page 1 7/53 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. 7/53 SERIAL No : 444800 - 449999 46673723_en_A_06/15...
- Page 3 Hereby declare that, under our sole responsibility the product(s) Machine description: Portable Screw Compressor Machine Model: 7/20; 7/26E; 7/31E; 7/41; 7/51; 7/53 ; 7/73-10/53; 7/125-9/115; 7/125-10/110; 14/90; SAMPLE 7/170; 10/125; 14/115; 12/154; 9/274; 9/304; 12/254; 17/244; 21/224 Commercial name: 7/20; 7/26E; 7/31E; 7/41; 7/51; 7/53 ; 7/73-10/53; 7/125-9/115; 7/125-10/110; 14/90;...
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Page 5: Table Of Contents
Pressure system Tyres/Tyre Pressure Running gear/wheels Brakes Running gear wheel bearings Lubrication Engine lubricating oil Engine lubricating oil specification Engine oil filter element Compressor lubricating oil Compressor oil filter element Speed & pressure regulation adjustment Torque Values Compressor lubrication 7/53... - Page 6 Latvian, Lettish Not illustrated Maltese † Option Dutch As required Norwegian High ambient machine Polish F.H.R.G. Fixed height running gear Portuguese Romanian V.H.R.G. Variable height running gear Russian Slovak Bulgarian Slovenian Czech Swedish Danish Chinese German Greek English Spanish 7/53...
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Page 7: Foreword
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 2015 DOOSAN COMPANY 7/53... - Page 8 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. 7/53...
- Page 9 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. 7/53...
- Page 10 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. 7/53...
- Page 11 DECALS Engine oil drain. 7/53...
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Page 12: Safety
OSHA Regulation 29CFR Section 1926.302(b). Rotating fan blade can cause serious injury. Do not operate without guard in place. Never allow the unit to sit stopped with pressure in the receiver- separator system. 7/53... - Page 13 Close and lock all access doors when the generator set is left unattended. Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only extinguishers suitable for class BC or class ABC fires. 7/53...
- Page 14 When adjusting the safety chains there should be sufficient free materials. 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. 7/53...
- Page 15 GENERAL INFORMATION 7/53 FIXED HEIGHT RUNNING GEAR 7/53 VARIABLE HEIGHT RUNNING GEAR 7/53...
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Page 16: General Information
GENERAL INFORMATION 7/53 SHIPPING SKID Contact Doosan Portable Power dealer for more information concerning the shipping skid, permanent skid and truck-mounted version. 2110 3325 7/53 Fixed Height - 1851 1290 1220 1430 1205 braked 2127 3380 2315 2733 7/53 Variable Height -... - Page 17 100 kg (165 lbs) system including separator / receiver, cooler and pipework must be flushed clear of the first fill fluid and new Doosan oil filters installed. VARIABLE HEIGHT RUNNING GEAR When this has been completed, the following oils are approved: Braked Version a) for ambient temperatures above -23°C(-9°F),...
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Page 18: Operating Instructions
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. 7/53... -
Page 19: Prior To Starting
7. CAUTION: Do not operate the machine with the canopy/doors in the open position as this may cause overheating and operators to be exposed to high noise levels. 8. Check the radiator coolant level (with the unit level). 7/53... - Page 20 Main switch Warning lamp, dirty IQ filters (IQ filters option) Service air button Warning lamp, High engine coolant temperature Air pressure gauge Warning lamp, low engine fuel level Hourmeter Warning lamp, low battery voltage Warning lamp, low engine oil pressure 7/53...
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Page 21: Emergency Stopping
Do not allow lubricants or coolants to be released into land surfaces or drains. CAUTION: Never allow the machine to stand idle with pressure in the system. • Do not dispose of a complete machine without documentation relating to instructions for its use. 7/53... - Page 22 Contact your Portable Power representative for flexible mounting kits. Dust and dirt, high humidity, and high temperatures will affect lubricant life and service intervals for components such as inlet air filters, oil separation elements and oil filters. 7/53...
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Page 23: Maintenance
= Test decrease in maintenance intervals. = Drain Contact your Doosan Infracore Portable Power dealer for more information or assistance in determining the optimum intervals for = Replace your application. - Page 24 = Check and adjust if required Contact your Doosan Infracore Portable Power dealer for more information or assistance in determining the optimum intervals for your application.
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Page 25: Routine Maintenance
The switch should operate at 120°C. Refit the switch. extreme temperatures, inflow and outflow of air, intermittently moving parts, safety valve discharge etc.). 7/53... -
Page 26: High Coolant Temperature Switch
Clean the exterior of the filter housing and remove the spin-on element supplier when adding or draining the antifreeze solution. It is by turning it in a counter-clockwise direction. advisable to wear personal protective equipment to prevent skin and eye contact with the antifreeze solution. 7/53... -
Page 27: Air Filter Elements
CHART for frequency) and re-tightened where necessary. Refer to the TORQUE SETTING TABLE later in this section. FUEL FILTER WATER SEPARATOR If the fuel filter water separator contains a filter element, it should be replaced at regular intervals (see the SERVICE/MAINTENANCE CHART). 7/53... -
Page 28: Brakes
Slight dragging noises that do not impede the free movement of the wheel are permissible. 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] 7/53... -
Page 29: Running Gear Wheel Bearings
COMPRESSOR LUBRICATING OIL 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] Refer to the SERVICE/MAINTENANCE CHART in this section for service intervals. 7/53... -
Page 30: Compressor Oil Filter Element
• Airend -- Remove the intake connection and pour the airend intake or has suffered long shutdown periods, then more frequent service full with Doosan compressor fluid PRO--TEC, XHP605 or XHP405. intervals will be required. Reconnect the intake connection. •... -
Page 31: 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). 7/53... -
Page 32: Torque Values
82-93 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 7/53... -
Page 33: 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 oxidisation representative. -
Page 34: Electrical System
ELECTRICAL SYSTEM 7/53... - Page 35 Alternator Hourmeter Crank relay Engine heater relay Contactor (Option) Warm up button Oil pressure switch Mini controller Fuel solenoid Warm up solenoid Generator speed solenoid (Option) Keyswitch Generator switch (Option) Airend temperature switch Airend temperature switch Water temperature switch 7/53...
- Page 36 ELECTRICAL SYSTEM 7/53...
- Page 37 ELECTRICAL SYSTEM IQ restriction switch Mini controller Low fuel switch Airend temperature Engine oil pressure Engine temperature Low fuel No charge IQ filter restriction 7/53...
- Page 38 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 7/53...
- Page 39 Pink 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 7/53...
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Page 40: Piping & Instrumentation System
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) Separator filter assembly (spin-on) 7/53... -
Page 41: Fault Finding
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. 7/53... - Page 42 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.
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Page 43: Options
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 if necessary. • Remove and clean the water separator float. FIGURE 2. FIGURE 3. 7/53... - Page 44 OPTIONS WATER SEPARATOR MAINTENANCE FIGURE 4. FIGURE 1. FIGURE 5. FIGURE 2. FIGURE 3. 7/53...
- Page 45 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. NOTICE: Do not operate at temperatures less that 2° C (35°F). FIGURE 6. 7/53...
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Page 46: Safety
When connecting electrical equipment to any of the socket outlets, it is recommended that the appropriate MCB is in the OFF position before making the connection, switching the MCB to the ON position immediately prior to using the equipment. 7/53... -
Page 47: Prior To Starting
Before starting the engine and switching in the generator load, ensure that :- • 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. 7/53... -
Page 48: Starting The Machine
The earth leakage circuit breaker must be mechanically tested daily by pushing the test button with the machine in its no load condition. The CAUTION: Never allow the machine to stand idle with pressure in the ELCB should trip to the off (down) position. system. 7/53... - Page 49 (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. 7/53...
- Page 50 Circuit breaker 63A Circuit breaker 32A Circuit breaker 16A Circuit breaker 16A Fuse 1A Fuse 1A Alternator - 1 phase Earth stud Contactor Connector - voltmeter Connector - general enable switch Socket outlet 32A/110V Socket outlet 16A/110V Socket outlet 16A/110V 7/53...
- Page 51 CB1/ Circuit breaker 32A Circuit breaker 16A Circuit breaker 16A Fuse 1A Fuse 2A Alternator - 1 phase Earth stud Contactor Connector - voltmeter Connector - generator enable switch Socket outlet 32A/230V Socket outlet 16A/230V Socket outlet 16A/230V 7/53...
- Page 52 CB1/ Circuit breaker 10A Circuit breaker 10A Circuit breaker 10A Fuse 1A Fuse 1A Alternator - 3 phase Earth stud Contactor Connector - voltmeter Connector - generator enable switch Socket outlet 16A/400V Socket outlet 16A/230V Socket outlet 16A/230V 7/53...
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Page 53: Fault Finding
Jammed valve - if in the course of adjusting the valve it jams on its seat, release by turning CLOCKWISE viewed from adjuster end of valve. 7/53... -
Page 54: Maintenance
Note: Ensure adequate ventilation if this check is carried out in an enclosed area. Note: The engine must not be put back into service until any problems identified by the above checks are rectified. 7/53... -
Page 55: 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 56 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 57 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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