Doosan HP375WJD-T3 Operation And Maintenance Manual
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Doosan HP375WJD-T3 Operation And Maintenance Manual

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OPERATION and MAINTENANCE
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this compressor.
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
DoosanPortablePower.com
P/N: 23209307 (5-2014) Rev F
MANUAL
COMPRESSOR MODELS
HP375WJD-T3 (C54)
XP375WJD-T3 (C48)
P425WJD-T3 (C46)
HP375WJD-FX-T3 (E68)
XP375WJD-FX-T3 (E69)
P425WJD-FX-T3 (E58)

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Summary of Contents for Doosan HP375WJD-T3

  • Page 1 P425WJD-FX-T3 (E58) This manual contains important safety information. Do not destroy this manual. This manual must be available to the personnel who operate and maintain this compressor. Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 DoosanPortablePower.com P/N: 23209307 (5-2014) Rev F...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE FOREWORD ............9 Information .
  • Page 4 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE OPERATING INSTRUCTIONS ..........41 Operating Instructions .
  • Page 5 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE Precautions for Welding on Engines Equipped with Electronic Engine Control Unit (ECU) ..68 Displaying of Diagnostic Trouble Codes (DTCs) ........74 Intermittent Fault Diagnostics (With Electronic Controls) .
  • Page 6 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE SERVICE TOOLS ............109 Service Tools .
  • Page 7 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE...

  • Page 9: Foreword

    Foreword...

  • Page 10: Information

    Operation & Maintenance Manual Foreword Information The contents of this manual are considered to be proprietary and confidential to Doosan Infracore Portable Power (herein referred to as “Portable Power”), and should not be reproduced without the prior written permission of Portable Power.
  • Page 11 Foreword Operation & Maintenance Manual This compressor should not be used: A. For direct or indirect human consumption of the compressed air. B. Outside the ambient temperature range specified in the general data section of this manual. C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists.
  • Page 12 Operation & Maintenance Manual Foreword...

  • Page 13: Decals

    Decals...

  • Page 14: Decals

    Operating & Maintenance Manual Decals DECALS Look for these signs on machines manufactured in Europe, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor. GRAPHIC FORM AND MEANING OF ISO SYMBOLS...
  • Page 15 Decals Operating & Maintenance Manual...
  • Page 16 Operating & Maintenance Manual Decals...
  • Page 17 Decals Operating & Maintenance Manual...
  • Page 18 Operating & Maintenance Manual Decals Look for these signs on machines manufactured in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor Indicates the presence of a hazard which WILL cause DANGER...
  • Page 19 Decals Operating & Maintenance Manual...
  • Page 20 Operating & Maintenance Manual Decals FREE SAFETY DECALS Safety Decals are available free of charge. Safety Decals are identified by the decal heading: DANGER, WARNING, or CAUTION. Decal part numbers are on the bottom of each decal and are also listed in the compressor parts manual.

  • Page 21: Safety

    Safety...

  • Page 22: Safety

    Operating & Maintenance Manual Safety Safety Indicates the presence of a hazard which WILL cause DANGER serious injury, death or property damage, if ignored. (Red Background) Indicates the presence of a hazard which CAN cause WARNING serious injury, death or property damage, if ignored. (Orange Background) Indicates the presence of a hazard which WILL or can CAUTION...

  • Page 23: Compressed Air

    Safety Operating & Maintenance Manual disconnecting battery cable(s) to prevent Compressed air must not be used for a direct accidental starting. feed to any form of breathing apparatus or mask. Do not use petroleum products (solvents or fuels) under high pressure as this can High pressure Air can cause serious injury or penetrate the skin and result in serious death.

  • Page 24: Materials

    Operating & Maintenance Manual Safety Never allow the unit to sit stopped with engine lubricants should be obtained from pressure in the receiver-separator system. the lubricant supplier. Never operate the engine of this machine inside a building without adequate Materials ventilation.

  • Page 25: Transport

    Safety Operating & Maintenance Manual Transport Steps for determining correct load limit: When loading or transporting machines Locate the statement “The weight of ensure that the specified lifting and tie down cargo should never exceed xxx kg or points are used. xxx lbs”...

  • Page 27: Noise Emission

    Noise Emission...

  • Page 28: Noise Emission Control Maintenance Log

    Operating & Maintenance Manual Noise Emission NOISE EMISSION CONTROL MAINTENANCE LOG COMPRESSOR MODEL_________________________ SERIAL NO. __________________________________ USER UNIT NO. _______________________________ UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: ENGINE MAKE & MODEL: SERIAL NO:_________________ __________________________________ PURCHASER OR OWNER:__________ __________________________________ ADDRESS: ____________________ DATE PURCHASED:_______________ The Noise Control Act of 1972 (86 Stat.

  • Page 29: Introduction

    Noise Emission Operating & Maintenance Manual Introduction The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air Compressors. The purpose of this book is to provide (1) the Maintenance Performance Schedule below for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when.

  • Page 30: Fasteners

    Operating & Maintenance Manual Noise Emission D. Fasteners All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be inspected for looseness after each 100 hours of operation. They should be retightened, repaired, or if missing, replaced immediately to prevent subsequent damage and noise emission increase.
  • Page 31 Noise Emission Operating & Maintenance Manual MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK OR COMMENTS HOURMETER MAINT/ INSPECT LOCATION CITY/ WORK DONE READING DATE STATE BY (NAME)

  • Page 33: General Arrangement

    General Arrangement...

  • Page 34: General Arrangement

    Operating & Maintenance Manual General Arrangement General Arrangement All dimensions in inches(mm) D Access items: A Instrument panel access door Fuel fill B Package air inlet Engine oil filter C Access items: Fuel filter Separator element & fill Engine and compressor air filter Compressor oil filter E Access items: Fuel filters...
  • Page 35 General Arrangement Operating & Maintenance Manual All dimensions in inches(mm) E Access items: A Instrument panel access door Radiator fill B Package air inlet F Package air outlet C Access items: G Track width Separator element & fill H Variable height drawbar Compressor oil filter 162 (4114) minimum/168 (4277) maximum Fuel filters...

  • Page 36: Compressor

    Operating & Maintenance Manual General Arrangement Compressor COMPRESSOR Actual free air delivery (7/120) (P425WJD) 12, 0 m (425 CFM) Actual free air delivery (9/110) (XP375WJD) 10, 5 m (375 CFM) Actual free air delivery (10/110) (HP375WJD) 10, 5m (375 CFM) Normal operating discharge pressure (7/120) (P425WJD) 7 bar (100 PSI) Normal operating discharge pressure (9/110) (XP375WJD)
  • Page 37 General Arrangement Operating & Maintenance Manual Operating ambient temperature. Whisperized -12°C TO +49°C(10°F TO 120°F) Maximum discharge temperature 120°C (248°F) Cooling system Oil injection Oil capacity 36 litres (9.5 GAL) Maximum oil system temperature 120°C (248°F) Maximum oil system pressure (7/120) (P425WJD) 8,6 bar (125 PSI) Maximum oil system pressure (9/110) (XP375WJD) 10.3 bar (150 PSI)

  • Page 38: Lubricating Oil Specification

    Operating & Maintenance Manual General Arrangement Lubricating Oil Specification LUBRICATING OIL SPECIFICATION (for the specified ambient temperatures). ABOVE -23°C(-9°F) Recommended: Pro-Tec Approved: SAE 10W, API CF-4/CG-4 BELOW -23°C(-9°F) Mandatory: Performance 500 Pro-Tec compressor fluid is factory-fitted, for use at all ambient temperatures above -23°C(- 9°F).

  • Page 39: Engine

    General Arrangement Operating & Maintenance Manual Engine MODELS P425WJD(7/120) XP375WJD (9/110), HP375WJD (10/110) Number of cylinders Oil capacity 13.2 litres (3.5 GAL) 2200 revs Speed at full load. min (RPM) Speed at idle. (RPM) 1500 revs min Electrical system 24V negative earth 93 kW (125 HP) Power available at 2200 revs min Fuel tank capacity...
  • Page 40 Operating & Maintenance Manual General Arrangement Ensure that all transport and packing materials are discarded. Ensure that the correct fork lift truck slots or marked lifting/tie down points are used whenever the machine is lifted or transported. When selecting the working position of the machine, ensure that there is sufficient clearance for ventilation and exhaust requirements, observing any specified minimum dimensions (to walls, floors etc.).

  • Page 41: Operating Instructions

    Operating Instructions...

  • Page 42: Operating Instructions

    Operating & Maintenance Manual Operating Instructions Operating Instructions Prior to Starting 1. Place the unit in a position that is as level as possible. The design of the unit permits a 15 degree lengthways and sideways limit on out of level operation. It is the engine, not the compressor, that is the limiting factor.
  • Page 43 Operating Instructions Operating & Maintenance Manual CAUTION Use only a No. 2-D diesel fuel oil with a minimum octane number of 45 and a sulphur content not greater than 0.5%. CAUTION When refueling: • switch off the engine. • do not smoke. •...

  • Page 44: Control Panel

    Operating & Maintenance Manual Operating Instructions Control Panel Diagnostic/Auto Shutdown (Standard) 1. Compressor Fault - Needs attention. See Wedge diagnostic panel for more detail. 2. Engine Fault - Needs attention. See Wedge diagnostic panel for more detail. 3. Hourmeter - Records running time for maintenance. 4.
  • Page 45 Operating Instructions Operating & Maintenance Manual Optional Controls 9. Engine Speed Gauge - Indicates engine speed. 10. Discharge Air Temp. Gauge - Indicates in °F and °C. Normal operating range: 185°F/85°C to 248°F/120°C. 11. Engine Oil Pressure Gauge - Indicates engine oil pressure (psi (kPa). 12.
  • Page 46 Operating & Maintenance Manual Operating Instructions WEDGE DIAGNOSTIC DISPLAY PANEL. The Wedge diagnostic display panel is arranged as shown above. A description of each diagnostic indicator is as follows: 1. High Compressor Temp: Fault indicator lamp. Indicates shutdown due to high compressor temperature.
  • Page 47 Operating Instructions Operating & Maintenance Manual 4. Restricted Air Filter: Alarm indicator lamp. Indicates engine/compressor air inlet filters need service. 5. High Engine Coolant Temp: Fault indicator lamp. Indicates shutdown due to high engine water temperature. 6. Spare 7. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to low fuel level. Lamp blinks at low fuel warning.
  • Page 48 Operating & Maintenance Manual Operating Instructions Alert Shutdown Delay Condition Code Light (Blinks) Code Light (Steady) (sec). Engine Shut Itself Down: reason CPRSR Malf. unknown Disch. Temp (RT2) CPRSR Malf. Sensor Fault Sep. Tank Pressure (PT1) CPRSR Malf. Sensor Fault Separator Tank Temp.
  • Page 49 Operating Instructions Operating & Maintenance Manual Listing of Diagnostic Trouble Codes (DTCs) Displayed Definition Code Analog Throttle (B) Input Voltage Error Analog Throttle (A) Input Voltage Error Multi-state Throttle Input Voltage Error Fuel Pressure Problem Engine Oil Pressure Problem Turbo Boost Problem Manifold Air Temperature Problem Atmospheric Pressure Reading Problem Engine Coolant Temperature Problem...

  • Page 50: Starting The Machine

    Operating & Maintenance Manual Operating Instructions Starting the Machine WARNING Under no circumstances should volatile liquids such as Ether be used for starting this machine. All normal starting functions are incorporated in the key operated switch. • Turn the key switch to position 1. The engine fault and compressor fault lamps will flash.

  • Page 51: Push After Warm Up

    Operating Instructions Operating & Maintenance Manual Push After Warm Up NOTE: In order to allow the machine to start at a reduced load, a valve, which is operated by a button located on the instrument panel, is incorporated in the regulation system.

  • Page 52: Re-Starting After An Emergency

    Operating & Maintenance Manual Operating Instructions Re-Starting After an Emergency If the machine has been switched off because of a machine malfunction, then identify and correct the fault before attempting to re-start. If the machine has been switched off for reasons of safety, then ensure that the machine can be operated safely before re-starting.

  • Page 53: Engine

    Operating Instructions Operating & Maintenance Manual Engine Engine Serial Number Plate Each engine has a 13-digit engine serial number. The engine's serial number plate is located on the right-hand side of cylinder block behind the fuel filter. Fuels, Lubricants and Coolant Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area.

  • Page 54: Bio-Diesel Fuel

    Operating & Maintenance Manual Operating Instructions Bio-Diesel Fuel Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM PS121, DIN 51606 or equivalent specification. It has been found that bio-diesel fuels may improve lubricity in concentrations up to a 5% blend in petroleum diesel fuel.

  • Page 55: Diesel Fuel Storage

    Operating Instructions Operating & Maintenance Manual Diesel Fuel Storage WARNING Handle fuel carefully. Do not fill the fuel tank when engine is running. DO NOT smoke while you fill the fuel tank or service the fuel system. Fill the fuel tank at the end of each day's operation to prevent water condensation and freezing during cold weather.

  • Page 56: Diesel Engine Oil

    Operating & Maintenance Manual Operating Instructions Diesel Engine Oil Use SAE 15W-40 oil viscosity based on the expected air temperature range of 10°F to 122°F (-12°C-40°C) during the period between oil changes. The following oil is preferred: • Pro-Tec Engine Fluid Other oils may be used if they meet one or more of the following: •...

  • Page 57: Supplemental Coolant Additives

    Operating Instructions Operating & Maintenance Manual Chlorides <40mg/L Sulfates <100 mg/L Total Dissolved Solids <340 mg/L Total Hardness <170 mg/L 5.5 to 9.0 IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives. Supplemental Coolant Additives The concentration of coolant additives is gradually depleted during engine operation.

  • Page 58: Operating In Warm Temperature Climates

    Operating & Maintenance Manual Operating Instructions Operating in Warm Temperature Climates These engines are designed to operate using glycol base engine coolants. Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required. IMPORTANT: Water may be used as coolant in emergency situations only.

  • Page 59: Lubrication

    Lubrication...

  • Page 60: Lubrication

    Operating & Maintenance Manual Lubrication Lubrication Lubrication and Maintenance Service Interval Chart NOTE: The Service intervals below are for standard industrial engines. See details in Sections which follow these charts. Item Lubrication and Maintenance Service Intervals 2000 500 Hours/ Check Engine Oil and Coolant Level Daily Hours/ 12months...

  • Page 61: Lubrication & Maintenance/Daily

    Lubrication Operating & Maintenance Manual Lubrication & Maintenance/Daily Daily Pre-starting Checks Do the following BEFORE STARTING THE ENGINE for the first time each day: Check engine oil level on dipstick. IMPORTANT: DO NOT add makeup oil until the oil level is below the crosshatch marks on the dipstick.

  • Page 62: To Change Engine Oil And Oil Filter

    Operating & Maintenance Manual Lubrication To change engine oil and oil filter: 1. Run engine approximately 5 minutes to warm up oil. Shut engine off. 2. Remove oil pan drain plug. 3. Drain crankcase oil from engine while warm. 4. Turn filter element using a suitable filter wrench to remove. Discard oil filter element.

  • Page 63: Cleaning Crankcase Vent Tube

    Lubrication Operating & Maintenance Manual Cleaning Crankcase Vent Tube If you operate the engine in dusty conditions, clean the tube at shorter intervals. 1. Remove and clean crankcase vent tube. 2. Install the vent tube. Be sure the O-ring fits correctly in the rocker arm cover for elbow adapter.

  • Page 64: Checking Belt Tensioner Spring Tension And Belt Wear (Automatic Tensioner)

    Operating & Maintenance Manual Lubrication 9. Install retaining ring onto mounting base making certain dust seal is in place on filter base. Hand tighten ring (about 1/3 turn) until it "snaps" into the detent. DO NOT overtighten retaining ring. NOTE: The proper installation is indicated when a "click" is heard and a release of the retaining ring is felt.

  • Page 65: Checking Engine Electrical Ground Connections

    Lubrication Operating & Maintenance Manual Specification Spring Tension-Torque 18-22 N.m (13-16 Ib-ft) NOTE: Threads on belt tensioner roller cap screw are LEFT-HAND threads. Checking Engine Electrical Ground Connections Keep all engine ground connections clean and tight to prevent electrical arcing which can damage electronic components.

  • Page 66: Replacing Fan And Alternator Belts

    Operating & Maintenance Manual Lubrication Replacing Fan and Alternator Belts Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Lubrication and Maintenance/500 Hour/12 Month Section for additional information on the belt tensioner. 1. Inspect belts for cracks, fraying, or stretched out areas. Replace if necessary. 2.

  • Page 67: At Fuel Injection Pump

    Lubrication Operating & Maintenance Manual At Fuel Injection Pump 1. Loosen fuel return line at fuel injection pump. 2. Operate fuel supply pump primer lever or primer button on fuel filter base (if equipped). 3. As soon as fuel flow is free from air bubbles, tighten fuel return line to specification.

  • Page 68: Troubleshooting

    Operating & Maintenance Manual Lubrication Troubleshooting General Troubleshooting Information Troubleshooting engine problems can be difficult. In this section is a list of possible engine problems that may be encountered accompanied by possible causes and corrections. The illustrated diagrams and troubleshooting information are of a general nature.
  • Page 69 Lubrication Operating & Maintenance Manual Symptom Problem Solution Engine cranks but will Incorrect starting procedure Verify correct starting procedure. not start No fuel. Check fuel in tank. Check and correct exhaust Exhaust restricted. restriction. Fuel filter plugged or full of Replace fuel filter or drain water from water filter.
  • Page 70 Operating & Maintenance Manual Lubrication Symptom Problem Solution Engine runs Low coolant temperature. Remove and check thermostat. irregularly or stalls Clogged fuel filter. Replace fuel filter element. frequently Drain, flush, fill, and bleed system. Dirty or Water, dirt, or air in fuel faulty injection nozzles.
  • Page 71 Lubrication Operating & Maintenance Manual Symptom Problem Solution Low oil pressure Low oil level. Add oil Drain, fill crankcase with oil of proper Improper type of oil. Viscosity and quality. High oil consumption Crankcase oil too light. Use proper viscosity oil. Check for leaks in lines, gaskets, and Oil leaks.
  • Page 72 Operating & Maintenance Manual Lubrication Symptom Problem Solution Engine overheats Engine overloaded. Reduce load. Fill radiator to proper level, check radiator Low coolant level. and hoses for loose connection s or leaks. Faulty radiator cap. Have technician check. Stretched poly-vee belt or Check automatic belt tensioner and check defective belt tensioner.
  • Page 73 Lubrication Operating & Maintenance Manual Symptom Problem Solution Battery uses too much Check for moisture and replace Cracked battery case. Water as necessary. Defective battery. Test battery. Battery charging rate too high. Test charging system. Batteries will not charge Loose or corroded connections. Clean and tighten connections.

  • Page 74: Displaying Of Diagnostic Trouble Codes (Dtcs)

    Operating & Maintenance Manual Lubrication Displaying of Diagnostic Trouble Codes (DTCs) Stored and active diagnostic trouble codes are output on the instrument panel according to the J1939 standard as a two-part code as shown on the tables in the Operating Instruction Section.

  • Page 75: Possible Causes Of Intermittent Faults

    Lubrication Operating & Maintenance Manual Possible causes of intermittent faults: • Faulty connection between sensor and actuator harness. • Faulty contact between terminals in connector. • Faulty terminal/wire connection. • Electromagnetic interference (EMI) from an improperly installed 2-way radio, etc., can cause faulty signals to be sent to the ECU.

  • Page 76: Removing Engine From Long Term Storage

    Operating & Maintenance Manual Lubrication 8. Clean the exterior of the engine with salt-free water and touch up any scratched or chipped painted surfaces with a good quality paint. 9. Coat all exposed (machined) metal surfaces with grease or corrosion inhibitor if not feasible to paint.

  • Page 77: Specifications

    Lubrication Operating & Maintenance Manual Specifications General Engine Specifications. ITEM Number of Cylinders Bore 106 mm (4.19 in.) Stroke 127 mm (5.0 in.) Displacement 4.5 L (276 cu in.) Compression Ratio 17.0:1 Aspiration Turbocharged Engine Firing Order 1-3-4-2 Valves Per Cylinder 1 Intake 1 Exhaust Valve Clearance (Cold)

  • Page 78: Engine Crankcase Oil Fill Quantities

    Operating & Maintenance Manual Lubrication ITEM Length 860 mm (33.9 in.) Width 612 mm (24.1 in.) Height 994 mm (39.l in.) Weight 451 kg (993 Ib) Engine Crankcase Oil Fill Quantities Crankcase Oil Capacity L (qt) 13.5 (14.3) Lubrication and Maintenance Records Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Section for detailed service procedures.

  • Page 79: Emissions Control System Certification Label

    Lubrication Operating & Maintenance Manual Emissions Control System Certification Label CAUTION Statutes providing severe penalties for tampering with emissions controls may apply to the user or dealer. The emissions warranty applies only to those engines marketed by John Deere that have been certified by the United States Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB);...

  • Page 81: Maintenance

    Maintenance...

  • Page 82: Maintenance

    Operating & Maintenance Manual Maintenance Maintenance Initial Monthly Daily Weekly Monthly Monthly Monthly miles/ 1000 250 hrs. 500 hrs. 850 km hrs. Compressor Oil Level Engine Oil Level *Radiator Coolant Level Gauges/Lamps *Air Cleaner Service Indicators Fuel Tank (Fill at end of day) *Fuel/Water Separator Drain Oil Leaks Fuel Leaks...
  • Page 83 Maintenance Operating & Maintenance Manual *Disregard if not appropriate for this particular machine (1) or 3000 miles/5000km whichever is the sooner (2) or as defined by local or national legislation C = Check (adjust, clean or replace as necessary) CBT = Check before towing. CR = Check and report D = Drain G = Grease...
  • Page 84 Operating & Maintenance Manual Maintenance Initial Monthly Monthly miles/ Daily Weekly Monthly Monthly Monthly 1000 1000 250 hrs. 500 hrs *Fuel/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease. Wheels (Bearings, Seals, etc.) *Engine Coolant Fuel Filter Element...
  • Page 85 Maintenance Operating & Maintenance Manual *Disregard if not appropriate for this particular machine (1) or 3000 miles/5000km whichever is the sooner (2) or as defined by local or national legislation C = Check (adjust, clean or replace as necessary) CBT = Check before towing. CR = Check and report D = Drain G = Grease...
  • Page 86 Operating & Maintenance Manual Maintenance Initial Daily Weekly Monthly Monthly Monthly Monthly miles/ 250 hrs. 500 hrs 1000 hrs 850 km Scavenge line Pressure system Engine breather element Pressure gauge Pressure regulator Separator tank (2) exterior Lubricator (Fill) 2 Yrs 4 Yrs 6 Yrs Safety valve...

  • Page 87: Routine Maintenance

    Maintenance Operating & Maintenance Manual Routine Maintenance This section refers to the various components which require periodic maintenance and replacement. The SERVICE/MAINTENANCE CHART indicates the various components' descriptions and the intervals when maintenance has to take place. Oil capacities, etc., can be found in the GENERAL INFORMATION section of this manual.
  • Page 88 Operating & Maintenance Manual Maintenance Prior to opening or removing panels or covers to work inside a machine, ensure that: • anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts. •...

  • Page 89: Productive Shutdown System

    Maintenance Operating & Maintenance Manual Productive Shutdown System Refer to the Wedge diagnostic display codes table for a listing of shutdown conditions. Low engine fuel level switch. At three month intervals, test the low engine fuel level switch circuit as follows: •...

  • Page 90: Compressor Oil Filter

    Operating & Maintenance Manual Maintenance Compressor Oil Filter Refer to the MAINTENANCE CHART in this section for the recommended servicing intervals. Removal WARNING Do not remove the filter(s) 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 INSTRUCTIONS section of this manual).

  • Page 91: Compressor Oil Separator Element

    Maintenance Operating & Maintenance Manual Compressor Oil Separator Element Normally the separator element will not require periodic maintenance provided that the air and oil filter elements are correctly maintained. If, however, the element has to be replaced, then proceed as follows: Removal WARNING Do not remove the filter(s) without first making sure that the machine is...

  • Page 92: Compressor Oil Cooler And Engine Radiator

    Operating & Maintenance Manual Maintenance 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. Compressor Oil Cooler and Engine Radiator When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator, the efficiency is impaired.

  • Page 93: Air Filter Elements

    Maintenance Operating & Maintenance Manual Air Filter Elements The air filter should be inspected regularly (refer to the SERVICE/MAINTENANCE CHART) and the element replaced when the restriction indicator shows red or every 6 Months (500 hours), whichever comes first. The dust collector box(es) should be cleaned daily (more frequently in dusty operating conditions) and not allowed to become more than half full.

  • Page 94: Fuel System

    Operating & Maintenance Manual Maintenance Fuel System The fuel tank should be filled daily or every eight hours. To minimize condensation in the fuel tank(s), it is advisable to top up after the machine is shut down or at the end of each working day.

  • Page 95: Battery

    Maintenance Operating & Maintenance Manual Battery Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion. The retaining clamp should be kept tight enough to prevent the battery from moving. Pressure System At 500 hour intervals it is necessary to inspect the external surfaces of the system (from the airend through to the discharge valve(s)) including hoses, tubes, tube fittings and the separator tank, for visible signs of impact damage, excessive corrosion, abrasion, tightness and chafing.

  • Page 96: Lubrication

    Operating & Maintenance Manual Maintenance Lubrication The engine is initially supplied with engine oil sufficient for a nominal period of operation (for more information, consult the Engine section of this manual). CAUTION Always check the oil levels before a new machine is put into service. If, for any reason, the unit has been drained, it must be re-filled with new oil before it is put into operation.

  • Page 97: Compressor Oil Filter Element

    Maintenance Operating & Maintenance Manual Completely drain the receiver/separator system including the piping and oil cooler by removing the drain plug(s) and collecting the used oil in a suitable container. Replace the drain plug(s) ensuring that each one is secure. NOTE: If the oil is drained immediately after the machine has been running, then most of the sediment will be in suspension and will therefore drain more readily.

  • Page 98: Speed And Pressure Regulation Adjustment

    Operating & Maintenance Manual Maintenance Speed and Pressure Regulation Adjustment Normally, regulation requires no adjusting, but if correct adjustment is lost, proceed as follows: Refer to the diagram above. A. Adjusting screw Start the machine (Refer to STARTING INSTRUCTIONS in the OPERATING INSTRUCTIONS section of this manual).
  • Page 99 Maintenance Operating & Maintenance Manual...
  • Page 100 Operating & Maintenance Manual Maintenance...
  • Page 101 Maintenance Operating & Maintenance Manual Compressor Lubrication Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change. NOTE: Fluids listed as "preferred"...
  • Page 102 Operating & Maintenance Manual Maintenance Design Operating Ambient Temperature Specification Pressure ° ° ° ° 100 psi to300 psi Preferred: Pro-Tec F to 125 F (-23 C to 52 Alternate: ISO Viscosity Grade 46 with rust and oxidation inhibitors, designed for air compressor service.

  • Page 103: Machine Systems

    Machine Systems...

  • Page 104: Machine Systems

    Operating & Maintenance Manual Machine Systems Machine Systems Battery Pressure transducer, separator tank 0-500 PSIG RS232C comms Pressure transducer, regulation system 0-100 PSIG ECON Engine controller Plug, machine ID Isochronous governor Idle sel J50-G2 Wait to start lamp Relay-spst J50-K3 Inlet heater Thermistor, separator tank temperature -30- 255 Coolant temp...
  • Page 105 Machine Systems Operating & Maintenance Manual POUT4 Engine fault lamp Spare POUT5 Start relay Spare POUT6 Spare Switch, start POUT7 Hour meter Transducer exitation POUT8 WCON Spare Wedge controller...

  • Page 106: Wedge To Engine Interface

    Operating & Maintenance Manual Machine Systems Wedge to Engine Interface Harness System Schematic...

  • Page 107: J1939 Can Communications Schematic

    Machine Systems Operating & Maintenance Manual J1939 CAN Communications Schematic...
  • Page 108 Operating & Maintenance Manual Machine Systems...

  • Page 109: Service Tools

    Service Tools...

  • Page 110: Service Tools

    Operating & Maintenance Manual Service Tools Service Tools Electronic Systems The following special tools are recommended to perform service procedures in this manual. The tools can be purchased from Portable Power or equivalent substitutes can be used. Tool Tool Description Fluke 87 Digital Multimeter Used to measure electrical circuits: volts,...
  • Page 111 Service Tools Operating & Maintenance Manual Tool Tool Description 22073878 Thermistor Simulator Plug Used to test thermistor circuits 54699616 Deutsch Terminal Removal Tool Used to repair Deutsch connectors 54699657 Deutsch Terminal Removal Tool Used to repair Deutsch connectors 54749643 Packard Metri-Pack Terminal Removal Tool Used to repair Metri-Pack connectors 54749635 Connector Repair Kit...

  • Page 112: Service Tools

    Operating & Maintenance Manual Service Tools Service Tools Tool No Tool Description Tool Illustration Digital multimeterAvailable Fluke 87 from electrical and electronic parts distributors Weather-Pack Terminal 54729660 Removal Tool Deutsch Terminal Removal 54699632 Tool (Blue) Deutsch Terminal Removal 54699640 Tool (Red) Deutsch Terminal Removal 54699624 Tool (Yellow)
  • Page 113 Service Tools Operating & Maintenance Manual Crimp Tool for Deutsh pins DT-RT1 Crimp Available from: Ladd Industries (800-223-1236) 54729710 Electrical Contact Cleaner 54729728 PDA Service Tool Deutsch Terminal Removal 54699616 Tool 22073886 Packard Crimp Tool 22073878 Thermistor Simulator...

  • Page 114: Electrical Parts

    Operating & Maintenance Manual Service Tools 54749635 Connector Repair Kit Deutsch Terminal Removal 54699657 Tool 54749643 Packard Metri-Pack Removal Tool Electrical Parts PARTS QTY PER PARTS QTY PER DESCRIPTION DESCRIPTION NUMBERS MACHINE NUMBERS MACHINE 0-100 psi PRESSURE 36920825 54731427 FUEL LEVEL SENDER TRANSDUSER 0-500 psi PRESSURE 54765946...

  • Page 115: Fault Finding

    Fault Finding...

  • Page 116: Fault Finding

    Operating & Maintenance Manual Fault Finding Fault Finding FAULT CAUSE REMEDY No reaction from Emergency stop Reset emergency stop button. instrument panel actuated. when key turned to Batteries not connected. Connect batteries. (I) position. Fuse at starter motor Replace fuse. ‘blown’.
  • Page 117 Fault Finding Operating & Maintenance Manual FAULT CAUSE REMEDY Engine starts but Electrical fault. Test the electrical circuits. will not run or Low engine oil pressure. Check the oil level and oil filter(s). engine shuts down prematurely. Safety shut-down Check the safety shut-down switches. system in operation.
  • Page 118 Operating & Maintenance Manual Fault Finding FAULT CAUSE REMEDY Excessive vibration. Engine speed too low. See ”Engine speed too low” Leaking oil seal. Improperly fitted oil seal. Replace the oil seal. Refer also to the Engine Manufacturer’s Manual. Air discharge Engine speed too low.
  • Page 119 Fault Finding Operating & Maintenance Manual FAULT CAUSE REMEDY Refer to SPEED AND PRESSURE Inlet valve set REGULATION ADJUSTMENT in the incorrectly. MAINTENANCE section of this manual. Loose pipe/hose Check all pipe/hose connections. connections. Check the relieving pressure. Replace the Faulty safety valve.
  • Page 120 22442578...

  • Page 121: Options

    Options...

  • Page 122: Options - Lubricator

    Operating & Maintenance Manual Options Options - Lubricator (For units manufactured in North America) Safety WARNING Ensure that the lubricator filler cap is re-tightened correctly after replenishing with oil. WARNING Do not replenish the lubricator oil, or service the lubricator 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 INSTRUCTIONS section of this manual).

  • Page 123: Operating Instructions

    Options Operating & Maintenance Manual Operating Instructions Commissioning Check the lubricator oil level and fill as necessary. Prior to Starting Check the lubricator oil level and replenish as necessary. Maintenance Check the lubricator oil level and replenish as necessary. Fault Finding FAULT CAUSE REMEDY...
  • Page 125 Revision History Rev. EC Number Comments Original release Text Edits Changed Model to WJD SVC31262 Text Edits Doosan references updated CN024821 Flex Models Added to Front Cover CN034866...
  • Page 126 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2012 Doosan Infracore Portable Power Printed in the U.S.A.

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