Doosan 7/71 Operation And Maintenance Manual
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Doosan 7/71 Operation And Maintenance Manual

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7/71, 12/56
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.
22258669_en_E_04/13
7/71, 12/56
SERIAL No :
520560
−>

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Summary of Contents for Doosan 7/71

  • Page 1 7/71, 12/56 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. 7/71, 12/56 SERIAL No : 520560 −> 22258669_en_E_04/13...

  • Page 3: Table Of Contents

    CONTENTS & ABBREVIATIONS CONTENTS ABBREVIATIONS & SYMBOLS FOREWORD #### Contact Doosan for serial number −>#### Up to Serial No. WARRANTY ####−> From Serial No. DECALS Not illustrated † Option SAFETY As required Brazil GENERAL INFORMATION Dimensions China Data Germany OPERATING INSTRUCTIONS...

  • Page 4: Foreword

    (1ph), 230v (3ph) and 400v (3ph) / 230v (1ph) nominal at 50 Hertz. The use of the machine in any of the situation types listed in table 1:− a) Is not approved, b) May impair the safety of users and other persons, and c) May prejudice any claims made. 7/71, 12/56...

  • Page 5: Warranty

    1. The original airend is returned assembled and unopened. 2.5 Kva Through to 8 Kva − The earlier of twelve (12) months 2. Continued use of genuine Doosan parts, fluids, oil and filters. from shipment to or the accumulation of 2,000 hours of operation by the initial user.
  • Page 6 2,000 (IN COMPRESSORS) 2,000 24 MONTHS / 4,000 HRS. AVAILABLE FROM THE (IN GENERATORS) COMPANY WITH USE OF GENUINE DOOSAN PARTS AND OILS AT PRESCRIBED SERVICE INTERVALS. CONTACT THE COMPANY NETWORK. KUBOTA 2,000 EXTENDED WARRANTY OF 36 MONTHS / 3,000 HRS.
  • Page 7 (rotors, housings, gears and bearings), and is automatically available when the following conditions are met: 1. The original airend is returned assembled and unopened. 2. Submissions of proof that Doosan fluid, filters and separators have been used. Refer to the Operation and Parts manual for the correct fluids, filters and separator elements required.
  • 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. 7/71, 12/56...

  • Page 9: Decals

    Do not open the service valve before the Do not exceed the trailer speed limit. No naked lights. airhose is attached. Use fork lift truck from this side only. Emergency stop. Tie down point 7/71, 12/56...
  • Page 10 Safety Decals are available free of charge. Decal part numbers are on the bottom of each decal and are also listed in the compressor’s parts manual. Submit orders for Safety Decals to the Doosan Portable Power EMEA Aftermarket Department. The no charge order should contain only Safety Decals.

  • Page 11: Safety Ar

    Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). 7/71, 12/56...
  • Page 12 Avoid contact with skin, eyes and generator set and/or interconnecting cables or conductors with any clothing. In case of contact, flush area immediately with water. part of the body or with any non−insulated conductive object. 7/71, 12/56...
  • Page 13 7/71, 12/56...
  • Page 14 GENERAL INFORMATION 7/71, 12/56 FIXED HEIGHT RUNNING GEAR Braked version 7/71, 12/56 VARIABLE HEIGHT RUNNING GEAR Braked version 7/71, 12/56...

  • Page 15: General Information

    / receiver, cooler and pipework must be flushed clear of the first fill fluid and new Doosan oil filters installed. When this has been completed, the following oils are approved: for ambient temperatures above −23_C (−9_F),...
  • Page 16 (where fitted). WARNING: If flexible discharge hoses are to carry more than 7 bar pressure then it is recommended that safety retaining wires are Ensure that all transport and packing materials are discarded. used on the hoses. 7/71, 12/56...

  • Page 17: Operating Instructions

    45 and a sulphur content not greater than 0,5%. 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. 7/71, 12/56...

  • Page 18: Emergency Stopping

    If the machine has been switched off because of a machine malfunction, then identify and correct the fault before attempting to NOTE: Wear hearing protection at all times when the engine is started re−start. with the service valve open and air is flowing from the valve. 7/71, 12/56...

  • Page 19: Monitoring During Operation

    Do not dispose of a complete machine without documentation High engine water temperature relating to instructions for its use. CAUTION: To ensure an adequate flow of oil to the compressor at low temperature, never allow the discharge pressure to fall below 3,5 bar. 7/71, 12/56...
  • Page 20 (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. 7/71, 12/56...

  • Page 21: Maintenance Nl

    (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. 7/71, 12/56...
  • Page 22 (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. 7/71, 12/56...

  • Page 23: Routine Maintenance

    NOTE: Do not press the load button. machine, ensure that:− the work carried out is limited to only those tasks which require the Disconnect each switch in turn. The machine should shutdown. machine to run. Re−connect the switch. 7/71, 12/56...
  • Page 24 Thoroughly clean the orifice/drop tube and filter gasket contact area lubricant is changed as any blockage will result in oil carryover into the before reassembly. Install the new element. discharge air. 7/71, 12/56...
  • Page 25 Inspection Check for cracks, holes or any other damage to the element by WARNING: Always disconnect the battery cables before holding it up to a light source, or by passing a lamp inside. performing any maintenance or service. 7/71, 12/56...
  • Page 26 ADJUSTING THE OVERRUN BRAKING SYSTEM CAUTION The compression spring [9] must only be lightly pre−tensioned and 1: Preparation when operating must never touch the axle tube. Jack up the machine Never adjust the brakes at the brake linkage [7]. 7/71, 12/56...

  • Page 27: Lubrication No

    If necessary adjust the brake linkage [7] again without play and without CAUTION: Always check the oil levels before a new machine is put into pre−tensioning service. There must still be a little play in cable [5] (Variable Height Only) 7/71, 12/56...
  • Page 28 (refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual). 7/71, 12/56...
  • Page 29 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). 7/71, 12/56...
  • Page 30 73−78 Separator tank cover 40−50 54−68 Euro−Loc adaptor to separator tank 58−67 78−91 Separator tank to frame 18−22 24−30 Exhaust flange to manifold 17−21 23−28 Service pipe (−20jic) 106−133 143−180 Sight glass 40−50 54−68 Wheel nuts 62−70 85−95 7/71, 12/56...

  • Page 31: Compressor Lubrication

    Alternate: XHP 405 ISO Viscosity Grade 68 Group 3 or 5 with Preferred Doosan Fluids − Use of these fluids with original Doosan rust and oxidation branded filters can extend airend warranty. Refer to operator’s manual inhibitors designed warranty section for details or contact your Portable Power for air compressor representative.
  • Page 32 ELECTRICAL SYSTEM 7/71, 12/56...

  • Page 33: Electrical System

    Compressor / generator switch, (Option) Dual pressure switch (Option) Solenoid, fuel Solenoid, load / unload (Option) Solenoid, generator speed (Option) Dual pressure solenoid (Option) High air temperature switch (airend) High air temperature switch (discharge) (Option) High water temperature switch (engine) 7/71, 12/56...
  • Page 34 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM Plug Black Light (right hand) Green Fog light Pink Light (left hand) Brown Orange Purple Grey Blue White Yellow 7/71, 12/56...
  • Page 35 Stop / turn (left hand) Black Tail (left hand) Green Stop / turn (right hand) Pink Tail (right hand) Brown Front side marker (left hand) Orange Front side marker (right hand) Purple Ground / earth Grey Blue White Yellow 7/71, 12/56...
  • Page 36 PIPING AND INSTRUMENTATION SYSTEM Air discharge Oil cooler Sonic orifice (restricts flow) Oil filter Pressure gauge Thermostatic valve (Where fitted) Separator tank Safety valve Compressor Engine Air/oil 7/71, 12/56...

  • Page 37: Fault Finding

    Clean the oil cooler fins. compressor oil oil cooler. Check the fan drive. blocked oil temperature. cooler. Incorrect Use Doosan recommended oil. Water present Check the water separator and grade of oil. in fuel system. clean if required. Recirculation Move the machine to avoid Faulty relay.
  • Page 38 Faulty load Replace the solenoid. Check the valve. Replace the safety valve if faulty. to load when solenoid. electrical circuit by feeling for DO NOT ATTEMPT A REPAIR. the load movement whilst depressing the button is load button. pressed. 7/71, 12/56...

  • Page 39: Options

    CAUTION: If the nylon tubes to the lubricator are disconnected then ensure that each tube is re−connected in its original location. Check the lubricator oil level and replenish as necessary. FAULT FINDING FAULT CAUSE REMEDY No oil flow. Incorrect Reverse nylon tube connection. connections to the lubricator. 7/71, 12/56...

  • Page 40: Generator

    Any warnings necessary have been suitably displayed (where applicable). CAUTION: Do not start or stop the machine with the compressor/generator mode switch in the Generator position. Ensure compressor / generator mode switch is set to compressor. 7/71, 12/56...
  • Page 41 NOTE: Wear hearing protection at all times when the engine is started Refer to the PRIOR TO STARTING and STARTING THE UNIT with the top open and air is flowing from the valve. instructions earlier in this section before re−starting the machine. 7/71, 12/56...

  • Page 42: Maintenance

    30 milliamperes on the connected appliance or in the connections to the generator. Do not dispose of a complete machine without documentation relating to instructions for its use. For alternator maintenance refer to Mecc Alte operation and maintenance manual. 7/71, 12/56...

  • Page 43: Fault Finding

    Replace the generator. damaged. Generator Engine is not Check the engine speed with a fails to running at full tachometer. Consult Doosan if the provide speed. engine is found to be running slow maximum (Refer to section 4 General output.
  • Page 44 A.C. Electrical Power Schematic Diagram. 115V 1 − phase. Circuit breaker Switch, start Socket outlet 32A Circuit breaker Socket outlet 16A Socket outlet 16A Circuit breaker Valve, solenoid Circuit breaker Voltmeter Fuse Voltmeter Alternator Contactor Fuse Voltmeter Pushbutton Resistor 7/71, 12/56...
  • Page 45 OPTIONS A.C. Electrical Power Schematic Diagram. 230V 1 − phase. Circuit breaker Switch, start Socket outlet 32A Circuit breaker Socket outlet 16A Socket outlet 16A Circuit breaker Valve, solenoid Alternator Voltmeter Contactor Fuse Voltmeter Pushbutton Fuse Resistor Voltmeter 7/71, 12/56...
  • Page 46 A.C. Electrical Power Schematic Diagram. 400/230V 3 − phase. Circuit breaker Switch, start Socket outlet 16A Circuit breaker Socket outlet 16A Socket outlet 16A Circuit breaker Valve, solenoid Alternator Voltmeter Contactor Fuse Voltmeter Pushbutton Fuse Resistor Voltmeter Resistor 7/71, 12/56...

  • Page 47: Engine Instruction Manual

    OPERATION Check before operation Check and operation after start− up Operation and care of a new engine PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance COLD WEATHER OPERATION MAINTENANCE SCHEDULE TROUBLESHOOTING 7/71, 12/56...

  • Page 48: Foreword

    All information, illustrations, and specifications contained in this Manual are based on the latest product information available at the time of publication. The company reserves the right to make changes in this Manual at any time without prior notice. 7/71, 12/56...

  • Page 49: External Views

    (10) Injection pump (3) Inlet manifold (11) Exhaust manifold (4) Injection nozzle (12) Oil filler cap (5) Oil dipstick (13) Thermostat housing (6) Starter motor (14) Oil filter (7) Flywheel (15) Alternator (8) Oil drain plug (16) Oil pan 7/71, 12/56...

  • Page 50: General Information

    Please feel free to contact your dealer for periodical inspection and maintenance. Doosan Genuine Parts Genuine Doosan parts are identical with those used in the engine production, and accordingly, they are warranted. Genuine Doosan parts are supplied by your branch or distributor.

  • Page 51: Fuel, Lubricant, And Coolant

    Engine failure or malfunction resulting from use of such manufacturer‘s instructions). Biocides are available from your dealer, improper fuel will not be warranted by Doosan. service stations, parts stores and other automotive places. See your authorized dealer for advice on using biocides in your area and for recommendations on which biocides you should use.

  • Page 52: Lubricant

    COOLANT • Be sure to use the mixing ratios specified by the LLC manufacturer All Doosan portable compressor engines are factory filled with a for your temperature range. 50/50 Ethylene glycol base antifreeze/water mix. which provides • Do not mix different types (brand) of LLC, chemical reactions may protection to −33_C (−27_F).

  • Page 53: Operation

    Oil can be poured either through the oil filler at the front of the cylinder cables after disconnection. Even a short period of reverse connection head cover or through the oil filler on the right side of the timing gear will damage the electrical parts. case. 7/71, 12/56...

  • Page 54: Check And Operation After Start− Up

    Cover the radiator cap with a thick cloth and loosen the cap slowly to reduce the pressure, then When disconnecting the terminals, start with “−” terminal. When connecting them, connect the “−” terminal last. remove the cap. 7/71, 12/56...

  • Page 55: Operation And Care Of A New Engine

    If the level is correct, found, please consult your local Doosan branch or dealer. contact your local Doosan branch or dealer to establish the cause. Overcooling (2) Coolant Temperature − The engine performance will be adversely Operating the engine at low coolant temperature will not only increase affected if engine coolant temperature is too hot or too cold.
  • Page 56 If you have a problem disposing of your used oil, it is suggested that you contact your local Doosan branch or dealer. This also applies to diesel fuel which is contaminated with water.

  • Page 57: Periodical Inspection And Maintenance

    Use of Genuine Doosan Fan Belt. Debris, mud or dried grass caught between radiator fins will block the Always use Genuine Doosan fan belts as they provide high driving air flow, resulting in lower cooling efficiency. Clean the radiator fins with ability and long operating durability.

  • Page 58: Fuel System

    Slacken the drain valve ‘E’ until water drains from the vent tube. (Note: Top of cartridge has locators which must align with slots in the When all the water has been evacuated, tighten the drain valve ‘E’ and base.) follow the “fuel system air bleeding” procedure below. 7/71, 12/56...

  • Page 59: Air Intake System

    Slightly loosen fuel return line connector B (fig 17). Operate supply pump priming lever E until fuel flow is free of ENGINE ELECTRICAL bubbles. The Doosan engines uses a 12 volt system and a negative grounding Tighten return line connector to 27Nm. for the electrical system. Battery Servicing...
  • Page 60 When the battery is charged from an external source, be sure to by a skilled and trained technician. disconnect the battery cables. Please consult your local Doosan branch or dealer when these Wiring Connections procedures become due. Check all of the electric wiring connections for looseness and damage Please also read the note refering to the service items marked with the on a regular basis.

  • Page 61: Cold Weather Operation

    This takes a longer period of running than in warm weather the year is highly recommended. operation. All Doosan portable compressor engines are factory filled with a The electrolyte in a partly discharged battery will freeze easier than 50/50 Ethylene glycol base antifreeze/water mix. which provides when it is fully charged.

  • Page 62: Maintenance Schedule

    1. After every 1500 hours of operation, the service intervals should be repeated in accordance with this check and maintenance schedule. 2. When servicing on the asterisked (*) items is necessary, consult your local Doosan branch or distributor. 7/71, 12/56...
  • Page 63 L This is a recommended maintenance. The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion engine useful life. Doosan, however, urges that recommended maintenance service is performed at the indicated intervals.
  • Page 64 Check and adjust every 1000 hours. Consult your local Doosan branch or distributor. Positive crankcase Check according to the equipment specifications. Perform the adjustment, cleaning, repair or replacement every ventilation valve cleaning 1500 hours. (This is a recommended maintenance item L). Consult your local Doosan branch or distributor. 7/71, 12/56...

  • Page 65: Troubleshooting

    This item contains a simple troubleshooting. When a failure takes place on your Doosan engine, diagnose the cause referring this troubleshooting. Should the cause of failure not be detected or you are unable to manage the failure, consult your machine supply source or nearest Doosan engine service outlet.
  • Page 66 Restricted coolant flow (high concentration of antifreeze, etc.) Low oil pressure Lack of oil Oil leakage High oil consumption Wrong oil Wrong type and viscocity. High coolant temperature. Over heat. Clogged filter and strainer. Worn bearings and oil pump. Faulty relief valve. 7/71, 12/56...
  • Page 67 Faulty valve stem seal. Damaged seal / Damaged turbocharger seal Oil leakage Loose joints/gaskets. Improper installation of filter and piping. Fuel leakage Damaged seals. Excessive fuel consumption Improper component installation or tightening. Excessive injection volume. Injection pump defective. Excessive mechanical loads 7/71, 12/56...
  • Page 68 Low coolant temperature Faulty turbocharger Battery overdischarge Low electrolyte level Crack in battery body. Natural consumption. Charging failure Loose or damaged belt. Faulty alternator. Damaged wiring or contact failure. Excessive electrical loads Insufficient battery capacity for the application. 7/71, 12/56...

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