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COMPRESSOR TRAINING
Small compressors
SMALL COMPRESSORS RANGE
• 7/20
- P65
- 7 bar (100 PSI), 1.9 m3/min (70 cfm)
• 7/26E
- P90
- 7 bar (100 PSI), 2.5 m3/min (90 cfm)
• 7/31E
- P110 - 7 bar (100 PSI), 3.0 m3/min (105 cfm)
• 7/41
- P135 -7 bar (100 PSI), 4.0 m3/min (140 cfm)
• 7/51
- XP185 -7 bar (100 PSI), 5.0 m3/min (175 cfm)
• 7/71
- P260
-7 bar (100 PSI), 7.1 m3/min (250 cfm)
• 12/56
-12 bar (170 PSI), 5.6 m3/min (200 cfm)
SUMMARY
• The compressor can be divided in the following subsystems
–
ENGINE & AIREND
–
LUBRICATION & COOLING SYSTEM
–
AIR FLOW REGULATION SYSTEM
–
SEPARATION SYSTEM
–
BLOWDOWN SYSTEM
–
INSTRUMENT/CONTROL PANEL
–
ELECTRICAL WIRING
•
Troubleshooting
Company Confidential
Company Confidential
10/12/2010
1
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Related Manuals for Doosan 7/51
Summarization of Contents
Compressor Training Introduction
Small Compressors Range
Lists available small compressor models with their specifications.
Compressor Subsystem Summary
Outlines the main subsystems of the compressor for training.
Engine Specifications and Tier Standards
Engine 7/20 Specifications
Details for the 7/20 compressor engine, including designation, model, and output.
Engine Tier 2 (7/26E – 7/51) Specifications
Technical data for Tier 2 engines used in 7/26E to 7/51 models.
Engine Tier 3 (7/51) from September 2008
Specifications for the Tier 3 7/51 engine model.
Advanced Engine Features and Improvements
Engine Tier 2 (7/71 – 12/56) Specifications
Engine details for the 7/71 and 12/56 models under Tier 2 emissions.
Engine Tier 3 (7/71 – 12/56) from October 2008
Specifications for Tier 3 engines from October 2008 for 7/71 and 12/56 models.
Yanmar ECO Engine Tier 3 Improvements
Highlights improvements in Yanmar ECO engines for Tier 3 compliance.
Yanmar ECO Engine Tier 3 Systems
Yanmar ECO Engine Tier 3 Control Systems
Illustrates the Eco-Governor and EGR control systems for Tier 3 engines.
EGR Control - Exhaust Gas Re-circulation
Explains the function and components of the EGR system for emissions reduction.
Cooled EGR System Explained
Details the cooled EGR system, including its components and purpose for low emissions.
Fuel Injection and Airend Systems
Yanmar ECO Engine Fuel Injection System
Diagram of the fuel injection system for Yanmar ECO engines.
Diesel Fuel Injector Components
Detailed breakdown of a diesel fuel injector and its parts.
Airend System Overview
General description of the airend's casing, rotors, bearings, and seals.
Airend Unit Specifications
Airend (7/20) Details
Specifics for the 7/20 airend, noting its usage and body material.
Airend (7/26E - 7/51) Features
Information on the 85 mm airend used in 7/26E to 7/51 models, including gear sets and body.
Lubrication and Cooling Systems
Airend CF 90 (7/71 - 12/56) Configuration
Details on the CF 90 airend used for 7/71 and 12/56 models.
Compressor Oil System Functions
Explains the roles of the oil system: lubrication, sealing, and cooling.
Lubrication & Cooling Diagram (7/20)
A cooling diagram for the 7/20 model, showing key components.
Lubrication and Cooling System Components
Separator Tank as Oil Reservoir
Explains the separator tank's dual role as oil reservoir and pressure provider.
Cool Box and Fan Design
Describes the cool box design with a pusher fan for cooling.
Radiator and Oil Cooler Details
Shows the radiator and oil cooler components of the cooling system.
Lubrication and Cooling System Details
Compressor Oil Filter Specifications
Details the 10-micron rating of the compressor oil filter.
Cooling & Lubrication Diagram (7/26E - 7/51)
Diagram illustrating the cooling and lubrication for 7/26E to 7/51 models.
Integrated Oil Filter Head
Notes the integration of the oil filter head directly to the airend.
Lubrication and Cooling System for 7/71 - 12/56 Models
Cooling Diagram (Bypass Valve Closed)
Illustrates the cooling flow for 7/71-12/56 when the bypass valve is closed.
Cooling Diagram (Bypass Valve Open)
Shows the cooling flow for 7/71-12/56 when the bypass valve is open.
Radiator Assembly (7/71 – 12/56)
Image of the radiator assembly used in 7/71-12/56 models.
Air Regulation System
Oil Temperature Regulation (7/71 – 12/56)
Explains regulation of oil temperature around 85°C and the thermostat's role.
Air Regulation System Overview
Describes how the system adjusts air production based on consumption.
Air Flow & Regulation (7/20) - Unit Stopped
Diagram showing the air flow regulation when the unit is stopped.
Air Flow and Regulation Operation (7/20)
Air Flow & Regulation (7/20) - Start-up
Diagram illustrating air flow during start-up.
Air Flow & Regulation (7/20) - Air Demand
Diagram showing air flow when there is air demand.
Air Flow & Regulation (7/20) - Off Load
Diagram depicting air flow during off-load operation.
Air Flow and Regulation Adjustments (7/20)
Regulated Pressure Adjustment Procedure
Step-by-step guide to adjust regulated pressure for the 7/20 model.
Regulation Orifice Function
Explains the role of the regulation orifice in bleeding air.
Anti-rumble Valve Operation
Describes the anti-rumble valve's function to limit vacuum at inlet.
Regulator Valve and Air Flow Control
Regulator Valve Operation Principle
Explains the diaphragm-actuated needle valve operation.
Air Flow Regulation: Mechanical vs. Electronic
Compares air flow regulation in mechanical and electronic engine systems.
Air Flow & Regulation (7/26E – 7/51) - Start-up
Diagram showing the start-up sequence for this model range.
Air Flow Regulation (7/26E – 7/51) Operation
Air Flow & Regulation (7/26E – 7/51) - Air Demand
Diagram illustrating air flow during air demand for these models.
Air Flow & Regulation (7/26E – 7/51) - Off Load
Diagram showing air flow when the unit is off-load.
Unloader Valve Component View
Image of the unloader valve assembly.
Air Flow Regulation Mechanisms
Unloader Valve Positions: Idle vs. Full Load
Illustrates the idle and full load positions of the unloader valve.
Regulation Orifice Connection
Shows the regulation orifice connection on the compressor inlet to reduce noise.
Air Flow & Regulation (7/71 – 12/56) - Start up
Diagram for the start-up sequence of 7/71-12/56 models.
Air Flow Regulation Operation (7/71 – 12/56)
Air Flow & Regulation (7/71 – 12/56) - Load Button Pressed
Diagram showing operation when the load button is pressed.
Air Flow & Regulation (7/71 – 12/56) - Off Load
Diagram illustrating operation when the unit is off load.
UL99 Unloader Identification
Image identifying the UL99 unloader component.
Separation System Functions and Operation
Regulation Orifice Location
Image showing the location of the regulation orifice.
Separation System Purpose
Defines the system's function of removing oil from compressed air.
Detailed Separation System Process
Explains how the separator receiver, element, and scavenge line work.
Separation System Components and Schematics (7/20)
Separation Schematic (7/20)
Diagram of the separation system for the 7/20 model.
Separator/Receiver Tank (7/20) View
Image and diagram of the separator/receiver tank for the 7/20.
Scavenge Line Function (7/20)
Explains the scavenge line's role in oil removal and check valve function.
Separation System Components and Safety (7/20)
Scavenge Line Air Inlet Return
Notes that scavenge lines return to air inlet and checks for clogs.
Safety Valve Function
Describes the safety valve's role when the separator element is blocked.
Sonic Orifice Purpose
Explains the sonic orifice's role in maintaining minimum receiver pressure.
Separator Element and System Schematics (7/26E – 7/51)
Separator Element Design (7/20)
Shows the separator element and mentions the scavenge tube.
Separation Schematic (7/26E – 7/51)
Diagram of the separation system for 7/26E to 7/51 models.
Scavenge Line Connection (7/26E – 7/51)
Image showing the scavenge line connection for these models.
Separation System Components and Schematics (7/71 – 12/56)
Scavenge Line Return Point
Image showing the scavenge return point.
Sonic Orifice Assembly (7/26E – 7/51)
Images of the sonic orifice components.
Separation Schematic (7/71 – 12/56)
Diagram of the separation system for 7/71-12/56 models.
Separator System Components (7/71 – 12/56)
Separator Tank View (7/71 – 12/56)
Image of the separator tank for these models.
Scavenge Line and Orifice (7/71 – 12/56)
Images showing the scavenge line and orifice.
Sonic Orifice Assembly (7/71 – 12/56)
Images of the sonic orifice for these models.
Blow Down System Operation
Blow Down System Purpose
Explains the system's role in relieving separator tank pressure.
Auto Blowdown Schematic (7/20)
Diagram illustrating the automatic blowdown system for the 7/20.
Auto Blowdown Component View (7/20)
Image of the auto blowdown system components.
Auto Blowdown System Operation Modes
Auto Blowdown Valve Positions
Shows the valve positions for full load/idle and blowdown.
Auto Blowdown Schematic (7/26E – 7/51)
Diagram of the automatic blowdown system for 7/26E-7/51 models.
Blow Down System Configurations
Auto Blowdown Pilot Line (7/26E – 7/51)
Image highlighting the pilot line for auto blowdown.
Blowdown Pilot Line (7/71 – 12/56)
Image showing the pilot line for blowdown systems.
Manual Blowdown Mechanism
Image of the manual blowdown connection.
Instrument Panel Layouts and Features
Instrument Panel (7/26E – 7/31E) Overview
Details components like hourmeter, pressure gauge, and buttons.
Instrument Panel (7/51 - 7/71) Controls
Shows controls and options for 7/51 and 7/71 models.
Instrument Panel (7/51) Tier 3 Controls
Describes the Tier 3 panel with diagnostic readout (SECU).
Instrument Panel: Alarms and Shutdowns
Compressor Alarms and Shutdowns (7/51 Tier 3)
Lists and explains compressor-related alarms and shutdown conditions.
Engine Alarms and Shutdowns (7/51 Tier 3)
Details engine-related alarms and shutdown fault codes.
Starting Procedures and Engine Diagnostics
Engine Alarms & Shutdowns Table (7/51 Tier 3)
Table detailing engine failures and corresponding flash codes.
Sequence Key Switch Operation
Explains the use of the sequence key switch for starting.
Starting Sequence: Air Inlet Heater
Instructions for using the key switch to engage the air inlet heater.
Compressor Starting and Stopping Operations
Engine Start and Release Procedure
Guides on turning the key switch to start and release.
Cold Weather Starting Procedures
Steps for starting in temperatures below 0°C or with starting difficulty.
Compressor Stopping Procedure
Details on closing valves and running unloaded to reduce engine temperature.
Electrics and Wiring Diagrams
Electrics Wiring Diagrams List
Lists the available wiring diagrams for different models.
Wiring Diagram (7/20)
Electrical schematic for the 7/20 model.
Wiring Diagram (7/26E – 7/31E)
Electrical schematic for the 7/26E to 7/31E models.
Wiring Diagrams for 7/41 Operation States
Electrics Diagnostics and Indicators (7/26E – 7/31E)
Optional diagnostics, shutdown indicators, and tachometer functions.
Wiring Diagram (7/41) - Machine Off
Electrical schematic for the 7/41 model when the machine is off.
Wiring Diagram (7/41) - Machine On
Electrical schematic for the 7/41 model when the machine is on.
Wiring Diagrams for 7/41 Operation States
Wiring Diagram (7/41) - Machine On (In Bypass)
Electrical schematic for 7/41 in bypass mode.
Wiring Diagram (7/41) - Crank State
Electrical schematic for 7/41 during the crank phase.
Wiring Diagrams for 7/41 Operation States
Wiring Diagram (7/41) - Running State
Electrical schematic for 7/41 when running.
Wiring Diagram (7/41) - Temperature Shutdown
Electrical schematic for 7/41 during temperature shutdown.
Wiring Diagram (7/51 Tier 2) - Machine Off
Electrical schematic for 7/51 Tier 2 when machine is off.
Wiring Diagrams for 7/51 Tier 2 Operation States
Wiring Diagram (7/51 Tier 2) - Machine On (Low Fuel)
Schematic for 7/51 Tier 2 with low fuel condition.
Wiring Diagram (7/51 Tier 2) - Machine On
Electrical schematic for 7/51 Tier 2 when machine is on.
Wiring Diagram (7/51 Tier 2) - In Bypass
Schematic for 7/51 Tier 2 in bypass mode.
Wiring Diagrams for 7/51 Tier 2 Operation States
Wiring Diagram (7/51 Tier 2) - Crank State
Schematic for 7/51 Tier 2 during crank.
Wiring Diagram (7/51 Tier 2) - Running State
Schematic for 7/51 Tier 2 when running.
Wiring Diagram (7/51 Tier 2) - Temperature Shutdown
Schematic for 7/51 Tier 2 during temperature shutdown.
Wiring Diagrams for 7/71 – 12/56 Tier 2 Operation
Wiring Diagram (7/71 – 12/56 Tier 2) - Machine OFF
Schematic for 7/71-12/56 Tier 2 when machine is off.
Wiring Diagram (7/71 – 12/56 Tier 2) - Machine ON
Schematic for 7/71-12/56 Tier 2 when machine is on.
Wiring Diagram (7/71 – 12/56 Tier 2) - IN BYPASS
Schematic for 7/71-12/56 Tier 2 in bypass mode.
Troubleshooting and Wiring Diagrams (7/71 – 12/56 Tier 2)
Wiring Diagram (7/71 – 12/56 Tier 2) - CRANK
Schematic for 7/71-12/56 Tier 2 during crank.
Wiring Diagram (7/71 – 12/56 Tier 2) - RUNNING
Schematic for 7/71-12/56 Tier 2 when running.
Troubleshooting Common Issues
Lists common problems like oil carryover, low air volume, and overheating.
Troubleshooting: Oil Carryover and Low Air Volume
Oil Carryover: Basic Checks
Checks for correct oil level, service valve status, and separator element condition.
Oil Carryover: Operational Checks
Verifies pressure, engine speed, oil type, and scavenge system.
Low Air Volume: System Checks
Checks air cleaners, leaks, separator element, and regulator orifice.
Troubleshooting: Overheating, High Pressure, and Starting
Overheating: Oil Circuit Checks
Verifies oil level, grade, restrictions, cooler, and bypass valve.
Overheating: Cooling Air Checks
Checks cooling air flow, orientation, fan belt, and ambient temperature.
High Pressure: Regulator and Unloader Checks
Verifies regulator operation, unloader function, and orifice size.
Starting Problems and Engine Procedures
Starting Problems: Engine Will Not Crank
Checks battery, inclination, fuel, and safety switches.
Starting Problems: Crank but No Start
Checks air heater, fuel lines, and fuel filter.
Engine Diagnostics and EGR Valve
Discusses flash codes, Yanmar YDT tool, and EGR valve self-test.
Engine Parts Replacement Procedures
Covers injector, pump, rack actuator, and ECU replacement.
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