Doosan 10/110 Operation & Maintenance Manual Download Page 83

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PARTS ORDERING

7/125 - 9/115, 7/125 - 10/110, 14/90

For parts, service or information regarding your local distributor (Europe, Middle East, Africa) please contact:

For Service information contact:

[email protected]

For Parts information contact:

[email protected]

Office hours:

Monday to Friday 8:30 a.m. to 5:15 p.m. (GMT)

For parts, service or information regarding your local distributor (U.S, Latin America or Asia Pacific) please contact:

Office hours:

Monday to Friday 8:00 a.m. to 5:30 p.m. (EST)

Facility:

Telephone:

Fax:

Doosan Portable Power EMEA Aftermarket

Drève Richelle 167

B-1410 Waterloo

Belgium

+32 (2) 404 0811

+32 (2) 371 6915

Facility:

Telephone:

Fax:

Doosan International USA, Inc

1293 Glenway Drive

Statesville

North Carolina 28625-9218

800-633-5206 (US & Canada)

305-222-0835 (Latin America)

65-860-6863 (Asia Pacific)

336-751-1579 (US & Canada)

336-751-4325 (Latin America)

336-751-4325 (Asia Pacific)

or visit our website and dealer locator at

www.doosanportablepower.com

Summary of Contents for 10/110

Page 1: ...portant safety information and must be made available to personnel who operate and maintain this machine 46641810_en_A_04 14 7 125 9 115 7 125 10 110 14 90 OPERATION MAINTENANCE MANUAL Original Instru...

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Page 3: ...hat the machine display the CE Mark and conform to various directives In such cases the design specification of this machine has been certified as complying with EC directives Any modification to any...

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Page 5: ...e settings table Compressor lubrication 61 MACHINE SYSTEMS 69 FAULT FINDING 72 OPTIONS 77 PARTS ORDERING ABBREVIATIONS SYMBOLS Contact the company for serial number Up to Serial No From Serial No Not...

Page 6: ...the approved parts list may create hazardous conditions over which the company has no control Therefore the company cannot be held responsible for equipment in which non approved repair parts are ins...

Page 7: ...re control WARNING Corrosion risk WARNING Air gas flow or Air discharge WARNING Pressurised vessel WARNING Hot and harmful exhaust gas WARNING Flammable liquid WARNING Maintain correct tyre pressure R...

Page 8: ...machine Do not remove the Operating and Maintenance manual and manual holder from this machine Do not stack Do not operate the machine without the guard being fitted Do not stand on any service valve...

Page 9: ...ken When parking use prop stand handbrake and wheel chocks Compressor oil filling Diesel fuel No open flame Parking brake Rough Service Designation Wet Location Operation Replace any cracked protectiv...

Page 10: ...protective equipment All pressure containing parts especially flexible hoses and their couplings must be regularly inspected be free from defects and be replaced according to the Manual instructions A...

Page 11: ...ne model if lower than the legal maximum The compressor must be towed in a level attitude in order to maintain correct handling braking and lighting functions This can be achieved by correct selection...

Page 12: ...8 GENERAL INFORMATION 7 125 9 115 7 125 10 110 14 90 Fixed Height Braked Variable Height Braked...

Page 13: ...GENERAL INFORMATION 9 7 125 9 115 7 125 10 110 14 90 KHD Variable Height LRG Less Running Gear...

Page 14: ...min cfm 12 0 425 10 7 377 10 6 374 8 3 294 Normal operating discharge pressure bar psi 6 9 100 8 6 125 10 3 150 13 8 200 Maximum allowable pressure bar psi 8 6 125 10 3 150 12 1 175 15 5 225 Safety v...

Page 15: ...0 revs min 1 RPM Speed at idle 1500 revs min 1 RPM Electrical system 24V negative earth Power available at 2200 revs min 1 93 kW 125 HP Fuel tank capacity 219 5 litres 58 US GAL Oil specification Refe...

Page 16: ...ons to walls floors etc Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks Ensure that the machine is positioned securely and on...

Page 17: ...d 6 Check the radiator coolant level with the unit level 7 Open the service valve s to ensure that all pressure is relieved from the system Close the service valve s when all pressure is relieved 9 Ch...

Page 18: ...tank 2 Engine Tachometer Indicates engine speed RPM 3 Hourmeter Indicates machine operating hours 4 Fuel Level Gauge Indicates level of fuel in tank 5 MidPort Display Indicates compressor and engine o...

Page 19: ...e item unit at a time Pressing and holding the UP Button continuously scrolls up through parameter lists menu choices or increases a value until the end of the parameter list menu choices or maximum p...

Page 20: ...diagnostic code is being displayed FMI Failure Mode Identifier defines the type of failure detected in the subsystem identified by the SPN OC occurrence amount of times this failure has occurred Displ...

Page 21: ...hours or it remains at 0 hours the SERVICE DUE display will appear every hour To disable the user can reset the hours to the OFF position by decreasing the value to OFF See Figure 3 Figure 3 The servi...

Page 22: ...nu To access the Setup Menu press and hold the ENTER Button while the Default Screen of Engine Hours is displayed until the Main Menu appears Scroll to the Setup option using the DOWN Button then pres...

Page 23: ...uously loops through the Quick View Screens i e when the last screen is reached pressing the DOWN Button displays the first screen and vice versa Figure 6 Note 1 Only the parameters that are available...

Page 24: ...in Screen menu item returns the user back to the Default Screen of Engine Hours Figure 7 AUTO POWER OFF The Compressor Control System has a power save feature designed to prevent drain on the batterie...

Page 25: ...ture Airend discharge temperature greater than or equal to 248 F 30 120 C 248 F 3 Low Airend Oil Pressure Airend oil pressure below 10 psi 31 0 7 bar 10 PSI 3 Airend Discharge Temperature Sensor Airen...

Page 26: ...or Regulation system pressure sensor reading out of range 54 0 5V 4 5V Emergency Stop Activated Emergency Stop button has been activated 55 3 Low Start Pressure Separator tank pressure below 50 psi 20...

Page 27: ...elerator Pedal or Lever Sensor System Error Received Network Data In Error 93 2 528 Engine Net Brake Torque Data Erratic Intermittent or Incorrect Auxiliary Constrained Operation Curve Validation Swit...

Page 28: ...evere Level Turbocharger 1 Speed Low Data Valid but Below Normal Operational Range Moderately Severe Level 105 0 155 Engine Intake Manifold 1 Temperature Data Valid but Above Normal Operational Range...

Page 29: ...alid but Above Normal Operational Range Most Severe Level Injector Metering Rail 1 Pressure Data Valid but Above Normal Operational Range Most Severe Level 157 1 2249 Engine Injector Metering Rail 1 P...

Page 30: ...age Below Normal or Shorted to Low Source Exhaust Gas Recirculation EGR Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source 412 15 2961 Engine Exhaust Gas Recirculation 1 Temperat...

Page 31: ...Update Rate VGT Actuator Driver Circuit Abnormal Update Rate 641 12 2634 Engine Variable Geometry Turbocharger Actuator 1 Bad Intelligent Device or Component VGT Actuator Controller Bad intelligent D...

Page 32: ...High Source 974 4 134 Remote Accelerator Pedal Position Voltage Below Normal or Shorted to Low Source Remote Accelerator Pedal or Lever Position Sensor Circuit Voltage Below Normal or Shorted to Low...

Page 33: ...ssure Sensor Input 2 Circuit Voltage Above Normal or Shorted to High Source 1388 4 298 Auxiliary Pressure 2 Voltage Below Normal or Shorted to Low Source Auxiliary Pressure Sensor Input 2 Circuit Volt...

Page 34: ...atment 1 Exhaust Gas Temperature 1 Voltage Below Normal or Shorted to Low Source Aftertreatment Exhaust Gas Temperature 1 Circuit Voltage Below Normal or Shorted to Low Source 3241 13 1663 Aftertreatm...

Page 35: ...Aftertreatment 1 Diesel Particulate Filter Differential Pressure Voltage Above Normal or Shorted to High Source Aftertreatment Particulate Filter Differential Pressure Sensor Circuit Voltage Above Nor...

Page 36: ...Engine Air Shutoff Circuit Voltage below normal or shorted to low source 3703 31 2777 Diesel Particulate Filter Active Regeneration Inhibited Due to Inhibit Switch Not Available or Condition Exists Pa...

Page 37: ...t Voltage Below Normal or Shorted to Low Source 520320 7 2699 Crankcase Depression Valve Mechanical System not Responding or Out of Adjustment Crankcase Depression Valve Mechanical System Not Respondi...

Page 38: ...tible with the compressor oil STARTING THE MACHINE 1 Press the Main Power Button 2 When the Wait To Start message on the MidPort changes to Total Engine Hours press and release Green Start Button 3 En...

Page 39: ...ressure regulator High pressure mode K Modes solenoid valve L Captive pressure solenoid valve M Orifice N Manual blowdown valve The compressor is capable of operating at two pressure modes 1 The Low P...

Page 40: ...d and the MidPort can be navigated using the UP DOWN and ENTER Buttons 5 If the Main Power Button is not pressed within 3 minutes if ambient temperature is above 45 F 7 C or 15 minutes if ambient temp...

Page 41: ...ain fuel system SHORT TERM STORAGE Machines that stand idle for extended periods of time greater than 30 days Start and operate the machine every 30 days Operate long enough to allow the engine and co...

Page 42: ...Emergency Stop T Lubricator Fill C Air Cleaner Precleaner Dumps C Fan Alternator Belts C Battery Connections Electrolyte C Hoses Oil Air Intake etc C Automatic Shutdown System C Air Cleaner System C C...

Page 43: ...nt R Separator Tank Exterior 2 CR Engine Coolant C R Engine Crankcase Breather Element R Water Pump Grease G Shutdown Switch Settings T Scavenge Orifice Related Parts C Scavenge Line C Valve Clearance...

Page 44: ...Running gear bolts 1 C Wheels Bearings Seals etc C G 2 Yrs 4 Yrs 6 Yrs Safety valve C Hoses R Separator tank 2 interior C Disregard if not appropriate for this particular compressor D Drain 1 or 3000...

Page 45: ...ing 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 m...

Page 46: ...and remove the filter element by releasing the nut If the safety element is to be renewed thoroughly clean the interior of the filter housing prior to removing the safety element Inspection Check for...

Page 47: ...nt taking care all seals are in place install the sensor connector Final Fuel Filter Water Separator The final fuel filter 3 micron is mounted on the engine For maintenance details refer to the engine...

Page 48: ...ervals 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 ensu...

Page 49: ...e wheel can be moved freely 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 Whe...

Page 50: ...eck the compression spring 9 for pre tensioning Test run If necessary carry out 2 3 test brake actions Test brake action Check the play in brake linkage 7 and if necessary adjust the length of brake l...

Page 51: ...e drawbar may NOT be connected to the towing vehicle After connecting the coupling to the towing vehicle turning the handle IS FORBIDDEN Lifting of the trailer by turning the handle IS STRICTLY FORBID...

Page 52: ...y now be removed If the bellows 36 is damaged it must be replaced Assembly Before mounting all the new and removed parts have to be lubricated in accordance with regulation SK70003 Attach the shaft of...

Page 53: ...MAINTENANCE 49 7 125 9 115 7 125 10 110 14 90 Replacement of the shock absorber To be carried out ONLY by skilled service personnel...

Page 54: ...into the drawtube 45 from the front and bolt together with the shock absorber bracket 35 Fasten the hexagonal nut 31 with a tightening moment of 30 5Nm Push the unit 46 from the front into the housin...

Page 55: ...art and secure it against falling off injury risk Remove the SL clip 24 and the disc 25 and pull out the pin 26 Unscrew the clevis 23 and hexagonal nuts 22 and 21 Pull out the cable and replace it Ass...

Page 56: ...ssary Put on shields 15 and 14 and secure them with blind rivets 13 Plug in the adaptor 7 and the winding handle 5 Secure the winding handle 5 with the pin 6 Put the coupling unit into the highest pos...

Page 57: ...high performance grease N3 Using a brush apply a thin even layer of SPHEEROL EPL2 or equivalent NLGI 2 Grade lubricant Part to be lubricated a Grease nipple b Bush c Piston rod d Hole e Top middle pa...

Page 58: ...based high performance grease N3 Using a brush apply a thin even layer of SPHEEROL EPL2 or equivalent NLGI 2 Grade lubricant Part to be lubricated a Grease nipple b Bush c Piston rod d Hole e Top midd...

Page 59: ...then adjust the gap in detail B to 0 5mm 6 If gap e is greater than 28mm in detail R then adjust the gap in detail B to 0 5mm Coupling cross section showing position of detail A Detail A a Fixing nut...

Page 60: ...Service Valves After Starting Unit 5 Push the Service Air Button on the Control Panel The unit should speed up and then unload and drop back to IDLE With the unit unloaded turn the adjusting cap on th...

Page 61: ...ERN TYPICAL CIRCULAR TORQUE PATTERN CAPSCREW OR NUT THREAD SIZE AND PITCH NOMINAL DESIGN TORQUE 8AE J249 GRADE 5 HEAD MARKING 8AE J249 GRADE 8 HEAD MARKING Nm FT LBF Nm FT LBF 1 4 20 11 8 16 12 5 16 1...

Page 62: ...8 X 1 25 26 19 36 27 43 31 M10 X 1 5 52 38 72 53 84 62 M12 X 1 75 91 67 126 93 147 109 M14 X 2 145 107 200 148 234 173 M16 X 2 226 166 313 231 365 270 M20 X 2 5 441 325 610 450 713 526 TABLE 3 WHEEL T...

Page 63: ...in storage an earlier change may be necessary as oil deteriorates with time as well as by operating conditions An oil change is good insurance against the accumulation of dirt sludge or oxidized oil p...

Page 64: ...manual warranty section for details or contact your Portable Power representative Design Operating Pressure Ambient Temperature Specification 6 9 bar to 20 6 bar 100 psi to 300 psi 23 C to 52 C 10 F...

Page 65: ...MACHINE SYSTEMS 61 7 125 9 115 7 125 10 110 14 90 Compressor and Engine Harness System Schematic 46622240 Rev B sheeet 1...

Page 66: ...62 MACHINE SYSTEMS 7 125 9 115 7 125 10 110 14 90 Compressor and Engine Harness System Schematic 46622240 Rev B sheeet 2...

Page 67: ...MACHINE SYSTEMS 63 7 125 9 115 7 125 10 110 14 90 Compressor and Engine Harness System Schematic 46622240 Rev B sheeet 3...

Page 68: ...64 MACHINE SYSTEMS 7 125 9 115 7 125 10 110 14 90 Compressor and Engine Harness System Schematic 46622240 Rev B sheeet 4...

Page 69: ...MACHINE SYSTEMS 65 7 125 9 115 7 125 10 110 14 90 IQ Option Harness Schematic 46636749 Rev A sheeet 1...

Page 70: ...66 MACHINE SYSTEMS 7 125 9 115 7 125 10 110 14 90 Control Panel Haness Schematic 46641699 Rev A sheeet 1...

Page 71: ...MACHINE SYSTEMS 67 7 125 9 115 7 125 10 110 14 90 Control Panel Haness Schematic 46641699 Rev A sheeet 2...

Page 72: ...68 MACHINE SYSTEMS 7 125 9 115 7 125 10 110 14 90...

Page 73: ...on t start or run Battery disconnect switch off Check switch position and operation Check switch position and operation Emergency stop pushed Check emergency stop switch position and operation Low bat...

Page 74: ...hten or replace belt set Loose wire connection Check wires at switches and connectors to find loose connection Make repairs See Electronic Service Manual Low battery voltage Check battery condition re...

Page 75: ...nditions Move compressor to cleaner environment Wrong air filter element s Install correct air filter element s Inadequate air filter element cleaning Install new air filter element s Incorrect stoppi...

Page 76: ...nates the need for collecting the condensate and the added cost of disposing of the condensate which is often regulated by local regulations Ensure that the compressed air temperature always remains a...

Page 77: ...s bypassed Standard Operation selected the delivered air pressure will be approximately equal to the separator tank pressure If the IQ System operation is selected the delivered air pressure will be s...

Page 78: ...74 OPTIONS 7 125 9 115 7 125 10 110 14 90 PRIMARY AND SECONDARY FILTER MAINTENANCE FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5...

Page 79: ...OPTIONS 75 7 125 9 115 7 125 10 110 14 90 WATER SEPARATOR MAINTENANCE FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5 FIGURE 6...

Page 80: ...levels causing overheating reduced engine life and reduced airend life CAUTION Excessively restricted filter elements may cause an increase in the amount of aerosol water and oil carryover which coul...

Page 81: ...oduction HOW TO USE PARTS LIST a Turn to Parts List b Locate the area or system of the compressor in which the desired part is used and find illustration page number c Locate the desired part on the i...

Page 82: ...in are exclusive and the total liability of the Company with respect to this order whether based on contract warranty negligence indemnity strict liability or otherwise shall not exceed the purchase p...

Page 83: ...distributor U S Latin America or Asia Pacific please contact Office hours Monday to Friday 8 00 a m to 5 30 p m EST Facility Telephone Fax Doosan Portable Power EMEA Aftermarket Dr ve Richelle 167 B...

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