Doosan 10/370 Operation And Maintenance Manual Download Page 17

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Safety

Operating & Maintenance Manual

Decals

Decals are located on the machine to point out potential safety hazards. Read and
follow these instructions. If you do not understand the instructions, inform your
supervisor.

Note that there are different decal headings:

DANGER

(Red Background)

Indicates the presence of a hazard which WILL cause serious injury,
death or property damage, if ignored.

WARNING

(Orange Background)

Indicates the presence of a hazard which CAN cause serious injury, death
or property damage, if ignored.

CAUTION

(Yellow Background)

Indicates the presence of a hazard which WILL or can cause injury or
property damage, if ignored.

NOTICE

(Blue Background)

Indicates important set-up, operating or maintenance information.

Summary of Contents for 10/370

Page 1: ...X T3 E49 HP1600FCU T3 E68 Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 DoosanPortablePower com Book 22523815 9 2013 Rev F This manual contains important safety information...

Page 2: ...2...

Page 3: ...chedule 30 A Compressed Air Leaks 30 B Safety and Control Systems 30 C Acoustic Materials 30 D Fasteners 31 E Enclosure Panels 31 F Air Intake and Engine Exhaust 31 G Cooling Systems 31 H Isolation Mo...

Page 4: ...em 58 Low engine fuel level switch 58 Scavenge Line 58 Compressor Oil Filter 59 Removal 59 lnspection 59 Reassembly 60 Compressor Oil Separator Element 60 Removal 60 lnspection 60 Reassembly 61 Compre...

Page 5: ...bly 73 D Find and Correct Basic Cause 73 General Information 73 Wedge Diagnostic Display Codes 77 Troubleshooting Chart 79 ELECTRICAL 83 General Information and Operational Theory 84 Wedge Controller...

Page 6: ...6...

Page 7: ...7 Foreword...

Page 8: ...Operating Maintenance Manual Foreword 8 Add in PDF Page for CE Mark...

Page 9: ...cant coolant accompanied with instructions for safe installation operation and maintenance Details of approved equipment are available from the Portable Power Service departments The use of repair par...

Page 10: ...s manual is to train the operator with functions operation and basic service and maintenance requirements of the compressor During the preparation of this manual every effort was made to ensure the ad...

Page 11: ...11 Safety...

Page 12: ...n particular safety related parts such as coupling hitch drawbar components road wheels and lifting bail should be checked for total security All components which are loose damaged or unserviceable mu...

Page 13: ...in serious injury or death Always carefully vent air supply line at tool or vent valve before performing any service The discharged air contains a very small percentage of compressor lubricating oil a...

Page 14: ...tery electrolyte WARNING Avoid ingestion skin contact and inhalation of fumes Should compressor lubricant come into contact with the eyes then irrigate with water for at least 5 minutes Should compres...

Page 15: ...al of each battery Connect one end of other cable to the negative terminal of the booster battery and other end to a ground connection away from dead battery to avoid a spark occurring near any explos...

Page 16: ...d in a level attitude in order to maintain correct handling braking and lighting functions This can be achieved by correct selection and adjustment of the vehicle towing hitch and on variable height r...

Page 17: ...DANGER Red Background Indicates the presence of a hazard which WILL cause serious injury death or property damage if ignored WARNING Orange Background Indicates the presence of a hazard which CAN cau...

Page 18: ...igns 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...

Page 19: ...Safety Operating Maintenance Manual 19...

Page 20: ...Operating Maintenance Manual Safety 20...

Page 21: ...Safety Operating Maintenance Manual 21...

Page 22: ...k 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 yo...

Page 23: ...Safety Operating Maintenance Manual 23...

Page 24: ...he air intake system or parts thereof c enclosure or parts thereof 2 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 3 Operation of the compressor with any...

Page 25: ...ailable 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 s parts manu...

Page 26: ...Operating Maintenance Manual Safety 26...

Page 27: ...27 Noise Emission...

Page 28: ...thereof b the air intake system or parts thereof c enclosure or parts thereof 2 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 3 Operation of the compresso...

Page 29: ...nd each subsequent purchaser that this air compressor was designed built and equipped to conform at the time of sale to the first retail purchaser with all applicable U S EPA Noise Control Regulations...

Page 30: ...diately and correct the leak s B Safety and Control Systems Repair or replace all safety and control systems or circuits as malfunction occurs No compressor should be operated with either system bypas...

Page 31: ...ould be inspected after each 100 hours of operation for loose damaged or deteriorated components Repairs or replacements should be made before the next period of use G Cooling Systems All components o...

Page 32: ...Maintenance Manual Noise Emission 32 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK HOURMETER READING MAINT INSPECT DATE LOCATION CITY STATE WORK DONE...

Page 33: ...33 General Data...

Page 34: ...Speed rpm 1800 1800 No Load Speed rpm 1200 1200 FLUID CAPACITIES U S Gallons litres Compressor Lubricant 55 208 55 208 Engine Lube including filter 12 46 12 46 Engine Coolant radiator 15 2 57 5 15 2...

Page 35: ...Inlet Primary Engine AE inlet 2 36864379 Filter Inlet Secondary Engine AE inlet 2 54662028 Filter Oil Engine QSX15 1 54662051 Filter Coolant Engine QSX15 1 54662036 Filter Fuel Engine QSX15 1 CAUTION...

Page 36: ...36...

Page 37: ...37 Operating Instructions...

Page 38: ...olled by Switch 14 2 High Compressor Temp Fault indicator lamp Indicates shutdown due to high compressor temperature 3 Low Radiator Coolant Level Alarm indicator lamp Indicates engine coolant needs se...

Page 39: ...s and service requirements 13 Ether Inject Injects a measured shot of ether for aid in cold weather starting of engine CAUTION Use Sparingly 14 Panel Light Switch Controls panel lamp 1 15 Pressure Con...

Page 40: ...or lower lunette eye Use tow vehicle whose towing capacity is greater than the gross weight of this unit see general data Do not tow this unit in excess of 65 mph Place wheel chocks under tires before...

Page 41: ...or any other source of compressed air without first making sure a check valve is used between the header and the unit If this unit is connected in parallel with another unit of higher discharge press...

Page 42: ...rfill To jump start connect the positive booster charger cable to the 24VDC positive terminal of the battery Then connect the negative booster charger cable to the engine block Not to the negative ter...

Page 43: ...efer to the Engine Operator s Section for fuel specifications NOTICE To minimize condensation water in the fuel tank it is recommended to fill the tank at the end of each day NOTE This machine will no...

Page 44: ...tures 3 When the keyswitch is turned to START the engine starter will be engaged Do not operate the engine starter motor for more than ten 10 seconds without allowing at least one minute cooling time...

Page 45: ...volume flow Operation Loaded Assume engine has been started and is running in the unload state at 1200 RPM If there is air demand pressure falls below the load point pressure compressor will load at 1...

Page 46: ...ler cleaner air than from a standard portable compressor The system utilizes an integral aftercooler high efficiency filtration and a patented condensate disposal system to provide the cool clean air...

Page 47: ...nsate water with a small amount of compressor lubricant exits the aftercooler and enters the moisture separator where most of the condensate is removed The compressed air then flows through two stages...

Page 48: ...the unit is operating under abnormal conditions i e an enclosure door open which would cause excessive cooling of the aftercooler a temperature sensor in the aftercooler outlet header will signal the...

Page 49: ...in damage to downstream equipment Normal service intervals should not be exceeded Filter Replacement With engine stopped ensure pressure is relieved from air system Remove all wires and hoses connecte...

Page 50: ...Turn adjustment screw counter clockwise one full turn After Starting Unit 2 Allow unit to warm up then push Service Air Switch on control panel 3 Open and adjust service valve on outside of the unit t...

Page 51: ...r idle speed 6 If necessary repeat steps 3 and 4 7 At pressure regulator PR tighten lock nut G 8 To adjust the unloaded pressure to any pressure between 80 psi 550 kPa and the rated operating pressure...

Page 52: ...52...

Page 53: ...53 Maintenance...

Page 54: ...recleaner Dumps C Fan Alternator Belts C Battery Connections Electrolyte C Tire Pressure and Surface C Wheel Lug Nuts C Hoses Oil Air Intake etc C Automatic Shutdown System C Air Cleaner System C Comp...

Page 55: ...fice Related Parts C Oil Separator Element R Feed Pump Strainer Cleaning C Valve Clearance Check C Lights running brake turn CBT Pintle Eye Bolts CBT Brakes C C Brake linkage C Emergency stop T Runnin...

Page 56: ...lowdown fails to operate then pressure must be gradually relieved by operating the manual blowdown valve Suitable personal protective equipment should be worn Ensure that maintenance personnel are ade...

Page 57: ...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 58: ...el switch Test the low engine fuel level switch circuit as follows Start the machine NOTE Do not press the load button Disconnect the switch the machine should shutdown Re connect the switch Test the...

Page 59: ...the filter housing and remove the spin on element lnspection Inspect the oil filter head to be sure the gasket was removed with the oil filter element Clean the gasket seal area on the oil filter hea...

Page 60: ...to the MAINTENANCE CHART in this section for the recommended servicing intervals If however the element has to be replaced then proceed as follows Removal WARNING Do not remove the filter s without f...

Page 61: ...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...

Page 62: ...the machine is running Clean the exterior of the filter housing and remove the filter element by releasing the nut Reassembly Assemble the new element into the filter housing ensuring that the seal s...

Page 63: ...should be checked periodically to keep the engine at peak efficiency At the recommended intervals see the MAINTENANCE CHART inspect all of the intake lines to the air filter and all flexible hoses use...

Page 64: ...the TORQUE SETTING TABLE later in this section Lifting jacks should only be used under the axle The bolts securing the running gear to the chassis should be checked periodically for tightness refer to...

Page 65: ...E MACHINE in the OPERATING INSTRUCTIONS section of this manual Completely drain the receiver separator system including the piping and oil cooler by removing the drain plug s and collecting the used o...

Page 66: ...66...

Page 67: ...67 Lubrication...

Page 68: ...nance Section All filters and filter elements for air and compressor lubricant must be obtained through Portable Power to assure the proper size and filtration for the compressor Compressor Oil Change...

Page 69: ...cooler If the oil is drained immediately after the unit has been run for some time most of the sediment will be in suspension and therefore will drain more readily However the fluid will be hot and c...

Page 70: ...ranty section for details or contact your Portable Power representative DesignOperating Pressure Ambient Temperature Specification 100 psi to 300 psi 10 F to 125 F 23 C to 52 C Preferred Pro Tec Alter...

Page 71: ...71 Troubleshooting...

Page 72: ...n to find the potential cause or causes The causes are listed in order 1 2 3 etc to suggest an order to follow in trouble shooting Action Plan A Think Before Acting Study the problem thoroughly and as...

Page 73: ...d Engine Fault and the other Compressor Fault When the engine fault lamp is on all codes displayed are engine faults When the compressor fault lamp is on all codes displayed are compressor or package...

Page 74: ...High 222 Ambient Air Pressure Sensor Circuit Shorted Low 223 Engine Oil Burn Valve Solenoid Circuit Shorted Low 227 Sensor Supply Voltage 2 Circuit Shorted High 234 Engine Speed High Critical 235 Eng...

Page 75: ...ply Voltage 1 Circuit Shorted High 394 Timing Actuator 1 Circuit Open Circuit 395 Timing Actuator 1 Circuit Grounded Circuit 396 Fueling Actuator 2 Circuit Open Circuit 397 Fueling Actuator 2 Circuit...

Page 76: ...ery Pressure Sensor Circuit Shorted High 547 Fuel Delivery Pressure Sensor Circuit Shorted Low 553 Injector Metering Rail 1 Pressure High Warning 581 Fuel Supply Pump Inlet Pressure Sensor Circuit Sho...

Page 77: ...wn reason unknown 29 CPRSR Malf 0 Low AE Oil Pressure 31 CPRSR Malf 20 Disch Temp RT2 Sensor Fault 33 32 CPRSR Malf 10 Sep Tank Pressure PT1 Sensor Fault 33 CPRSR Malf Sep Tank Press 20 psi during sta...

Page 78: ...m for 17 sec 73 CPRSR Malf Low Fuel Level fuel level fuel level 3 Air Filter Restriction soiled filter Low Battery Voltage battery charging cond Low Engine Oil Pressure low engine oil press Low Coolan...

Page 79: ...oltage Check electrolyte level Check connections Blown Fuse Replace fuse Malfunctioning Start Switch Replace switch Clogged Fuel Filters Service filters See Engine Operator s Manual Out of Fuel Add CL...

Page 80: ...in this manual Dirty Cooler Clean exterior surfaces Dirty Operating Conditions Move unit to cleaner environment Clogged Oil Filter Elements Replace elements Change oil Loose or Broken Belts Tighten or...

Page 81: ...element 10 Short Air Cleaner Life Dirty Operating Conditions Move unit to cleaner environment Inadequate Element Cleaning Install new element Incorrect Stopping Procedure Read procedure in this manua...

Page 82: ...82...

Page 83: ...83 Electrical...

Page 84: ...to scan all analog and digital inputs at a fixed interval These inputs are scanned every 50 milliseconds The analog values are then compared against minimum and maximum values and an ALERT or SHUTDOWN...

Page 85: ...F 0 V DC These digital inputs are connected to switches within the package such as the key start switch air filter switches and IQ filter switches The WEDGE controller provides 24V DC digital outputs...

Page 86: ...e tools Electrical System The electrical system consists of the wiring harnesses and associated electrical devices such as relays switches lights solenoids and alarm horn There are two wiring harnesse...

Page 87: ...mmunications not working Check for 24FDC key switch at engine CAN network wiring problem Ensure 24VDC power to engine ECM Check connector pins Engine cranks but will not start Ensure key switch 24VDC...

Page 88: ...88...

Page 89: ...89 Electrical Schematics...

Page 90: ...Operating Maintenance Manual Electrical Schematics 90...

Page 91: ...Electrical Schematics Operating Maintenance Manual 91...

Page 92: ...Operating Maintenance Manual Electrical Schematics 92...

Page 93: ...Electrical Schematics Operating Maintenance Manual 93...

Page 94: ...94...

Page 95: ...C Number Comments A Original release B General Data Update C Maintenance Section Update D STA10011 Added containment notice to Safety Section E CN026601 Doosan reference updates F CN034865 Added Flex...

Page 96: ...2012 Doosan Infracore Portable Power Printed in the U S A Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 www doosanportablepower com...

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