Doosan 12/154 Operation & Maintenance Manual Download Page 81

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MAINTENANCE

12/154

TORQUE VALUES

TABLE 1

INCH FASTENERS

TYPICAL RECTANGULAR TORQUE PATTERN

TYPICAL SQUARE TORQUE PATTERN

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

5/16 - 18

3/8 - 16

7/16 - 14

1/2 - 13

102

144

106

9/16 - 12

148

109

208

154

5/8 - 11

203

150

287

212

3/4 - 10

361

266

509

376

Summary of Contents for 12/154

Page 1: ...ontains important safety information and must be made available to personnel who operate and maintain this machine 46663720_en_A_12 14 12 154 OPERATION MAINTENANCE MANUAL Original Instruction SERIAL No 705000 707000 ...

Page 2: ......

Page 3: ...that 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 part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid A declaration of that conformity follows SAMPLE ...

Page 4: ......

Page 5: ...filter water separator Charge cooler pipework Hoses Electrical system Battery Pressure system Tyres tyre pressure Running gear wheels Brakes Adjusting the overrun braking system Re adjusting the overrun braking system Running gear height adjustment Lubrication General information Torque values Compressor lubrication 80 MACHINE SYSTEMS Electrical system Piping instrumentation system 92 SERVICE TOOL...

Page 6: ...those included within 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 installed The company reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvement...

Page 7: ...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 Refer to the GENERAL INFORMATION section of this manual WARNING Before connecting the tow bar or commencing to tow consult the Operation Maintenance manual WARNING For operating temperature below 0 C 32 F consult...

Page 8: ... 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 or other parts of the pressure system Do not operate with the doors or enclosure open Do not use fork lift truck from this side Do not exceed the trailer speed limit No naked lights Do not open the service valv...

Page 9: ...ks Compressor oil filling Diesel fuel No open flame Parking brake Rough Service Designation Wet Location Operation Replace any cracked protective shield Separator tank drain Engine coolant drain Engine oil drain Compressor coolant drain Fual tank drain Operational status of the engine emission filter Engine emissions system temperature may be high Disable active regeneration of the engine emission...

Page 10: ...int Tie down Prohibition Do not start WARNING Maintenance work in progress Engine oil Fuel level point Pressure control Malfunction Battery charging condition Low pressure High pressure Engine malfunction High compressor temperature Compressor malfunction Low engine oil pressure High engine temperature ...

Page 11: ...ds hair clothing tools blow gun tips etc well away from moving parts Compressed air Compressed air can be dangerous if incorrectly handled Before doing any work on the unit ensure that all pressure is vented from the system and that the machine cannot be started accidentally Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel Al...

Page 12: ...ning gear Before towing the machine ensure that the tyres and towing hitch are in a serviceable condition the canopy is secure all ancillary equipment is stored in a safe and secure manner the brakes and lights are functioning correctly and meet necessary road traffic requirements break away cables safety chains are connected to the towing vehicle The machine must be towed in a level attitude the ...

Page 13: ... air inlet C Access items Separator element fill Compressor oil filter Fuel filters Dipstick Engine oil fill Coolant bottle fill D Access items Fuel fill Engine oil filter Fuel filter Engine and compressor air filter E Access items Radiator fill F Package air outlet G Track width H Fixed height drawbar ...

Page 14: ...Access items Separator element fill Compressor oil filter Fuel filters Dipstick Engine oil fill Coolant bottle fill D Access items Fuel fill Engine oil filter Fuel filter Engine and compressor air filter E Access items Radiator fill F Package air outlet G Track width J Variable height drawbar 438mm minimum 968mm maximum ...

Page 15: ... Access items Separator element fill Compressor oil filter Fuel filters Dipstick Engine oil fill Coolant bottle fill D Access items Fuel fill Engine oil filter Fuel filter Engine and compressor air filter E Access items Radiator fill F Package air outlet G Track width J Variable height drawbar 320mm minimum 1090mm maximum ...

Page 16: ...ss door B Package air inlet C Access items Separator element fill Compressor oil filter Fuel filters Dipstick Engine oil fill Coolant bottle fill D Access items Fuel fill Engine oil filter Fuel filter Engine and compressor air filter E Access items Radiator fill F Package air outlet ...

Page 17: ...ximum mass 3500kg 7716Lbs Maximum horizontal towing force 3100kg 6835Lbs Maximum vertical coupling load nose weight 150 kgf 331Lbs Mass in running order means the mass of the vehicle including the fuel and liquids fitted with the standard equipment Actual mass with optional equipment may be different WHEELS AND TYRES Number of wheels 2 Tyre size 215 75R17 5 Tyre pressure 6 0 bar 87 psi COMPRESSOR ...

Page 18: ...ransport 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 Adequate clearance need...

Page 19: ...el filter water separator of water ensuring that any released fuel is safely contained 7 Check the radiator coolant level with the unit level 8 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 10 Check that the emergency stop switch is not engaged Pull knob to release if necessary 11 Close the manual relief val...

Page 20: ...ndicates machine operating hours 4 Fuel Level Gauge Indicates level of fuel in tank 5 MidPort Display Indicates compressor and engine operating parameters including diagnostic fault codes 6 Main Power Button Used to start and shutdown the compressor control system and gauge panel 7 KeyPad Used to start shutdown and operate the compressor 8 Emergency Stop Switch Used to stop the machine in the even...

Page 21: ...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 Displayed in case of a compressor related fault CPR Code one or two digit number identifying the component or system fault Figure 1 When present an ALERT with the number of alert conditions will popup on the screen t...

Page 22: ... 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 service intervals can be changed by pressing the ENTER Button while on the default screen that displays the engine hours Using the UP or DOWN Buttons to highlight the desired interval and press the ENTER Button to se...

Page 23: ...s 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 press the ENTER Button Use the DOWN or UP Buttons to highlight the chosen unit and PRESS the ENTER Button to select To return to the Default Screen of Engine Hours use the DOWN Button to highlight the Main Screen me...

Page 24: ...s 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 from the engine or compressor will be displayed Note 2 Unit times out after 3 minutes of inactivity and returns to the Default Screen of Engine Hours Note 3 Pressing the Enter Button while viewing a Quickview S...

Page 25: ...enu 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 batteries when the compressor engine is not running If the Control Panel is powered ON and the engine has not run for 3 minutes above 45 F 7 C or 15 minutes at or below 45 F 7 C the control system will automatically pow...

Page 26: ...essure Too High To Start 34 20 PSI All Safety Valve Open 36 2 sec Note 4 Intake Air Filter Restricted 38 All Alternator Not Charging 39 Note 5 All Fuel Level Sensor Fail 42 5V 4 5V Note 4 IQ Filter Restriction 44 10 PSI IQ Option 52 15 PSI 3 sec IQ Option High Separator Tank Temperature 50 251 F 3 sec All Machine ID Not Valid 51 0 All Separator Tank Temperature Sensor Fault 53 10 sec All Regulatio...

Page 27: ...horted to High Source Accelerator Pedal or Lever Position Sensor 1 Circuit Voltage above normal or shorted to high source 91 4 132 Accelerator Pedal Position 1 Voltage Below Normal or Shorted to Low Source Accelerator Pedal or Lever Position Sensor 1 Circuit Voltage below normal or shorted to low source 91 9 3326 Accelerator Pedal Position 1 Abnormal Update Rate SAE J1939 Multiplexed Accelerator P...

Page 28: ...l Pressure Data Valid but Below Normal Operating Range Moderately Severe Level Engine Oil Rifle Pressure Data Valid But Below Normal Operating Range Moderately Severe Level 101 0 556 Engine Crankcase Pressure Data Valid but Above Normal Operational Range Most Severe Level Crankcase Pressure Data valid but above normal operational range Most Severe Level 101 2 1942 Engine Crankcase Pressure Data Er...

Page 29: ...nge Least Severe Level 105 16 488 Engine Intake Manifold 1 Temperature Data Valid but Above Normal Operating Range Moderately Severe Level Intake Manifold 1 Temperature Data Valid But Above Normal Operating Range Moderately Severe Level 105 18 3385 Engine Intake Manifold 1 Temperature Data Valid but Below Normal Operating Range Moderately Severe Level Intake Manifold 1 Temperature Data Valid But B...

Page 30: ... 196 Engine Coolant Level Voltage Below Normal or Shorted to Low Source Coolant Level Sensor 1 Circuit Voltage below normal or shorted to low source 111 9 3613 SAE J1939 Multiplexing PGN Timeout Abnormal Update Rate SAE J1939 Multiplexing PGN Timeout Error Abnormal update rate 111 17 2448 Engine Coolant Level Data Valid but Below Normal Operating Range Least Severe Level Coolant Level Data Valid B...

Page 31: ...ircuit Voltage below normal or shorted to low source 171 9 3531 Ambient Air Temperature Abnormal Update Rate Ambient Air Temperature Abnormal update rate 171 19 3532 Ambient Air Temperature Received Network Data in Error Ambient Air Temperature Received Network Data In Error 174 0 266 Engine Fuel Temperature 1 Data Valid but Above Normal Operational Range Most Severe Level Engine Fuel Temperature ...

Page 32: ...on Output Shaft Speed Received Network Data In Error 237 2 4722 Vehicle Identification Number Data Erratic Intermittent or Incorrect Vehicle Identification Number Data erratic intermittent or incorrect 237 13 4517 Vehicle Identification Number Out of Calibration Vehicle Identification Number Out of Calibration 237 31 4721 Vehicle Identification Number Not Available or Condition Exists Vehicle Iden...

Page 33: ...e rate 563 31 4215 Anti Lock Braking ABS Active Not Available or Condition Exists Anti Lock Braking ABS Active Condition Exists 596 2 3841 Cruise Control Enable Switch Data Erratic Intermittent or Incorrect Cruise Control Enable Switch Data erratic intermittent or incorrect 596 7 3839 Cruise Control Enable Switch Mechanical System not Responding or Out of Adjustment Cruise Control Enable Switch Me...

Page 34: ...ernal Protection Input Special Instructions Auxiliary Commanded Dual Output Shutdown Special Instructions 641 7 2387 Engine Variable Geometry Turbocharger Actuator 1 Mechanical System not Responding or Out of Adjustment VGT Actuator Driver Circuit Motor Mechanical system not responding or out of adjustment 641 9 2636 Engine Variable Geometry Turbocharger Actuator 1 Abnormal Update Rate VGT Actuato...

Page 35: ...sponding or out of adjustment 655 5 323 Engine Injector Cylinder 05 Current Below Normal or Open Circuit Injector Solenoid Driver Cylinder 5 Circuit Current below normal or open circuit 655 7 1144 Engine Injector Cylinder 05 Mechanical System not Responding or Out of Adjustment Injector Solenoid Driver Cylinder 5 Mechanical system not responding or out of adjustment 656 5 325 Engine Injector Cylin...

Page 36: ... Heater Driver 1 Voltage Below Normal or Shorted to Low Source Engine Intake Air Heater 1 Circuit Voltage below normal or shorted to low source 748 9 3641 Transmission Output Retarder Abnormal Update Rate Transmission Output Retarder Abnormal update rate 862 3 3733 Crankcase breather Heater Ciruit Voltage Above Normal or Shorted to High Source Crankcase Breather Filter Heater Circuit Voltage above...

Page 37: ...termittent or incorrect 1172 3 691 Engine Turbocharger 1 Compressor Intake Temperature Voltage Above Normal or Shorted to High Source Turbocharger 1 Compressor Intake Temperature Circuit Voltage above normal or shorted to high source 1172 4 692 Engine Turbocharger 1 Compressor Intake Temperature Voltage Below Normal or Shorted to Low Source Turbocharger 1 Compressor Intake Temperature Circuit Volt...

Page 38: ...al or shorted to low source 1322 31 1718 Engine Misfire for Multiple Cylinders Not Available or Condition Exists Engine Misfire for Multiple Cylinders Condition Exists 1323 31 1654 Engine Misfire Cylinder 1 Not Available or Condition Exists Engine Misfire Cylinder 1 Condition Exists 1324 31 1655 Engine Misfire Cylinder 2 Not Available or Condition Exists Engine Misfire Cylinder 2 Condition Exists ...

Page 39: ...raph Output Shaft Speed Received Network Data In Error 1632 14 2998 Engine Torque Limit Feature Special Instructions Engine Torque Limit Feature Special Instructions 1632 31 5193 Engine Torque Limit Feature Not Available or Condition Exists Engine Torque Limit Feature Condition Exists 1639 0 4789 Fan Speed Data Valid but Above Normal Operational Range Most Severe Level Fan Speed Data Valid but Abo...

Page 40: ...te 2623 3 1239 Accelerator Pedal 1 Channel 2 Voltage Above Normal or Shorted to High Source Accelerator Pedal or Lever Position Sensor 2 Circuit Voltage above normal or shorted to high source 2623 4 1241 Accelerator Pedal 1 Channel 2 Voltage Below Normal or Shorted to Low Source Accelerator Pedal or Lever Position Sensor 2 Circuit Voltage below normal or shorted to low source 2629 15 2347 Engine T...

Page 41: ...atment 1 Diesel Exhaust Fluid Tank Temperature Data erratic intermittent or incorrect 3031 3 1678 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Voltage Above Normal or Shorted to High Source Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor Voltage above normal or shorted to high source 3031 4 1677 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Voltage Below Normal or ...

Page 42: ...treatment 1 Diesel Particulate Filter Intake Gas Temperature Data Valid but Above Normal Operational Range Most Severe Level Aftertreatment 1 Diesel Particulate Filter Intake Temperature Data valid but above normal operation 3242 2 3318 Aftertreatment 1 Diesel Particulate Filter Intake Gas Temperature Data Erratic Intermittent or Incorrect Aftertreatment 1 Diesel Particulate Filter Intake Temperat...

Page 43: ...east Severe Level Aftertreatment Diesel Particulate Filter Differential Pressure Data valid but above normal Operating Range 3251 16 1921 Aftertreatment 1 Diesel Particulate Filter Differential Pressure Data Valid but Above Normal Operating Range Moderately Severe Level Aftertreatment Diesel Particulate Filter Differential Pressure Data Valid But Above Normal Operating Range 3255 9 4145 Aftertreat...

Page 44: ...reatment 1 Diesel Exhaust Fluid Tank 1 Quality Abnormal Update Rate Aftertreatment Diesel Exhaust Fluid Quality Abnormal update rate 3364 10 4277 Aftertreatment 1 Diesel Exhaust Fluid Tank 1 Quality Abnormal Rate of Change Aftertreatment Diesel Exhaust Fluid Quality Abnormal Rate of Change 3364 11 1715 Aftertreatment 1 Diesel Exhaust Fluid Tank 1 Quality Root Cause Not Known Aftertreatment Diesel ...

Page 45: ...ve Normal or Shorted to High Source Sensor Supply 2 Circuit Voltage above normal or shorted to high source 3510 4 187 Sensor supply voltage 2 Voltage Below Normal or Shorted to Low Source Sensor Supply 2 Circuit Voltage below normal or shorted to low source 3511 3 239 Sensor supply voltage 3 Voltage Above Normal or Shorted to High Source Sensor Supply 3 Circuit Voltage above normal or shorted to h...

Page 46: ...er Output Supply Voltage 1 Voltage Above Normal or Shorted to High Source ECU Power Output Supply Voltage 1 Voltage above normal or shorted to high source 3597 4 1941 ECU Power Output Supply Voltage 1 Voltage Below Normal or Shorted to Low Source ECU Power Output Supply Voltage 1 Voltage below normal or shorted to low source 3597 12 351 ECU Power Output Supply Voltage 1 Bad Intelligent Device or C...

Page 47: ...oltage Above Normal or Shorted to High Source Aftertreatment Fuel Drain Valve Circuit Voltage above normal or shorted to high source 4097 4 2733 Aftertreatment 1 Fuel Drain Actuator Voltage Below Normal or Shorted to Low Source Aftertreatment Fuel Drain Valve Circuit Voltage below normal or shorted to low source 4097 7 2878 Aftertreatment 1 Fuel Drain Actuator Mechanical System not Responding or O...

Page 48: ...r 1 State Voltage Above Normal or Shorted to High Source Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 Circuit Voltage above normal or shorted to high source 4340 4 3238 Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 State Voltage Below Normal or Shorted to Low Source Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 Circuit Voltage below normal or shorted to low source 4340 5 3258 Af...

Page 49: ...ut Below Normal Operating Range Moderately Severe Level 4376 3 3577 Aftertreatment 1 Diesel Exhaust Fluid Return Valve Voltage Above Normal or Shorted to High Source Aftertreatment Diesel Exhaust Fluid Return Valve Voltage above normal or shorted to high source 4376 4 3578 Aftertreatment 1 Diesel Exhaust Fluid Return Valve Voltage Below Normal or Shorted to Low Source Aftertreatment Diesel Exhaust...

Page 50: ...mittent or incorrect 4809 3 3152 Aftertreatment Warm Up Diesel Oxidation Catalyst Intake Temperature Voltage Above Normal or Shorted to High Source Aftertreatment Warm Up Diesel Oxidation Catalyst Intake Temperature Sensor Circuit Voltage above normal 4809 4 3153 Aftertreatment Warm Up Diesel Oxidation Catalyst Intake Temperature Voltage Below Normal or Shorted to Low Source Aftertreatment Warm Up...

Page 51: ...rately Severe Level Aftertreatment 1 Diesel Oxidation Catalyst Conversion Efficiency Data Valid But Below Normal Operating Range Moderately Severe Level 5319 31 3376 Aftertreatment 1 Diesel Particulate Filter Incomplete Regeneration Not Available or Condition Exists Aftertreatment Diesel Particulate Filter Incomplete Regeneration Condition Exists 5357 31 4713 Engine Fuel Injection Quantity Error f...

Page 52: ... Fuel Pressure Relief Valve Condition Exists 5585 18 4691 Engine Injector Metering Rail 1 Cranking Pressure Data Valid but Below Normal Operating Range Moderately Severe Level Engine Injector Metering Rail 1 Cranking Pressure Data Valid But Below Normal Operating Range Mo 5603 9 3843 Cruise Control Disable Command Abnormal Update Rate Cruise Control Disable Command Abnormal update rate 5603 31 384...

Page 53: ...ating Range Moderately Severe Level Aftertreatment Selective Catalytic Reduction Temperature Sensor Module Data Valid But Above Normal 5745 3 4168 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Heater Voltage Above Normal or Shorted to High Source Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Heater Voltage Above Normal or Shorted to High 5745 4 4169 Aftertreatment 1 Diesel Exhaust Fluid Do...

Page 54: ...r Shorted to High Source Water in Fuel Indicator 2 Sensor Circuit Voltage above normal or shorted to high source 6301 4 4689 Water in Fuel Indicator 2 Sensor Circuit Voltage Below Normal or Shorted to Low Source Water in Fuel Indicator 2 Sensor Circuit Voltage below normal or shorted to low source 6653 16 4841 Cold Start Injector Metering Rail 1 Pressure Data Valid but Above Normal Operating Range...

Page 55: ...ove Normal or Shorted to High Source Fan Blade Pitch Position Sensor Circuit Voltage Above Normal or Shorted to High Source 520784 4 5184 Fan Blade Pitch Position Sensor Circuit Voltage Below Normal or Shorted to Low Source Fan Blade Pitch Position Sensor Circuit Voltage Below Normal or Shorted to Low Source 520784 5 5185 Fan Blade Pitch Current Below Normal or Open Circuit Fan Blade Pitch Mechani...

Page 56: ...ed Assume engine has been started and is running in the unload state at idle speed If there is air demand pressure falls below the load point pressure compressor will load at idle speed by opening the inlet valve As air demand rises and falls engine speed is controlled between idle speed and full load speed to match the required flow while maintaining load point pressure Operation Unloaded If ther...

Page 57: ...purpose of the SCR system is to reduce levels of NOx oxides of nitrogen emitted from engines that are harmful to our health and the environment SCR is the aftertreatment technology that treats exhaust gas downstream of the engine Small quantities of diesel exhaust fluid DEF are injected into the exhaust upstream of a catalyst where it vaporizes and decomposes to form ammonia and carbon dioxide The...

Page 58: ...ed to the NORMAL position 0 the engine ECM will automatically perform the regeneration of the diesel particulate filter when the soot reaches a high level When the switch is turned to the INITIATE position Right a request is sent to the engine ECM for a manual regeneration of the diesel particulate filter This manual regeneration will only happen when the machine is in a non mission condition and ...

Page 59: ...curring due to low exhaust temperatures This will be a very infrequent occurrence However at the next convenient opportunity such as end of shift the operator should park the equipment and initiate a manual regeneration when it is safe to do so Normal Operation Regeneration Inhibit Regeneration DISABLE position should only be selected if the compressor is to be used in a location that could be con...

Page 60: ...n Start switch Takes 30 to 45 minutes to fully regenerate This is required when PM soot loading reaches 50 in the filter shown by the DPF lamp Manual regen is required due to the active regen function disabled by the Inhibit ON switch or because the system cannot reach the necessary exhaust temperature or flow for duty cycle initiated active regen to occur Continually removes PM soot from the Dies...

Page 61: ...ection Engine cooling system Treat with rust inhibitor and drain Check with engine dealer for further recommendations Compressor Oil Filter s fill with Doosan compressor fluid PRO TEC XHP605 or XHP405 Seal all opening with waterproof tape Place a desiccant in the exhaust pipes engine and compressor air intake pipes Loosen tension on belts fan airend etc Block axles so tyres are off ground and do n...

Page 62: ... 2000 hrs 4500 hrs 5000 hrs Compressor Oil Level C Engine Oil Level C Coolant Level C Gauges Lamps C Air Cleaner Service Indicators C Air Cleaner Dust Ejector Valve C Aftertreatment Exhaust Piping C Fuel Tank C Refill Fuel Water Separator D Fluid Leaks C Radiator Filler Cap C Diesel Exhaust Fluid DEF Level C Refill Air Cleaner Precleaner Dump C Fan Alternator Belts C Battery Connections Electrolyt...

Page 63: ...igh humidity as well Contact your Doosan Infracore Portable Power dealer for more information or assistance in determining the optimum intervals for your application Daily Weekly Monthly 6 months or 500 hrs 1 year or 1000 hrs 2000 hrs 4500 hrs 5000 hrs Wheels Bearings Seals etc C Shutdown Switch Settings T Scavenger Orifice Related C Lights Brake Running Turn CBT Pintle Eye Bolts CBT Brakes C C Br...

Page 64: ...ths 1000 hrs 12 Months 2000 hrs Brake linkage C C Brakes C C Lights running brake turn CBT Pintle Eye Bolts CBT Tire Pressure and Condition C Wheel Lug Nuts C Running gear linkage G 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 ...

Page 65: ...nd intermittently moving parts the machine cannot be started accidentally or otherwise by posting warning signs and or fitting appropriate anti start devices Prior to attempting any maintenance work on a running machine ensure that the work carried out is limited to only those tasks which require the machine to run the work carried out with safety protection devices disabled or removed is limited ...

Page 66: ... cleaning solvent over the exterior core of the cooler radiator This should remove any accumulation of oil grease and dirt from the exterior core of the cooler so that the entire cooling area can radiate the heat of the lubricating and cooling oil water into the air stream CAUTION If there is any indication of the formation of varnishes shellacs or lacquers on the filter element it is a warning th...

Page 67: ...d with a variable speed fan clutch that requires no periodic maintenance The fan belt s should be checked regularly for wear and correct tensioning FUEL SYSTEM The fuel tank should be filled daily or every eight hours To minimise 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 At six month intervals drain any sediment or co...

Page 68: ...e valve s including hoses tubes tube fittings and the separator tank for visible signs of impact damage excessive corrosion abrasion tightness and chafing Any suspect parts should be replaced before the machine is put back into service TYRES TYRE PRESSURE Tyre Pressure 600kPa RUNNING GEAR WHEELS Check the wheel nut torque 20 miles 30 kilometres after refitting the wheels Refer to the TORQUE SETTIN...

Page 69: ...the play in the brake linkage 7 If necessary adjust the brake linkage 7 again without play and without pre tensioning There must still be a little play in cable 5 Variable Height Only Check the position of the hand brake lever 1 The start of resistance should be approximately 10 15mm above the horizontal position Check that the wheels move freely when the handbrake is disengaged Final test Check t...

Page 70: ...orward travel of the handbrake lever up to 2 3 of maximum is allowed Check the handbrake cable 5 for a small amount of play and adjust if necessary Variable height only Check the compression spring 9 for slight pre tensioning RUNNING GEAR HEIGHT ADJUSTMENT KNOTT KHD Operating the height adjusting mechanism To adjust the coupling to the proper height the lock spring must first be removed Turning th...

Page 71: ...t loaded journey After 500 km Every 2000 3000 km 1 Function check of the coupling head or the towing eye 2 Mobility check of the drawtube handbrake lever and rods 3 Mobility and ease of operation check of the height adjusting mechanism 4 Coupling head lubrication 5 Drawtube support lubrication at the housing of the overrun coupling 6 Clamping jig bolts tightening ...

Page 72: ...moved 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 the coupling head 1 onto the drawtube 45 and adjust until the holes overlap Insert both bolts 2 Screw on new fixing nuts 3 and fasten them with a torque wrench Bolt M12 to 77 5Nm Bolt M14 to 125 5Nm Replace the...

Page 73: ...er 33 Push the shock absorber 33 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 housing place the disc 37 if present between the housing and the shock absorber bracket 35 and fasten with lock bolts 40 41 At the same time mount the hand grip 42 Fasten the...

Page 74: ...ure 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 Assembly Before mounting all the new and removed parts must be lubri cated in accordance with regulation SK70003 Push the new cable through the cable bracket into the drawbar screw in the hexagonal nut 21 and faste...

Page 75: ...n 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 position and adjust the whole braking system KHD axles Replacement of the coupling head or the spring pack To be carried out ONLY by skilled service personnel Disassembly Loosen the balance bar 58 tandem or 59 sing...

Page 76: ...rmance 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 part f Bottom middle part g Holes for handbrake h Drawbar coupling i Conversion lever coupling j Tube k Pin l Adjustement bolt welded m Gearing n Top spindle o Thread p Bottom spindle q Adjustment nut welded r Are...

Page 77: ...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 part f Bottom middle part g Holes for handbrake h Drawbar coupling i Conversion lever coupling j Tube k Pin l Adjustement bolt welded m Gearing n Top spindle o Thread p Bottom spindle q Adjustment nut welded ...

Page 78: ... 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 M10 8 DIN980 ATTENTION Do NOT lock fixing nuts M10 8 DIN980 b Hexagonal head nut M16x1 5 DIN936 Torque 30Nm 2Nm Cross section showing positions of details B C and R c Hexagonal head nut M16x1 5 DIN936 Torque 30N...

Page 79: ...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 products Completely drain the separator tank piping and cooler If the oil is drained immediately after the compressor has been run for some time most of the sediment will be in suspension and therefore will drain...

Page 80: ...er to STARTING INSTRUCTIONS in the OPERATING INSTRUCTIONS section of this manual Adjust the service valve on the outside of the machine to maintain rated pressure at full speed If full speed is not maintained at rated pressure then turn the adjusting screw clockwise to increase the pressure Optimum adjustment is achieved when full speed is achieved at rated pressure Close the service valve The eng...

Page 81: ... 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 18 24 17 33 25 3 8 16 42 31 59 44 7 16 14 67 49 95 70 1 2 13 102 75 144 106 9 16 12 148 109 208 154 5 8 11 203 150 287 212 3 4 10 361 266 509 376 ...

Page 82: ... AND PITCH NOMINAL DESIGN TORQUE PROPERTY GRADE 8 8 HEAD MARKING PROPERTY GRADE 10 9 HEAD MARKING PROPERTY GRADE 12 9 HEAD MARKING Nm FT LBF Nm FT LBF Nm FT LBF M6 X 1 0 11 8 15 11 18 13 M8 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 ...

Page 83: ...ranty 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 to 125 F Preferred PRO TEC Alternate ISO Viscosity Grade 46 with rust and oxidisation inhibitors designed for air compressor service 24 1 bar 350 psi 23 C to 52 C 10 F to 125 F Preferred XHP 605 Alternate XHP 40...

Page 84: ...80 MACHINE SYSTEMS 12 154 page ...

Page 85: ...l beacon option L1 Valve start run solenoid L2 Valve unloader solenoid L3 Valve dual pressure solenoid option P1 Titan controller P4 Connector control panel PT1 Sensor separator tank pressure PT2 Sensor regulation system pressure RT1 Sensor separator tank temperature RT2 Sensor discharge air temperature RT3 Sensor ambient air temperature S10 Switch engine air filter restriction S11 Switch airend a...

Page 86: ...82 MACHINE SYSTEMS 12 154 ...

Page 87: ...3 Connector MAF engine harness C34 Sensor MAF F11 Fuse alternator 100A F12 Fuse engine intake air heater 150A FB1 Fuse Relay centre G1 Alternator engine HR1 Heater engine intake air HR2 Heater HR3 Heater HR4 Heater HR5 Heater J12 Connector regulation heaters option K1 Relay engine starter K2 Relay engine intake air heater ...

Page 88: ...84 MACHINE SYSTEMS 12 154 ...

Page 89: ...ector harness J11 Sensor coolant level J20 Connector air shutoff valve option J24 Connector 24 pin breakout J26E Module DEF supply J27E Valve DEF tank heating J31E Module DEF dosing P6 Connector harness P6A Interface engine RT4 Sensor CAC out temperature S12 Switch engine overspeed valve option S13 Switch aftercooler option TR2 Resistor terminating ...

Page 90: ...86 MACHINE SYSTEMS 12 154 ...

Page 91: ...upstream NOx J10E Controllers SCR thermistor J17E Controllers DOC DPF thermocouple J19 Controllers WiFi option J28E Heated hose DEF pressure line J29E Heated hose DEF backflow line J30E Heated hose DEF suction line J78E Sensor downstream NOx TR3 Resistor terminating ...

Page 92: ...88 MACHINE SYSTEMS 12 154 ...

Page 93: ...HM1 Hourmeter J4 Connector control panel KP1 Keypad M1 Gauge air pressure M2 Tachometer engine M7 Gauge fuel level M8 Gauge DEF level M9 Gauge DEF status P4A Connector control panel S1 Switch power S2 Switch TR1 Resistor terminating ...

Page 94: ...90 MACHINE SYSTEMS 12 154 ...

Page 95: ...91 12 154 KEY J17 Connector J18 Connector PT100 Sensor primary filter inlet PT101 Sensor secondary filter outlet HR100 Heater water separator drain HR101 Heater primary filter drain HR102 Heater secondary filter drain ...

Page 96: ...al Tool Red Used to repair Deutsch connectors 54729694 Deutsch Terminal Removal Tool Yellow Used to repair Deutsch connectors 22216667 Deutsch Terminal Crimp Tool Used to crimp Deutsch connector terminals 54729710 Electrical Contact Cleaner Used to clean electrical contacts and connectors 22073886 Packard Crimp Tool Used to crimp Packard connector terminals 22073878 Thermistor Simulator Plug Used ...

Page 97: ...m in operation Check the safety shut down switches Fuel starvation Check the fuel level and fuel system components Replace the fuel filter if necessary Switch failure Test the switches High compressor oil temperature Check the compressor oil level and oil cooler Check the fan drive Water present in fuel system Check the water separator and clean if required Faulty relay Check the relays and replac...

Page 98: ...eplace Perforated separator element Replace the separator element Pressure in the system is too low Check the minimum pressure valve Safety valve operates Operating pressure too high Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in the MAINTENANCE section of this manual Incorrect setting of the regulator Adjust the regulator Faulty regulator Replace the regulator Inlet valve set incorrectly Re...

Page 99: ...densate and the added cost of disposing of the condensate which is often regulated by local regulations Ensure that the compressed air temperature always remains above freezing temperatures typically 7 C 45 F at any ambient temperature down to 23 C 20 F This prevents the need for heat tracing systems or any manual adjustment to prevent freezing of the compressed air system All drain points for the...

Page 100: ...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 slightly less depending on the restriction of the filters MAINTENANCE Daily Maintenance Verify during fullload maximum compressed air delivery operation the IQ System filter restriction is not excessive Filter re...

Page 101: ...OPTIONS 97 12 154 PRIMARY AND SECONDARY FILTER MAINTENANCE FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5 ...

Page 102: ...98 OPTIONS 12 154 WATER SEPARATOR MAINTENANCE FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5 FIGURE 6 ...

Page 103: ...using 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 could result in damage to downstream equipment Normal service intervals should not be exceeded CAUTION Blockage of the condensate will result in flooding of the vessels If flooding occurs excessive condensate may e...

Page 104: ...eps 2 to 5 until the first setting at which the engine does not shut down at high idle speed Then either A Use the results of shutdown speed versus adjuster setting as a calibration check to make a final adjustment to give the required setting typically 10 to 15 over high idle or B If a very precise setting is not required turn the adjuster a further one turn clockwise to take the shutdown above h...

Page 105: ...OW 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 illustration by visual identification and make note of part number and description HOW TO ORDER The satisfactory ordering of parts by a purchaser is greatly dependent upon the proper use of all available informa...

Page 106: ...lusive 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 price of the part upon which such liability is based The Company shall in no event be liable to the Purchaser any successors in interest or any beneficiary of this order for any consequential incidental indirect...

Page 107: ...r 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...

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