Doosan 7/26E Operation And Maintenance Manual Download Page 62

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ENGINE INSTRUCTION MANUAL

7/26E, 7/31E, 7/41

3TNV82A, 3TNV88, & 4TNV88
ENGINES

CONTENTS

FOREWORD

EXTERNAL VIEW :
3TNV82A, 3TNV88, & 4TNV88

GENERAL INFORMATION
3TNV82A, 3TNV88, & 4TNV88

Main data and specifications

Engine identification

After sales support

EMISSION CONTROL LABEL

FUEL, LUBRICANT, AND COOLANT

Fuel

Lubricant

Coolant

OPERATION

Check before operation

Check and operation after start- up

Operation and care of a new engine

MAINTENANCE SCHEDULE

PERIODICAL INSPECTION AND
MAINTENANCE

Lubricating system

Cooling system

Fuel system

Air intake system

Routine maintenance

TROUBLESHOOTING

Summary of Contents for 7/26E

Page 1: ...must be made available to personnel who operate and maintain this machine 46671281_en_B_06 18 7 26E 7 31E 7 41 OPERATION AND MAINTENANCE MANUAL Original Instruction 7 26E SERIAL No 109600 109999 7 31E...

Page 2: ...Directive 13 2000 14 EC The Noise Emission Directive 14 2014 68 EU The Pressure Equipment Directive 15 2014 29 EU The Simple Pressure Vessels Directive 16 97 68 EC The emission of engines for no road...

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Page 5: ...Polymer Canopy General information Generator Safety General Information Operating Instructions Maintenance Fault Finding Cold Start Description Safety General information Operating instructions Spark...

Page 6: ...ts without notice and without incurring any obligation to make such changes or add such improvements to products sold previously The intended uses of this machine are outlined below and examples of un...

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...

Page 8: ...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 or othe...

Page 9: ...nual before operation or maintenance of this machine is undertaken When parking use prop stand handbrake and wheel chocks Compressor oil filling Diesel fuel No open flame Parking brake Rough Service D...

Page 10: ...gerous 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 operat...

Page 11: ...n accordance with recognised electrical codes and local health and safety codes The generator set should be operated by those who have been trained in its use and delegated to do so and who have read...

Page 12: ...vel When adjusting variable height running gear Ensure front towing eye section is set level When raising towing eye set rear joint first then front joint When lowering towing eye set front joint firs...

Page 13: ...GENERAL INFORMATION 9 7 26E 7 31E 7 41 7 26E 7 31E FIXED HEIGHT RUNNING GEAR 7 26E 7 31E VARIABLE HEIGHT RUNNING GEAR...

Page 14: ...10 GENERAL INFORMATION 7 26E 7 31E 7 41 7 26E 7 31E FIXED HEIGHT RUNNING GEAR 7 26E 7 31E VARIABLE HEIGHT RUNNING GEAR...

Page 15: ...GENERAL INFORMATION 11 7 26E 7 31E 7 41 7 41 FIXED HEIGHT RUNNING GEAR 7 41 VARIABLE HEIGHT RUNNING GEAR...

Page 16: ...12 GENERAL INFORMATION 7 26E 7 31E 7 41 7 41 FIXED HEIGHT RUNNING GEAR 7 41 VARIABLE HEIGHT RUNNING GEAR...

Page 17: ...GENERAL INFORMATION 13 7 26E 7 31E 7 41 7 26E 7 31E SHIPPING SKID 7 41 PERMANENT SKID...

Page 18: ...kg 2135 MIN 2316 MAX 3155 MIN 3370 MAX 405 MIN 820 MAX 1808 365 970 1335 1369 1220 1138 1138 1390 1205 20 7 41 variable height below 900 kg 2260 MIN 2440 MAX 3332 MIN 3587 MAX 405 MIN 840 MAX 1808 365...

Page 19: ...2004 FIXED HEIGHT RUNNING GEAR Unbraked version 7 26E 7 31E Shipping weight 735 kg 1621 lbs Maximum weight 750 kg 1653 lbs Maximum horizontal towing force 7 12 kN 1600 lbs Maximum vertical coupling lo...

Page 20: ...l towing force 12 1 kN 2720 lbs Maximum vertical coupling load nose weight 75 kgf 165 lbs WHEELS AND TYRES Number of wheels 2 x 41 2 J x 13 7 26E 7 31E 7 41 Tyre size 155 R13 7 26E 7 31E 7 41 Tyre pre...

Page 21: ...sport 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 work...

Page 22: ...f water ensuring that any released fuel is safely contained 6 Open the service valve s to ensure that all pressure is relieved from the system Leave the service valve s open 8 Check the radiator coola...

Page 23: ...charge light is extinguished 6 Close service valve as soon as engine runs freely 7 Do not allow machine to run for long periods with service valve open 8 Allow the engine to reach operating temperatur...

Page 24: ...RING DURING OPERATION Should any of the safety shut down conditions occur the unit will stop These are Low engine oil pressure High air discharge temperature High engine water temperature DECOMMISSION...

Page 25: ...ts C Generator Drive Belt 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 Compressor Oil Co...

Page 26: ...Oil Separator Element R Feed Pump Strainer Cleaning C Coolant Replacement R Valve Clearance Check C Lights running brake turn CBT Pintle Eye Bolts CBT Brakes C C Brake linkage C Emergency stop T Faste...

Page 27: ...icator Fill C 2 Yrs 4 Yrs 6 Yrs Safety valve C Hoses R Separator tank 2 interior C Disregard if not appropriate for this particular machine 1 or 3000 miles 5000km whichever is the sooner 2 or as defin...

Page 28: ...sabled or removed all hazards present are known e g pressurised components electrically live components removed panels covers and guards extreme temperatures inflow and outflow of air intermittently m...

Page 29: ...lace the compressor oil refer to LUBRICATION later in this section COMPRESSOR OIL COOLER AND ENGINE RADIATOR When grease oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator...

Page 30: ...the intake lines to the air filter and all flexible hoses used for air lines oil lines and fuel lines Periodically inspect all pipework for cracks leaks etc and replace immediately if damaged ELECTRIC...

Page 31: ...play Remove the M10 safety screw from the handbrake pivot All Models Engage the handbrake lever 1 and check that the position of the equaliser plate 10 is at right angles to the pulling direction If...

Page 32: ...nths The type of grease used should conform to specification MIL G 10924 LUBRICATION The engine is initially supplied with engine oil sufficient for a nominal period of operation for more information...

Page 33: ...d the service valve is fully open Refer to the GENERAL INFORMATION section of this manual Adjust the service valve on the outside of the machine to maintain 7 bar without the throttle arm moving from...

Page 34: ...nd to chassis 54 58 73 78 Euro Loc adaptor to separator tank 58 67 78 91 Exhaust flange to manifold 17 21 23 28 Fan guard 9 11 12 15 Fan to hub 12 15 16 20 Lifting bail bracket to engine 29 35 39 47 O...

Page 35: ...amage Please read the engine manual for more details Design operating pressure Ambient temperature Compressor oil specification 7 bar to 14 bar 100 psi to 200 psi 23 C to 52 C 10 F to 125 F Preferred...

Page 36: ...W18 G18 G18 U18 U18 U18 N18 Y18 U16 U18 N16 N16 N16 N16 R2 R1 FP PS1 TS3 TS1 H P1 SV1 AH M B 12V U18 Y18 G18 F1 15A A B F2 5A A B 1 2 3 4 5 6 9 10 11 12 13 14 15 7 8 16 17 18 19 20 21 22 23 B P 1 2 1...

Page 37: ...gine LED3 Low oil pressure engine LED4 Low fuel LED5 No charge M Starter motor P1 Connector minicontroller P2 Connector minicontroller Option PS1 Engine oil pressure switch R2 Engine heater relay 7 26...

Page 38: ...34 ELECTRICAL SYSTEM 7 26E 7 31E 7 41 7 41...

Page 39: ...nload Option PS1 Engine oil pressure switch R1 Relay control shut down R3 Relay crank R6 Relay air heater R7 Relay fuel solenoid SO Key switch SV1 Solenoid fuel SV2 Solenoid load unload Option TS1 Hig...

Page 40: ...PINS KEY IL LH Indicator light left hand IL RH Indicator light right hand FL Fog light SL LH Stop light left hand SL RH Stop light right hand TL LH Tail light left hand TL RH Tail light right hand PL...

Page 41: ...CANOPY OPTION KEY IL LH Indicator light left hand IL RH Indicator light right hand FL Fog light RL Reverse light SL LH Stop light left hand SL RH Stop light right hand TL LH Tail light left hand TL RH...

Page 42: ...ht polymer canopy option SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM KEY IL LH Indicator light left hand IL RH Indicator light right hand FL Fog light RL Reverse light SL LH Stop light left hand...

Page 43: ...SYSTEM 39 7 26E 7 31E 7 41 KEY 1 Air discharge 2 Sonic orifice restricts flow 3 Pressure gauge 4 Separator tank 5 Safety valve 6 Compressor 7 Engine 8 Oil cooler 9 Oil filter 10 Thermostatic valve Wh...

Page 44: ...essor 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 relay in the...

Page 45: ...correct setting of the regulator Adjust the regulator Faulty regulator Replace the regulator Inlet valve set incorrectly Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in the MAINTENANCE section of...

Page 46: ...NING Ensure that the lubricator filler cap is re tightened correctly after replenishing with oil WARNING Do not replenish the lubricator oil or service the lu bricator without first making sure that t...

Page 47: ...he machine A drain for the rear space of the unit is located at the rear left side behind the left hand fender DRAINING OF CONTAMINATED FLUIDS Contaminated fluid must be removed by authorized personne...

Page 48: ...s or other mechanical damage of the canopy surface Temperatures above 80C may cause heat damage of the canopy Do not expose the units with polymer canopy option to temperatures above 80C The inner sur...

Page 49: ...s GENERAL INFORMATION 8 5 kVA 7 31E 7 41 Rated output 6 8 kW 0 8 Power factor PF lagging Rated voltage 110V 1ph or 230V 1ph or 230V 3ph or 400V 3ph 230V 1ph 3000 revs min 1 Voltage regulation 6 Maximu...

Page 50: ...TING GENERATOR If the generator should become exposed or saturated with moisture water deposits it must be safely dried off before attempting to make any part or conductor electrically live This shoul...

Page 51: ...PTIONS 47 7 26E 7 31E 7 41 Key to compressor generator mode switch A Selects operation of compressor only B Selects operation of compressor and generator together C Selects operation of generator only...

Page 52: ...ocumentation relating to instructions for its use MAINTENANCE General Ensure all electrical equipment is properly maintained and controlled Ensure all earth connections are secure and regularly mainta...

Page 53: ...t the company if the engine is found to be running slow Refer to section 4 General Information Drive belt is not tensioned correctly Re tension the drive belt Drive pulley is loose on the drive shaft...

Page 54: ...50 OPTIONS 7 26E 7 31E 7 41 A C Electrical Power Schematic Diagram 7 26E 110V 6kVA...

Page 55: ...OPTIONS 51 7 26E 7 31E 7 41 A C Electrical Power Schematic Diagram 7 31E 7 41 110V 8 5kVA...

Page 56: ...52 OPTIONS 7 26E 7 31E 7 41 A C Electrical Power Schematic Diagram 7 26E 7 31E 7 41 230V 6kVA...

Page 57: ...OPTIONS 53 7 26E 7 31E 7 41 A C Electrical Power Schematic Diagram 7 26E 7 31E 7 41 400 230V...

Page 58: ...erature otherwise the electronics may suffer permanent damage The heater must be operated at the nominal voltage specified on the rating plate be disabled by removing the fuse if smoke develops if unu...

Page 59: ...ine start position Hold in this position for no longer than 20 seconds If the engine does not fire wait 30 seconds before the next start attempt Release to position 2 when the engine starts Close serv...

Page 60: ...or significant areas of damage i e dents of more than a few millimetres in depth Three Monthly Remove spark arrestor Tap with a soft mallet to loosen any internal deposits and shake out Also by shakin...

Page 61: ...al operation If so turn the adjuster clockwise by a further one half turn 7 Ensure the adjuster locknut is fully tightened MAINTENANCE Three Monthly 1 Disconnect the intake pipework and release the va...

Page 62: ...cations Engine identification After sales support 64 EMISSION CONTROL LABEL 65 FUEL LUBRICANT AND COOLANT Fuel Lubricant Coolant 67 OPERATION Check before operation Check and operation after start up...

Page 63: ...peration Should your engine require servicing please contact your nearest branch or distributor All information illustrations and specifications contained in this Manual are based on the latest produc...

Page 64: ...il 8 Fuel injection pump 9 Engine oil cooler 4TNV88 10 Engine oil filter 11 Dipstick engine oil 12 Governor lever 13 Intake manifold 14 Fuel filter 15 Fuel oil inlet 16 Fuel filter mounting with fuel...

Page 65: ...and accordingly they are warranted by Genuine Doosan parts are supplied by your branch or distributor Please ensure that only genuine Doosan parts lubricants and fluids are used for service and or re...

Page 66: ...and accordingly they are warranted by Genuine Doosan parts are supplied by your branch or distributor Please ensure that only genuine Doosan parts lubricants and fluids are used for service and or re...

Page 67: ...and accordingly they are warranted by Genuine Doosan parts are supplied by your branch or distributor Please ensure that only genuine Doosan parts lubricants and fluids are used for service and or rep...

Page 68: ...d on the top of the rocker arm cover The following is the detail of a label required for engine emission control information along with location Label location A Emission control information label 4TN...

Page 69: ...tent should not exceed 35 by volume Less than 30 is preferred The PAH polycyclic aromatic hydrocarbons content should be below 10 by volume The metal content of Na Mg Si and Al should be equal to or l...

Page 70: ...NOTE Using a mixture of different brands or quality of oils will adversely af fect the original oil quality therefore never mix different brand or dif ferent type oils Do not use API CA CB grade and r...

Page 71: ...it causes belt slippage or slackness CAUTION When adding oil take care not to spill it If you spill oil on the engine or equipment wipe it properly to prevent the risk of fire and personal injury and...

Page 72: ...akage Exhaust smoke or gas leakage Checking coolant level The coolant level could drop because any mixed air is expelled in about 5 minutes after the engine started Stop the engine remove radiator cap...

Page 73: ...will lead to premature parts wear which may result in engine failure Ensure that the engine reaches normal operating temperature 75 to 85 C 167 to 185 F within ten minutes of starting 3 Hourmeter This...

Page 74: ...check and refill C Draining from fuel tank C Draining from oil water separator C Cleaning oil water separator C Fuel filter replacement R Engine oil Engine oil level C Engine oil replacement R 1st tim...

Page 75: ...olant level Check coolant level and add coolant if necessary 9 Coolant leakage check Replace any damaged or malfunctioning parts which could cause leakage 10 Radiator filler cap fitting condition The...

Page 76: ...with the mounting surface and tighten it further to 3 4 of a turn with the filter wrench Tightening torque 19 6 23 5N m 2 0 2 4kgf m 7 Fill with the new engine oil until it reaches the specified level...

Page 77: ...Always use genuine Doosan fan belts as they provide high driving ability and long operating durability Use of non Doosan fan belts could result in premature belt wear or belt elongation leading to eng...

Page 78: ...ill with battery fluid available in the market to the upper limit If operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode Battery...

Page 79: ...ction 2 of inspection at 50 hours IMPORTANT Be sure to use genuine Yanmar part super fine mesh filter Otherwise it results in engine damage uneven engine performance and shorter engine life 4 Changing...

Page 80: ...ing until it comes into contact with the mounting surface and tighten it further to 1 2 at a turn using a filter wrench Tightening torque 11 8 15 6N m 1 2 1 6kgf m 4 Bleed the fuel system Refer to sec...

Page 81: ...requires specialized knowledge and skill consult your dealer Checking and adjusting the EPA emission related parts The inspection and servicing require specialized knowledge and techniques Consult yo...

Page 82: ...ery discharged Bad cable connections Starter or starter switch failure Safety relay failure Starter turns but engine does not fire No fuel injection Engine stop solenoid malfunction No fuel in the fue...

Page 83: ...injection amount between cylinders Deteriorated governor spring Incorrect valve clearance adjustment Deteriorated valve spring Engine speed stuck at high idle Engine control restriction or seizure En...

Page 84: ...pression pressure Cylinder compression leakage Incorrect valve clearance adjustment Injector nozzle misalignment Cylinder bore wear Insufficient air intake volume Air cleaner clogged Restricted air fl...

Page 85: ...orrect fuel Excessive white smoke Water mixing in fuel Low compression pressure Injection timing incorrect Low coolant temperature Faulty turbocharger Battery over discharge Low electrolyte level Crac...

Page 86: ...n 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 illustra...

Page 87: ...egligence 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 succes...

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Page 90: ...Doosan Bobcat EMEA s r o U Kodetky 1810 263 12 Dob Czech Republic www doosanportablepower eu...

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