Doosan 7/73-10/53 Operation And Maintenance Manual Download Page 1

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This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.

46674184_en_C_09/18

7/73 - 10/53

OPERATION AND MAINTENANCE MANUAL
Original Instruction

SERIAL No : 543500 -> 543999

Summary of Contents for 7/73-10/53

Page 1: ...ns important safety information and must be made available to personnel who operate and maintain this machine 46674184_en_C_09 18 7 73 10 53 OPERATION AND MAINTENANCE MANUAL Original Instruction SERIA...

Page 2: ......

Page 3: ...ility 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...

Page 4: ......

Page 5: ...mpressor oil filter element Running gear wheel bearings Engine storage long term Decomissioning Compressor mounting Speed and pressure regulation Torque values table Compressor lubrication 38 ELECTRIC...

Page 6: ...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 improveme...

Page 7: ...NING 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 GE...

Page 8: ...d air from this 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 an...

Page 9: ...en 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 protective...

Page 10: ...6 DECALS 7 73 10 53 Engine oil drain Compressor oil drain...

Page 11: ...ored Yellow background Indicates the presence of a hazard which WILL or can cause injury or property damage if ignored Blue background Indicates important set up operating or maintenance information D...

Page 12: ...ry or death When using air tools attach safety device OSHA Valve at source of air supply for each tool WARNING High pressure air Can cause serious injury or death Relieve pressure before removing fill...

Page 13: ...injury Clamp propstand securely WARNING Excessive towing speed Can cause serious injury or death Do NOT exceed 65 mph 105 km hr For Non Highway Towable Machines WARNINGExcessive Towing Speed CAN caus...

Page 14: ...an 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...

Page 15: ...oved with due care and attention Do not remove the pressure cap from a HOT radiator Allow radiator to cool down before removing pressure cap Transport When loading or transporting machines ensure that...

Page 16: ...whilst still allowing enough slackness for the trailer to articulate without the handbrake being applied Where brakes and safety chains are fitted a Loop the chains onto the towing vehicle using the...

Page 17: ...GENERAL INFORMATION 13 7 73 10 53 7 73 10 53 FIXED HEIGHT RUNNING GEAR Braked version 7 73 10 53 VARIABLE HEIGHT RUNNING GEAR Braked version...

Page 18: ...78 125 265 515 1019 2300 2434 191 1238 1429 36 0 659 3 127 0 195 5 127 0 551 2 64 0 406 5 127 0 406 5 7 73 10 53 PERMANENT SKID MOUNTED 1 10mm 2 40mm T4898_00 11 15 1200 70 2X 150 223 0 378 125 265 51...

Page 19: ...INFORMATION 15 7 73 10 53 1200 70 2X 150 223 0 414 125 265 515 1019 2300 2434 191 1274 1464 36 0 659 3 127 0 195 5 127 0 551 2 64 0 406 5 127 0 406 5 1 10mm 2 40mm T4899_00 11 15 7 73 10 53 TRUCK SKID...

Page 20: ...ure could cause damage to the airend In the event that PRO TEC is not available and or the end user needs to use an approved single grade engine oil the complete system including separator receiver co...

Page 21: ...rt 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...

Page 22: ...he service valve s to ensure that all pressure is relieved from the system Close the service valve s 8 Check the radiator coolant level with the unit level Check the air restriction indicator s Refer...

Page 23: ...e consulted about suitability of whipchecks mounts mounting points shackles and fittings as well as strength rating of materials Whipchecks must be used at the hose origination termination and each ho...

Page 24: ...ure gauge E Hourmeter F Diagnostic lamp red G Diagnostic lamp yellow H Warning lamp low engine oil pressure I Warning lamp high airend oil temperature J Warning lamp dirty IQ filters IQ filters option...

Page 25: ...matic blowdown valve fails to operate then pressure must be relieved from the system by means of the service valve s EMERGENCY STOPPING In the event that the unit has to be stopped in an emergency TUR...

Page 26: ...duration of 2 seconds Example Diagnostic lamp diagrams Fault Code 244 Fault Code 112 Fault lamps If the keyswitch is turned ON but the diagnostic switch remains OFF the indicator lamps will illuminat...

Page 27: ...Level C Coolant Level C Gauges Lamps C Air Cleaner Service Indicators C Fuel Tank C Fuel Water Separator D Fluid Leaks C Radiator Filler Cap C Crankcase Breather Tube C Air Cleaner Dust Ejector Valve...

Page 28: ...als for your application Daily Weekly Monthly 6 months or 500 hrs 1 year or 1000 hrs 2000 hrs Wheels Bearings Seals etc C Fan Hub C Cooling Fan Belt Tensioner C Shutdown Switch Settings T Scavenger Or...

Page 29: ...resent are known e g pressurised components electrically live components removed panels covers and guards extreme temperatures inflow and outflow of air intermittently moving parts safety valve discha...

Page 30: ...or 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 a...

Page 31: ...sioning 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...

Page 32: ...Tighten the canister Torque value 28 Nm 248 in lb If required connect the wiring harness to the water in fuel sensor Connect the batteries See equipment manufacturer service information Prime CAUTION...

Page 33: ...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 t...

Page 34: ...isation assembly 8 this should be at right angles to the pulling direction Check the play in the brake linkage 7 If necessary adjust the brake linkage 7 again without play and without pre tensioning T...

Page 35: ...ng 9 for slight pre tensioning LUBRICATION The engine is initially supplied with engine oil sufficient for a nominal period of operation for more information consult the Engine section of this manual...

Page 36: ...er 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...

Page 37: ...gs the valve guides the crossheads and the push rods with preservative oil Install the rocker lever covers intake and exhaust manifolds Brush or spray the preservative oil on all the exposed metal sur...

Page 38: ...to be permanently decommissioned or dismantled it is important to ensure that all hazard risks are either eliminated or notified to the recipient of the machine In particular Do not destroy batteries...

Page 39: ...ce 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 the Low...

Page 40: ...8 21 24 28 Airend to bracket 153 156 207 212 Airend bracket to frame 18 21 24 28 Fan guards 18 21 24 28 Part ft lbf N m Discharge hose to Airend Separator 24 JIC 158 167 214 226 Fan clutch to adapter...

Page 41: ...ge 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 PRO...

Page 42: ...38 ELECTRICAL SYSTEM 7 73 10 53 elec...

Page 43: ...ve Hi Lo Pressure Solenoid PS2 IQ Filter Restriction PT2 Sensor Regulation System Pressure 0 30 PSI RT5 Sensor Discharge Oil Temperature S1 Keyswitch S3 Button Warm Up S4 Switch Hi Lo TS1 Switch Airen...

Page 44: ...40 ELECTRICAL SYSTEM 7 73 10 53...

Page 45: ...olant Level J5A Connector Engine ECM Service K1 Relay Engine Starter K2 Relay Engine Intake Air Heater K7 Relay Service Mode P18 Connector IQ Heaters Option RT4 Sensor Temperature CAC S8 Switch Diag S...

Page 46: ...42 ELECTRICAL SYSTEM 7 73 10 53 KEY B2 Fan Electric B3 Fan Electric CS Cold Start Option C33 Connector TBAP Engine Harness C34 Sensor TBAP K3 Relay Electric Fans...

Page 47: ...S 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 Plu...

Page 48: ...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 Tail light r...

Page 49: ...10 53 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 when fitted 11 Separato...

Page 50: ...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 o...

Page 51: ...e in the system is too low Check the minimum pressure valve or sonic orifice Safety valve operates Operating pressure too high Check the setting and operation of the regulator valve piping Incorrect s...

Page 52: ...perature Data Valid But Above Normal Operating Range Moderately Severe Level 147 91 1 Stop Solid Accelerator Pedal or Lever Position 1 Sensor Circuit Frequency Data valid but below normal operational...

Page 53: ...ove normal or shorted to high source 294 441 4 Warning Solid Auxiliary Temperature Sensor Input 1 Circuit Voltage below normal or shorted to low source 296 1388 14 Stop Solid Auxiliary Pressure Sensor...

Page 54: ...Position Data erratic intermittent or incorrect 691 1172 3 Warning Solid Turbocharger 1 Compressor Intake Temperature Circuit Voltage above normal or shorted to high source 692 1172 4 Warning Solid Tu...

Page 55: ...sts 2321 190 2 None Engine Crankshaft Speed Position Data erratic intermittent or incorrect 2322 723 2 None Engine Camshaft Speed Position Sensor Data erratic intermittent or incorrect 2351 2791 4 War...

Page 56: ...eceived Network Data In Error 3526 84 9 Warning Solid Wheel Based Vehicle Speed Abnormal update rate 3527 558 19 Stop Solid Accelerator Pedal or Lever Idle Validation Switch Received Network Data In E...

Page 57: ...This is to prevent cooler damage at freezing temperatures These drains are plugged through the compressor frame and will expel condensation to atmosphere Should site contamination by this condensate b...

Page 58: ...54 OPTIONS 7 73 10 53 WATER SEPARATOR MAINTENANCE FIGURE 4 FIGURE 5 FIGURE 1 FIGURE 2 FIGURE 3...

Page 59: ...power 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...

Page 60: ...e Bunded base must be drained daily DRAINING OF CONTAMINATED FLUIDS Contaminated fluid must be removed by authorized personnel only Captured fluids can be drained from the bund by removing the plug or...

Page 61: ...the same as on the standard unit Identify the correct port to be drained Remove the plug connect the enclosed hose with coupling to the valve then open valve and drain all volume of fluid into an appr...

Page 62: ...the shutdown above high idle speed by a suitable margin When using this setting procedure it may be found that the engine occasionally shuts down during the normal operation If so turn the adjuster c...

Page 63: ...ubricator oil level and replenish as necessary MAINTENANCE Check the lubricator oil level and replenish as necessary FAULT FINDING OPTION LUBRICATOR WARNING Ensure that the lubricator filler cap is re...

Page 64: ...nificant 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 shaking chec...

Page 65: ...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 illustratio...

Page 66: ...igence 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 successor...

Page 67: ......

Page 68: ...Doosan Bobcat EMEA s r o U Kodetky 1810 263 12 Dob Czech Republic www doosanportablepower eu...

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