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Troubleshooting

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Страница 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...

Страница 2: ...2...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ...6...

Страница 7: ...7 Foreword...

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

Страница 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...

Страница 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...

Страница 11: ...11 Safety...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 19: ...Safety Operating Maintenance Manual 19...

Страница 20: ...Operating Maintenance Manual Safety 20...

Страница 21: ...Safety Operating Maintenance Manual 21...

Страница 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...

Страница 23: ...Safety Operating Maintenance Manual 23...

Страница 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...

Страница 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...

Страница 26: ...Operating Maintenance Manual Safety 26...

Страница 27: ...27 Noise Emission...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 33: ...33 General Data...

Страница 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...

Страница 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...

Страница 36: ...36...

Страница 37: ...37 Operating Instructions...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 52: ...52...

Страница 53: ...53 Maintenance...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 66: ...66...

Страница 67: ...67 Lubrication...

Страница 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...

Страница 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...

Страница 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...

Страница 71: ...71 Troubleshooting...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 82: ...82...

Страница 83: ...83 Electrical...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 88: ...88...

Страница 89: ...89 Electrical Schematics...

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

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

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

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

Страница 94: ...94...

Страница 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...

Страница 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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