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Operating & Maintenance Manual

Trouble Shooting

52

 

Trouble Shooting

Introduction

Trouble shooting for a portable air 
compressor is an organized study of a 
particular problem or series of problems and 
a planned method of procedure for 
investigation and correction. The trouble 
shooting chart that follows includes some of 
the problems that an operator may encounter 
during the operation of a portable 
compressor.

The chart does not attempt to list all of the 
troubles that may occur, nor does it attempt 
to give all of the answers for correction of the 
problems. The chart does give those 
problems that are most apt to occur. To use 
the trouble shooting chart:

A. Find the “complaint” depicted as a bold

heading.

B. Follow down that column 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 ask 
yourself these questions:

1. What were the warning signals that

preceded the trouble?

2. Has a similar trouble occurred before? 

3. What previous maintenance work has

been done?

4. If the compressor will still operate, is it

safe to continue operating it to make
further checks?

B. Do The Simplest Things First

Most troubles are simple and easily 
corrected. For example, most complaints are 
“low capacity” which may be caused by too 
low an engine speed or “compressor over- 
heats” which may be caused by low oil level.

Always check the easiest and most obvious 
things first; following this simple rule will save 
time and trouble.

NOTE: For trouble shooting electrical
problems, refer to the Wiring Diagram
Schematic found in Parts List Section.

C. Double Check Before Disassembly

The source of most compressor troubles can 
be traced not to one component alone, but to 
the relationship of one component with 
another. Too often, a compressor can be 
partially disassembled in search of the cause 
of a certain trouble and all evidence is 
destroyed during disassembly. Check again 
to be sure an easy solution to the problem 
has not been overlooked.

D. Find And Correct Basic Cause

After a mechanical failure has been 
corrected, be sure to locate and correct the 
cause of the trouble so the same failure will 
not be repeated. A complaint of “premature 
breakdown” may be corrected by repairing 
any improper wiring connections, but 
something caused the defective wiring. The 
cause may be excessive vibration.

Содержание P185WJD

Страница 1: ...sanportablepower com Book 22610380 4 09 Rev A This manual contains important safety information Do not destroy this manual This manual must be available to the personnel who operate and maintain this...

Страница 2: ...2...

Страница 3: ...Safety Precautions 1 10 NOISE EMISSION 2 19 Noise Emission 2 20 This section pertains only to machines distributed within the United States 2 20 Noise Emission Control Maintenance Log 2 21 Noise Emiss...

Страница 4: ...49 Battery 6 49 Fasteners 6 49 Radiator 6 50 Hoses 6 50 Compressor Oil Cooler 6 51 Compressor Oil 6 51 Receiver Separator Systems 6 51 Scavenge Line 6 52 Exterior Finish Care 6 52 MAINTENANCE SCHEDUL...

Страница 5: ...Book 22610380 4 09 Rev A 3 Foreword...

Страница 6: ...unique specification for USA Canada is adopted and tailored to the territory All components accessories pipes and connectors added to the compressed air system should be of good quality procured from...

Страница 7: ...the original English version TABLE 1 Use of the machine to produce compressed air for a direct human consumption b indirect human consumption without suitable filtration and purity checks Use of the m...

Страница 8: ...6 Book 22610380 4 09 Rev A...

Страница 9: ...Book 22610380 4 09 Rev A 7 Drawbar Notice...

Страница 10: ...1 Remove hardware box from compressor toolbox 2 Open box and remove the bag containing hardware safety chains and assembly instructions 3 Using the jack raise the front of the unit so that the legs a...

Страница 11: ...Book 22610380 4 09 Rev A 9 Safety...

Страница 12: ...f at least the machine safety valve rating If more than one compressor is connected to one common downstream plant effective check valves and isolation valves must be fitted and controlled by work pro...

Страница 13: ...Do not operate without guard in place Use care to avoid contacting hot surfaces engine exhaust manifold and piping air receiver and air discharge piping etc Ether is an extremely volatile highly flamm...

Страница 14: ...Operating Maintenance Manual Safety 12 Book 22610380 4 09 Rev A...

Страница 15: ...Safety Operating Maintenance Manual Book 22610380 4 09 Rev A 13...

Страница 16: ...Operating Maintenance Manual Safety 14 Book 22610380 4 09 Rev A...

Страница 17: ...m your supervisor DANGER DANGER Red Background indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING Orange Background indicates a pot...

Страница 18: ...Operating Maintenance Manual Safety 16 Book 22610380 4 09 Rev A maintenance information...

Страница 19: ...heading DANGER WARNING or CAUTION Decal part numbers are on the bottom of each decal and are also listed in the compressor s parts manual Submit orders for Safety Decals to the Portable Power Parts S...

Страница 20: ...Operating Maintenance Manual Safety 18 Book 22610380 4 09 Rev A...

Страница 21: ...Book 22610380 4 09 Rev A 19 Section 3 Noise Emission...

Страница 22: ...ystem or parts thereof b the air intake system or parts thereof c enclosure or parts thereof 4 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 5 Operation o...

Страница 23: ...r part component or system of the air compressor Defects in the design assembly or in any part component or system of the compressor which at the time of sale to the first retail purchaser caused nois...

Страница 24: ...checked and adjusted at this time to insure continuous seating between gasket or acoustic material and the mating frame F Air Intake and Engine Exhaust Engine and compressor air intake and engine exh...

Страница 25: ...ing Maintenance Manual Book 22610380 4 09 Rev A 23 Maintenance Record For Noise Emission Control And Extended Warranty Item No Description Of Work Hourmeter Reading Maint inspect Date Location City st...

Страница 26: ...Operating Maintenance Manual Noise Emission 24 Book 22610380 4 09 Rev A...

Страница 27: ...Book 22610380 4 09 Rev A 25 Section 4 General Data...

Страница 28: ...APACITIES Compressor Lubricant 12 quarts 11 4 litres Engine Crankcase Lubricant 10 8 quarts 10 2 litres Fuel Tank 27 U S gal 103 litres UNITS MEASUREMENTS WEIGHTS Overall Length 11 5 3 5 meters Overal...

Страница 29: ...Compressor Oil Separator Element 54625942 Air Cleaner Element Primary Compressor 35393685 Optional Secondary Compressor 35393651 Air Cleaner Element Engine 35393685 Optional Secondary Engine 35393651...

Страница 30: ...Operating Maintenance Manual General Data 28 Book 22610380 4 09 Rev A...

Страница 31: ...29 OPERATION...

Страница 32: ...t lights running stop and turn signals WARNING Always raise or remove jack for maximum ground clearance before towing SETTING UP ALL UNITS Position as level as possible The design of these units permi...

Страница 33: ...e of jack Disconnect safety chains Crank jack to raise eye or coupler from hitch Tow vehicle can be moved UTILITY PACKAGE SET UP no running gear This unit must be located on vehicle bed to allow acces...

Страница 34: ...n receiver tank psi kPa Standard 11 Fuel Level Gauge Indicates amount of fuel in tank 12 Power Switch Rotate ON to activate system prior to starting Rotate OFF to stop engine Standard 13 Engine Speed...

Страница 35: ...he engine Check the compressor lubricating fluid level between bottom and midway of the sight glass on the separator tank WARNING This machine produces loud noise with doors open Extended exposure to...

Страница 36: ...Exercise extreme caution when using a booster battery to start To jump start Connect the ends of one booster cable to the positive terminals of each battery Then connect one end of the other cable to...

Страница 37: ...air downstream of the valve may be trapped A vent hole in the service valve will slowly bleed air from the hose Do not disconnect hoses until all pressure has been vented NOTICE Do NOT wire around or...

Страница 38: ...air actuating cylinder A and then turn cylinder rod D until throttle arm G is forced against the governor stop After Starting Unit 4 If equipped push the SERVICE AIR button on the control panel making...

Страница 39: ...OPERATION Operating Maintenance Manual 37...

Страница 40: ...39 Section 6 MAINTENANCE...

Страница 41: ...ve maintenance is the easiest and the least expensive type of maintenance Maintaining your unit and keeping it clean at all times will facilitate servicing Scheduled Maintenance The maintenance schedu...

Страница 42: ...agnostic lamps prior to start up During operation observe the gauges and any lamps for proper functioning Refer to Operating Controls for the normal readings Fuel Tank CLEAN fuel in the fuel tanks is...

Страница 43: ...Pulling on the tubing will cause the inner sleeve to withdraw and compress thus tightening the connection The tubing can be withdrawn only while holding the sleeve against the fitting The tubing can b...

Страница 44: ...and dirt from the exterior surfaces of the oil cooler core so that the entire cooling area can transmit the heat of the lubricating and cooling oil to air stream In the event foreign deposits such as...

Страница 45: ...s section 2 Thoroughly clean scavenge line any orifice and check valve 3 Assure minimum pressure valve orifice is operational 4 Run unit at rated operating pressure for 30 to 40 minutes to permit elem...

Страница 46: ...d use about 2 5 pounds of air pressure This will allow the primer to splatter causing the textured look NOTE You must be careful not to put too much primer on at one time this will effect the amount o...

Страница 47: ...PreCleaner 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 Test C Air Cleaner System...

Страница 48: ...47 Section 7 LUBRICATION...

Страница 49: ...warranty section for details or contact your IR representative Design Operating Pressure Ambient Temperature Specification 100 psi to 300 psi 100F to 1250F 230 C to 520 C Preferred IR Pro Tec Alternat...

Страница 50: ...LUBRICATION Operating Maintenance Manual 49...

Страница 51: ...51 Trouble Shooting...

Страница 52: ...e 4 If the compressor will still operate is it safe to continue operating it to make further checks B Do The Simplest Things First Most troubles are simple and easily corrected For example most compla...

Страница 53: ...nctioning Relay Replace relay Blown Fuse Replace fuse Check for Short 10 Volts at Shutdown Solenoid Check battery and alternator Make repairs Engine Malfunctioning See Trouble Shooting in Engine Secti...

Страница 54: ...Operating Conditions Move unit to cleaner environment Out of Level 15 degrees Relocate or reposition unit Ambient Temp 125 F 52 C Above spec limit Loose Wire Connection Repair or replace Broken Engine...

Страница 55: ...lace switch Defective Sep Temp Switch Replace switch Defective Engine Temp Switch Replace switch Defective Engine Oil Pressure Switch Pull wire off Replace switch Defective Shutdown Solenoid Carefully...

Страница 56: ...adjust Defective Separator Element Install new element Engine Malfunctioning See Trouble Shooting in Engine Section Airend Malfunctioning Consult Dealer Complaint Corrective Action Dirty Fuel Filters...

Страница 57: ...stall new Scavenge Tube Blocked Remove scavenge tube Clean and Replace Sep Tank Blow Down Too Quickly Allow unit to blow down automatically Defective Minimum Pressure Valve Remove valve Repair valve a...

Страница 58: ...Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual Malfunctioning Pressure Regulator Replace regulator Leak In Regulator Piping Repair leak s Malfunctioning Inlet Unloader Inspe...

Страница 59: ...2009 Doosan Infracore International Inc Printed in the USA Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 www doosanportablepower com...

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