Doosan 12/150, Operation And Maintenance Mannual

Page 1: ... 12 150 OPERATION AND MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to personnel who operate and maintain this machine SERIAL No 705000 707000 12 150 ...

Page 2: ...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 3: ...rical system Piping instrumentation system 47 SERVICE TOOLS 50 FAULT FINDING 52 OPTIONS 54 ENGINE INSTRUCTION MANUAL 75 PARTS ORDERING ABBREVIATIONS SYMBOLS Contact the company for serial number Up to Serial No From Serial No Not illustrated Option AR As required HA High ambient machine F H R G Fixed height running gear V H R G Variable height running gear bg Bulgarian cs Czech da Danish de German...

Page 4: ...ids other than 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 s...

Page 5: ...in warranty is available for the following compressor types European built 7 20 7 26E 7 31E 7 41 7 51 7 71 12 56 P65 P90 7 120 9 1 10 14 85 10 105 14 1 15 10 125 7 170 12 150 USA built Model Serial Code P185WJD T4I D75 P185WYM T4I D76 C185WKUB T2 D80 P250WJD T3 D81 P260 HP220WYM T3 D82 C185SKUB T2 E04 C185WKUB T4I D95 P425 XP375 HP350 P600 HP450 VHP400 WIR John Deere engines only The original aire...

Page 6: ...aler Major components 3yrs 10 000hrs starts after base warranty expires Encompass extended warranty program available at Cummins dealer JOHN DEERE in compressors 24 2000 5 yrs 5000 hrs using OEM fluids and filters with 250 deductible in generators as of 1 1 01 24 2000 24 months 4 000 hrs available from the company with use of genuine Doosan parts and oils at prescribed service intervals Contact th...

Page 7: ...ousings gears and bearings and is automatically available when the following conditions are met 1 The original airend is returned assembled and unopened 2 Submissions of proof that Doosan fluid filters and separators have been used Refer to the Operation and Parts manual for the correct fluids filters and separator elements required 3 Submissions of proof that maintenance intervals have been follo...

Page 8: ...warranty fill out the Warranty Registration form 83242 11 99 supplied as part of the machine documentation keep a copy for your records and mail the original to Doosan Warranty Team Doosan BENELUX S A Drève Richelle 167 1410 Waterloo Belgium Fax 32 2 371 69 15 Email doosanwarranty dii doosan com Note Completion of this form validates the warranty ...

Page 9: ...Provider Details Company Name Service Provider Distributor Contact Name Branch Office Signature Company Address Machine Details Product Type Model Serial Number Engine Serial Number Engine Model Number Post Zip Code Airend Serial Number Country Alternator Serial Number Phone Number Date of start up Fax Number e mail ...

Page 10: ...WARNING Corrosion risk WARNING Air gas flow or Air discharge WARNING Pressurised vessel WARNING Hot and harmful exhaust gas WARNING Flammable liquid X XBAR 0 C 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 and maintenance manual WARNING For operating temperature below 0...

Page 11: ...ne 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 other parts of the pressure system Do not operate with the doors or enclosure open Do not use fork lift truck from this side XX km h Do not exceed the trailer speed limit No naked lights Do not open the...

Page 12: ...ng use prop stand handrake and wheel chocks Compressor oil filling Diesel fuel No open flame Parking brake Rough Service Designation Wet Location Operation Replace any cracked protective shield Oil drain Engine Oil Fuel level point Pressure control Malfunction Battery charging condition Low pressure High pressure Engine malfunction High compressor temperature Compressor malfunction ...

Page 13: ... 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 Doosan Portable Power EMEA Aftermarket Department The no charge order should contain only Safety Decals Help promote product safety Assure that decals are present on the machines Replace decals that are not readable ...

Page 14: ...R STARTING AIDS OR ENGINE DAMAGE WILL RESULT Never operate unit with guards covers or screens removed Keep hands 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 th...

Page 15: ...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 maximum permissible drawbar angle is between 0 and 5 from horizontal in order to maintain correct handling braking and lighting functions This can be achieved by co...

Page 16: ... panel access 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 G Track width J Fixed height drawbar ...

Page 17: ...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 G Track width J Variable height drawbar 438mm minimum 968mm maximum ...

Page 18: ...egative earth Power available at 2000 revs min 1 164 kW 220 HP Fuel tank capacity 310 litres 82 U S GAL Oil specification Refer engine section Coolant capacity 10 litres 2 6 U S GAL INFORMATION ON AIRBORNE NOISE W model The A weighted emission sound pressure level 80 dB A uncertainty 1 dB A The A weighted emission sound power level 99 dB A uncertainty 1 dB A The operating conditions of the machine...

Page 19: ...he hours of darkness ensure that the lights are functioning correctly where fitted Ensure that all transport 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...

Page 20: ...il with a minimum octane number of 45 and a sulphur content not greater than 0 5 CAUTION When refuelling S switch off the engine S do not smoke S extinguish all naked lights S do not allow the fuel to come into contact with hot surfaces S wear personal protective equipment 5 Drain the fuel filter water separator of water ensuring that any released fuel is safely contained 6 Open the service valve ...

Page 21: ...tank CONTROLS STANDARD 6 Power Switch Flip ON to activate systems prior to Starting Flip OFF to stop engine 7 Service Air Switch After warm up PUSH Provides full air pressure at the service outlet 8 Wait To Start Lamp 9 Engine Speed Gauge Indicates engine speed 10 Discharge Air Temp Gauge Indicates in _F and _C Normal operating range 185_F 85_C to 248_F 120_C 11 Engine Oil Pressure Gauge Indicates...

Page 22: ...e to low fuel level Lamp blinks at low fuel warning 5 Low Battery Voltage Alarm indicator lamp Indicates battery or charging system requires service 6 Low Radiator Coolant Level Alarm indicator lamp Indicates engine coolant needs service 7 Restricted Air Filter Alarm indicator lamp Indicates engine compressor air inlet filters need service 8 Restricted IQ Air Filters Fault indicator lamp Indicates...

Page 23: ... Malfunction High Intake Manifold Temperature 6 CPRSR Malfunction Water In Fuel CUMMINS 8 CPRSR Malfunction Engine Not Responding To Throttle command 10 CPRSR Malfunction Too Many Start Attempts During Autostart 11 CPRSR Malfunction 0 Engine Shut Itself Down reason unknown 29 CPRSR Malfunction 0 Low AE Oil Pressure 31 CPRSR Malfunction 20 Disch Temp RT2 Sensor Fault 32 CPRSR Malfunction 10 Sep Tan...

Page 24: ...tion 55 CPRSR Malfunction 3 Minimum Pressure Not Met 56 CPRSR Malfunction Serial Comm Problem 70 CPRSR Malfunction CAN Bus Problem 71 CPRSR Malfunction Communication With Autostart Module Lost 73 CPRSR Malfunction Dedicated Lights Low Fuel Level Fuel Level 3 Air Filter Restriction Soiled Filter Low Battery Voltage Battery Charging Condition Low Engine Oil Pressure Low Engine Oil Pressure Low Coola...

Page 25: ...w 197 Engine Coolant Level Low Warning 212 Engine Oil Temperature Sensor 1 Circuit Voltage Above Normal or Shorted High 213 Engine Oil Temperature Sensor 1 Circuit Voltage Below Normal or Shorted Low 214 Engine Oil Temperature High Critical 221 Barometric Pressure Sensor Circuit Voltage Above Normal or Shorted High 222 Barometric Pressure Sensor Circuit Voltage Below Normal or Shorted Low 227 Sens...

Page 26: ...33 Intake Manifold Pressure Sensor Circuit Data Incorrect 435 Engine Oil Pressure Sensor Circuit Data Incorrect 441 Battery Voltage Low Warning 442 Battery Voltage High Warning 449 Fuel Pressure High Warning 451 Injector Metering Rail Pressure Sensor Circuit Voltage Above Normal or Shorted High 452 Injector Metering Rail Pressure Sensor Circuit Voltage Below Normal or Shorted Low 488 Intake Manifo...

Page 27: ...ge Below Normal or Shorted Low 2117 Engine Coolant Pressure 2 Low Warning 2185 Sensor Supply Voltage 4 Circuit Voltage Above Normal or Shorted High 2186 Sensor Supply Voltage 4 Circuit Voltage Below Normal or Shorted Low 2215 Fuel Pump Delivery Pressure Low Warning 2216 Fuel Pump Delivery Pressure High Warning 2249 Injector Metering Rail Pressure Low Critical 2265 Fuel Priming Pump Control Signal ...

Page 28: ...witch inside the unit This switch selects between 7 bar 100 psi and the machine rated pressure cfm remains nominally constant Starting and stopping are unaffected by the selection and during normal running the selector switch may be safely operated Precaution must be taken to ensure that downstream equipment is rated to suit the available pressure The pressure gauge indicates which setting has bee...

Page 29: ...ng of the fuel tank is needed tank should be removed from compressor Captured fluids can be drained from the bund by uncoupling the flexible pipe secured at the rear side This pipe must be re secured after draining WARNING Major leakages or spillages must be drained before the machine is towed LONG TERM STORAGE RECOMMENDATIONS 6 months or more SPARE AIRENDS Long term storage of airends should incl...

Page 30: ...and Surface C Wheel Lug Nuts C Hoses Oil Air Intake etc C Automatic Shutdown System C Air Cleaner System C Compressor Oil Cooler Exterior C Engine Rad Oil Cooler Exterior C Fasteners Guards C Air Cleaner Elements R WI Disregard if not appropriate for this particular machine 1 or 3000 miles 5000km whichever is the sooner 2 or as defined by local or national legislation C Check adjust clean or repla...

Page 31: ... Replacement R Valve Clearance Check C Lights running brake turn CBT Pintle Eye Bolts CBT Brakes C C Brake linkage C Emergency stop T Fasteners C Running gear linkage G Safety valve C Running gear bolts 1 C Disregard if not appropriate for this particular machine 1 or 3000 miles 5000km whichever is the sooner 2 or as defined by local or national legislation C Check adjust clean or replace as neces...

Page 32: ...ssure is vented from the system and that the machine cannot be started accidentally If the automatic blowdown 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 adequately trained competent and have read the Maintenance Manuals Prior to attempting any maintenanc...

Page 33: ...s stopped and the system has been completely relieved of all air pressure Refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual Clean the exterior of the filter housing and remove the spin on element by turning it in a counter clockwise direction INSPECTION Examine the filter element CAUTION If there is any indication of the formation of varnishes shellacs or lacquers on ...

Page 34: ...g the rubber diaphragm Assemble the dust collector box parts ensuring that they are correctly positioned Before restarting the machine check that all clamps are tight VENTILATION Always check that the air inlets and outlets are clear of debris etc CAUTION Never remove and replace element s when the machine is running COOLING FAN DRIVE Periodically check that the fan mounting bolts in the fan hub h...

Page 35: ... THE OVERRUN BRAKING SYSTEM KNOTT RUNNING GEAR 1 PREPARATION Jack up the machine Disengage the handbrake lever 1 Fully extend the draw bar 2 on the overrun braking system 1 Handbrake lever 2 Draw bar and bellows 3 Handbrake lever pivot 4 Transmission lever 5 Brake cable 6 Breakaway Cable Requirements During the adjustment procedure always start with the wheel brakes Always rotate the wheel in the ...

Page 36: ...ot be pre tensioned Excessive operation of the handbrake lever which may have been caused by worn brake linings must not be corrected by re adjusting shortening the brake linkage 7 Re adjustment The handbrake lever 1 should be engaged forcefully several times to set the braking system Check the setting of the brake equalisation assembly 8 which should be at right angles to the pulling direction Ch...

Page 37: ...of the sediment will be in suspension and will therefore drain more readily CAUTION Some oil mixtures are incompatible and result in the formation of varnishes shellacs or lacquers which may be insoluble NOTE Always specify PRO TEC oil for use at all ambient temperatures above 23 C COMPRESSOR OIL FILTER ELEMENT Refer to the SERVICE MAINTENANCE CHART in this section for service intervals RUNNING GE...

Page 38: ...ne Refer 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 T...

Page 39: ...PICAL RECTANGULAR TORQUE PATTERN CAPSCREW OR NUT THREAD SIZE AND PITCH TYPICAL SQUARE TORQUE PATTERN 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 TYPICAL CIRCULAR TORQUE 3 4 10 361 266 509 376 TYPICAL CIRCULAR TORQUE PATTERN ...

Page 40: ...NG TYPICAL RECTANGULAR TORQUE PATTERN CAPSCREW OR NUT THREAD SIZE AND PITCH TYPICAL SQUARE TORQUE PATTERN 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 TYPICAL CIRCULAR TORQUE PATTERN M20 X 2 5 441 325 610 450 713 526 ...

Page 41: ...ompressor service 350 psi 10 F to 125 F 23 C to 52 C Preferred XHP 605 Alternate XHP 405 ISO Viscosity Grade 68 Group 3 or 5 with rust and oxidation inhibitors designed for air compressor service 65 F to 125 F 18 C to 52 C Preferred XHP 605 XHP1001 XHP605 PRO TEC 100 300 PSI RATED OPERATING PRESSURE 350 PSI XHP 1001 10 F 125 F 50 C 40 C 30 C 20 C 10 C 0 C 10 C 20 C 30 C 40 C 104 F 86 F 65 F 50 F 3...

Page 42: ...MACHINE SYSTEMS 40 12 150_23136591 C en ...

Page 43: ...itch Key Start 1 22127385 S2 Switch Start Run 1 22054076 S4 S5 Switch Air Filter Restriction 2 36847838 S7 Option Emergency Stop Operator 2 89303127 KEY DESCRIPTION QTY CCN SI Switch inputs SS Starter solenoid SW1 IQ filter restriction SW2 Alert low fuel SW3 Low fuel shutdown SW4 Switch Start Run SW5 Switch Air Filter Restriction SW7 Option Emergency Stop Operator SW8 Start switch TE Transducer ex...

Page 44: ...MACHINE SYSTEMS 42 12 150_23136591 C en WIRING DIAGRAM 23296643_B SHEET 2 ...

Page 45: ...tion Low Fuel Beacon PT1 Solenoid Valve Unloader 1 54496773 PT2 Transducer Regulation Pressure 1 36920825 RP1 Sender Engine Oil Pressure RT1 Sensor Temperature Seperator Tank 1 36898922 RT2 Sensor Temperature Airend Discharge 1 36898922 RT3 Sender Engine Oil Pressure 1 36870608 RT4 Sender Temperature Engine 1 35604180 S4 Switch Air Filter Restriction S5 Switch Air Filter Restriction S6 Emergency S...

Page 46: ...MACHINE SYSTEMS 44 12 150_23136591 C en WIRING DIAGRAM 23296643_B SHEET 3 ...

Page 47: ... HR2 Air Intake Heater 1 J11 Cummins Datalink Service Connector 1 K1 Relay Starter Solenoid 1 36853521 K3 Relay Air Intake Heater 1 36853521 P4 Cummins Engine Controller Connector 1 P5 Cummins Engine Controller Power Connector 1 P14 Accessory Connector 1 TR1 J1939 Can Buss Terminating Resistor 1 TR2 J1939 Can Buss Terminating Resistor 1 U2 Sensor Coolant Level 1 22769186 KEY DESCRIPTION SHEET 2 Co...

Page 48: ...e wire devices excitation signal and ground return connections Digital Inputs and Outputs The WEDGE controller scans digital inputs such as switch contacts These are either ON 24V DC or OFF 0V DC These digital inputs are connectd 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 to control sol...

Page 49: ...l Removal 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 Plu...

Page 50: ...tal Multimeter 54729660 Weather Pack Terminal Removal Tool 54699632 Deutsch Terminal Removal Tool Blue 54699640 Deutsch Terminal Removal Tool Red 54699624 Deutsch Terminal Removal Tool Yellow 22216667 Crimp Tool for Deutsch Pins Crimp 54729710 Electrical Contact Cleaner 54699616 Deutsch Terminal Removal Tool ...

Page 51: ...RVICE TOOLS 49 12 150_23136591 C en 22073886 Packard Crimp Tool 22073878 Thermistor Simulator 54749635 Connector Repair Kit 54699657 Deutsch Terminal Removal Tool 54749643 Packard Metri Pack Removal Tool ...

Page 52: ...nd 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 replace if necessary Engine Overheats Low water level Check the level and replenish if necessar...

Page 53: ...PRESSURE REGULATION ADJUST MENT in the MAINTENANCE section of this manual Incorrect 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 this manual Loose pipe hose connections Check all pipe hose connections Faulty safety valve Check the relieving pressure Re...

Page 54: ...e valve when the IQ System is enabled This will result in operation at excessive horsepower 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 could result in damage to downstream equipment Normal service intervals should not be exceeded CAUTION Blockage o...

Page 55: ...show outlet pressure When compared with control panel gauge pressure the difference in pressure is the pressure drop over the IQ filter elements The optional pressure drop sensor will indicate a need to change the filter elements with a warning light on the control panel FILTER REPLACEMENT Remove all wires and hoses connected to drains on bottom of each filter housing Inspect fittings and hoses fo...

Page 56: ...rt EMISSION CONTROL LABEL 59 FUEL LUBRICANT AND COOLANT Fuel Lubricant Coolant 61 OPERATION Check before operation Check and operation after start up Operation and care of a new engine 64 MAINTENANCE SCHEDULE 65 PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance 68 COLD WEATHER OPERATION 69 TROUBLESHOOTING ...

Page 57: ... trouble free and economical engine operation 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 product information available at the time of publication The company reserves the right to make changes in this Manual at any time without prior notice The pictures cont...

Page 58: ...Starter 10 Belt tensioner 11 Alternator 12 Coolant outlet 13 Coolant temperature sensor 14 Turbocharger air outlet 15 Coolant inlet 16 Lubricating oil cooler 17 Oil pan drain plug 18 Turbocharger exhaust outlet 19 Flywheel housing 20 Turbocharger compressor inlet 21 Turbocharger wastegate 22 Crankcase breather 23 Barometric pressure temperature sensor 24 Fuel rail pressure sensor 25 Fuel rail 26 H...

Page 59: ...0 015 0 030 Intake Adjusting mm in 0 254 0 010 Exhaust Adjusting mm in 0 508 0 020 Max Crank Case Pressure kPa 4in H2O 1 4 Vibration Damper Maximum Radial Runout 0 50 mm 0 020 in Thermostat Start To Open Temperature 82 C 180 F Thermostat Fully Open Temperature 95 C 203 F Oil Pressure At Rated Speed Full Load 15 psi 207 kPa 30 psi Oil Pressure At Low Idle Minimum 69 kPa 10 psi Engine dimensions Wei...

Page 60: ... the company branch or distributor for repair service or parts ordering CAUTION Conduct confirmation of engine serial number with the engine stopped To avoid being injured do not check it while the engine is still hot ENGINE AFTER SERVICE Please feel free to contact your dealer for periodical inspection and maintenance Doosan Genuine Parts Genuine Doosan parts are identical with those used in the ...

Page 61: ... using a blend of bio diesel fuel the engine oil level must be check daily when the air temperature is 10 C 14 F or lower If the oil becomes diluted with fuel shorten oil change intervals accordingly IMPORTANT Raw pressed vegetable oils are NOT acceptable for use for fuel in any concentration These oils do not burn completely and will cause engine failure by leaving deposits on injectors and in th...

Page 62: ...n at lower temperatures is required consult your dealer for recommendations Water quality is important to the performance of the cooling system Distilled or de mineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate Chlorides 40mg L Sulfates 100 mg L Total Dissolved Solids 340 mg L Total Hardness 170 mg L pH 5 5 to 9 0 IMPORTANT Do not use cooling system se...

Page 63: ...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 or equipment damage Fan and Belt Check The engine is fitted with an automatic belt tensioner Check the fan belt for tension and abnormalities A loose belt will cause belt slippage which may result in a damaged belt abnormalnois...

Page 64: ...pressure The engine oil pressure gauge readings where fitted may vary dependingon ambient temperature and type of oil The gauge should register around 55 to 85 psi in the warming up period Engine noise and exhaust smoke color Listen to the engine and if any abnormal noise is heard check to determinethe cause Check the fuel combustion condition by observing the exhaust smoke color The exhaust smoke...

Page 65: ... it stops before proceeding The engine coolant level should be between the MAX COLD and MIN marks on the reserve tank Make sure the fan belt is not broken or off the pulley and that the fan turns when the engine is started If the engine coolant level in the reserve tank is low look for leaks at the radiator hoses and connections radiator and water pump If you find major leaks do not run the engine...

Page 66: ...d belt wear Change Engine Oil And Replace Oil Filter B Clean Crankcase Vent Tube Check Air Intake Hoses Connections System Replace Fuel Filter Elements Bleed Fuel System Check Belt Tensioner and Belt Wear Check Engine Electrical Ground Connection Check Cooling System Pressure Test Cooling System Replace Air Cleaner Elements Flush Cooling System Test Thermostats Check and Adjust Engine Valve Cleara...

Page 67: ...pecifications Section of this manual IMPORTANT Immediately after completing any oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase within crosshatch marks on dipstick DO NOT overfill 10 Start engine and run to check for poss...

Page 68: ...TENSION AND BELT WEAR in Lubrication and Maintenance 500 Hour 6 Month Section for additional information on the belt tensioner 1 Inspect belts for cracks fraying or stretched out areas Replace if necessary 2 To replace belt with automatic tensioner release tension on belt using a breaker bar and socket on tension arm To replace belt with manual tensioner release tension at belt tensioner 3 Remove ...

Page 69: ... control system to machine ground before welding on engine or machine High currents or electro static discharge in electronic components from welding may cause permanent damage 1 Remove the ground connection for the engine control system to machine frame 2 Disconnect the connectors from the ECU 3 Connect the welder ground close to the welding point and be sure ECU or other electronic components ar...

Page 70: ...ca gelation problems NOTE Usage and mixing ratio etc should be followed to the antifreeze manufacture s recommendations ENGINE OIL At low ambient temperatures engine oil viscocity can affect engine starting It is important to use the correct grade of oil as recommended Try to position the compressor where it will not be affected by cold winds when not running BATTERY 1 Always ensure that the batte...

Page 71: ... fuel line Bleed fuel line Cold weather Use cold weather starting aids Slow starter speed See Starter Cranks Slowly Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier use proper type fuel for operating conditions Water dirt or air in fuel system Drain flush fill and bleed system Clogged fuel filter Replace filter element Dirty or faulty injection nozzle...

Page 72: ... servicing dealer Turbocharger not functioning Turbocharger engines only See your authorized servicing dealer Leaking exhaust manifold gasket See your authorized servicing dealer Defective aneroid control line See your authorized servicing dealer Restricted fuel hose Clean or replace fuel hose Low fast idle speed See your authorized servicing dealer Low oil pressure Low oil level Add oil Improper ...

Page 73: ...ooling system Defective thermostat Remove and check thermostat Defective temperature gauge or sender Check coolant temperature with thermometer and replace if necessary Incorrect grade of fuel Use correct grade of fuel High fuel consumption Improper type of fuel Use proper type of fuel Clogged or dirty air cleaner Service air cleaner Engine overloaded Reduce load Improper valve clearance See your ...

Page 74: ...slowly Low battery output See your authorized servicing dealer Crankcase oil too heavy Use proper viscosity oil Loose or corroded connections Clean and tighten loose connections Entire electrical system does not f ti f ti Faulty battery connection Clean and tighten connections function function Sulfated or worn out batteries See your authorized servicing dealer DISPLAYING OF DIAGNOSTIC TROUBLE COD...

Page 75: ... storage preparations are good for long term engine storage up to one year After that the engine should be started warmed up and retreated for an extended storage period IMPORTANT Any time your engine will not be used for over six 6 months the following recommendations for storing it and removing it from storage will help to minimize corrosion and deterioration 1 Change engine oil and replace filt...

Page 76: ...Spec CE reads and resets vehicle trip data QuickCheck CE reads electronic engine and vehicle subsystem data QuickCheck CE reads engine vehicle operating parameters QuickCheck CE reads and stores active and inactive faults QuickCheck CE reads and stores dataplate information Stored information on the QC5100 handheld computer can be downloaded to a PC with an ActiveSync operation Operating parameter...

Page 77: ...n adjacent page The quantities specified are the number of parts used per one assembly and are not necessarily the total number of parts used in the machine Where no quantity is specified the quantity is assumed to be one Each description of a part is based upon the noun first method i e the identifying noun or item name is always the first part of the description The noun name is generally follow...

Page 78: ...ted to the exact terms contained herein If purchaser s order form is used for acceptance of an offer it is expressly understood and agreed that the terms and conditions of such order form shall not apply unless expressly agreed to by Doosan Company Company in writing No additional or contrary terms will be binding upon the Company unless expressly agreed to in writing Taxes Any tax or other govern...

Page 79: ...page impairment of other goods loss by reason of shutdown or non operation increased expenses of operation or claims of customers of Purchaser for service interruption whether or not such loss or damage is based on contract warranty negligence indemnity strict liability or otherwise AIREND EXCHANGE PROGRAM Doosan offers an airend exchange program to benefit portable compressor users On the airend ...

Page 80: ...da 336 751 4325 Latin America 336 751 4325 Asia Pacific Facility Office hours Monday Friday 8 00 a m to 5 30 p m EST Facility For information on how to order parts or information regarding your local distributor Europe Middle East Africa please contact Doosan Portable Power EMEA Aftermarket ESA Dréve Richelle 167 B 1410 Waterloo Belgium Telephone 32 2 404 0811 Fax 32 2 371 6915 For Service Informa...

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