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PARTS ORDERING

51

 

7/53

GENERAL

This  publication,  which  contains  an  illustrated  parts  breakdown,  has
been prepared as an aid in locating those parts which may be required
in the maintenance of the unit. All of the compressor parts, listed in the
parts  breakdown,  are  manufactured  with  the  same  precision  as  the
original  equipment.  For  the  greatest  protection  always  insist  on
genuine Doosan parts for your compressor.

NOTICE

Doosan  can  bear  no  responsibility  for  injury  or  damages  resulting
directly from the use of non-approved repair parts.

Doosan Infracore service facilities and parts are available worldwide.

There are Authorised Distributors or Company Sales offices in principal
cities of many countries.

Special  order  parts  may  not  be  included  in  the  manual.  Contact
Doosan  Parts  Department  with  the  unit  serial  number  for  assistance
with these special parts.

DESCRIPTION

The  illustrated  parts  breakdown  illustrates  and  lists  the  various
assemblies,  subassemblies  and  detailed  parts  which  make  up  this
particular  machine.  This  covers  the  standard  models  and  the  more
popular options that are available.

A series of illustrations show each part distinctly and in location relative
to the other parts in the assembly. The part number, the description of
the  part  and  the  quantity  of  parts  required  are  shown  on  each
illustration  or  on  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  followed  by  a  single
descriptive  modifier.  The  descriptive  modifier  may  be  followed  by
words or abbreviations such as upper, lower, inner, outer, front, rear,
RH, LH, etc. when they are essential.

In  referring  to  the  rear,  the  front  or  to  either  side  of  the  unit,  always
consider the 

drawbar end

 of the unit as the 

front

. Standing at the rear

of  the  unit  facing  the  drawbar  (front)  will  determine  the  right  and  left
sides.

FASTENERS

Both SAE/inch, ISO/metric hardware have been used in the design and
assembly of these units. In the disassembly and reassembly of parts,
extreme care must be taken to avoid damaging threads by the use of
wrong  fasteners.  In  order  to  clarify  the  proper  usage  and  for  exact
replacement parts, all standard fasteners have been identified by part
number,  size  and  description.  This  will  enable  a  customer  to  obtain
fasteners locally rather than ordering from the factory. These parts are
identified in tables that will be found at the rear of the parts illustrations.
Any fastener that has not been identified by both part number and size
is a specially engineered part that must be ordered by part number to
obtain the exact replacement part.

MARKINGS AND DECALS 

NOTICE

Do not paint over safety warnings or instructional decals. If safety
warning decals become illegible, immediately order replacements
from the factory.

Part  numbers  for  original  individual  decals  and  their  mounting
locations are shown within Parts List Section. These are available
as long as a particular model is in production.

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 illustration by visual identification
and make note of part number and description.

HOW TO ORDER

The satisfactory ordering of parts by a purchaser is greatly dependent
upon  the  proper  use  of  all  available  information.  By  supplying  your
nearest  sales  office,  autonomous  company  or  authorised  distributor,
with  complete  information,  you  will  enable  them  to  fill  your  order
correctly and to avoid any unnecessary delays.

In  order  that  all  avoidable  errors  may  be  eliminated,  the  following
instructions  are  offered  as  a  guide  to  the  purchaser  when  ordering
replacement parts:

a.

Always  specify  the  model  number  of  the  unit  as  shown  on  the
general data decal attached to the unit.

b.

Always  specify  the  serial  number  of  the  unit.  THIS  IS
IMPORTANT. The serial number of the unit will be found stamped
on a plate attached to the unit. (The serial number on the unit is
also permanently stamped in the metal of the frame side rail.)

c.

Always specify the number of the parts list publication.

d.

Always specify the quantity of parts required.

e.

Always specify the part number, as well as the description of the
part, or parts, exactly as it is given on the parts list illustration.

In  the  event  parts  are  being  returned  to  your  nearest  sales  office,
autonomous  company  or  authorised  distributor,  for  inspection  or
repair, it is important to include the serial number of the unit from which
the parts were removed.

TERMS AND CONDITIONS ON PARTS ORDERS

Acceptance:

 Acceptance of an offer is expressly limited 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 governmental charge now or hereafter levied

upon the production, sale, use or shipment of material and equipment
ordered  or  sold  is  not  included  in  the  Company's  price  and  will  be
charged to and paid for by the Purchaser.

Shipping dates shall be extended for delays due to acts of God, acts of
Purchaser,  acts  of  Government,  fires,  floods,  strikes,  riot,  war,
embargo, transportation shortages, delay or default on the part of the
Company's  vendors,  or  any  other  cause  beyond  the  Company's
reasonable control. 

Should  Purchaser  request  special  shipping  instruction,  such  as
exclusive use of shipping facilities, including air freight when common
carrier  has been quoted  and  before  change  order  to purchase order
can  be  received  by  the  Company,  the  additional  charges  will  be
honoured by the Purchaser.

Warranty:

 The Company warrants that parts manufactured by it will be

as  specified  and  will  be  free  from  defects  in  materials  and
workmanship.  The  Company's  liability  under  this  warranty  shall  be
limited to the repair or replacement of any part which was defective at
the time of shipment provided Purchaser notifies the Company of any
such defect promptly upon discovery, but in no event later than three
(3)  months  from  the  date of  shipment  of  such part  by  the Company.
The only exception to the previous statement is the extended warranty
as it applies to the special airend exchange program.

Summary of Contents for 7/53

Page 1: ...ns important safety information and must be made available to personnel who operate and maintain this machine 46673723_en_A_06 15 7 53 OPERATION AND MAINTENANCE MANUAL Original Instruction 7 53 SERIAL...

Page 2: ......

Page 3: ...13 2000 14 EC The Noise Emission Directive 14 97 23 EC The Pressure Equipment Directive 15 2009 105 EC The Simple Pressure Vessels Directive 16 97 68 EC The emission of engines for no road mobile mach...

Page 4: ......

Page 5: ...separator Hoses Electrical system Battery Pressure system Tyres Tyre Pressure Running gear wheels Brakes Running gear wheel bearings Lubrication Engine lubricating oil Engine lubricating oil specific...

Page 6: ...ent 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 el Greek en English es Spanish et Estonian fi Finnish fr French hu Hungaria...

Page 7: ...hout 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 unapprov...

Page 8: ...G 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 GENER...

Page 9: ...ir 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 any s...

Page 10: ...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 sh...

Page 11: ...DECALS 7 7 53 Engine oil drain...

Page 12: ...ver 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 handle...

Page 13: ...e socket control panel in the event of electrical hazards associated with generator operation Use this second control to immediately isolate all electrical power to all sockets then use the key contro...

Page 14: ...r adjustment of the drawbar To ensure full braking efficiency the front towing eye section must always be set level To ensure full braking efficiency the front towing eye section must always be set le...

Page 15: ...GENERAL INFORMATION 11 7 53 7 53 FIXED HEIGHT RUNNING GEAR 7 53 VARIABLE HEIGHT RUNNING GEAR...

Page 16: ...on A B H J O P Q R S T U V W X mm mm mm mm mm mm mm mm mm mm mm mm mm mm 1 7 53 Fixed Height braked 2110 MIN 2127 MAX 3325 MIN 3380 MAX 405 1851 386 904 1290 1220 TBA 940 1430 1205 2 7 53 Variable Hei...

Page 17: ...When this has been completed the following oils are approved a for ambient temperatures above 23 C 9 F SAE 10W API CF 4 CG 4 Safety data sheets can be obtained on request from your Doosan dealership...

Page 18: ...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 po...

Page 19: ...ose restraints whipchecks must be used to prevent hose whipping if a connection fails Whipchecks are to be constructed of woven stainless steel galvanized steel wire rope or chain with aminimum streng...

Page 20: ...sure gauge D Hourmeter E Warning lamp low engine oil pressure F Warning lamp high airend discharge temperature G Warning lamp dirty IQ filters IQ filters option H Warning lamp High engine coolant temp...

Page 21: ...e machine has been switched off for reasons of safety then ensure that the machine can be operated safely before re starting Refer to the PRIOR TO STARTING and STARTING THE UNIT instructions earlier i...

Page 22: ...g kits Warranty does not cover failures attributable to mounting of the compressor package to the carrier base unless it is a Portable Power provided system NOTE The maintenance schedule in this manua...

Page 23: ...Waterseparator element R Final Fuel Filter R Engine Oil Filter R C Check and act if required T Test D Drain R Replace R WI Replace or when indicated earlier C R Check and replace if required G C Grea...

Page 24: ...ior C Lubricator Fill C Engine Air inlet shutdown valve C C Check and act if required T Test D Drain R Replace R WI Replace or when indicated earlier C R Check and replace if required G C Grease and c...

Page 25: ...e tasks which require the machine to be running with safety protection devices disabled or removed all hazards present are known e g pressurised components electrically live components removed panels...

Page 26: ...ase oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator the efficiency is impaired It is recommended that each month the oil cooler and radiator be cleaned by directing a j...

Page 27: ...E CHART HOSES All components of the engine cooling air intake system should be checked periodically to keep the engine at peak efficiency At the recommended intervals see the SERVICE MAINTENANCE CHART...

Page 28: ...es 11 operate smoothly 2 Brake Shoe Adjustment Tighten adjusting screw 12 clockwise until the wheel locks Loosen adjusting screw 12 anti clockwise approx turn until the wheel can be moved freely Sligh...

Page 29: ...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 l...

Page 30: ...es Loosen tension on belts fan airend etc Block axles so tyres are off ground and do not support any weight Disconnect battery cables Drain fuel system SHORT TERM STORAGE Machines that stand idle for...

Page 31: ...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 the fu...

Page 32: ...ssis 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 Oil pipe 1...

Page 33: ...rranty section for details or contact your Portable Power representative Design Operating Pressure Ambient Temperature Specification 100 psi to 300 psi 7 bar to 21 bar 10 F to 125 F 23 C to 52 C Prefe...

Page 34: ...30 ELECTRICAL SYSTEM 7 53 7 53...

Page 35: ...A G1 Alternator H1 Hourmeter K1 Crank relay K2 Engine heater relay K3 Contactor Option PB1 Warm up button PS1 Oil pressure switch P1 Mini controller SV1 Fuel solenoid SV2 Warm up solenoid SV3 Generato...

Page 36: ...32 ELECTRICAL SYSTEM 7 53 7 53...

Page 37: ...ECTRICAL SYSTEM 33 7 53 KEY PS2 IQ restriction switch P2 Mini controller S3 Low fuel switch 1 Airend temperature 2 Engine oil pressure 3 Engine temperature 4 Low fuel 5 No charge 6 IQ filter restricti...

Page 38: ...EY 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 Plug B...

Page 39: ...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 Tail...

Page 40: ...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 Where fitted 11 Separator f...

Page 41: ...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 holde...

Page 42: ...t 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...

Page 43: ...ate in the aftercooler to drain 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 co...

Page 44: ...40 OPTIONS 7 53 WATER SEPARATOR MAINTENANCE FIGURE 4 FIGURE 5 FIGURE 1 FIGURE 2 FIGURE 3...

Page 45: ...r 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 cou...

Page 46: ...8 5 mins off load Air in temp 35 40 C 50 mins hr 0 8 10 mins off load Air in temp 40 C 45 mins hr 0 8 15 mins off load Socket outlets 110V 1ph 230V 1ph 1 x 32 amperes 2 x 16 amperes 230V 3ph 1 x 16 a...

Page 47: ...dure which has been issued by supervisory personnel and that it is understood by all persons concerned with the operation of the generator Ensure that the safety procedure to be applied is based on th...

Page 48: ...G THE UNIT instructions earlier in this section before re starting the machine DECOMMISSIONING When the machine is to be permanently decommissioned or dismantled it is important to ensure that all haz...

Page 49: ...ring The No load voltage falls when a load is applied Check the capacitors and associated wiring Loss of residual magnetic field Refer to Mecc Alte maintenance manual No output Output winding s damage...

Page 50: ...ove the generator KEY CB1 RCD Circuit breaker 63A CB2 Circuit breaker 32A CB3 Circuit breaker 16A CB4 Circuit breaker 16A F1 Fuse 1A F2 Fuse 1A G Alternator 1 phase GND Earth stud KM1 Contactor P1 Con...

Page 51: ...machine above the generator KEY CB1 RCD Circuit breaker 32A CB2 Circuit breaker 16A CB3 Circuit breaker 16A F1 Fuse 1A F2 Fuse 2A G Alternator 1 phase GND Earth stud KM1 Contactor P1 Connector voltme...

Page 52: ...he machine above the generator KEY CB1 RCD Circuit breaker 10A CB2 Circuit breaker 10A CB3 Circuit breaker 10A F1 Fuse 1A F2 Fuse 1A G Alternator 3 phase GND Earth stud KM1 Contactor P1 Connector volt...

Page 53: ...own occurs 6 Repeat the above steps 2 to 5 until the first setting at which the engine does not shut down at high idle speed Then either A Use the results of shut down speed versus adjuster setting as...

Page 54: ...hake out Also by shaking check for any loose internal baffles Six Monthly or 1500 hours operation whichever is sooner Examine the exhaust discharge in darkness whilst repeatedly loading and accelerati...

Page 55: ...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 illustration b...

Page 56: ...ive and the total liability of the Company with respect to this order whether based on contract warranty negligence indemnity strict liability or otherwise shall not exceed the purchase price of the p...

Page 57: ...n regarding your local distributor U S Latin America or Asia Pacific please contact Office hours Monday to Friday 8 00 a m to 5 30 p m EST Facility Telephone Fax Doosan Portable Power EMEA Aftermarket...

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