Doosan 9/235, Operation And Maintenance Manual

Page 1: ...AL No 814000 9 235 COMPRESSOR MODEL 9 235 This manual contains important safety information and must be made available to personnel who operate and maintain this machine OPERATION AND MAINTENANCE MANUAL Original Instruction ...

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Page 3: ...DING 53 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 el Greek en English es Spanish et Estonian fi Finnish fr French hu Hungarian it Italian lt Lithuanian lv Latvia...

Page 4: ...ice 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 unapproved usage are also given however the company cannot anticipate every application or work situation that may arise IF IN DOUBT CONSULT SUPERVISION This machine has been designed and supplied for use only in the...

Page 5: ...ation of 2 000 hours of operationby the initial user Light Source model only the earlier of twenty four 24 months from shipment to or the accumulation of 4 000 hours of operation by the initial user F Platinum Drive Train Extended Warranty Platinum drive train 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...

Page 6: ...NTROLS SWITCHES SHEET METAL ELECTRICAL CIRCUIT ETC ALTERNATOR 12 MONTHS 2 000 HOURS EXTENDED WARRANTY OF 24 MONTHS 4 000 HRS FOR LIGHTSOURCE INTRODUCED 8 16 99 ENGINE SEE BELOW ENGINES MONTHS HOURS COMMENTS CATERPILLAR 12 UNLIMITED EXTENDED WARRANTY PROVIDED VIA ENGINE SUPPLIER S OWN APPROVED NETWORK AT TIME OF PURCHASE CUMMINS 24 2 000 EXTENDED WARRANTY PROVIDED VIA ENGINE SUPPLIER S OWN APPROVED...

Page 7: ...om shipment to or the accumulation of 10 000 hours of service The optional warranty is limited to defects in major components rotors housings 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 m...

Page 8: ...upervisor GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition Mandatory Information Instructions Warning WARNING Electrical shock risk WARNING Pressurised component or system WARNING Hot surface WARNING Pressure control WARNING Corrosion risk WARNING Air gas flow or Air discharge X XBAR WARNING Pressurised vessel WARNING Hot and harmful exhaust gas WARNING Maintain correct tyre pressure Refer to t...

Page 9: ...WARNING Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved WARNING Consult the operation and maintenance manual before commencing any maintenance Do not breathe the compressed 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 ...

Page 10: ...hts Do not open the service valve before the airhose is attached Use fork lift truck from this side only Emergency stop Tie down point Lifting point On power Off power Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken When parking use prop stand handrake and wheel chocks Compressor oil filling Diesel fuel No open flame Parking brake Rough Servi...

Page 11: ...oil pressure Engine high temperature FREE SAFETY DECALS Safety Decals are available free of charge 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 Doosan Portable Power EMEA Aftermarket Department The no charge order should contain only Safety Decals Help promote product safety Assure that decals are pre...

Page 12: ...n blade can cause serious injury 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 inflammable gas When it is specified as a starting aid use sparingly DO NOT USE ETHER IF THE MACHINE HAS GLOW PLUGS OR INLET HEATER STARTING AIDS OR ENGINE DAMAGE WILL RESU...

Page 13: ...To jump battery connect ends of one booster cable to the positive terminal 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 explosive gases that may be present After starting unit always disconnect cables in reverse order Radiator Hot engine coolant and stea...

Page 14: ...he effective cable length is as short as possible 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 towing vehicle hitch as an anchorage point or any other point of similar strength b Ensure that the effective chain length is as short as possible whil...

Page 15: ...e min 1 RPM 1500 Power available at Full Load 205kW 275hp Electrical system 24V negative earth Fuel tank capacity 462 litres 122 gal Oil specification Refer engine section Coolant capacity 34 litres 9 gal SOUND LEVEL DATA A To Pneurop code PN8NTC2 Equivalent continuous sound pressure level Rated load 86 dB A Operator position 1m from machine Sound power level 2000 14 EC 102 Lwa B In compliance wit...

Page 16: ...pressors which are modified to remove the running gear and mount the machine direct to trailers truck beds or frame etc may experience failure of the enclosure frame and or other components It is necessary to isolate the compressor package from the carrier base with a flexible mounting system Such a system must also prevent detachment of the package from the carrier base in the event the isolators...

Page 17: ...r diesel fuel specification CAUTION When refuelling switch off the engine do not smoke extinguish all naked lights do not allow the fuel to come into contact with hot surfaces 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 s to ensure that all pressure is relieved from the system Close...

Page 18: ...FF to stop engine 5 Service Air Switch After warm up PUSH Provides full air pressure at the service outlet 6 Engine Speed Gauge Indicates engine speed RPM 7 Discharge Air Temp Gauge Indicates airend discharge temperature 8 Engine Oil Pressure Gauge Indicates engine oil pressure psi kPa 9 Engine Water Temp Gauge Indicates coolant temperature with normal operating range from 180 F 82 C to 210 F 99 C...

Page 19: ... Temp Fault indicator lamp Indicates shutdown due to high engine water temperature 4 Low Fuel Level Fault indicator lamp Indicates shutdown due 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 Engine Coolant Level Alarm indicator lamp Indicates coolant level in engine radiator is low 7 Restricte...

Page 20: ...ins 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 been selected STOPPING THE MACHINE Close the service valve Allow the machine to run unloaded for a short p...

Page 21: ...ly Do not dispose of any pressure vessel that is not clearly marked with its relevant data plate information or rendered unusable by drilling cutting etc Do not allow lubricants or coolants to be released into land surfaces or drains Do not dispose of a complete machine without documentation relating to instructions for its use ...

Page 22: ... sales support 24 FUEL LUBRICANT AND COOLANT Fuel Lubricant Coolant 26 OPERATION Check before operation Check and operation after start up Operation and care of a new engine 29 PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance 33 COLD WEATHER OPERATION 34 MAINTENANCE SCHEDULE 37 TROUBLESHOOTING ...

Page 23: ...e 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 contained w...

Page 24: ...plate 8 Fuel injection pump 9 Fuel drain line 10 Intake manifold 11 Turbocharger wastegate actuator 12 Turbocharger air outlet 13 Oil filler cap 14 Lubricating oil pressure after filter 15 Lubricating oil pressure before filter 16 Coolant heater port 17 Lubricating oil cooler 18 Lubricating oil filter 19 Turbocharger oil drain 20 Coolant filter 21 Starter motor 22 Turbocharger exhaust outlet ...

Page 25: ...12 Exhaust 0 61 024 ENGINE IDENTIFICATION Serial No Location The engine serial number is stamped on a plate located on the rear right of the cylinder body near the fuel filter Fig 3 A Engine serial number Confirmation of Engine Number It is advisable to quote the engine serial number together with the machine serial number as it is required when you contact the company branch or distributor for re...

Page 26: ...ause engine damage Handling of the Fuel Any fuel containing dust particles or water might cause engine failure Therefore the following must be observed Take care to protect the fuel from ingress of dust particles or water when filling the fuel tank If refuelling is done from an oil drum directly ensure that it has been kept stationary to allow any dust sediment or water to settle at the bottom Do ...

Page 27: ...t lubricants with the correct viscosity for the operating temperature are used Refer to fig 5 NOTE Using a mixture of different brands or quality of oils will adversely affect the original oil quality therefore never mix different brand or different type oils Do not use API CA CB grade and reconstituted engine oil Engine damage due to improper maintenance or using oil of the improper quality and o...

Page 28: ...ss 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 abnormalnoise poor ...

Page 29: ...e 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 color ...

Page 30: ...s 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 until t...

Page 31: ... new engine oil via the most convenient oil filler port Wait at least ten minutes until the oil drains down to the oil pan Then check the oil level with the dipstick Check after Oil and Filter Changes Oil leakage check Run the unit for five to ten minutes then visually check for oil leakage Oil level recheck Stop the engine for at least ten minutes Use the dipstick to recheck the oil level If nece...

Page 32: ...nt Filter Replacement Fig 13 Rotate clockwise to close shut off valve Remove and replace coolant filter Open shut off valve Fig 14 Filling with coolant Ensure that the engine is cool Close the coolant drain plug and tighten the bottom hose clamp Use clean water mixed 50 50 with antifreeze as a coolant Fill slowly to prevent air entering the cooling system For Coolant volume refer to General Inform...

Page 33: ... element A should be changed every 500 operating hours or 6 months whichever comes first Change procedure Disconnect fuel sensor where fitted Loosen drain plug B and empty fuel into suitable container Fig 16 Unscrew the element A from the head taking care not to spill fuel inside the machine Remove fuel sensor where fitted and re fit to new filter element Discard the old element into a suitable co...

Page 34: ...a short period of reverse connection will damage the electrical parts Cleaning of Battery When the battery terminals are fouled clean them with clean tepid water and wipe with a dry cloth to remove the water Apply a light coat of vaseline or a grease Alternator Servicing The polarity of the alternator is negative grounding type Do not reverse the polarity connection otherwise a short circuit will ...

Page 35: ...of the cooling system and because of its low boiling point NOTE High silicate antifreeze is not recommended because of causing serious silica 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 rec...

Page 36: ...4 Fan and belt check O O 15 Coolant temperature gage reading where fitted O 16 Coolant replacement O 17 Coolant filter replacement O 18 Radiator external face cleaning O O O O O O 19 Cooling system circuit cleaning O 20 Radiator filler cap function check O O O 21 Electrolyte level check O 22 Battery cleaning O 23 Battery charge lamp O 24 Starter and alternator check and cleaning O 25 Wiring and co...

Page 37: ...ter element replacement Replace both primary filter separator and secondary elements at 500 hours or 6 months whichever come first 10 Injection nozzle check Check injection opening pressure and spray condition This is a recommended maintenance item Consult your local branch or distributor 11 Coolant level Check coolant level and add coolant if necessary 12 Coolant leakage check Replace any damaged...

Page 38: ...ine starting condition and noise condition Check engine stability and noise 29 Exhaust smoke condition Check exhaust smoke color 30 Cylinder compression pressure Consult your dealer or distributor 31 Valve clearance check Check wear condition of brush and commutator Consult your local branch or distributor Incorrect valve clearance will result in increased engine noise and lower engine output ther...

Page 39: ...not turn Bad cable connections Starter or starter switch failure Safety relay failure Engine stop solenoid malfunction No fuel in the fuel tank No fuel injection Clogged fuel filter element Air in the fuel system Starter turns but engine does not fire Control rack is stuck at no fuel position Incorrect preheating operation Glow plug malfunction Fuel is injected but engine does not fire Incorrect i...

Page 40: ...ction amount between cylinders Deteriorated governor spring Incorrect valve clearance adjustment Deteriorated valve spring Engine speed stuck at high idle Engine control restriction or seizure Engine overheat Insufficient coolant volume Fan belt slippage Cooling system defect Thermostat malfunction Radiator filler cap malfunction Cooling system interior fouled Radiator clogged Engine over loaded I...

Page 41: ...ance adjustment Cylinder compression leakage Injector nozzle misalignment Low cylinder compression pressure Cylinder bore wear Insufficient air intake volume Air cleaner clogged Restricted air flow Excessive oil consumption Incorrect oil Wrong selection of type and viscosity Too much oil quantity Engine burning oil Faulty piston rings damaged cylinder bores Faulty valve stem seal Damaged seal Dama...

Page 42: ...ct fuel Water mixing in fuel Excessive white smoke Low compression pressure Injection timing incorrect Low coolant temperature Faulty turbocharger Battery overdischarge Low electrolyte level Crack in battery body Natural consumption Charging failure Loose or damaged belt Faulty alternator Damaged wiring or contact failure Excessive electrical loads Insufficient battery capacity for the application...

Page 43: ...tions 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 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 legisla...

Page 44: ...d 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 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 C...

Page 45: ...owdown 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 maintenance work ensure that all air pressure is fully discharged and isolated from the system If the automatic blowdown valve is used for this purpose then allow enough time for it to complete the operat...

Page 46: ...r of the filter housing and remove the spin on element by turning it in a counter clockwise direction Inspection 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 head CAUTION If there is any indication of the formation of varnishes shellacs or lacquers on the filter element it is a warning that the compressor lub...

Page 47: ...nning 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 seats properly Secure element by tightening nut Before restarting the machine check that all clamps are tight VENTILATION Always check that the air inlets and outlets are clear of debris etc COOLING FAN DRIVE Periodical...

Page 48: ...rs manual section for engine oil specifications Refer to the Engine section of this manual COMPRESSOR LUBRICATING OIL Refer to the MAINTENANCE CHART in this section for service intervals NOTE If the machine has been operating under adverse conditions or has suffered long shutdown periods then more frequent service intervals will be required WARNING DO NOT under any circumstances remove any drain p...

Page 49: ...r 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 32 F 14 F...

Page 50: ...nd the 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 normal operating discharge pressure without the throttle arm moving from the full speed position before normal operating discharge pressure is attained Turn the adjusting screw clockwise to increase the pressure Optimum adjustment is achieved...

Page 51: ...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 Wheel Torque Chart Nut Bolt Size Wheel Size Torque ft lb M12 13 inch 60 70 1 2 lug nuts 13 inch 80 90 1 2 lug nuts 15 inch 105 115 1 2 lug nuts 16 inch 105 115 1 2 lug nuts 16 5 inch 105 ...

Page 52: ...TERN 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 Wheel Torque Moments For Knott Running Gear Wheel Nut Bolt Size Torque Moment Nm Torque Moment ft lb M12 x 1 5 90 5 66 4 ...

Page 53: ...el and oil filter s prematurely Safety shut down system 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 oil temperature Check the compressor oil level and oil cooler Check the fan drive Water present in fuel system Check the water separator and clea...

Page 54: ...r Perforated separator element Replace the separator element Pressure in the system is too low Check the minimum pressure valve Safety valve operates Operating pressure too high Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT 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 t...

Page 55: ...nt 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 ...

Page 56: ...he 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 c...

Page 57: ...pairment 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 exchang...

Page 58: ...ddle 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 Information contact service_emea dii doosan com For Parts Information contact parts_emea dii doosan com Operating hours Monday Friday 8 30 a m to 5 15 p m GMT ...

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