Doosan 9/235HA Operation & Maintenance Manual
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Doosan 9/235HA Operation & Maintenance Manual

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9/235HA, 10/215HA
Operation & MAINTENANCE MANUAL
Original Instruction
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
22488183_en_E_04/18
9/235HA,
SERIAL No : 812400 - 819999
10/215HA

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  • Page 1 9/235HA, 10/215HA OPERATION & MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to personnel who operate and 9/235HA, SERIAL No : 812400 - 819999 maintain this machine. 10/215HA 22488183_en_E_04/18...
  • Page 3 High speed running gear MAINTENANCE MACHINE SYSTEMS Bulgarian Czech FAULT FINDING Danish German OPTIONS Greek English PARTS ORDERING Spanish Estonian Finnish French Hungarian Italian Lithuanian Latvian, Lettish Maltese Dutch Norwegian Polish Portuguese Romanian Russian Slovak Slovenian Swedish Chinese 9/235HA, 10/215HA...
  • Page 4 English version. 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 such improvements to products sold previously. © COPYRIGHT 2018 DOOSAN COMPANY 9/235HA, 10/215HA...
  • Page 5 WARNING - Before connecting the tow bar WARNING - For operating temperature (Refer to the GENERAL INFORMATION or commencing to tow consult the below 0°C, consult the operation and section of this manual). operation and maintenance manual. maintenance manual. 9/235HA, 10/215HA...
  • Page 6 Do not use fork lift truck from this side. Do not exceed the trailer speed limit. No naked lights. Do not open the service valve before the Use fork lift truck from this side only. Emergency stop. airhose is attached. 9/235HA, 10/215HA...
  • Page 7 No open flame. Rough Service Designation. Replace any cracked protective shield. Coolant fill. Wet Location Operation. Prohibition: Do not start. Start and stop device. Mandatory action: Hearing protection must be worn. Diesel fuel drain. Engine coolant drain. Compressor oil drain. 9/235HA, 10/215HA...
  • Page 8 DECALS Engine oil drain. 9/235HA, 10/215HA...
  • Page 9 Hot engine coolant and steam can cause injury. Ensure that the radiator filler cap is removed with due care and attention. If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided. 9/235HA, 10/215HA...
  • Page 10 • the canopy is secure. • all ancillary equipment is stored in a safe and secure manner. When parking always use the handbrake and, if necessary, suitable wheel chocks. 9/235HA, 10/215HA...

  • Page 11: General Information

    GENERAL INFORMATION 76.2 mm NATO R553.0 5350 1918 1804 3858 1676 2246 1950 T7140_00 3400 1906 07/17 (3357) 1918 1804 2x727.8 2023 1500 3400 3634 3953 (979.7) 2x2223.4 4x14.3 8x17.5 R553 (918.1) T7141_00 07/17 2x101.6 2x2143.4 2x101.6 9/235HA, 10/215HA...
  • Page 12 GENERAL INFORMATION MODEL 9/235HA (High Ambient) 10/235HA (High Ambient) COMPRESSOR Actual free air delivery 23,4/ 21,2/ /min/ Normal operating discharge pressure psi/bar/ 125/8,6/ 150/10,3/ 1030 Maximum allowable pressure psi/bar/ 150/10,3/ 174/12/ 1030 1200 Safety valve setting psi/bar/ 200/13,8/ 200/13,8/ 1380...
  • Page 13 GENERAL INFORMATION MODEL 9/235HA-10/235HA (High Ambient) ENGINE 6C8.3 (275hp) Number of cylinders / Displacement /Litre 6/8,3 Oil capacity Litre Speed at full load 2000 Rev min Speed at idle 1500 Rev min Electrical system V DC Power available at rated speed...

  • Page 14: Operating Instructions

    WARNING: If flexible discharge hoses are to carry more than is sufficient clearance for ventilation and exhaust requirements, observing any specified minimum dimensions (to walls, floors etc.). 7 bar pressure then it is recommended that safety retaining wires are used on the hoses. 9/235HA, 10/215HA...
  • Page 15 This prevents condensation from occurring in the tank. 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. 9/235HA, 10/215HA...
  • Page 16 4. Power switch - “ON” to activate systems prior to Starting. Flip “OFF” to stop engine. 10. Voltmeter - Indicates charging system voltage. 5. Service air switch - After warm-up, PUSH. Provides full air 11. Spare - Used for optional accessories. pressure at the service outlet. 9/235HA, 10/215HA...
  • Page 17 3. High engine coolant temperature - Fault indicator lamp. Indicates 8. DIAGNOSTICS AUTO SHUTDOWN. shutdown due to low engine oil pressure. 9. LAMP TEST - WITH ENGINE OFF, TURN POWER SWITCH TO “OFF”, THEN TO “ON”. ALL LAMPS SHOULD LIGHT. 9/235HA, 10/215HA...
  • Page 18 Do not allow lubricants or coolants to be released into land surfaces between 7 bar (100 psi) and the machine rated pressure, cfm remains or drains. nominally constant. • Do not dispose of a complete machine without documentation relating to instructions for its use. 9/235HA, 10/215HA...

  • Page 19: Table Of Contents

    ENGINE INSTRUCTION MANUAL 6C8.3 ENGINE CONTENTS FOREWORD EXTERNAL VIEWS GENERAL INFORMATION FUEL, LUBRICANT, AND COOLANT OPERATION PERIODICAL INSPECTION AND MAINTENANCE COLD WEATHER OPERATION MAINTENANCE SCHEDULE TROUBLESHOOTING 9/235HA, 10/215HA...

  • Page 20: Foreword

    The company reserves the right to make changes in this Manual at any time without prior notice. The pictures contained within are for guidance only and might not reflect the physical characteristics of each individual engine covered. 9/235HA, 10/215HA...

  • Page 21: External Views

    17. Lubricating oil cooler. Engine data plate. 18. Lubricating oil filter. Fuel injection pump. 19. Turbocharger oil drain. Fuel drain line. 20. Coolant filter. 10. Intake manifold. 21. Starter motor. 11. Turbocharger waste gate actuator. 22. Turbocharger exhaust outlet. 9/235HA, 10/215HA...

  • Page 22: General Information

    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 engine production, and accordingly, they are warranted. Genuine Doosan parts are supplied by your branch or distributor.

  • Page 23: Fuel, Lubricant, And Coolant

    If the tank is too full, fuel could be forced additive other than those specifically recommended by Doosan. out. This could lead to a fire and the risk of personal injury and/or equipment damage.
  • Page 24 Fig. 2 A. (Single-grade) COOLANT B. Ambient Temperature All Doosan portable compressor engines are factory filled with a 50/50 Ethylene glycol base antifreeze/water mixture. which provides C. (Multi - grade) protection to -33°C (-27°F). NOTE: Using a mixture of different brands or quality of oils will adversely affect the original oil quality;...

  • Page 25: Operation

    Fig. 4 Use of genuine Doosan fan belt Always use genuine Doosan fan belts as they provide high driving ability and long operating durability. Use of non-Doosan fan belts could result in premature belt wear or belt elongation leading to engine overheating or excessive belt noise.
  • Page 26 If the level is As highly flammable hydrogen gas is released from the correct, contact your local Doosan branch or dealer to establish the batteries, do not create a spark or allow any naked flame near cause.
  • Page 27 (5) Abnormal engine noise - In the event of any abnormal engine mixture.) noise, please consult your local Doosan branch or dealer. (6) State of the exhaust smoke - Check for any abnormal exhaust CAUTION: To avoid being burned, do not spill antifreeze or smoke colour.

  • Page 28: Periodical Inspection And Maintenance

    If you have a problem disposing of your used oil, it is suggested that you contact your local Doosan branch or dealer. This also applies to diesel fuel which is contaminated with water.
  • Page 29 Place a suitable container under the separator to prevent any spillage inside the machine. Slacken the drain valve ‘B’ until water drains from the vent tube. When all the water has been evacuated, tighten the drain valve ‘B’. Fig. 11 9/235HA, 10/215HA...
  • Page 30 Fig. 14 service procedures marked with an asterisk (*) need to be carried out by a skilled and trained technician. A. Normal Please consult your local Doosan branch or dealer when these B. Clogged procedures become due. C. Indicator Please also read the note refering to the service items marked with the star symbol.

  • Page 31: Cold Weather Operation

    When operating in cold ambient conditions, or when starting from cold, All Doosan portable compressor engines are factory filled with a 50/50 if the engine does not start at the first attempt, allow the battery to Ethylene glycol base antifreeze/water mix. which provides protection to recover for at least 30 seconds.

  • Page 32: Maintenance Schedule

    1. After every 1500 hours of operation, the service intervals should be repeated in accordance with this check and maintenance schedule. 2. When servicing on the asterisked (*) items is necessary, consult your local Doosan branch or distributor. 9/235HA, 10/215HA...
  • Page 33 This is a recommended maintenance. The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion engine useful life. Doosan, however, urges that recommended maintenance service is performed at the indicated intervals.

  • Page 34: Troubleshooting

    Glow plug malfunction. Fuel is injected but engine does Incorrect injection timing. not fire. Low cylinder compression pressure. Engine stop solenoid not fully returned. Engine fires but stalls Air in the fuel system. immediately. Incorrect low idle speed adjustment. 9/235HA, 10/215HA...
  • Page 35 Restricted coolant flow (high concentration of antifreeze, etc.) Low oil pressure. Lack of oil. Oil leakage. High oil consumption. Wrong oil. Wrong type and viscocity. High coolant temperature. Over heat. Clogged filter and strainer. Worn bearings and oil pump. Faulty relief valve. 9/235HA, 10/215HA...
  • Page 36 Faulty valve stem seal. Damaged seal / Damaged turbocharger seal Oil leakage. Loose joints/gaskets. Improper installation of filter and piping. Fuel leakage. Damaged seals. Excessive fuel consumption. Improper component installation or tightening. Excessive injection volume. Injection pump defective. Excessive mechanical loads. 9/235HA, 10/215HA...
  • Page 37 Low coolant temperature Faulty turbocharger Low electrolyte level. Crack in battery body. Battery overdischarge. Natural consumption. Charging failure. Loose or damaged belt. Faulty alternator. Damaged wiring or contact failure. Excessive electrical loads. Insufficient battery capacity for the application. 9/235HA, 10/215HA...
  • Page 38 = Grease and check Contact your Doosan Infracore Portable Power dealer for more = Check and adjust if required information or assistance in determining the optimum intervals for your application.
  • Page 39 = Grease and check Contact your Doosan Infracore Portable Power dealer for more information or assistance in determining the optimum intervals for = Check and adjust if required your application.
  • Page 40 9/235HA, 10/215HA...
  • Page 41 Disconnect all hoses and tubes from the separator tank cover plate. Remove the drop-tube from the separator tank cover plate and then slide the cover plate towards the airend. Remove the separator element. 9/235HA, 10/215HA...
  • Page 42 CHART), inspect all of the intake lines to the air filter, and all flexible The fan belt(s) should be checked regularly for wear and correct hoses used for air lines, oil lines and fuel lines. tensioning. Periodically inspect all pipework for cracks, leaks, etc. and replace immediately if damaged. 9/235HA, 10/215HA...
  • Page 43 Refer to the TORQUE SETTING TABLE later in this section. amount of Doosan Part No. 22409114 electrical grease to the The bolts securing the running gear to the frame should be checked terminals.
  • Page 44 NOTE: If the oil is drained immediately after the machine has been running, then most 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. 9/235HA, 10/215HA...
  • Page 45 Refer to the diagram above. CAUTION: Never allow the idle pressure to exceed maximum Start the machine (Refer to STARTING INSTRUCTIONS in the allowable pressure on the pressure gauge, otherwise the safety valve OPERATING INSTRUCTIONS section of this manual). will operate. 9/235HA, 10/215HA...
  • Page 46 AND PITCH TYPICAL SQUARE TORQUE PATTERN (Nm.) (FT-LBF) (Nm.) (FT-LBF) 1/4 - 20 5/16 - 18 3/8 - 16 7/16 - 14 1/2 - 13 9/16 - 12 TYPICAL CIRCULAR TORQUE PATTERN 5/8 - 11 3/4 - 10 9/235HA, 10/215HA...
  • Page 47 THREAD SIZE AND PITCH TYPICAL SQUARE TORQUE PATTERN (Nm.) (FT-LBF) (Nm.) (FT-LBF) (Nm.) (FT-LBF) M6 X 1.0 M8 X 1.25 M10 X 1.5 M12 X 1.75 M14 X 2 M16 X 2 TYPICAL CIRCULAR TORQUE PATTERN M20 X 2.5 9/235HA, 10/215HA...
  • Page 48 Such deposits can cause serious problems including clogging of the filters. NOTE: Doosan Portable Power provides compressor oil specifically formulated for Portable Compressors and requires the use of these Where possible, do NOT mix oils of different types and avoid mixing fluids in order to obtain extended limited airend warranty.
  • Page 49 (-10°F to 125°F) XHP 605 Alternate: XHP 405 Doosan preferred fluids - the use of these fluids with original Doosan ISO Viscosity Grade branded filters can extend airend warranty. Refer to operator’s manual 68 Group 3 or 5 with warranty section for details or contact your Portable Power rust and oxidization representative.
  • Page 50 MACHINE SYSTEMS 9/235HA, 10/215HA...
  • Page 51 MACHINE SYSTEMS 9/235HA, 10/215HA...
  • Page 52 MACHINE SYSTEMS 9/235HA, 10/215HA...
  • Page 53 MACHINE SYSTEMS 9/235HA, 10/215HA...
  • Page 54 MACHINE SYSTEMS 9/235HA, 10/215HA...
  • Page 55 MACHINE SYSTEMS 9/235HA, 10/215HA...

  • Page 56: Fault Finding

    Check the regulation and the operation of the air cylinder. Excessive vibration. Engine speed too low. See ”Engine speed too low”. Leaking oil seal. Improperly fitted oil seal. Replace the oil seal. Refer also to the Engine Manufacturer’s Manual. 9/235HA, 10/215HA...
  • Page 57 Top up the oil level and check for leaks. Dirty or blocked oil cooler. Clean the oil cooler fins. Incorrect grade of oil. Use Doosan recommended oil. Defective bypass valve. Check the operation of the element and replace if necessary. Recirculation of cooling air.
  • Page 58 At the bottom of the moisture separator and both filters are strainers and constant-bleed orifices, which are sized to allow the maximum flow Standard Non-Louvred configuration not to be operated below of condensate while minimising compressed air loss. freezing. 9/235HA, 10/215HA...
  • Page 59 Verify the part number of new element vs. old element, as the two IQ filters are of different media. • Verify that the orifices below the Y-strainers are not clogged. 9/235HA, 10/215HA...
  • Page 60 OPTIONS PRIMARY AND SECONDARY FILTER MAINTENANCE FIGURE 1. FIGURE 4. FIGURE 2. FIGURE 5. FIGURE 3. 9/235HA, 10/215HA...
  • Page 61 OPTIONS WATER SEPARATOR MAINTENANCE FIGURE 1. FIGURE 4. FIGURE 2. FIGURE 5. FIGURE 3. FIGURE 6. 9/235HA, 10/215HA...
  • Page 62 CAUTION: Blockage of the condensate will result in flooding of the vessels. If flooding occurs, excessive condensate may enter the air stream and could result in damage to downstream equipment. NOTICE: Do not operate at temperatures less that 2°C (35° F). FIGURE 7. FIGURE 8. 9/235HA, 10/215HA...
  • Page 63 PT101 differential pressure sensors. Repair harness as needed. TCU controller indicating the IQ displayed on the ViewPort. filters are restricting air flow past 3. If steps 1 and 2 checkout OK, replace IQ TCU controller. a usable level. 9/235HA, 10/215HA...
  • Page 64 3. Release locknut. Turn adjuster clockwise one turn. Tighten locknut. exposed and, by experience, may need to be varied. 4. Refit inlet hose to Chalwyn valve. 5. Start engine. Slowly accelerate. Note speed at which shut down occurs. 9/235HA, 10/215HA...
  • Page 65 NOTICE HOW TO ORDER Doosan can bear no responsibility for injury or damages resulting directly from the use of non-approved repair parts. The satisfactory ordering of parts by a purchaser is greatly dependent Doosan Infracore service facilities and parts are available worldwide.
  • Page 66 The company makes no other warranty or representation of any kind whatsoever, expressed or implied, except that of title, and all implied Doosan offers an airend exchange program to benefit portable warranties, including any warranty of merchantability and fitness for a compressor users.
  • Page 68 Doosan Bobcat EMEA s.r.o U Kodetky 1810 263 12 Dobříš Czech Republic www.doosanportablepower.eu...

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