Doosan 9/235 Operation And Maintenance Manual
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Doosan 9/235 Operation And Maintenance Manual

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OPERATION AND MAINTENANCE MANUAL
Original Instruction
COMPRESSOR MODEL
9/235
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
9/235
SERIAL No :
814000 −>
22488183_en_11/11

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  • Page 1 OPERATION AND MAINTENANCE MANUAL Original Instruction COMPRESSOR MODEL 9/235 This manual contains important safety information and must be made available to personnel who operate and maintain this machine. 9/235 SERIAL No : 814000 −> 22488183_en_11/11...

  • Page 3: Table Of Contents

    Danish Emergency stopping German Re−starting Greek Monitoring during operation English Decommissioning Spanish Estonian ENGINE INSTRUCTION MANUAL Finnish French MAINTENANCE Hungarian Italian Lithuanian FAULT FINDING Latvian, Lettish Maltese PARTS ORDERING Dutch Norwegian Polish Portuguese Romanian Russian Slovak Slovenian Swedish Chinese 9/235...

  • Page 4: Foreword

    The company accepts no responsibility for errors in translation of of unapproved usage are also given, however the company cannot this manual from the original English version. anticipate every application or work situation that may arise. IF IN DOUBT CONSULT SUPERVISION © COPYRIGHT 2011 DOOSAN COMPANY 9/235...

  • Page 5: Warranty

    1. The original airend is returned assembled and unopened. 2.5 Kva Through to 8 Kva − The earlier of twelve (12) months 2. Continued use of genuine Doosan parts, fluids, oil and filters. from shipment to or the accumulation of 2,000 hours of operation by the initial user.
  • Page 6 2,000 (IN COMPRESSORS) 2,000 24 MONTHS / 4,000 HRS. AVAILABLE FROM THE (IN GENERATORS) COMPANY WITH USE OF GENUINE DOOSAN PARTS AND OILS AT PRESCRIBED SERVICE INTERVALS. CONTACT THE COMPANY NETWORK. KUBOTA 2,000 EXTENDED WARRANTY OF 36 MONTHS / 3,000 HRS.
  • Page 7 (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 manual for the correct fluids, filters and separator elements required.
  • Page 8 WARNING − Pressure control. WARNING − Corrosion risk. WARNING − Air/gas flow or Air discharge. WARNING − Maintain correct tyre pressure. WARNING − Pressurised vessel. WARNING − Hot and harmful exhaust gas. (Refer to the GENERAL INFORMATION section of this manual). 9/235...

  • Page 9: Decals

    Do not remove the Operating and Maintenance Do not operate the machine without the guard Do not stack. manual and manual holder from this machine. being fitted. 9/235...
  • Page 10 Read the Operation and Maintenance manual When parking use prop stand, handrake and Compressor oil filling before operation or maintenance of this wheel chocks. machine is undertaken. Diesel fuel Rough Service Designation. Parking brake. No open flame. Wet Location Operation. 9/235...
  • Page 11 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.
  • Page 12 Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). 9/235...

  • Page 13: Safety

    A battery contains sulphuric acid and can give off gases which are corrosive and potentially explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water. When lowering towing eye, set front joint first, then rear joint. 9/235...
  • Page 14 Ensure that the effective cable length is as short as possible, whilst still allowing enough slackness for the trailer to articulate without the handbrake being applied. 9/235...

  • Page 15: General Information

    Speed at Full Load min (RPM) 2000 −1 Speed at Idle. min (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) 9/235...
  • Page 16 OPERATING INSTRUCTIONS COMMISSIONING Warranty does not cover failures attributable to mounting of the compressor package to the carrier base unless it is an Doosan Upon receipt of the unit, and prior to putting it into service, it is provided system.

  • Page 17: Operating Instructions

    9/235...
  • Page 18 10. Voltmeter − Indicates charging system voltage. 5. Service Air Switch − After warm−up, PUSH. Provides full air pressure at the service outlet. 11. Spare− Used for optional accessories. 6. Engine Speed Gauge − Indicates engine speed. (RPM) 12. Spare− Used for optional accessories. 9/235...
  • Page 19 8. DIAGNOSTICS AUTO SHUTDOWN. 3. High Engine Coolant Temp: Fault indicator lamp. Indicates 9. LAMP TEST − WITH ENGINE OFF, TURN POWER SWITCH TO “OFF”, THEN TO “ON”. ALL LAMPS SHOULD LIGHT. shutdown due to high engine water temperature. 9/235...

  • Page 20: Emergency Stopping

    At this point in the operation of the machine it is safe to apply full load dismantled, it is important to ensure that all hazard risks are either to the engine. eliminated or notified to the recipient of the machine. In particular:− 9/235...
  • Page 21 Do not dispose of any pressure vessel that is not clearly marked Do not dispose of a complete machine without documentation with its relevant data plate information or rendered unusable by drilling, relating to instructions for its use. cutting etc. 9/235...

  • Page 22: Engine Instruction Manual

    PERIODICAL INSPECTION GENERAL INFORMATION: AND MAINTENANCE Main data and specifications Lubricating system Engine identification Cooling system After sales support Fuel system FUEL, LUBRICANT, AND COOLANT Air intake system Fuel Routine maintenance Lubricant COLD WEATHER OPERATION Coolant MAINTENANCE SCHEDULE OPERATION TROUBLESHOOTING 9/235...

  • Page 23: Foreword

    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 within are for guidance only and might not reflect the physical characteristics of each individual engine covered 9/235...

  • Page 24: External Views

    (17) Lubricating oil cooler. (7) Engine dataplate. (18) Lubricating oil filter. (8) Fuel injection pump (19) Turbocharger oil drain. (9) Fuel drain line. (20) Coolant filter. (10) Intake manifold. (21) Starter motor (11) Turbocharger wastegate actuator. (22) Turbocharger exhaust outlet. 9/235...

  • Page 25: General Information

    The engine serial number is stamped on a plate located on the rear right of the cylinder body, near the fuel filter 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 26: Fuel, Lubricant, And Coolant

    Engine failure or malfunction resulting from use of such manufacturer‘s instructions). Biocides are available from your dealer, improper fuel will not be warranted by Doosan. service stations, parts stores and other automotive places. See your authorized dealer for advice on using biocides in your area and for recommendations on which biocides you should use.

  • Page 27: Lubricant

    Refer to fig 5. Fig. 5 A. (Single − grade) COOLANT B. Ambient Temperature All Doosan portable compressor engines are factory filled with a 50/50 Ethylene glycol base antifreeze/water mix. which provides C. (Multi − grade) protection to −33_C (−27_F). 9/235...
  • Page 28 Fig. 7 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 29: Operation

    Cover the radiator cap with a thick cloth and loosen the cap slowly to reduce the pressure, then When disconnecting the terminals, start with “−” terminal. When connecting them, connect the “−” terminal last. remove the cap. 9/235...

  • Page 30: Operation And Care Of A New Engine

    If the level is correct, contact your local Doosan branch or dealer to establish the cause. If the engine coolant level in the reserve tank is at the correct level but there is still an indication of an overheat condition and no cause was found, please consult your local Doosan branch or dealer.

  • Page 31: 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 32: Cooling System

    When the cooling system circuit is contaminated with water scales or sludge particles, cooling efficiency will be lowered. Periodically clean the circuit interior with a suitable cleaner. Clean the cooling system circuit every 1000 operating hours or 12 months, whichever comes first. 9/235...

  • Page 33: Fuel System

    ‘A’ should be changed every 500 operating hours or 6 months, A Normal whichever comes first. B Clogged Change procedure: C Indicator Disconnect fuel sensor (where fitted). Loosen drain plug B and empty fuel into suitable container D Red signal 9/235...
  • Page 34 (*) need to be carried out Battery Servicing by a skilled and trained technician. Please consult your local Doosan branch or dealer when these Battery terminal connections procedures become due. Check the battery cable connections for looseness or corrosion.

  • Page 35: Cold Weather Operation

    The electrolyte in a partly discharged battery will freeze easier than All Doosan portable compressor engines are factory filled with a when it is fully charged. Try to keep the batterys fully charged and warm 50/50 Ethylene glycol base antifreeze/water mix.

  • Page 36: Maintenance Schedule

    Note: 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. 9/235...
  • Page 37 L 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 38 Check and clean the breather tube daily during cold weather. Check according to the equipment specifications. ventilation valve cleaning Perform the adjustment, cleaning, repair or replacement every 1500 hours. (This is a recommended maintenance item L). Consult your local branch or distributor. 9/235...
  • Page 39 Incorrect preheating operation. Glow plug malfunction. Fuel is injected but engine does not Incorrect injection timing. fire. cylinder compression pressure. Engine stop solenoid not fully returned. Engine fires but stalls immediately. Air in the fuel system. Incorrect low idle speed adjustment. 9/235...
  • Page 40 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. 9/235...
  • Page 41 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 9/235...
  • Page 42 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. 9/235...
  • Page 43 (2) or as defined by local or national legislation =Replace = Check (adjust, clean or replace as necessary) = Test =Check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 9/235...
  • Page 44 (2) or as defined by local or national legislation =Replace = Check (adjust, clean or replace as necessary) = Test =Check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 9/235...
  • Page 45 Ensure that maintenance personnel are adequately trained, removed is limited to only those tasks which require the machine to be competent and have read the Maintenance Manuals. running with safety protection devices disabled or removed. 9/235...
  • Page 46 Do not use gasket sealant since this will affect electrical relieved of all air pressure. (Refer to STOPPING THE UNIT in the conductance. OPERATING INSTRUCTIONS section of this manual). 9/235...
  • Page 47 Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion. VENTILATION The retaining clamp should be kept tight enough to prevent the Always check that the air inlets and outlets are clear of debris etc. battery from moving. 9/235...
  • Page 48 (refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual). 9/235...
  • Page 49 Alternate: XHP 405 ISO Viscosity Grade 68 Group 3 or 5 with Preferred Doosan Fluids − Use of these fluids with original Doosan rust and oxidation branded filters can extend airend warranty. Refer to operator’s manual inhibitors designed warranty section for details or contact your Portable Power for air compressor representative.
  • Page 50 E. Inlet Unloader normal operating discharge pressure. Close the service valve. The engine will slow to idle speed. CAUTION: Never allow the idle pressure to exceed maximum allowable pressure on the pressure gauge, otherwise the safety valve will operate. 9/235...
  • Page 51 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 105−115 5/8” lug nuts 16 inch 190−210 5/8” lug nuts 17.5 inch 190−210 9/235...
  • Page 52 Wheel Nut / Bolt Size Torque Moment (Nm) Torque Moment (ft−lb) 66 ± 4 M12 x 1.5 90± 5 110 ± 4 M14 x 1.5 150± 5 133 ± 4 M16 x 1.5 180± 5 155 ± 4 M18 x 1.5 210± 5 9/235...
  • Page 53 REGULATION ADJUSTMENT in the MAINTENANCE section of this manual. Premature unloading. Check the regulation system. 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. 9/235...
  • Page 54 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 by-pass valve. Check the operation of the element and replace if necessary. Recirculation of cooling air.
  • Page 55 Standing at the rear of the unit facing the NOTICE drawbar (front) will determine the right and left sides. Doosan can bear no responsibility for injury or damages FASTENERS resulting directly from the use of non−approved repair parts. Both SAE/inch, ISO/metric hardware have been used in the design and assembly of these units.
  • Page 56 Part numbers for original individual decals and unless expressly agreed to by Doosan Company their mounting locations are shown within Parts (“Company”) in writing. No additional or contrary terms List Section.
  • Page 57 Doosan offers an airend exchange program to benefit implied, except that of title, and all implied warranties, portable compressor users. including any warranty of merchantability and fitness for a particular purpose, are hereby disclaimed.
  • Page 58 PARTS ORDERING For information on how to order parts or information regarding your local distributor (Europe, Middle East, Africa) please contact: Facility: 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 −...

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