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
 CONTENTS & ABBREVIATIONS 1
1 CONTENTS & ABBREVIATIONS ABBREVIATIONS & SYMBOLS

2 FOREWORD #### Contact the company for serial number

->#### Up to Serial No.
3 DECALS
####-> From Serial No.
7 SAFETY * Not illustrated
† Option
9 GENERAL INFORMATION
WDG Generator option
12 OPERATING INSTRUCTIONS AR As required
HA High ambient machine
17 ENGINE INSTRIUCTION MANUAL S.R.G. Site running gear
H.R.G. High speed running gear
36 MAINTENANCE

48 MACHINE SYSTEMS
bg Bulgarian
cs Czech
54 FAULT FINDING
da Danish
de German
56 OPTIONS
el Greek
en English
63 PARTS ORDERING
es Spanish
et Estonian
fi Finnish
fr French
hu Hungarian
it Italian
lt Lithuanian
lv Latvian, Lettish
mt Maltese
nl Dutch
no Norwegian
pl Polish
pt Portuguese
ro Romanian
ru Russian
sk Slovak
sl Slovenian
sv Swedish
zh Chinese

9/235HA, 10/215HA
2 FOREWORD
The contents of this manual are considered to be proprietary and The intended uses of this machine are outlined below and examples of
confidential to and should not be reproduced without the prior written unapproved usage are also given, however the company cannot
permission of the company. anticipate every application or work situation that may arise.

Nothing contained in this document is intended to extend any promise, IF IN DOUBT CONSULT SUPERVISION.
warranty or representation, expressed or implied, regarding the
This machine has been designed and supplied for use only in the
products described herein. Any such warranties or other terms and
following specified conditions and applications:
conditions of sale of products shall be in accordance with the standard
terms and conditions of sale for such products, which are available • Compression of normal ambient air containing no known or
upon request. detectable additional gases, vapours. or particles
• Operation within the ambient temperature range specified in the
This manual contains instructions and technical data to cover all GENERAL INFORMATION section of this manual.
routine operation and scheduled maintenance tasks by operation and The use of the machine in any of the situation types listed in table
maintenance staff. Major overhauls are outside the scope of this 1:
manual and should be referred to an authorised service department.
a) Is not approved,
The design specification of this machine has been certified as b) May impair the safety of users and other persons, and
complying with EC directives. As a result: c) May prejudice any claims made against the company.
a) Any machine modifications are strictly prohibited, and will invalidate
EC certification. TABLE 1
b) A unique specification for USA/Canada is adopted and tailored to
Use of the machine to produce compressed air for:
the territory.
a) direct human consumption
All components, accessories, pipes and connectors added to the b) indirect human consumption, without suitable filtration and purity
compressed air system should be: checks.
• of good quality, procured from a reputable manufacturer and,
Use of the machine outside the ambient temperature range
wherever possible, be of a type approved by the company.
specified in the GENERAL INFORMATION SECTION of this
• clearly rated for a pressure at least equal to the machine maximum manual.
allowable working pressure.
• compatible with the compressor lubricant/coolant. This machine is not intended and must not be used in potentially
• accompanied with instructions for safe installation, operation and explosive atmospheres, including situations where flammable
maintenance. gases or vapours may be present.

Details of approved equipment are available from the company Use of the machine fitted with non approved components /
Service departments. lubricants / fluids.

The use of repair parts / lubricants / fluids other than those included Use of the machine with safety or control components missing or
within the approved parts list may create hazardous conditions over disabled.
which the company has no control. Therefore the company cannot be
held responsible for equipment in which non-approved repair parts are The company accepts no responsibility for errors in translation of this
installed. manual from the original 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
 DECALS 3
GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk WARNING - Pressurised component or WARNING - Hot surface.
system.

WARNING - Pressure control. WARNING - 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. 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
4 DECALS

WARNING - Maintenance work in progress. WARNING - Do not undertake any WARNING - Consult the operation and
maintenance on this machine until the maintenance manual before commencing
electrical supply is disconnected and the air any maintenance.
pressure is totally relieved.

Do not breathe the compressed air from this Do not remove the Operating and Maintenance Do not stack.
machine. manual and manual holder from this machine.

Do not operate the machine without the guard Do not stand on any service valve or other parts Do not operate with the doors or enclosure
being fitted. of the pressure system. open.

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
 DECALS 5

Lashing point (Tie down). Lifting point. On (power).

Off (power). Read the Operation and Maintenance manual When parking use prop stand, handbrake and
before operation or maintenance of this wheel chocks.
machine is undertaken.

Compressor oil filling. Diesel fuel. Parking brake.

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
6 DECALS

Engine oil drain.

9/235HA, 10/215HA
 SAFETY 7
When using compressed air, always use appropriate personal
WARNINGS
protective equipment.
Warnings call attention to instructions which must be followed
precisely to avoid injury or death. All pressure containing parts, especially flexible hoses and their
couplings, must be regularly inspected, be free from defects and be
CAUTIONS
replaced according to the Manual instructions.
Cautions call attention to instructions which must be followed
precisely to avoid damaging the product, process or its surroundings. Avoid bodily contact with compressed air.
NOTES The safety valve, located in the separator tank, must be checked
Notes are used for supplementary information. periodically for correct operation.

GENERAL INFORMATION MATERIALS

Ensure that the operator reads and understands the decals and The following substances may be produced during the operation of this
consults the manuals before maintenance or operation. machine:
Ensure that the Operation & Maintenance manual, and the manual • brake lining dust
holder, are not removed permanently from the machine. • engine exhaust fumes
Ensure that maintenance personnel are adequately trained, competent AVOID INHALATION.
and have read the Maintenance Manuals.
Ensure that adequate ventilation of the cooling system and exhaust
Ensure that ice and snow do not block the cooling air inlets. gases is maintained at all times.
Use hearing protectors when machine is running. The following substances are used in the manufacture of this machine
and may be hazardous to health if used incorrectly:
Make sure that all protective covers are in place and that the canopy/
doors are closed during operation. • anti-freeze
The specification of this machine is such that the machine is not • compressor lubricant
suitable for use in flammable gas risk areas. If such an application is • engine lubricant
required then all local regulations, codes of practice and site rules must • preservative grease
be observed. To ensure that the machine can operate in a safe and • rust preventative
reliable manner, additional equipment such as gas detection, exhaust • diesel fuel
spark arresters, and intake (shut-off) valves may be required, • battery electrolyte
dependant on local regulations or the degree of risk involved.
AVOID INGESTION, SKIN CONTACT AND INHALATION OF
A weekly visual check must be made on all fasteners/fixing screws FUMES.
securing mechanical parts. In particular, safety-related parts such as
coupling hitch, drawbar components, road-wheels, and lifting bail Should compressor lubricant come into contact with the eyes, then
should be checked for total security. irrigate with water for at least 5 minutes.

All components which are loose, damaged or unserviceable, must be Should compressor lubricant come into contact with the skin, then
rectified without delay. wash off immediately.

Consult a doctor if large amounts of compressor lubricant are ingested.

COMPRESSED AIR Consult a doctor if compressor lubricant is inhaled.

Compressed air can be dangerous if incorrectly handled. Before doing Never give fluids or induce vomiting if the patient is unconscious or
any work on the machine, ensure that all pressure is vented from the having convulsions.
system and that the machine cannot be started accidentally.
Safety data sheets for compressor and engine lubricants should be
Ensure that the machine is operating at the rated pressure and that the obtained from the lubricant supplier.
rated pressure is known to all relevant personnel.

All air pressure equipment installed in or connected to the machine BATTERY

must have safe working pressure ratings of at least the machine rated
pressure. Batteries contain corrosive liquid and produce explosive gas. Do not
expose to naked flames or sparks. Always wear personal protective
If more than one compressor is connected to one common
clothing when handling. When starting the machine from a slave
downstream plant, effective check valves and isolation valves must be
battery ensure that the correct polarity is observed and that
fitted and controlled by work procedures, so that one machine cannot
connections are secure.
accidentally be pressurised / over pressurised by another.
DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY
Compressed air must not be used for a direct feed to any form of SINCE THIS MAY CAUSE IT TO EXPLODE.
breathing apparatus or mask.

The discharged air contains a very small percentage of compressor RADIATOR

lubricating oil and care should be taken to ensure that downstream
equipment is compatible.
Hot engine coolant and steam can cause injury. Ensure that the
If the discharged air is to be ultimately released into a confined space, radiator filler cap is removed with due care and attention.
adequate ventilation must be provided.

9/235HA, 10/215HA
8 SAFETY
TRANSPORT When loading or transporting machines, ensure that the towing vehicle,
its size, weight, towing hitch and electrical supply are all suitable to
When loading or transporting machines ensure that the specified lifting provide safe and stable towing at speeds either, up to the legal
and tie down points are used and cables or chains are in safe limits. maximum for the country in which it is being towed or, as specified for
the machine model if lower than the legal maximum.

Before towing the machine, ensure that:

• the tyres and towing hitch are in a serviceable condition.

• 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
 GENERAL INFORMATION 9

76.2 mm NATO
R553.0

5350
1918
1804 3858
2334

2367
2179

2X R832.1
234
1676 2246 568 1950
T7140_00
1906 3400 07/17

1918 (3357)
1804
2020

1988

1832

2x727.8

880
200 2023
1500
3400
3634

3953

(979.7) 2x2223.4

4x14.3
8x17.5
2X1355.0

4x762.0

R553

(918.1)
T7141_00
07/17
2x101.6 2x2143.4 2x101.6

9/235HA, 10/215HA
10 GENERAL INFORMATION

MODEL 9/235HA (High Ambient) 10/235HA (High Ambient)

COMPRESSOR
Actual free air delivery m3/min/ 23,4/ 21,2/
cfm 825 750

Normal operating discharge pressure psi/bar/ 125/8,6/ 150/10,3/

kPa 860 1030
Maximum allowable pressure psi/bar/ 150/10,3/ 174/12/
kPa 1030 1200
Safety valve setting psi/bar/ 200/13,8/ 200/13,8/
kPa 1380 1380
Maximum pressure ratio (absolute) 8:1 8:1
Operating ambient temperature °C/ -10 to +52/ -10 to +52/
range °F 14 to 126 14 to 126
Maximum discharge temperature °C/ 120/ 120/
°F 248 248
Cooling system Oil Injection
Oil capacity Litre 64 64
Maximum oil system temperature °C/ 120/ 120/
°F 248 248
Maximum oil system pressure psi/bar/ 200/13,8/ 200/13,8/
kPa 1380 1380
LUBRICATING OIL
SPECIFICATION SEE ‘COMPRESSOR LUBRICATION’ IN THE MAINTENANCE SECTION
(for the specified ambient
temperatures)

9/235HA, 10/215HA
 GENERAL INFORMATION 11

MODEL 9/235HA-10/235HA (High Ambient)

ENGINE 6C8.3 (275hp)

Number of cylinders / Displacement /Litre 6/8,3
Oil capacity Litre 24
Speed at full load Rev min-1 2000

Speed at idle Rev min -1 1500

Electrical system V DC 24
Power available at rated speed KW 205
Fuel tank capacity Litre 462
Coolant capacity Litre 30

TOWING SPEED
WEIGHT
Shipping weight 3900 kg Maximum towing speed 30 km h-1
(20 mile h-1)
Maximum weight 4280 kg

WHEELS AND TYRES - SITE RUNNING GEAR Further information may be obtained by request through the
customer services department.
Number of wheels 4
Tyre size 750 x 16 x 6PR

Tyre pressure 4,5 bar (65 lbf in-2)

9/235HA, 10/215HA
12 OPERATING INSTRUCTIONS
COMMISSIONING Adequate clearance needs to be allowed around and above the
machine to permit safe access for specified maintenance tasks.
Upon receipt of the machine, and prior to putting it into service, it is
Ensure that the machine is positioned securely and on a stable
important to adhere strictly to the instructions given below in PRIOR
foundation. Any risk of movement should be removed by suitable
TO STARTING.
means, especially to avoid strain on any rigid discharge piping.
Ensure that the operator reads and understands the decals and
Attach the battery cables to the battery(s) ensuring that they are
consults the manuals before maintenance or operation.
tightened securely. Attach the negative cable before attaching the
Ensure that the position of the emergency stop device is known and positive cable.
recognised by its markings. Ensure that it is functioning correctly and
that the method of operation is known. WARNING: All air pressure equipment installed in or connected
to the machine must have safe working pressure ratings of at
Before towing the machine, ensure that the tire pressures are correct least the machine rated pressure, and materials compatible with
(refer to the GENERAL INFORMATION section of this manual) and the compressor lubricant (refer to the GENERAL INFORMATION
that the handbrake is functioning correctly (refer to the section).
MAINTENANCE section of this manual). Before towing the machine
during the hours of darkness, ensure that the lights are functioning
correctly (where fitted). WARNING: If more than one compressor is connected to one
common downstream plant, effective check valves and isolation
Ensure that all transport and packing materials are discarded.
valves must be fitted and controlled by work procedures, so that
Ensure that the correct fork lift truck slots or marked lifting / tie down one machine cannot accidentally be pressurised / over
points are used whenever the machine is lifted or transported. pressurised by another.

When selecting the working position of the machine ensure that there
is sufficient clearance for ventilation and exhaust requirements, WARNING: If flexible discharge hoses are to carry more than
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
 OPERATING INSTRUCTIONS 13

PRIOR TO STARTING 5. Drain the fuel filter water separator of water, ensuring that any
released fuel is safely contained.
1. Place the machine in a position that is as level as possible. The
6. Check the radiator coolant level (with the machine level).
design of the machine permits a 10 degree lengthways and
sideways limit on out of level operation. It is the engine, not the 7. Open the service valve(s) to ensure that all pressure is relieved
compressor, that is the limiting factor. from the system. Close the service valve(s).
When the machine has to be operated out of level, it is important to
8. CAUTION: Do not operate the machine with the canopy/doors
keep the engine oil level near the high level mark (with the machine
in the open position as this may cause overheating and
level).
operators to be exposed to high noise levels.
CAUTION: Do not overfill either the engine or the compressor
with oil. 9. Check the emergency stop. Pull knob to release.

10.Close the manual relief valve inside the machine, on the top of the
2. Check the engine lubrication oil in accordance with the operating separator tank.
instructions in the Engine Operator’s Manual.
When starting or operating the machine in temperatures below or
3. Check the compressor oil level in the sight glass located on the approaching 0°C (32°F), ensure that the operation of the regulation
separator tank. system, the unloader valve, the safety valve, and the engine are not
impaired by ice or snow, and that all inlet and outlet pipes and ducts
4. Check the diesel fuel level. A good rule is to top up at the end of
are clear of ice and snow.
each working day. 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
14 OPERATING INSTRUCTIONS

CONTROL PANEL 6. Engine speed gauge - Indicates engine speed (RPM).

7. Discharge air temperature gauge - Indicates airend discharge

1. Hourmeter - Records running time for maintenance.
temperature.
2. Compressor discharge pressure gauge - Indicates pressure in
8. Engine oil pressure gauge - Indicates engine oil pressure, psi
receiver tank, psi (kPa).
(kPa).
3. Fuel level gauge - Indicates amount of fuel in tank.
9. Engine water temperature gauge - Indicates coolant temperature,
4. Power switch - “ON” to activate systems prior to Starting. Flip with normal operating range from 180°F/82°C to 210°F/99°C.
“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
 OPERATING INSTRUCTIONS 15

DIAGNOSTICS DISPLAY PANEL 4. Low fuel level - Fault indicator lamp. Indicates shutdown due to low
fuel level. Lamp blinks at low fuel warning.
The diagnostic display panel is arranged as shown above. A
5. Low battery voltage - Alarm indicator lamp. Indicates battery or
description of each diagnostic indicator is as follows.
charging system requires service.
1. High compressor temperature - Fault indicator lamp. Indicates
6. Low engine coolant level - Alarm indicator lamp. Indicates coolant
shutdown due to high compressor temperature.
level in engine radiator is low.
2. Low engine oil pressure - Fault indicator lamp. Indicates
7. Restricted air filter - Alarm indicator lamp. Indicates engine/
shutdown due to low engine oil pressure.
compressor air inlet filters need service.
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
16 OPERATING INSTRUCTIONS
STARTING THE MACHINE Starting and stopping are unaffected by the selection and during
normal running the selector switch may be safely operated.
Precautions 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

1. Close the service valve.

2. Allow the machine to run unloaded for a short period of time to

reduce the engine temperature.

3. Turn the start switch to the off position (0).

NOTE: As soon as the engine stops, the automatic blowdown

valve will relieve all pressure from the system.
All normal starting functions are incorporated in the key operated
switch.
If the automatic blowdown valve fails to operate, then pressure must be
1. Turn the key switch to position (1). The engine fault and compressor relieved from the system by means of the service valve(s).
fault lamps will flash.
CAUTION: Never allow the machine to stand idle with pressure
2. Turn the key switch to crank position (3) (engine start position)
in the system.
NOTE: Position (2) not used on this model. Pre-heaters or glow
plugs are not fitted on this model. EMERGENCY STOPPING

3. Release to position (1) when engine starts. The engine will now be In the event that the unit has to be stopped in an emergency, TURN
running at a reduced speed. THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO
THE OFF POSITION (0), or push the EMERGENCY STOP SWITCH
At temperatures below 32°F (0°C) or if there is difficulty starting first
(when fitted).
time:

1. Open the manual blowdown valve fully.

RE-STARTING AFTER AN EMERGENCY
2. Complete starting sequence above.
If the machine has been switched off because of a machine
3. Close manual blowdown valve as soon as engine runs freely. malfunction, then identify and correct the fault before attempting to re-
Do not allow machine to run for long periods with manual blowdown start.
valve open. If the machine has been switched off for reasons of safety, then ensure
4. Allow the engine to reach operating temperature. that the machine can be operated safely before re-starting.

5. At this point in the operation of the machine it is safe to apply full Refer to the PRIOR TO STARTING and STARTING THE UNIT
load to the engine. instructions earlier in this section before re-starting the machine.

NOTE: Wear hearing protection at all times when the engine is MONITORING DURING OPERATION
started with the manual blowdown valve open and air is flowing
from the valve. Should any of the safety shut-down conditions occur, the unit will stop.

Refer to the diagnostic display page for a listing of shutdown

PUSH AFTER WARM-UP conditions.

NOTE: In order to allow the machine to start at a reduced load, a CAUTION: To ensure an adequate flow of oil to the compressor
valve, which is operated by a button located on the instrument at low temperature, never allow the discharge pressure to fall
panel, is incorporated in the regulation system. (The valve below 3,5 bar (50 psi).
automatically returns to the start position when the machine is
switched off and air pressure relieved from the system).
DECOMMISSIONING

Allow the engine to reach its operating temperature and then press the When the machine is to be permanently decommissioned or
button. dismantled, it is important to ensure that all hazard risks are either
At this point in the operation of the machine it is safe to apply full load eliminated or notified to the recipient of the machine. In particular:
to the engine. • Do not destroy batteries or components containing asbestos
without containing the materials safely.
DUAL PRESSURE REGULATION (WHEN FITTED) • Do not dispose of any pressure vessel that is not clearly marked
with its relevant data plate information or rendered unusable by
Machines which operate in excess of 7 bar (100 psi) can optionally be drilling, cutting etc.
fitted with a dual pressure switch inside the unit. This switch selects
between 7 bar (100 psi) and the machine rated pressure, cfm remains • Do not allow lubricants or coolants to be released into land surfaces
nominally constant. or drains.

• Do not dispose of a complete machine without documentation

relating to instructions for its use.

9/235HA, 10/215HA
 ENGINE INSTRUCTION MANUAL 17
6C8.3 ENGINE
CONTENTS

18 FOREWORD

19 EXTERNAL VIEWS

20 GENERAL INFORMATION

21 FUEL, LUBRICANT, AND COOLANT

23 OPERATION

26 PERIODICAL INSPECTION AND MAINTENANCE

29 COLD WEATHER OPERATION

30 MAINTENANCE SCHEDULE

32 TROUBLESHOOTING

9/235HA, 10/215HA
18 ENGINE INSTRUCTION MANUAL
FOREWORD
In order to get the most use and benefit from your engine, it is important that you operate and maintain it correctly. This Manual is designed to help
you do this.

Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of 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 contained within are for guidance only and might not reflect the physical characteristics of each individual engine covered.

9/235HA, 10/215HA
 ENGINE INSTRUCTION MANUAL 19
EXTERNAL VIEWS

1. Engine air inlet. 12. Turbocharger air outlet.

2. Shut off solenoid. 13. Oil filler cap.

3. Fuel filter. 14. Lubricating oil pressure (after filter).

4. Fuel transfer pump. 15. Lubricating oil pressure (before filter).

5. Oil drain plug. 16. Coolant heater port.

6. Dipstick (engine oil). 17. Lubricating oil cooler.

7. Engine data plate. 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 waste gate actuator. 22. Turbocharger exhaust outlet.

9/235HA, 10/215HA
20 ENGINE INSTRUCTION MANUAL
GENERAL INFORMATION
EPA CERTIFIED ENGINE DATA AND SPECIFICATIONS

Engine model name

6C8.3
Engine type Water-Cooled, four cycle, in-line overhead valve type
Combustion type Direct injection
No. of cylinders - bore x stroke. mm(in) 6-114 x 134.9 (4.49 x 5.31)
Engine displacement L (cid) 8.3 (506)
Compression ratio 18:1
Firing order 1-5-3-6-2-4
Exhaust emission control system Engine modification
Governor Mechanical type
Specified fuel Diesel fuel (ASTM D975 No. 2-D)
Starter (V-kW) 24 - 7.2
Alternator (V-A) 24 - 50
Specified engine oil (API grade) CG - 4, CH - 4, or better
Coolant volume (Engine only) L(qts) 11.4 (12)
Engine dry weight kg (lb) 617 (1360)
Overall length mm(in) 1128 (44.4)

Engine dimensions Overall width mm(in) 749 (29.5)

Overall height mm(in) 1096 (43.2)

Valve clearance (cold) mm(in) Intake 0,30 (.012) Exhaust 0,61 (.024)

ENGINE IDENTIFICATION Confirmation of engine number

It is advisable to quote the engine serial number together with the

Serial No. location
machine serial number, as it is required when you contact the company
The engine serial number is stamped on a plate located on the rear branch or distributor for repair, service or parts ordering.
right of the cylinder body, near the fuel filter
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 engine
production, and accordingly, they are warranted.

Genuine Doosan parts are supplied by your branch or distributor.

Please ensure that only genuine Doosan parts, lubricants and fluids
are used for service and/or repair.

Fig. 1

A. Engine serial number

9/235HA, 10/215HA
 ENGINE INSTRUCTION MANUAL 21
FUEL, LUBRICANTS AND COOLANT Check with the fuel supplier to be sure you get the properly blended
fuel.
FUEL
NOTE: Do not use home heating oil or gasoline in your diesel
Fuel selection engine; either may cause engine damage.

The following properties are required of the diesel fuel:

Handling of the fuel
• Must be free from minute dust particles.
Any fuel containing dust particles or water might cause engine failure.
• Must have adequate viscosity.
Therefore, the following must be observed:
• Must have high cetane value.
• Take care to protect the fuel from ingress of dust particles or water
• Must have high fluidity at low temperature. when filling the fuel tank.

• Must have low sulphur content. • 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
• Must have low residual carbon. bottom. Do not draw fuel direct from the bottom of the drum to
It is strongly advisable to use ASTM D975 No. 2D (the general prevent pick-up of any settled foreign material.
automotive diesel engine purpose fuel oil) or equivalent which fully • Always fully fill the fuel tank. Drain the sedimented particles in the
meets the above requirements. fuel tank frequently.

Water in fuel
Applicable Standard Recommendation
JIS (Japanese Industrial Standard) NO. 2 During refuelling, it is possible for water (and other contaminants) to be
pumped into your fuel tank along with the diesel fuel. This can happen
DIN (DEUTSCHE INDUSTRIE NORMEN) DIN 51601
if a fuel provider does not regularly inspect and clean its fuel tanks, or
SAE (Society of Automotive Engineers) Based NO. 2-D receives contaminated fuel from its supplier(s). To protect your engine
on SAE-J-313C
from contaminated fuel, there is a fuel filter system on the engine which
BS (BRITISH STANDARD) Based on BS/ Class A-1 allows you to drain excess water.
2869-1970
EURONORM EN590 NOTE: The water/diesel fuel mixture is flammable, and could be
hot. To avoid personal injury and/or property damage, do not
Fuel requirements touch the fuel coming from the drain valve, and do not expose
the fuel to open flames or sparks.
NOTE: The fuel injection pump, injector or other parts of the fuel
system and engine can be damaged if you use any fuel or fuel Be sure you do not overfill the fuel tank. Heat (such as from the engine)
additive other than those specifically recommended by Doosan. can cause the fuel to expand. If the tank is too full, fuel could be forced
out. This could lead to a fire and the risk of personal injury and/or
equipment damage.
NOTE: If any fuel other than the one specified is used, engine
operation will be impaired. Engine failure or malfunction Biocides
resulting from use of such improper fuel will not be warranted In warm or humid weather, fungus and/or bacteria may form in diesel
by Doosan. fuel if there is water in the fuel.

To help avoid fuel system or engine damage, please read the following: NOTE: Fungus or bacteria can cause fuel system damage by
plugging the fuel lines, fuel filters or injector. They can also
Do not use diesel fuel which has been contaminated with engine oil.
cause fuel system corrosion.
Besides causing engine damage, such fuel can also affect emission
control. Before using any diesel fuel, check with the fuel supplier to see
if the fuel has been mixed with engine oil. If fungus or bacteria has caused fuel system problems, you should
have your authorized dealer correct these problems. Then, use a
Your engine is designed to use either Number 1-D or Number 2-D diesel fuel biocide to sterilize the fuel system (follow the biocide
diesel fuel. However, for better fuel economy, use Number 2-D diesel manufacturer‘s instructions). Biocides are available from your dealer,
fuel whenever possible. At temperatures less than -7°C, (20°F), service stations, parts stores and other automotive places. See your
Number 2-D fuel may pose operating problems (see “Cold weather authorized dealer for advice on using biocides in your area and for
operation” which follows). At colder temperatures, use Number 1-D fuel recommendations on which biocides you should use.
(if available) or use a “winterized” Number 2-D (a blend of Number 1-D
and Number 2-D). This blended fuel is usually called Number 2-D also, Smoke suppressants
but can be used in colder temperatures than Number 2-D fuel which The use of a smoke suppressant additive is not allowed because of the
has not been “winterized.” greater possibility of stuck rings and valve failure, resulting from
excessive ash deposits.

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22 ENGINE INSTRUCTION MANUAL
LUBRICANT Oil viscosity

Engine oil viscosity affects engine startability, performance, oil

Use of unsuitable engine oil will result in piston ring, piston and cylinder
consumption, wear and the potential for seizure, etc. Always ensure
seizure and accelerate surface wear causing increased oil
that lubricants with the correct viscosity for the operating temperature
consumption, lowered output and, finally engine failure. To avoid this,
are used. Refer to fig 2.
use the specified engine oil:

• Engine Oil Selection - PRO-TEC

Fig. 2

A. (Single-grade) COOLANT

B. Ambient Temperature
All Doosan portable compressor engines are factory filled with a 50/50
C. (Multi - grade) Ethylene glycol base antifreeze/water mixture. which provides
protection to -33°C (-27°F).
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/or viscosity, is not covered by the
warranty.

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 ENGINE INSTRUCTION MANUAL 23
OPERATION CAUTION: When adding oil, take care not to spill it. If you spill
oil on the engine or equipment, wipe it off properly, to prevent
ENGINE OPERATION
the risk of fire and personal injury and/or equipment damage.

Engine exhaust gas caution (carbon monoxide)

Fan and belt check
CAUTION: Do not breathe exhaust gas because it contains The engine is fitted with an automatic belt tensioner
carbon monoxide, which by itself has no colour or odour.
Carbon monoxide is a dangerous gas. It can cause Check the fan belt for tension and abnormalities.
unconsciousness and can be lethal. A loose belt will cause belt slippage which may result in a damaged
Do not run the engine in confined areas (such as garages or next belt, abnormal noise, poor battery charging and engine overheating.
to a building). Keep the exhaust pipe clear of snow and other
material to help reduce the buildup of exhaust gases under the
equipment. This is particularly important when parked in
blizzard conditions.

CHECK BEFORE OPERATION

CAUTION: For safety reasons, conduct the inspection with the

engine stopped.

Engine oil level

Place the engine or the machine on a level surface.

Remove the dipstick, wipe it with a cloth. Insert it fully and take it out
gently again.

Check the oil level against the marks on the dipstick. The oil level must
be between the “H” level mark and the “L” level mark as illustrated.

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.

Coolant level check

Fig. 3
Check and ensure that the level is correct.
Also check the sample oil on the dipstick for contamination and
viscosity. CAUTION: When removing the radiator filler cap, while the
engine is still hot, cover the cap with cloth, then turn it slowly to
Take care not to add too much engine oil.
gradually release the internal steam pressure. this will prevent
Oil can be poured either through the oil filler at the front of the cylinder anyone from being scalded by hot steam spurting out from the
head cover or through the oil filler on the right side of the timing gear filler neck.
case.
Add coolant mixed to the correct ratio: 50/50 ethylene glycol/water.
A certain period of time is required before the engine oil completely
flows down from the oil filler to the crankcase. Wait at least ten minutes Radiator cap condition
before checking the oil level.
After the replenishment of the coolant, install the radiator filler cap.
Make sure the cap is securely installed.
NOTE: Take care to avoid engine oil being splashed on the fan
drive belt because it causes belt slippage or slackness. Crankcase breather

Check and clean the breather tube daily during cold weather.

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24 ENGINE INSTRUCTION MANUAL
Battery cable connection Leakage in the systems

Check the battery cable connections for looseness or corrosion. A Check the following items:
loosened cable connection will result in hard engine starting or
• Lubrication oil leakage - Check the engine for oil leaks, paying
insufficient battery charge. The battery cables must be tightened
particular attention to oil filter and oil pipe joints.
securely. Never reverse “+” and “-” terminals when reconnecting
cables after disconnection. Even a short period of reverse connection • Fuel leakage - Check the fuel injection pump, fuel lines and fuel
will damage the electrical parts. filter for leakage.

• Coolant leakage - Check the radiator and water pump hose

connections and the water drain cock on the cylinder block for
leakage.

• Exhaust smoke or gas leakage

Checking coolant level

The coolant level could drop because any mixed air is expelled in about
5 minutes after the engine started.

Stop the engine, remove radiator cap, and add coolant.

CAUTION: Hot steam can rush out and you could get burnt if the
Fig. 5 radiator cap is removed when the engine is hot. Cover the
radiator cap with a thick cloth and loosen the cap slowly to
A. Battery cable reduce the pressure, then remove the cap.
B. Connection
OPERATION AND CARE OF A NEW ENGINE
Battery electrolyte level

The amount of electrolyte in the batteries will be reduced after repeated Your engine is carefully tested and adjusted in the factory, however,
discharge and recharge. Check the electrolyte level in the batteries, further run-in is necessary. Avoid any harsh engine operation within the
replenish with a commercially available electrolyte such as distilled initial 100 operating hours.
water, if necessary. The battery electrolyte level checking procedure
Do not operate the unit at full load until the engine is warmed-up.
will vary with battery type.
Do not allow the engine to run unloaded for extended periods so as to
NOTE: Do not replenish with dilute sulfuric acid in the daily minimise the risk of cylinder bore glazing.
service.
During operation, pay attention to the following points if the engine
shows any sign of abnormalities:
CAUTION: When inspecting the batteries, be sure to stop the
(1) Engine Oil Pressure - The engine oil pressure is monitored by a
engine first.
switch that will stop the engine if the pressure falls below a pre-set
As dilute sulphuric acid is used as electrolyte, be careful not to
value.
contaminate your eyes, hands, clothes, and metals with the
electrolyte. If it gets in your eye, wash with a large amount of If the oil pressure gauge shows below 30 psi or if the reading fluctuates
water at once, then seek medical advice. continually, stop the engine and check the oil level. 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.
the batteries.
When handling such metallic articles as tools near the batteries, (2) Coolant Temperature - The engine performance will be adversely
be sure not to contact the “+” terminal because the compressor affected if engine coolant temperature is too hot or too cold. The
body is “-” and a dangerous short circuit might result. normal coolant temperature is 75 to 85°C (167 to 185°F).
When disconnecting the terminals, start with “-” terminal. When Overheating
connecting them, connect the “-” terminal last.
CAUTION: If you see or hear escaping steam or have other
CHECKS AND OPERATION AFTER START-UP reason to suspect there is a serious overheat condition, stop the
engine immediately.
Check after the engine start-up

Check the following items in the engine warming-up operation: If the Engine Coolant Temperature gauge (where fitted) shows an
overheat condition, or you have reason to suspect the engine may be
• Engine oil pressure - The engine oil pressure gauge readings overheating, take the following steps:
(where fitted) may vary depending on ambient temperature and
type of oil. The gauge should register around 55 to 85 psi in the • Close the service valve to reduce the load.
warming-up period. • Let the engine run at normal idle speed for two or three minutes. If
• Engine noise and exhaust smoke color - Listen to the engine the engine coolant temperature does not start to drop, turn off the
and, if any abnormal noise is heard, check to determine the cause. engine and proceed as follows:

Check the fuel combustion condition by observing the exhaust CAUTION: To help avoid being burned:
smoke color. The exhaust smoke color after engine warm-up and at Do not open the canopy or door if you see or hear steam or
no-load condition should be colorless or light blue. engine coolant escaping. Wait until no steam or engine coolant
can be seen or heard before opening the engine canopy or door.
Black or white smoke indicates incorrect combustion. Do not remove the radiator filler cap if the engine coolant in the
reserve tank is boiling. Also do not remove the radiator filler cap
NOTE: After start-up from cold the engine might be noisier and while the engine and radiator are still hot. Scalding fluid and
the exhaust smoke color darker than when it has warmed up. steam can be blown out under pressure if either cap is taken off
However this condition will disappear after warm up. too soon.

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 ENGINE INSTRUCTION MANUAL 25
• If no steam or engine coolant can be seen or heard, open the Overcooling
canopy or door. If the engine coolant is boiling, wait until it stops
before proceeding. The engine coolant level should be between the Operating the engine at low coolant temperature will not only increase
“MAX COLD” and “MIN” marks on the reserve tank. the oil and fuel consumption but also will lead to premature parts wear
which may result in engine failure. Ensure that the engine reaches
• Make sure the fan belt is not broken, or off the pulley, and that the normal operating temperature 75 to 85°C (167 to 185°F) within ten
fan turns when the engine is started. If the engine coolant level in minutes of starting.
the reserve tank is low, look for leaks at the radiator hoses and
(3) Hourmeter - This meter indicates the machine operation hours.
connections, radiator, and water pump. If you find major leaks, do
not run the engine until these problems have been corrected. If you Make sure that the meter is always working during engine operation.
do not find a leak or other problem, WAIT UNTIL THE ENGINE HAS Periodical machine maintenance is scheduled on the operation hours
indicated on the hourmeter.
COOLED DOWN then carefully add engine coolant to the reserve
tank. (4) Liquid and exhaust smoke leakage - Make regular checks for
(Engine coolant is a mixture of ethylene glycol antifreeze and water. lubricant, fuel, coolant and exhaust smoke leakage.
See “Engine Care in cold season” for the proper antifreeze and (5) Abnormal engine noise - In the event of any abnormal engine
mixture.) noise, please consult your local Doosan branch or dealer.

CAUTION: To avoid being burned, do not spill antifreeze or (6) State of the exhaust smoke - Check for any abnormal exhaust
engine coolant on the exhaust system or hot engine parts. smoke colour.
Under some conditions the ethylene glycol in engine coolant is Engine stopping
combustible.
• Close service valves.
If the engine coolant level in the reserve tank is at the correct level but • Before stopping the engine, cool down the engine by operating it at
there is still an indication of an overheat condition and no cause was reduced load about three minutes. In this period, check the engine
found, please consult your local Doosan branch or dealer. noise and the engine oil pressure (where a gage is fitted) for
abnormalities.

Long term storage

If the equipment is to be out of operation for an extended period, it

should be started at least once per week and run on load for about
15 minutes after it has reached normal operating temperature.

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26 ENGINE INSTRUCTION MANUAL
PERIODICAL INSPECTION AND Oil Filter Element Installation

MAINTENANCE Lightly apply engine oil to the O-ring.

LUBRICATING SYSTEM

Servicing of the engine oil and oil filter element will affect the engine
performance as well as the engine life. Change the engine oil and the
oil filter in accordance with the recommended service intervals.

Engine oil and oil filter element change

Engine oil change and oil filter element change must be made
simultaneously according to the following change schedule.

NOTE: For change intervals: Refer to maintenance schedule

section.

Engine oil draining

CAUTION: To help avoid the risk of being burned, do not drain Fig.8
oil while the engine is still hot.
Screw in the new cartridge hand tight as the O-ring comes in contact
Wipe clean around the oil filler cap taking care so that no foreign with the engine block. Tighten a further 3/4 to 1 1/4 turns. DO NOT
articles enter. Remove the filler cap. overtighten.

It is advisable that draining be done while the engine is warm to Fill with new engine oil via the most convenient oil filler port.
minimize the draining time. Wait at least ten minutes until the oil drains down to the oil pan. Then
Remove the oil pan drain plug and drain the engine oil completely. check the oil level with the dipstick.

Check after oil and filter changes

NOTE: Use a receptacle to catch the drained oil so that the
engine and equipment will not be contaminated. 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 necessary replenish with
engine oil to the specified level

NOTE: When the engine is started, the oil level will slightly drop
from the initial level as the oil fills the entire oil circuit.

Engine oil additives

Engine oils contain a variety of additives. Your engine should not need
Fig. 6
any extra additives if you use the recommended oil quality and change
Remove drain plug arrowed to drain the engine oil completely. intervals.

Oil Filter Element Removal Used engine oil

Do not dispose of used engine oil (or any other oil) in a careless
manner such as pouring it on the ground, into sewers, or into streams
or bodies of water. Instead, recycle it by taking it to a used oil collection
facility which may be found in your community. 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.

CAUTION: Used engine oil contains harmful contaminants that

have caused skin cancer in laboratory animals. Avoid prolonged
skin contact. Clean skin and nails thoroughly using soap and
water - not mineral oil, fuels, or solvents. Launder or discard
clothing, shoes, or rags containing used engine oil.

Discard used engine oil and other oils properly.

Fig. 7 COOLING SYSTEM
A. Cartridge
Coolant change

The coolant must be changed at intervals of 1000 hours or twelve

months, whichever come first.

If the coolant becomes sludged up it will lead to engine overheating or

coolant blow-off from the radiator.

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 ENGINE INSTRUCTION MANUAL 27
Coolant draining Filling with coolant

Ensure that the engine is cool.

WARNING: Hot engine coolant and steam can cause injury.
When adding to or draining coolant or antifreeze solution from Close the coolant drain plug and tighten the bottom hose clamp.
the engine radiator, stop the engine at least one minute prior to
releasing the radiator filler cap. Using a cloth to protect the Use clean water mixed 50/50 with antifreeze as a coolant.
hand, slowly release the filler cap, absorbing any released fluid Fill slowly to prevent air entering the cooling system.
with the cloth. Do not remove the filler cap until all excess fluid
is released and the engine cooling system fully depressurised. For coolant volume, refer to “General Information section”.

When the system has been filled, operate the engine about five
WARNING: Follow the instructions provided by the antifreeze minutes at a low idle speed, then as the air contained in the coolant
supplier when adding or draining the antifreeze solution. It is circuit is bled off the coolant level will drop.
advisable to wear personal protective equipment to prevent skin
Stop the engine and replenish with the correct coolant mix.
and eye contact with the antifreeze solution.
Cleaning outside of radiator, oil cooler and charge air cooler
Remove the radiator cap.
Debris, mud or dried grass caught between radiator fins will block the
Slacken the bottom radiator hose clamp to drain the coolant from the air flow, resulting in lower cooling efficiency. Clean the radiator fins with
radiator. steam or low pressure (< 5 Bar) compressed air every 250 hours or 3
months (whichever comes first) or more frequently in adverse
operating conditions.

Cooling system circuit cleaning

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.

FUEL SYSTEM

The fuel injection pump and injector nozzles are precisely

manufactured, and therefore, using fuel which contains water or dust
particles will result in either injection pump plunger seizure or injector
nozzle seizure. A fuel filter element blocked with sludge or dust
Fig. 9 particles will lead to reduced engine output.

A. Cylinder block water drain valve Perform inspection and maintenance periodically as follows:

Coolant filter replacement

Fig. 12
Fig. 10
A.Filter Element
Rotate clockwise to close shut-off valve. Remove and replace coolant
filter. Open shut-off valve. B.Drain Valve

Draining water from fuel filter/separator

The fuel filter/separator is provided to allow water to be drained from

the fuel system. Water is heavier than fuel so any water contained in
the system will collect in the bottom of the bowl.

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

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28 ENGINE INSTRUCTION MANUAL
Fuel filter/separator element change Air cleaner with dust indicator
This indicator is attached to the air cleaner. When the air cleaner
NOTE: The cartridge and bowl contain fuel. Take care not to spill element is clogged, air intake resistance becomes greater and the dust
it during disassembly and reassembly. indicator signal turns to red indicating the element needs to be
changed.
When the signal turns to red, replace the element. Then press the dust
indicator button to reset the indication.
Air intake piping
Inspect air intake and charge air cooling pipes and connections for
damage or loose fitting. Replace or re-fit as necessary.

Fig. 13

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 container.

Using a clean cloth, wipe the sealing face of the filter/separator head
to ensure correct seating of the sealing ring. Fig. 15
Fill the element/bowl assembly with clean fuel oil then apply a light coat ENGINE ELECTRICAL
of clean engine oil to the new element seal ring.

Screw the new element onto the head firmly by hand. The engine uses a 24 volt system and a negative grounding for the
electrical system.
The engine has a self priming system that purges air from the fuel
Battery servicing
system.
Battery Terminal Connections:
AIR INTAKE SYSTEM
Check the battery cable connections for looseness or corrosion. Poor
Air cleaner cable connections will result in difficult engine starting or insufficient
battery charge
Engine performance and life vary with the air intake conditions.
The battery cables must be tightened securely.
A dirty air cleaner element reduces the amount of intake air, causing Never reverse “+” and “-” terminals when reconnecting cables after
reduced engine output and possible engine damage. removal. Even a short period of reverse connection will damage the
electrical parts.
Also, a damaged element leads to abrasion of cylinders and valves,
resulting in increased oil consumption, reduced output and shortened Cleaning of battery
engine life.
When the battery terminals are fouled clean them with clean tepid
The filter element should be changed at 500 hours or 6 months, water and wipe with a dry cloth to remove the water. Apply a light coat
whichever comes first, or sooner if the restriction indicator shows red. of vaseline or a grease.
See below: Alternator servicing
The polarity of the alternator is negative (-) grounding type.
Do not reverse the polarity connection, otherwise a short circuit will
occur resulting in alternator failure.
Do not put water directly on the alternator. Entry of water into the
alternator creates electrolytic corrosion causing failure.
When the battery is charged from an external source, be sure to
disconnect the battery cables.
Wiring connections
Check all of the electric wiring connections for looseness and damage
on a regular basis.
SERVICE AND MAINTENANCE

Please refer to the engine maintenance schedule.

For continued trouble free engine operation throughout its life, the
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.
D. Red signal
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 ENGINE INSTRUCTION MANUAL 29
COLD WEATHER OPERATION ENGINE OIL

At low ambient temperatures, engine oil viscosity can affect engine

FUEL SELECTION starting. It is important to use the correct grade of oil as recommended
in fig 2.
In cold weather, the fuel might freeze resulting in difficult engine
Try to position the compressor where it will not be affected by cold
starting; therefore, select a suitable fuel for such engine operation.
winds when not running.
Use ASTM 975 No. 2-D fuel if you expect temperature above 20°F
(-7°C).
BATTERY
Use Number 1-D if you expect temperatures below 20°F (-7°C).
Always ensure that the batteries are kept fully charged in the cold
If Number 1-D is not available, a “winter” blend of 1-D and 2-D is
season. This takes a longer period of running than in warm weather
available in some areas during the winter months.
operation.
Check with your fuel supplier to be sure you get the correct blended
fuel. NOTE: The electrolyte in a partly discharged battery will freeze
easier than when it is fully charged. Try to keep the batteries
fully charged and warm in cold weather operation.
COOLANT

Top up the battery with distilled water immediately before starting the
Where the ambient temperature falls below freezing point, the cooling
engine.
system should be drained after engine operation, but to eliminate the
need for repeated draining, refilling and to provide all year protection
against corrosion, the use of anti-freeze solution throughout the year is COLD STARTING
highly recommended.

All Doosan portable compressor engines are factory filled with a 50/50 When operating in cold ambient conditions, or when starting from cold,
Ethylene glycol base antifreeze/water mix. which provides protection to if the engine does not start at the first attempt, allow the battery to
-33°C (-27°F). recover for at least 30 seconds.

Concentrations over about 65% adversely affect freeze protection, Observe the following procedures:
heat transfer rates, and silicate stability which may cause water pump • In order to protect the starter, do not engage for longer than 10
leakage. seconds during any attempt.

CAUTION: Never exceed a 60/40 antifreeze/water mixture. • If during cranking, the starter motor repeatedly engages and
(which provides protection to about-50°C (-58°F). disengages the battery power could be low. Either recharge the
battery or replace it with one that is fully charged.

NOTE: Methyl alcohol base antifreeze is not recommended NOTE: Do not use starting “aids” in the air intake system. Such
because of its effect on the non-metallic components of the aids can cause immediate engine damage.
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.

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30 ENGINE INSTRUCTION MANUAL
ENGINE MAINTENANCE SCHEDULE
When performing the following items, the daily inspection items should also be carried out.

No Description of check Daily (operation hours) Remark

and maintenance
250 500 750 1000 1250 1500
1 Oil level O
2 Oil leakage O
3 Oil pressure gage reading O
(where fitted)
4 Oil pressure warning lamp O
(where fitted)
5 Engine oil replacement O O O
6 Oil filter element O O O See “EXPLANATION OF
replacement MAINTENANCE SCHEDULE”
7 Fuel leakage O
8 Draining water in fuel filter/ O
separator
9 Fuel filter element O O O
replacement
10 Injection nozzle check (*) O
11 Coolant level O
12 Coolant leakage check O
13 Radiator filler cap fitting O
condition
14 Fan and belt check O O
15 Coolant temperature gage O
reading (where fitted)
16 Coolant replacement O
17 Coolant filter replacement O
18 Radiator external face O O O O O O
cleaning
19 Cooling system circuit O
cleaning
20 Radiator filler cap O O O
function check (*)
21 Electrolyte level check O
22 Battery cleaning O
23 Battery charge lamp O
24 Starter and alternator check O
and cleaning (*)
25 Wiring and connection O O O
check
26 Air cleaner element O O O
replace
27 Air intake piping O
28 Engine starting conditions O
and noise conditions
29 Exhaust smoke condition O
30 Cylinder compression O
pressure (*)
31 Valve clearance check (*) O
32 Positive crankcase O O
ventilation valve cleaning

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.

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 ENGINE INSTRUCTION MANUAL 31

NOTE: 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.

EXPLANATION OF MAINTENANCE SCHEDULE

The following is a brief explanation of the services listed in the preceding Engine Maintenance schedule.

1. Oil level Check that the oil level is within cross hatch area (ref fig. 3).
Fill or drain as necessary.
2. Oil leakage check Replace any damaged or malfunctioning parts which could cause leakage.
3. Oil pressure gauge Normal oil pressure is 30 to 85 psi. Check and repair the lubrication system if it is abnormal.
4. Oil pressure warning lamp If it stays on whilst running, check and repair the lamp and/or lubrication system.
5. Engine oil replacement Change at 500 hours or 6 months, whichever comes first.
6. Oil filter element Change at 500 hours or 6 months, whichever comes first.
replacement
7. Fuel leakage Replace any damaged or malfunctioning parts which could cause leakage.
8. Draining water in fuel Drain off water in the fuel filter/separator bowl.
filter/separator
9. Fuel filter element Replace both primary (filter/separator) and secondary elements at 500 hours or 6 months whichever come
replacement 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 or malfunctioning parts which could cause leakage.
13. Radiator filler cap fitting The radiator cap must be installed tightly and sealing correctly.
condition
14. Fan and belt check Look for cracks, fraying and wear. Replace if necessary.
15. Coolant temperature Normal running temperature is 75 to 85°C (167 to 185°F). Check and repair the cooling system if temperature
is abnormal.
16. Coolant replacement Change coolant at intervals of 1000 hours or 12 months, whichever comes first.
17. Coolant filter replacement Replace filter at 500 hours
18. Radiator external face Check monthly. Clean at intervals of 250 hours or 3 months, whichever comes first. In very dusty
cleaning environments, more frequent cleaning might be necessary.
19. Cooling system circuit Clean at intervals of 1000 hours or 12 months, whichever comes first.
cleaning
20. Radiator filling cap Check radiator pressure cap periodically for proper operation. Consult your local branch or distributor.
function check
21. Battery electrolyte level Replenish with distilled water if necessary.
check
22. Battery cleaning Clean the terminals.
23. Battery charge condition If the lamp stays on while engine is running, check charging circuit.
24. Starter and generator Check wear condition of brush and commutator. Consult your local branch or distributor.
check and cleaning
25. Wiring and connection Check for loose terminals/connections and integrity of insulation.
check
26. Air cleaner element Change element at 500 hours or 6 months, whichever come first, or sooner if the restriction indicator shows
replace red.
27. Air intake piping Check pipes and connections for damage or loose fitting.
28. Engine starting condition Check engine stability and noise.
and noise condition
29. Exhaust smoke condition Check exhaust smoke color.
30. Cylinder compression Consult your dealer or distributor.
pressure
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 thereby adversely
affecting engine performance. Check and adjust every 1000 hours. Consult your local branch or distributor.
32. Positive crankcase Check and clean the breather tube daily during cold weather. Check according to the equipment
ventilation valve cleaning specifications. Perform the adjustment, cleaning, repair or replacement every 1500 hours. (This is a
recommended maintenance item ). Consult your local branch or distributor.

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32 ENGINE INSTRUCTION MANUAL

ENGINE TROUBLESHOOTING
This item contains a simple troubleshooting. When a failure takes place on your engine, diagnose the cause referring this troubleshooting. Should
the cause of failure not be detected or you are unable to manage the failure, consult your machine supply source or nearest company engine service
outlet.

Engine does not start. Battery discharged.

Starter does 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 Control rack is stuck at no fuel
fire. position.

Incorrect preheating operation.

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
 ENGINE INSTRUCTION MANUAL 33

Unstable engine running. Crack in injection pipe.

Unstable low idling. Injection nozzle failure.

Engine stop solenoid return failure.

Uneven compression pressure between cylinders.

Incorrect high idle speed

Incorrect control lever adjustment.
adjustment.

Governor internal malfunction.

Engine hunting in medium speed

Governor spring deteriorated.
range.

Air in the fuel system.

Insufficient fuel supply. Clogged fuel filter element.

Piping failure (squeezed/
restricted etc.).

Engine malfunction in high speed

Uneven fuel injection amount between cylinders.
range.

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.

Improper servicing. Air cleaner element clogged.

Insufficient airflow/restriction.

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
34 ENGINE INSTRUCTION MANUAL

Low engine output. Incorrect injection timing Too far advanced.

Too far retarded.

Injection nozzle malfunction Incorrect injection pressure.

Incorrect spray condition.

Incorrect injection pump Lack of fuel in tank.

adjustment
Insufficient fuel supply to the
injection pump Air in injection pump.

Fuel filter clogged.

Overflow valve malfunction.

Incorrect engine control

Governor malfunction adjustment.

Deteriorated governor spring.

Incorrect valve clearance

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 / Damaged turbocharger seal

Oil leakage. Loose joints/gaskets.

Improper installation of filter and piping.

Excessive fuel consumption. Fuel leakage. Damaged seals.

Improper component installation or tightening.

Excessive injection volume. Injection pump defective.

Excessive mechanical loads.

9/235HA, 10/215HA
 ENGINE INSTRUCTION MANUAL 35

Improper exhaust. Clogged air cleaner.

Damaged injector nozzle.

Excessive black smoke. Wrong injector nozzle.

Injection timing incorrect.

Excessive injection volume.

Incorrect 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.

9/235HA, 10/215HA
36 MAINTENANCE

MAINTENANCE
Initial Daily Weekly Monthly 6 Months 1 Year 2000 hrs 5000hrs
850 km (500 hrs) (1000 hrs)
(500 miles)
Compressor Oil Level C
Engine Oil Level C
Coolant Level C
Gauges/Lamps C
Air Cleaner Service Indicators C
Air Cleaner Dust Ejector Valve C
Aftertreatment Exhaust Piping C
Fuel Tank C
Fuel/Water Separator Drain D
Fluid Leaks C
Radiator Filler Cap C
Air Cleaner Precleaner Dumps C
Air Cleaner Precleaner Dumps C
Fan/Alternator Belts C
Battery Connections/Electrolyte C
Tyre Pressure and Surface C
Wheel Lug Nuts C
Hoses (Oil, Air, Intake, etc.) C
Automatic Shutdown System C
Air Cleaner System C
Coolers and Radiator C
Fasteners, Guards C
Primary Air Cleaner Elements R/WI
Secondary Air Cleaner Elements R/WI
Fuel/Water Separator Element R
Final Fuel Filter R
Engine Oil Filter R
Engine Oil R
Engine Breather Filter R
Engine Coolant Conditioner Filter R
Engine Valve Lash C/A
Engine DPF Filter R/WI

C = Check and act if required Refer to specific sections of the operator’s manual for more
information.
T = Test
D = Drain NOTE: 500 and 1000 hour intervals are meant to be repeated at
every 500 or 1000 hours. Other intervals only to be performed at
R = Replace hours indicated.
CBT = Check before towing
R/WI = Replace or when indicated earlier NOTE: All fluid and filter intervals are valid for near perfect conditions
only. High ambient temperatures - high dust concentration - high
C/R = Check and replace if required humidity as well as using lower grade oils and fuels will require a
G/C = Grease and check decrease in maintenance intervals.
Contact your Doosan Infracore Portable Power dealer for more
C/A = Check and adjust if required information or assistance in determining the optimum intervals for
your application.

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 MAINTENANCE 37

MAINTENANCE
Initial Daily Weekly Monthly 6 Months 1 Year 2000 hrs 5000hrs
850 km (500 hrs) (1000 hrs)
(500 miles)
Aftertreatment DEF Unit Filter C/A
Compressor Oil Filter R
Compressor Oil R
Oil Separator Element R
Engine Coolant C R
Wheels (bearings, seals, etc.) C
Shutdown Switch Settings T
Scavenger Orifice and related C
Lights (brake, running and turn) CBT
Pintle Eye Bolts CBT
Brakes C C
Brake Linkage C
Emergency Stop T
Fasteners C
Running Gear Linkage and Bolts C G/C
Safety Valve C
Minimum Pressure Valve C
Pressure System C
Pressure Gauge C
Pressure Regulator C
Separator Tank Exterior C
Lubricator (Fill) C
Engine Air Inlet Shutdown Valve C
Engine Vibration Damper C/R

C = Check and act if required Refer to specific sections of the operator’s manual for more
information.
T = Test
D = Drain NOTE: 500 and 1000 hour intervals are meant to be repeated at
every 500 or 1000 hours. Other intervals only to be performed at
R = Replace hours indicated.
CBT = Check before towing
R/WI = Replace or when indicated earlier NOTE: All fluid and filter intervals are valid for near perfect conditions
only. High ambient temperatures - high dust concentration - high
C/R = Check and replace if required humidity as well as using lower grade oils and fuels will require a
decrease in maintenance intervals.
G/C = Grease and check Contact your Doosan Infracore Portable Power dealer for more
C/A = Check and adjust if required information or assistance in determining the optimum intervals for
your application.

9/235HA, 10/215HA
38 MAINTENANCE
DRAIN LOCATIONS
NOTE: Pressure will always remain in the part of the system between
the minimum pressure valve and the discharge valve after operation
of the auto blowdown valve.

THIS PRESSURE MUST BE RELIEVED BY CAREFULLY:

A. DISCONNECTING ANY DOWNSTREAM EQUIPMENT.

B. OPENING THE DISCHARGE VALVE TO ATMOSPHERE.

(USE HEARING PROTECTION IF NECESSARY).

• the machine cannot be started accidentally or otherwise, by posting

warning signs and/or fitting appropriate anti-start devices.

• all residual electrical power sources (mains and battery) are

isolated.

Prior to opening or removing panels or covers to work inside a

machine, ensure that:

• anyone entering the machine is aware of the reduced level of

protection and the additional hazards, including hot surfaces and
intermittently moving parts.

• the machine cannot be started accidentally or otherwise, by posting

warning signs and/or fitting appropriate anti-start devices.

Prior to attempting any maintenance work on a running machine,

ensure that:
1. Separator tank drain. • the work carried out is limited to only those tasks which require the
machine to run.
2. Engine oil drain.
• the work carried out with safety protection devices disabled or
3. Fuel tank drain.
removed is limited to only those tasks which require the machine to
Ensure the compressor is stopped and all pressure is relieved before be running with safety protection devices disabled or removed.
draining fluids. Check and close all drain valves, remove the plug from
• all hazards present are known (e.g. pressurised components,
the drain outlet using the tool provided. Place the empty container
electrically live components, removed panels, covers and guards,
underneath the drain outlet and open the valve. Do not leave
extreme temperatures, inflow and outflow of air, intermittently
unattended as some fluids will drain very rapidly and could spill.
moving parts, safety valve discharge etc.).

WARNING: Use caution when draining fluids as these can be hot • appropriate personal protective equipment is worn.
and could cause injury.
• loose clothing, jewellery, long hair etc. is made safe.

• warning signs indicating that Maintenance Work is in Progress are

ROUTINE MAINTENANCE
posted in a position that can be clearly seen.
This section refers to the various components which require periodic Upon completion of maintenance tasks and prior to returning the
maintenance and replacement. machine into service, ensure that:-
The SERVICE/MAINTENANCE CHART indicates the various • the machine is suitably tested.
components’ descriptions and the intervals when maintenance is
recommended. Oil capacities, etc., can be found in the GENERAL • all guards and safety protection devices are refitted.
INFORMATION section of this manual. • all panels are replaced, canopy and doors closed.
For any specification or specific requirement on service or preventative • hazardous materials are effectively contained and disposed of.
maintenance for the engine, refer to the Engine Manufacturer’s
Manual.
PROTECTIVE SHUTDOWN SYSTEM
Compressed air can be dangerous if incorrectly handled. Before doing
any work on the machine, ensure that all pressure is vented from the Refer to the Wedge diagnostic display codes table for a listing of
system and that the machine cannot be started accidentally. shutdown conditions.
If the automatic blowdown fails to operate, then pressure must be
gradually relieved by operating the manual blowdown valve. Suitable SCAVENGE LINE
personal protective equipment should be worn.

Ensure that maintenance personnel are adequately trained, competent The scavenge line runs from the combined orifice/drop tube in the
and have read the Maintenance Manuals. separator tank, to the orifice fitting located in the airend.

Prior to attempting any maintenance work, ensure that: Examine the orifice, check valve and hoses at every service or in the
event of oil carryover into the discharge air.
• all air pressure is fully discharged and isolated from the system. If
the automatic blowdown valve is used for this purpose, then allow It is good preventative maintenance to check that the scavenge line
enough time for it to complete the operation. and tube are clear of any obstruction each time the compressor
lubricant is changed as any blockage will result in oil carryover into the
discharge air.

9/235HA, 10/215HA
 MAINTENANCE 39
COMPRESSOR OIL FILTER Inspection

Examine the filter element. Examine all hoses and tubes, and replace
Refer to the SERVICE/MAINTENANCE CHART in this section for the
if necessary.
recommended servicing intervals.
Reassembly
Removal
Thoroughly clean the orifice/drop tube and install a new o-ring before
WARNING: Do not remove the filter(s) without first making sure reassembly. Install the new element.
that the machine is stopped and the system has been
completely relieved of all air pressure. (Refer to STOPPING THE Reposition the cover plate, taking care not to damage the o-ring, and
MACHINE in the OPERATING INSTRUCTIONS section of this replace the cover plate screws tightening in a criss-cross pattern to the
manual). recommended torque (refer to the TORQUE SETTING TABLE later in
this section).
Clean the exterior of the filter housing and remove the spin-on element Replace the drop-tube and reconnect all hoses and tubes to the
by turning it in a anticlockwise direction. separator tank cover plate.
Inspection Replace the compressor oil (refer to LUBRICATION later in this
section).
Examine the filter element.
CAUTION: Start the machine (refer to PRIOR TO STARTING and
CAUTION: If there is any indication of the formation of varnishes,
STARTING THE MACHINE in the OPERATING INSTRUCTIONS
shellacs or lacquers on the filter element, it is a warning that the
section of this manual) and check for leakage before the machine is
compressor lubricating and cooling oil has deteriorated and that it
put back into service.
should be changed immediately. Refer to LUBRICATION later in this
section.
COMPRESSOR OIL COOLER AND ENGINE RADIATOR AIR
Reassembly CHARGE COOLER

Clean the filter gasket contact area and install the new element by When grease, oil and dirt accumulate on the exterior surfaces of the oil
screwing in a clockwise direction until the gasket makes contact with cooler and radiator, the efficiency is impaired. It is recommended that
the filter housing. Tighten a further 1/2 to 3/4 of a revolution.
each month the oil cooler and radiator be cleaned by directing a jet of
compressed air, (carrying if possible a non-flammable cleaning
CAUTION: Start the machine (refer to PRIOR TO STARTING and solvent) over the exterior core of the cooler/radiator. This should
STARTING THE MACHINE in the OPERATING INSTRUCTIONS remove any accumulation of oil, grease and dirt from the exterior core
section of this manual) and check for leakage before the machine is of the cooler so that the entire cooling area can radiate the heat of the
put back into service. lubricating and cooling oil/water into the air stream.

COMPRESSOR OIL SEPARATOR ELEMENT WARNING: Hot engine coolant and steam can cause injury.
When adding coolant or antifreeze solution to the engine
Refer to the SERVICE / MAINTENANCE CHART in this section for radiator, stop the engine at least one minute prior to releasing
service intervals. the radiator filler cap. Using a cloth to protect the hand, slowly
release the filler cap, absorbing any released fluid with the cloth.
Removal Do not remove the filler cap until all excess fluid is released and
the engine cooling system fully depressurised.
WARNING: Do not remove the filter(s) without first making sure
that the machine is stopped and the system has been
completely relieved of all air pressure. (Refer to STOPPING THE WARNING: Follow the instructions provided by the antifreeze
MACHINE in the OPERATING INSTRUCTIONS section of this supplier when adding or draining the antifreeze solution. It is
manual). advisable to wear personal protective equipment to prevent skin
and eye contact with the antifreeze solution.
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
40 MAINTENANCE
AIR FILTER ELEMENT FUEL FILTER MAINTENANCE

The air filter should be inspected regularly (refer to the SERVICE/

MAINTENANCE CHART) and the element replaced when the
restriction indicator lamp illuminates. The dust collector box(es) should
be cleaned daily (more frequently in dusty operating conditions) and
not allowed to become more than half full.

The safety element should be renewed every 2000 hours or every

other main filter element change, whichever comes first.

Removal

CAUTION: Never remove and replace element(s) when the machine

is running.

Clean the exterior of the filter housing and remove the filter element by
releasing the nut.

If the safety element is to be renewed, thoroughly clean the interior of

the filter housing prior to removing the safety element.

Inspection

Check for cracks, holes or any other damage to the element by holding
it up to a light source, or by passing a lamp inside.

CAUTION: If inspection reveals damage to the main element, the 1. Primary fuel filter / water separator (30 microns).
safety element must be replaced.
Primary fuel filter / water separator
Check the seal at the end of the element and replace if any sign of The fuel filter water separator contains a filter element which should be
damage is evident. replaced at regular intervals (see the SERVICE/MAINTENANCE
Reassembly CHART).

Assemble the new element into the filter housing ensuring that the seal Unscrew the element from the head taking care not to spill fuel inside
seats properly. the machine. Remove fuel sensor (where fitted) and re-fit to new filter
element.
Secure the element in the housing by hand tightening the nut.
Discard the old element into a suitable container.
Assemble the dust collector box parts, ensuring that they are correctly
positioned. Using a clean cloth, wipe the sealing face of the filter/separator head
to ensure correct seating of the sealing ring.
Before restarting the machine, check that all clamps are tight.
Fill the element/bowl assembly with clean fuel oil then apply a light coat
of clean engine oil to the new element sealing ring.
CAUTION: Safety elements must not be cleaned or re-used.
Screw the new element onto the head firmly by hand.
VENTILATION The engine has a self priming system that purges air from the fuel
system.
Always check that the air inlets and outlets are clear of debris etc.

AUTOMATIC FUEL SUPPLY

CAUTION: NEVER clean by blowing air inwards.

The engine has an electric fuel priming pump. After a filter change, let
COOLING FAN DRIVE the lift pump run it’s 30 second cycle before cranking.

Periodically check that the fan mounting bolt in the fan hub has not
HOSES
loosened. If, for any reason, it becomes necessary to remove the fan
or re-tighten the fan mounting bolt, apply a good grade of commercially
available thread locking compound to the bolt threads and tighten to All components of the engine cooling air intake system should be
the torque value shown in the TORQUE SETTING TABLE later in this checked periodically to keep the engine at peak efficiency.
section. At the recommended intervals, (see the SERVICE/MAINTENANCE
The fan belt(s) should be checked regularly for wear and correct CHART), inspect all of the intake lines to the air filter, and all flexible
tensioning. hoses used for air lines, oil lines and fuel lines.

Periodically inspect all pipework for cracks, leaks, etc. and replace
immediately if damaged.

9/235HA, 10/215HA
 MAINTENANCE 41
ELECTRICAL SYSTEM TYRES/TYRE PRESSURE

See the GENERAL INFORMATION section of this manual.

WARNING: Always disconnect the battery switch before
performing any maintenance or service.
RUNNING GEAR/WHEELS
When removing connectors from electrical devices and sensors,
inspect the terminals to ensure they have electrical grease on them. If Check the wheel nut torque 30 kilometres (20 miles) after refitting the
electrical grease is not present or very minimal, then add a small wheels. Refer to the TORQUE SETTING TABLE later in this section.
amount of Doosan Part No. 22409114 electrical grease to the
terminals. Dirty and or corroded electrical terminals can be cleaned The bolts securing the running gear to the frame should be checked
using electrical contact cleaner. periodically for tightness (refer to the SERVICE/MAINTENANCE
CHART for frequency) and re-tightened where necessary. Refer to the
Inspect the safety shutdown system switches and the instrument panel TORQUE SETTING TABLE later in this section.
relay contacts for evidence of arcing and pitting. Clean where
necessary.
LUBRICATION
Check the mechanical action of the components.
The engine is initially supplied with engine oil sufficient for a nominal
Check the security of electrical terminals on the switches and relays i.e.
period of operation (for more information, consult The Engine
loose nuts or screws, which may cause local hot spot oxidation.
Manufacturer's Manual).
Inspect the components and wiring for signs of overheating i.e.
discolouration, charring of cables, deformation of parts, acrid smells CAUTION: Always check the oil levels before a new machine is put
and blistered paint. into service.

BATTERY WARNING: High oil viscosity during cold start up, clogged oil
filters or valve malfunction can result in oil starvation.
Keep the battery terminals and cable clamps clean and lightly coated
with petroleum jelly to prevent corrosion. If, for any reason, the machine has been drained, it must be re-filled
The retaining clamp should be kept tight enough to prevent the battery with new oil before it is put into operation.
from moving.
ENGINE LUBRICATING OIL
CAUTION: Exercise extreme caution when using booster battery. To
jump battery, connect ends of one booster cable to the positive (+) The engine oil should be changed at the engine manufacturer's
terminal of each battery. Connect one end of other cable to the recommended intervals. Refer to the SERVICE/MAINTENANCE
negative (-) terminal of the booster battery and other end to a ground CHART.
connection away from dead battery (to avoid a spark occurring near
any explosive gases that may be present). After starting the
compressor, always disconnect cables in reverse order. ENGINE LUBRICATING OIL SPECIFICATION

Refer to the Engine Manufacturer's Manual or Lubrication Specification

PRESSURE SYSTEM
list.

At 3 month intervals it is necessary to inspect the external surfaces of

the system (from the airend through to the discharge valve(s)) ENGINE OIL FILTER ELEMENT
including hoses, tubes, tube fittings and the separator tank, for visible
signs of impact damage, excessive corrosion, abrasion, tightness and The engine oil filter element should be changed at the engine
chafing. Any suspect parts should be replaced before the machine is manufacturer's recommended intervals. Refer to the SERVICE/
put back into service. MAINTENANCE CHART.

9/235HA, 10/215HA
42 MAINTENANCE
COMPRESSOR LUBRICATING OIL RUNNING GEAR WHEEL BEARINGS

Refer to the SERVICE/MAINTENANCE CHART in this section for Wheel bearings should be packed with heavy duty wheel bearing
service intervals. grease every 6 months.

Wheel bearings should be greased per the Maintenance Schedule in

NOTE: If the machine has been operating under adverse conditions,
this manual. The type of grease used should conform to specifications
or has suffered long shutdown periods, then more frequent service
below:
intervals will be required.
Grease

WARNING: DO NOT, under any circumstances, remove any Thickener Type Lithium Complex
drain plugs or the oil filler plug from the compressor lubricating
and cooling system without first making sure that the machine Dropping Point 215°C (419°F) Minimum
is stopped and the system has been completely relieved of all air Consistency NLGI No.2
pressure (refer to STOPPING THE MACHINE in the OPERATING
INSTRUCTIONS section of this manual). Additives EP, Corrosion & Oxidation Inhibitors

Viscosity Index 80 Minimum

Completely drain the receiver/separator system including the piping
and oil cooler by removing the drain plug(s) and collecting the used oil
in a suitable container.

Replace the drain plug(s) ensuring that each one is secure.

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
 MAINTENANCE 43

KEY
Inspect the throttle arm on the engine governor to see that it is
A. Throttle Arm extended in the full speed position when the engine is running at full
load speed and the service valve is fully open. (Refer to the GENERAL
B. Adjusting Screw
INFORMATION section of this manual).
C. Engine Governor
Adjust the service valve on the outside of the machine to maintain
D. Separator Tank
normal operating discharge pressure without the throttle arm moving
E. Inlet Unloader from the full speed position before normal operating discharge
pressure is attained. Turn the adjusting screw clockwise to increase
SPEED AND PRESSURE REGULATION ADJUSTMENT the pressure. Optimum adjustment is achieved when the throttle arm
just moves from its full speed position and the pressure gauge reads
normal operating discharge pressure.
Normally, regulation requires no adjusting, but if correct adjustment is
lost, proceed as follows: Close the service valve. The engine will slow to idle speed.
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
44 MAINTENANCE
TORQUE VALUES

TABLE 1 INCH FASTENERS

NOMINAL DESIGN TORQUE

8AE J249 8AE J249

GRADE 5 GRADE 8
(HEAD MARKING) (HEAD MARKING)
TYPICAL 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 TYPICAL CIRCULAR TORQUE PATTERN

5/8 - 11 203 150 287 212

3/4 - 10 361 266 509 376

9/235HA, 10/215HA
 MAINTENANCE 45

TABLE 2 METRIC FASTENERS

NOMINAL DESIGN TORQUE

PROPERTY PROPERTY PROPERTY

GRADE 8.8 GRADE 10.9 GRADE 12.9
(HEAD MARKING) (HEAD MARKING) (HEAD MARKING)
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

9/235HA, 10/215HA
46 MAINTENANCE
LUBRICATION - GENERAL INFORMATION If the compressor has been operated for the time/hours indicated in the
Maintenance Schedule, it should be completely drained of oil. If the
Lubrication is an essential part of preventive maintenance, affecting to compressor has been operated under adverse conditions, or after long
a great extent the useful life of the compressor. Different lubricants are periods in storage, an earlier change may be necessary as oil
needed and some components require more frequent lubrication than deteriorates with time as well as by operating conditions.
others. Therefore, it is important that the instructions regarding types
of lubricants and the frequency of their application be explicitly CAUTION: In most severe applications such as sandblasting, quarry
followed. Periodic lubrication of the moving parts reduces to a drilling, well drilling, and oil and gas drilling, more frequent service
minimum the possibility of mechanical failures. intervals will be required to ensure long component life.

The Maintenance Schedule shows those items requiring regular

service and the interval in which they should be performed. A regular WARNING: High pressure air can cause severe injury or death
service program should be developed to include all items and fluids. from hot oil and flying parts. Always relieve pressure before
These intervals are based on average operating conditions. In the removing caps, plugs, covers or other parts from pressurized
event of extremely severe (hot, cold, dusty or wet) operating air system. Ensure that the air pressure gauge reads zero (0)
conditions, more frequent lubrication than specified may be necessary. pressure and ensure there is no air discharge when opening the
manual blowdown valve.
All filters and filter elements for air and compressor oil must be
obtained through Portable Power to assure the proper size and
filtration for the compressor. An oil change is good insurance against the accumulation of dirt,
sludge, or oxidized oil products.
Compressor oil change
Completely drain the separator tank, piping, and cooler. If the oil is
These compressors are normally furnished with an initial supply of oil drained immediately after the compressor has been run for some time,
sufficient to allow operation until the first service interval indicated in most of the sediment will be in suspension and, therefore, will drain
the Maintenance Schedule. If a compressor has been completely more readily. However, the oil will be hot and care must be taken to
drained of all oil, it must be refilled with new oil before it is placed in avoid contact with the skin or eyes.
operation. Refer to specifications in the Portable Compressor Fluid
Chart. After the compressor has been completely drained of all old oil, close
the drain valves and/or plugs and install new oil filter elements. Add oil
in the specified quantity at the filler plug. Tighten the filler plug and run
NOTE: Some oil types are incompatible when mixed and result in the
the compressor to circulate the oil. Check the oil level. DO NOT
formation of varnishes, shellacs, or lacquers which may be insoluble.
OVERFILL.
Such deposits can cause serious problems including clogging of the
filters.
NOTE: Doosan Portable Power provides compressor oil specifically
Where possible, do NOT mix oils of different types and avoid mixing formulated for Portable Compressors and requires the use of these
different brands. A type or brand change is best made at the time of fluids in order to obtain extended limited airend warranty.
a complete oil drain and refill.

9/235HA, 10/215HA
 MAINTENANCE 47
COMPRESSOR LUBRICATION
RATED OPERATING PRESSURE
Portable Compressor Fluid Chart

Refer to these charts for correct compressor fluid required. Note that
the selection of fluid is dependent on the design operating pressure of
the machine and the ambient temperature expected to be encountered
before the next oil change.

Note: Fluids listed as “preferred” are required for extended

warranty.

Compressor oil carryover (oil consumption) may be greater with

the use of alternative fluids.

Design operating Ambient Compressor oil

pressure temperature specification
7 bar to 14 bar -23°C to 52°C Preferred:
(100 psi to 200 psi) (-10°F to 125°F) PRO-TEC
Alternate:
ISO Viscosity Grade
46 with rust and
oxidization inhibitors, consult consult
designed for air factory factory
compressor service.
14 bar and above -23°C to 52°C Preferred:
(200 psi and above) (-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.
inhibitors, designed
for air compressor
service.
18°C to 52°C Preferred:
(65°F to 125°F) XHP 605
XHP 1001

Doosan preferred fluids

PRO-TEC engine oil 46652105 (20.0 Litres) 46652106 (208.0 Litres)
Stage 3B and 4 engine oil 46551222 (20.0 Litres) 46551223 (208.0 Litres)
PRO-TEC compressor oil 89292973 (20.0 Litres) 89292981 (208.0 Litres)
XHP 605 compressor oil 22252076 (19.0 Litres) 22252050 (208.2 Litres)
XHP 1001 compressor oil - 35300516 (208.2 Litres)
XHP 405 compressor oil 22252126 (19.0 Litres) 22252100 (208.2 Litres)

Note: Stage 3B & Stage 4 engines are required to use CJ-4/ACEA E9 engine oil only, failure to do so will result in engine after treatment
damage. Please read the engine manual for more details.

9/235HA, 10/215HA
48 MACHINE SYSTEMS

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MACHINE SYSTEMS 49

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50 MACHINE SYSTEMS

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MACHINE SYSTEMS 51

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52 MACHINE SYSTEMS

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MACHINE SYSTEMS 53

9/235HA, 10/215HA
54 FAULT FINDING

FAULT CAUSE REMEDY

No reaction from Emergency stop actuated. Reset emergency stop button.
instrument panel when
key turned to (I) Batteries not connected. Connect batteries.
position.
Fuse at starter motor ‘blown’. Replace fuse.

Engine fails to start. Low battery charge. Check the fan belt tension, battery and cable connections.

Bad earth connection. Check the earth cables, clean as required.

Loose connection. Locate and make the connection good.

Fuel starvation. Check the fuel level and fuel system components. Replace the fuel filter if
necessary.

Relay failed. Replace the relay.

Faulty stop solenoid. Check the stop solenoid.

Engine stops while in Low fuel level. Fill fuel tank and bleed air from fuel system if necessary. (Refer to
service or is reluctant MAINTENANCE SECTION).
to start.
Safety shut–down system in Check the safety shut–down switches.
operation.

Engine starts but stalls Electrical fault. Test the electrical circuits.
when the switch
returns to (I) position. Low engine oil pressure. Check the oil level and the oil filter(s).

Low water level. Check if the low water lamp is extinguished.

Faulty relay. Check the relays.

Faulty key-switch. Check the key-switch.

Engine starts but will Electrical fault. Test the electrical circuits.
not run or engine shuts
down prematurely. Low engine oil pressure. Check the oil level and oil filter(s).

Safety shut–down system in Check the safety shut–down switches.

operation.

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 clean if required.

Faulty relay. Check the relay in the holder and replace if necessary.

Engine Overheats. Low water level. Check the level and replenish if necessary.

Blocked radiator. Stop the machine and clean the cooling fins with compressed air or steam.
Use reduced pressure for cleaning the fins.

Reduced cooling air from fan. Check the fan and the drive belts. Check for any obstruction inside the cowl.

Faulty thermostat. Check the thermostat and replace if necessary.

Engine speed too low. Blocked fuel filter. Check and replace if necessary.

Blocked air filter. Check and replace the element if necessary.

Faulty regulator valve. Check the regulation system.

Premature unloading. 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
 FAULT FINDING 55

FAULT CAUSE REMEDY

Air discharge capacity Engine speed too low. Check the air cylinder and air filter(s).
too low.
Blocked air cleaner. Check the restriction indicators and replace the element(s) if necessary.

High pressure air escaping. Check for leaks.

Incorrectly set regulation system. Reset the regulation system. Refer to SPEED AND PRESSURE
REGULATION ADJUSTMENT in the MAINTENANCE section of this
manual.

Compressor overheats. Low oil level. 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. Move the machine to avoid recirculation.

Reduced cooling air from fan. Check the fan and the drive belts. Check for any obstruction inside the fan
cowl.

Excessive oil present Blocked scavenge line. Check the scavenge line, drop tube and orifice. Clean and replace.
in the discharge air.
Perforated separator element. Replace the separator element.

Pressure in the system is too low. Check the minimum pressure valve or sonic orifice.

Safety valve operates. Operating pressure too high. Check the setting and operation of the regulator valve piping.

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. Replace the safety valve if faulty. DO NOT
ATTEMPT A REPAIR.

Oil is forced back into Incorrect stopping procedure used. Always employ the correct stopping procedure. Close the discharge valve
the air filter. and allow the machine to run on idle before stopping.

Faulty inlet valve. Check for free operation of the inlet valve(s).

Machine goes to full Inlet valve set incorrectly. Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in the
pressure when started. MAINTENANCE section of this manual.

Faulty load valve. Replace the valve.

Machine fails to load Faulty load solenoid. Replace the valve.

when the load button is
pressed.

9/235HA, 10/215HA
56 OPTIONS

OPTION - IQ SYSTEM

STANDARD OPERATION

IQ SYSTEM OPERATION

KEY

1. Three way valve 5. Filters

2. Ball valve 11/4” 6. Aftercooler
3. Ball valve 2” 7. Minimum pressure valve
4. Safety valve 8. Separator tank

IQ SYSTEM IQ SYSTEM OPERATING INSTRUCTIONS - 2

The IQ System is a complete, self-contained system which provides The compressed air exits the separator tank through the top cover
cooler, cleaner air than from a standard portable compressor. The piping, and can then travel along one of two paths, selectable via
system utilises an integral aftercooler, high-efficiency filtration, and a manual valving.
patented condensate disposal system to provide the cool, clean air.
The condensate disposal system injects all liquid condensed from the One path allows Standard Operation, which bypasses the IQ System,
and delivers air quality equivalent to a standard oil-flooded portable
moisture separator and filters into the engine exhaust system where it
is vaporised by heat. This eliminates the need for collecting the compressor. If the IQ System is enabled by proper setting of the
condensate, and the added cost of disposing of the condensate, which selector valve, the compressed air first enters the aftercooler.
is often regulated by local regulations. The aftercooler is cooled by the incoming compressor package air,
which is controlled by movable louvres mounted on the aftercooler (if
When equipped with the low ambient feature, the IQ System
equipped with low ambient option). At most conditions, the louvres are
automatically adjusts movable louvres to control airflow through the
fully open, and maximum aftercooling is available. The compressed air
aftercooler, ensuring that the compressed air temperature always
and condensate (water with a small amount of compressor lubricant)
remains above freezing temperatures (typically 7°C (45°F)) at any
exits the aftercooler and enters the moisture separator, where most of
ambient temperature down to -23°C (-20°F). This prevents the need for
the condensate is removed. The compressed air then flows through
heat tracing systems, or any manual adjustment to prevent freezing of
two stages of filtration, where the oil - water and particles are removed
the compressed air system. All drain points for the condensate
down to 0.01 micron.
handling system are heated with 24 VDC heaters, which are integral to
the compressor heater system. 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
 OPTIONS 57
The condensate lines are then piped together, and the condensate is • Verify that the piping from the orifice purge points to the exhaust
injected at a single point into the engine exhaust piping. The system is not clogged.
compressed air then travels through the minimum pressure valve, and
out through the service air valve. The air pressure gauge on the Yearly Maintenance:
instrument panel indicates the pressure inside the separator tank. A The normal maintenance interval on the primary and secondary
service air pressure gauge is located inside the front door of the IQ System filters is one year, or earlier if pressure drop becomes
compressor on the filter support. excessive. The compressor will shut down if restriction exceeds
recommended values.
If the IQ System is bypassed (Standard Operation selected), the
delivered air pressure will be approximately equal to the separator tank FILTER REPLACEMENT
pressure. If the IQ System operation is selected, the delivered air
pressure will be slightly less, depending on the restriction of the filters. • With engine stopped, ensure pressure is relieved from air system.

MAINTENANCE • Remove all wires and hoses connected to drains on bottom of each
filter housing. Inspect fittings and hoses for any blockage. Clean if
Daily Maintenance: necessary.
Verify, during full-load (maximum compressed air delivery) that the IQ • Using a chain wrench or similar tool, loosen the housing. The
System does not show excessive restriction. Excessive restriction will housing should be removed by hand after loosening, taking care to
be shown on the Viewport, and will shut down the compressor if prevent the housing from falling to the floor panel.
restriction exceeds recommended values.
• Lower the housing to floor panel and lean it against the airend.
Weekly Maintenance: Remove and replace the filter element, being careful not to damage
• Remove Y-strainer screens at the bottom of the moisture separator outer wrap.
and both filters and clean out any residue. Verify the part number of new element vs. old element, as the two
• Verify that the orifices below the Y-strainers are not clogged. IQ filters are of different media.

9/235HA, 10/215HA
58 OPTIONS
PRIMARY AND SECONDARY FILTER MAINTENANCE

FIGURE 1. FIGURE 4.

FIGURE 2. FIGURE 5.

FIGURE 3.

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 OPTIONS 59
WATER SEPARATOR MAINTENANCE

FIGURE 1. FIGURE 4.

FIGURE 2. FIGURE 5.

FIGURE 3. FIGURE 6.

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60 OPTIONS
SAFETY

CAUTION: The compressor regulation system is adjusted to

maintain regulated pressure at the separator tank. DO NOT adjust
regulation to provide full regulation pressure at the service 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 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.

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 OPTIONS 61
HIGH IQ FILTER RESTRICTION - TROUBLESHOOTING

STANDARD OPERATION IQ SYSTEM OPERATION

Service Air Service Air

CONDITION EFFECT REMEDY

The TITAN controller has Code 44 is an ALERT condition and 1. Replace IQ filters.
received a message over the will not stop the compressor. Code
J1939 CAN network from the IQ 2. Check all harness connections between IQ TCU and PT100 /
44 and the ALERT name will be
TCU controller indicating the IQ displayed on the ViewPort. PT101 differential pressure sensors. Repair harness as needed.
filters are starting to restrict air
flow. 3. If steps 1 and 2 checkout OK, replace IQ TCU controller.

The TITAN controller has Code 52 is a FAULT condition and 1. Replace IQ filters.
received a message over the will stop the compressor. Code 52
2. Check all harness connections between IQ TCU and PT100 /
J1939 CAN network from the IQ and the FAULT name will be
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
62 OPTIONS
6. Repeat the above steps ’2’ to ’5’ until the first setting at which the
OPTION - OVERSPEED (CHALWYN) VALVE engine does not shut down at high idle speed (i.e. maximum
DESCRIPTION throttle, no load).

Then either:
Chalwyn valves provide emergency overspeed shutdown protection
for diesel engines and are the most effective way of preventing a a) Use the results of shut down speed versus adjuster setting as a
runaway situation. The valves completely block the engine air intake calibration check to make a final adjustment to give the required setting
system, cutting off an uncontrolled external fuel source and the air (typically 10% to 15% over high idle).
required to keep the engine running. or

b) If a very precise setting is not required, turn the adjuster a further one
turn clockwise to take the shutdown above high idle speed by a
suitable margin. When using this setting procedure it may be found that
the engine occasionally shuts down during the normal operation. If so,
turn the adjuster clockwise by a further one half turn.

7. Ensure the adjuster locknut is fully tightened.

(Use a thread lock adhesive on the locknut threads).

NOTES:
Turbocharged Engines - When setting up a valve on a
turbocharged engine using the preceding method, it may be found
that at high power outputs, the engine will shut down at a lower speed
than required. If this occurs, further small adjustments in steps of one
half turn clockwise should be made until the problem is eliminated.

Jammed Valve - If in the course of adjusting the valve it jams on its

seat, release by turning CLOCKWISE viewed from adjuster end of
valve.

MAINTENANCE
A Adjuster
Three monthly
B Locknut
C Hold with spanner when adjusting 1. Disconnect intake pipework and release the valve from any support
brackets etc. to allow it to be removed.
D Air flow
2. Inspect the valve internally for cleanliness. If necessary, clean in
Once the Chalwyn valve is installed, adjustment of the overspeed trip paraffin or white spirit taking normal precautions. Dry the valve
setting is carried out using the adjuster and locknut (refer to diagram). thoroughly.
Basically rotating the adjuster clockwise will increase the engine speed 3. Check there is no excessive wear and that the valve moves
at which automatic shut down occurs. smoothly over its complete operating stroke. DO NOT LUBRICATE.
1. Start engine. Slowly accelerate. Note speed at which shut down 4. Refit valve. Check valve setting based on the ’Adjustment’
occurs. instructions given herein.
2. Remove hose at air inlet to Chalwyn valve to expose the adjuster
and locknut (see diagram). NOTE: The three monthly routine maintenance period requirement is
dependent on the operating conditions to which the equipment is
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
 PARTS ORDERING 63
GENERAL HOW TO USE PARTS LIST

This publication, which contains an illustrated parts breakdown, has a. Turn to Parts List.
been prepared as an aid in locating those parts which may be required
in the maintenance of the machine. All of the compressor parts, listed b. Locate the area or system of the compressor in which the desired
part is used and find illustration page number.
in the parts breakdown, are manufactured with the same precision as
the original equipment. For the greatest protection always insist on c. Locate the desired part on the illustration by visual identification
genuine Doosan parts for your compressor. and make note of part number and description.
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. upon the proper use of all available information. By supplying your
There are Authorised Distributors or Company Sales offices in principal nearest sales office, autonomous company or authorised distributor,
cities of many countries. with complete information, you will enable them to fill your order
correctly and to avoid any unnecessary delays.
Special order parts may not be included in the manual. Contact
Doosan Parts Department with the machine serial number for In order that all avoidable errors may be eliminated, the following
assistance with these special parts. instructions are offered as a guide to the purchaser when ordering
replacement parts:
DESCRIPTION a. Always specify the model number of the machine as shown on the
general data decal attached to the machine.
The illustrated parts breakdown illustrates and lists the various b. Always specify the serial number of the machine. THIS IS
assemblies, subassemblies and detailed parts which make up this IMPORTANT. The serial number of the machine will be found
particular machine. This covers the standard models and the more stamped on a plate attached to the machine. (The serial number
popular options that are available. on the machine is also permanently stamped in the metal of the
A series of illustrations show each part distinctly and in location relative frame side rail.)
to the other parts in the assembly. The part number, the description of
c. Always specify the number of the parts list publication.
the part and the quantity of parts required are shown on each
illustration or on adjacent page. The quantities specified are the d. Always specify the quantity of parts required.
number of parts used per one assembly and are not necessarily the
total number of parts used in the machine. Where no quantity is e. Always specify the part number, as well as the description of the
specified the quantity is assumed to be one. part, or parts, exactly as it is given on the parts list illustration.

Each description of a part is based upon the "noun first" method, i.e., In the event parts are being returned to your nearest sales office,
the identifying noun or item name is always the first part of the autonomous company or authorised distributor, for inspection or
description. The noun name is generally followed by a single repair, it is important to include the serial number of the machine from
descriptive modifier. The descriptive modifier may be followed by which the parts were removed.
words or abbreviations such as upper, lower, inner, outer, front, rear,
RH, LH, etc. when they are essential. TERMS AND CONDITIONS ON PARTS ORDERS
In referring to the rear, the front or to either side of the machine, always
consider the drawbar end of the machine as the front. Standing at the Acceptance: Acceptance of an offer is expressly limited to the exact
rear of the machine facing the drawbar (front) will determine the right terms contained herein. If purchaser's order form is used for
and left sides. acceptance of an offer, it is expressly understood and agreed that the
terms and conditions of such order form shall not apply unless
FASTENERS 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.
Both SAE/inch, ISO/metric hardware have been used in the design and
assembly of these units. In the disassembly and reassembly of parts, Taxes: Any tax or other governmental charge now or hereafter levied
extreme care must be taken to avoid damaging threads by the use of upon the production, sale, use or shipment of material and equipment
wrong fasteners. In order to clarify the proper usage and for exact ordered or sold is not included in the Company's price and will be
replacement parts, all standard fasteners have been identified by part charged to and paid for by the Purchaser.
number, size and description. This will enable a customer to obtain Shipping dates shall be extended for delays due to acts of God, acts of
fasteners locally rather than ordering from the factory. These parts are Purchaser, acts of Government, fires, floods, strikes, riot, war,
identified in tables that will be found at the rear of the parts illustrations. embargo, transportation shortages, delay or default on the part of the
Any fastener that has not been identified by both part number and size Company's vendors, or any other cause beyond the Company's
is a specially engineered part that must be ordered by part number to reasonable control.
obtain the exact replacement part.
Should Purchaser request special shipping instruction, such as
exclusive use of shipping facilities, including air freight when common
MARKINGS AND DECALS
carrier has been quoted and before change order to purchase order
can be received by the Company, the additional charges will be
NOTICE honoured by the Purchaser.
Do not paint over safety warnings or instructional decals. If safety Warranty: The Company warrants that parts manufactured by it will be
warning decals become illegible, immediately order replacements as specified and will be free from defects in materials and
from the factory. workmanship. The Company's liability under this warranty shall be
limited to the repair or replacement of any part which was defective at
Part numbers for original individual decals and their mounting
the time of shipment provided Purchaser notifies the Company of any
locations are shown within Parts List Section. These are available
such defect promptly upon discovery, but in no event later than three
as long as a particular model is in production.
(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.

9/235HA, 10/215HA
64 PARTS ORDERING
Repairs and replacements shall be made by the Company F.O.B. point The Company shall in no event be liable to the Purchaser, any
of shipment. The Company shall not be responsible for costs of successors in interest or any beneficiary of this order for any
transportation, removal or installation. consequential, incidental, indirect, special or punitive damages arising
out of this order or any breach thereof, or any defect in, or failure of, or
Warranties applicable to material and equipment supplied by the
Company but wholly manufactured by others shall be limited to the malfunction of the parts hereunder, whether based upon loss of use,
warranties extended to the Company by the manufacturer which are lost profits or revenue, interest, lost goodwill, work stoppage,
impairment of other goods, loss by reason of shutdown or non-
able to be conveyed to the Purchaser.
operation, increased expenses of operation or claims of customers of
Delivery: Shipping dates are approximate. The Company will use best Purchaser for service interruption whether or not such loss or damage
efforts to ship by the dates specified; however, the Company shall not is based on contract, warranty, negligence, indemnity, strict liability or
be liable for any delay or failure in the estimated delivery or shipment otherwise.
of material and equipment or for any damages suffered by reason
thereof. AIREND EXCHANGE PROGRAM
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.
particular purpose, are hereby disclaimed.
Your nearest sales office, autonomous company or authorised
Limitation of Liability: distributor must first contact the Parts Service Department at the
factory at which your portable air compressor was manufactured for
The remedies of the Purchaser set forth herein are exclusive, and the
further instructions.
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 part upon which
such liability is based.

For parts, service or information regarding your local distributor (Europe, Middle East, Africa) please contact:

Facility: Website:
Doosan Bobcat EMEA s.r.o. (DBEM), www.doosanportablepower.eu
U Kodetky 1810, 263 12 Dobris,
Czech Republic

9/235HA, 10/215HA
Doosan Bobcat EMEA s.r.o
U Kodetky 1810
263 12 Dobříš
Czech Republic www.doosanportablepower.eu