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ENGINE INSTRUCTION MANUAL

9/235HA, 10/215HA

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.

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Содержание 10/215HA

Страница 1: ...nt safety information and must be made available to personnel who operate and maintain this machine 22488183_en_E_04 18 9 235HA 10 215HA OPERATION MAINTENANCE MANUAL Original Instruction 9 235HA SERIA...

Страница 2: ......

Страница 3: ...he company for serial number Up to Serial No From Serial No Not illustrated Option WDG Generator option AR As required HA High ambient machine S R G Site running gear H R G High speed running gear bg...

Страница 4: ...proved parts list may create hazardous conditions over which the company has no control Therefore the company cannot be held responsible for equipment in which non approved repair parts are installed...

Страница 5: ...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 Refer to the...

Страница 6: ...ssed air from this machine Do not remove the Operating and Maintenance manual and manual holder from this machine Do not stack Do not operate the machine without the guard being fitted Do not stand on...

Страница 7: ...taken When parking use prop stand handbrake and wheel chocks Compressor oil filling Diesel fuel No open flame Parking brake Rough Service Designation Wet Location Operation Replace any cracked protect...

Страница 8: ...6 DECALS 9 235HA 10 215HA Engine oil drain...

Страница 9: ...compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible If the discharged air is to be ultimately released into a confined space adequate ventilation must...

Страница 10: ...electrical supply are all suitable to provide safe and stable towing at speeds either up to the legal maximum for the country in which it is being towed or as specified for the machine model if lower...

Страница 11: ...350 76 2 mm NATO R553 0 2334 1676 1918 1804 2179 3858 2246 3400 568 1950 234 2367 2X R832 1 T7141_00 07 17 1804 1918 1500 3400 200 880 2023 3634 2020 1988 1832 3357 2x727 8 4x762 0 2x101 6 2X1355 0 2x...

Страница 12: ...ting psi bar kPa 200 13 8 1380 200 13 8 1380 Maximum pressure ratio absolute 8 1 8 1 Operating ambient temperature range C F 10 to 52 14 to 126 10 to 52 14 to 126 Maximum discharge temperature C F 120...

Страница 13: ...ectrical system V DC 24 Power available at rated speed KW 205 Fuel tank capacity Litre 462 Coolant capacity Litre 30 WEIGHT Shipping weight 3900 kg Maximum weight 4280 kg WHEELS AND TYRES SITE RUNNING...

Страница 14: ...of the machine ensure that there is sufficient clearance for ventilation and exhaust requirements observing any specified minimum dimensions to walls floors etc Adequate clearance needs to be allowed...

Страница 15: ...eleased fuel is safely contained 6 Check the radiator coolant level with the machine level 7 Open the service valve s to ensure that all pressure is relieved from the system Close the service valve s...

Страница 16: ...OFF to stop engine 5 Service air switch After warm up PUSH Provides full air pressure at the service outlet 6 Engine speed gauge Indicates engine speed RPM 7 Discharge air temperature gauge Indicates...

Страница 17: ...emperature Fault indicator lamp Indicates shutdown due to low engine oil pressure 4 Low fuel level Fault indicator lamp Indicates shutdown due to low fuel level Lamp blinks at low fuel warning 5 Low b...

Страница 18: ...N THE INSTRUMENT PANEL TO THE OFF POSITION 0 or push the EMERGENCY STOP SWITCH when fitted RE STARTING AFTER AN EMERGENCY If the machine has been switched off because of a machine malfunction then ide...

Страница 19: ...10 215HA 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 MAI...

Страница 20: ...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...

Страница 21: ...e 8 Fuel injection pump 9 Fuel drain line 10 Intake manifold 11 Turbocharger waste gate actuator 12 Turbocharger air outlet 13 Oil filler cap 14 Lubricating oil pressure after filter 15 Lubricating oi...

Страница 22: ...our branch or distributor Please ensure that only genuine Doosan parts lubricants and fluids are used for service and or repair Engine model name 6C8 3 Engine type Water Cooled four cycle in line over...

Страница 23: ...long with the diesel fuel This can happen if a fuel provider does not regularly inspect and clean its fuel tanks or receives contaminated fuel from its supplier s To protect your engine from contamina...

Страница 24: ...t lubricants with the correct viscosity for the operating temperature are used Refer to fig 2 Fig 2 A Single grade B Ambient Temperature C Multi grade COOLANT All Doosan portable compressor engines ar...

Страница 25: ...ture belt wear or belt elongation leading to engine overheating or excessive belt noise Coolant level check Check and ensure that the level is correct Add coolant mixed to the correct ratio 50 50 ethy...

Страница 26: ...bnormalities 1 Engine Oil Pressure The engine oil pressure is monitored by a switch that will stop the engine if the pressure falls below a pre set value If the oil pressure gauge shows below 30 psi o...

Страница 27: ...fuel consumption but also will lead to premature parts wear which may result in engine failure Ensure that the engine reaches normal operating temperature 75 to 85 C 167 to 185 F within ten minutes of...

Страница 28: ...recheck the oil level If necessary replenish with engine oil to the specified level Engine oil additives Engine oils contain a variety of additives Your engine should not need any extra additives if...

Страница 29: ...lean 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 fu...

Страница 30: ...rge air cooling pipes and connections for damage or loose fitting Replace or re fit as necessary Fig 15 ENGINE ELECTRICAL The engine uses a 24 volt system and a negative grounding for the electrical s...

Страница 31: ...or where it will not be affected by cold winds when not running BATTERY Always ensure that the batteries are kept fully charged in the cold season This takes a longer period of running than in warm we...

Страница 32: ...nd belt check O O 15 Coolant temperature gage reading where fitted O 16 Coolant replacement O 17 Coolant filter replacement O 18 Radiator external face cleaning O O O O O O 19 Cooling system circuit c...

Страница 33: ...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...

Страница 34: ...ged 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 e...

Страница 35: ...l injection amount between cylinders Deteriorated governor spring Incorrect valve clearance adjustment Deteriorated valve spring Engine speed stuck at high idle Engine control restriction or seizure E...

Страница 36: ...clearance adjustment Cylinder compression leakage Injector nozzle misalignment Low cylinder compression pressure Cylinder bore wear Insufficient air intake volume Air cleaner clogged Restricted air f...

Страница 37: ...ncorrect fuel Water mixing in fuel Excessive white smoke Low compression pressure Injection timing incorrect Low coolant temperature Faulty turbocharger Battery overdischarge Low electrolyte level Cra...

Страница 38: ...ment 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 T Test...

Страница 39: ...let Shutdown Valve C Engine Vibration Damper C R C Check and act if required T Test D Drain R Replace CBT Check before towing R WI Replace or when indicated earlier C R Check and replace if required G...

Страница 40: ...ork 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 c...

Страница 41: ...adiator This should remove any accumulation of oil grease and dirt from the exterior core of the cooler so that the entire cooling area can radiate the heat of the lubricating and cooling oil water in...

Страница 42: ...ighten to the torque value shown in the TORQUE SETTING TABLE later in this section The fan belt s should be checked regularly for wear and correct tensioning FUEL FILTER MAINTENANCE 1 Primary fuel fil...

Страница 43: ...orque 30 kilometres 20 miles after refitting the wheels Refer to the TORQUE SETTING TABLE later in this section The bolts securing the running gear to the frame should be checked periodically for tigh...

Страница 44: ...imum Consistency NLGI No 2 Additives EP Corrosion Oxidation Inhibitors Viscosity Index 80 Minimum NOTE If the machine has been operating under adverse conditions or has suffered long shutdown periods...

Страница 45: ...this manual Adjust the service valve on the outside of the machine to maintain normal operating discharge pressure without the throttle arm moving from the full speed position before normal operating...

Страница 46: ...ICAL CIRCULAR TORQUE PATTERN CAPSCREW OR NUT THREAD SIZE AND PITCH NOMINAL DESIGN TORQUE 8AE J249 GRADE 5 HEAD MARKING 8AE J249 GRADE 8 HEAD MARKING Nm FT LBF Nm FT LBF 1 4 20 11 8 16 12 5 16 18 24 17...

Страница 47: ...SIZE AND PITCH NOMINAL DESIGN TORQUE PROPERTY GRADE 8 8 HEAD MARKING PROPERTY GRADE 10 9 HEAD MARKING PROPERTY GRADE 12 9 HEAD MARKING Nm FT LBF Nm FT LBF Nm FT LBF M6 X 1 0 11 8 15 11 18 13 M8 X 1 25...

Страница 48: ...an earlier change may be necessary as oil deteriorates with time as well as by operating conditions An oil change is good insurance against the accumulation of dirt sludge or oxidized oil products Co...

Страница 49: ...amage Please read the engine manual for more details Design operating pressure Ambient temperature Compressor oil specification 7 bar to 14 bar 100 psi to 200 psi 23 C to 52 C 10 F to 125 F Preferred...

Страница 50: ...48 MACHINE SYSTEMS 9 235HA 10 215HA...

Страница 51: ...MACHINE SYSTEMS 49 9 235HA 10 215HA...

Страница 52: ...50 MACHINE SYSTEMS 9 235HA 10 215HA...

Страница 53: ...MACHINE SYSTEMS 51 9 235HA 10 215HA...

Страница 54: ...52 MACHINE SYSTEMS 9 235HA 10 215HA...

Страница 55: ...MACHINE SYSTEMS 53 9 235HA 10 215HA...

Страница 56: ...r engine shuts down prematurely Electrical fault Test the electrical circuits Low engine oil pressure Check the oil level and oil filter s Safety shut down system in operation Check the safety shut do...

Страница 57: ...place 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 C...

Страница 58: ...be operated below freezing IQ SYSTEM OPERATING INSTRUCTIONS 2 The compressed air exits the separator tank through the top cover piping and can then travel along one of two paths selectable via manual...

Страница 59: ...ceeds recommended values Weekly Maintenance Remove Y strainer screens at the bottom of the moisture separator and both filters and clean out any residue Verify that the orifices below the Y strainers...

Страница 60: ...58 OPTIONS 9 235HA 10 215HA PRIMARY AND SECONDARY FILTER MAINTENANCE FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5...

Страница 61: ...OPTIONS 59 9 235HA 10 215HA WATER SEPARATOR MAINTENANCE FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5 FIGURE 6...

Страница 62: ...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 resul...

Страница 63: ...2 Check all harness connections between IQ TCU and PT100 PT101 differential pressure sensors Repair harness as needed 3 If steps 1 and 2 checkout OK replace IQ TCU controller The TITAN controller has...

Страница 64: ...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 cl...

Страница 65: ...OW TO USE PARTS LIST a Turn to Parts List b Locate the area or system of the compressor in which the desired part is used and find illustration page number c Locate the desired part on the illustratio...

Страница 66: ...egligence indemnity strict liability or otherwise shall not exceed the purchase price of the part upon which such liability is based The Company shall in no event be liable to the Purchaser any succes...

Страница 67: ......

Страница 68: ...Doosan Bobcat EMEA s r o U Kodetky 1810 263 12 Dob Czech Republic www doosanportablepower eu...

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