Operation and Maintenance Manual Original Instruction: SERIAL No: 543500 - 543999

7/73 - 10/53
OPERATION AND MAINTENANCE MANUAL

Original Instruction
This manual contains

important safety information
and must be made available to
personnel who operate and
maintain this machine.
SERIAL No : 543500 -> 543999
46674184_en_C_09/18
Machine models represented in this manual may be used in various locations world-wide. Machines sold and
shipped into European Union Territories require that the machine display the CE Mark and conform to various
directives. In such cases, the design specification of this machine has been certified as complying with EC
directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking
being rendered invalid. A declaration of that conformity follows:
1)
EC Declaration of Conformity 2)
Original declaration
3) 4)
We: Represented in EC by:
Doosan International USA, Inc Doosan Trading Limited
1293 Glenway Drive Block B, Swords Business Campus
Statesville Swords
North Carolina 28625-9218 Co. Dublin
USA Ireland
5)
Hereby declare that, under our sole responsibility the product(s)
6)
Machine description: Portable Screw Compressor
7)
Machine Model: 7/20; 7/26E; 7/31E; 7/41; 7/53; 7/53R; 7/73-10/53; 7/124-10/104; 10/124-14/114; 14/84;
SAMPLE
7/204; 10/174; 10/204; 12/154; 14/144; 9/274; 9/304; 12/254; 17/244; 21/224
8)
Commercial name: 7/20; 7/26E; 7/31E; 7/41; 7/53; 7/53R; 7/73-10/53; 7/124-10/104; 10/124-14/114; 14/84;
7/204; 10/174; 10/204; 12/154; 14/144; 9/274; 9/304; 12/254; 17/244; 21/224
9)
VIN / Serial number: UN5
10)
is (are) in conformity with the relevant provisions of the following EC Directive(s)
11)
2006/42/EC The Machinery Directive
12)
2014/30/EU The Electromagnetic Compatibility Directive
13)
2000/14/EC The Noise Emission Directive
14)
2014/68/EU The Pressure Equipment Directive
15)
2014/29/EU The Simple Pressure Vessels Directive
16)
97/68/EC The emission of engines for no-road mobile machinery
31)
2014/35/EU The Low Voltage Equipment Directive
17)
and their amendments
18)
Conformity with the Noise Emission Directive 2000/14/EC
19) Directive 2000/14/EC, Annex VI, Part I
20) Notified body: AV Technology, Warrington, UK. Nr 1067
21) 21)
Machine 23)
Measured sound 24)
Guaranteed sound Machine 23)
Measured sound 24)
Guaranteed
22)
Type kW power level power level 22)
Type kW power level sound power level
7/20 17,5 96LWA 97LWA 7/124-10/104 97

7/26E 21,3 97LWA 98LWA 10/124-14/114 122 98LWA 99LWA
7/31E 25,9 97LWA 98LWA 14/84 97
7/41 35 98LWA 98LWA 7/204; 10/174;
168
7/53; 7/53R 36 97LWA 98LWA 12/154; 14/144 98LWA 99LWA
7/73-10/53 55 96LWA 98LWA 10/204 186
9/274 226 99LWA 100LWA
9/304; 12/254;
247 99LWA 100LWA
17/244; 21/224
25)
Conformity with the Pressure Equipment directive 2014/68/EU
26)
We declare that this product has been assessed according to the Pressure Equipment Directive 2014/68/EU and, in accordance with the terms of
this Directive, has been excluded from the scope of this Directive. It may carry "CE" marking in compliance with other applicable EC directives.
Jan Moravec
27)
Engineering Director
28) 29)
Issued at Dobris, Czech Republic Date
30)
The technical documentation for the machinery is available from:
Doosan Bobcat EMEA s.r.o. (DBEM), U Kodetky 1810, 263 12 Dobris, Czech Republic
CPN 46552199 rev P

CONTENTS & ABBREVIATIONS 1
1 CONTENTS 46 FAULT FINDING
2 FOREWORD 59 OPTIONS
3 DECALS Lubricator
Safety
10 SAFETY General Information
Operating Instructions
13 GENERAL INFORMATION
Maintenance
Dimensions
Fault Finding
Data
Chalwyn Valve
17 OPERATING INSTRUCTIONS Adjustment
Commissioning Maintenance
Prior to starting
Air hose restraint installation Aftercooler and Water Separator
Starting Operating Instructions
Two pressure modes of operation Maintenance
Stopping Safety
Emergency stopping
61 PARTS ORDERING
Re-starting
Monitoring during operation ABBREVIATIONS & SYMBOLS
Decommissioning #### Contact the company for serial number
Long term storage ->#### Up to Serial No.
Short term storage
####-> From Serial No.
Compressor mounting
Onboard engine diagnostics * Not illustrated
23 MAINTENANCE † Option
Routine maintenance AR As required
Protective shutdown system F.H.R.G. Fixed height running gear
Scavenge line V.H.R.G. Variable height running gear
Compressor oil filter HA High ambient machine
Compressor spin-on oil separator element SECU Small electronic control unit
Compressor oil cooler and engine radiator
bg Bulgarian
Air filter elements
cs Czech
Ventilation
Cooling fan drive da Danish
Fuel system de German
Hoses el Greek
Electrical system en English
Battery es Spanish
Pressure system et Estonian
Tyres
fi Finnish
Running gear
fr French
Brakes
Lubrication hu Hungarian
Engine lubricating oil it Italian
Engine oil filter element lt Lithuanian
Lubricating oil filter lv Latvian, Lettish
Lubrication - general mt Maltese
Compressor oil filter element nl Dutch
Running gear wheel bearings
no Norwegian
Engine storage - long term
pl Polish
Decomissioning
Compressor mounting pt Portuguese
Speed and pressure regulation ro Romanian
Torque values table ru Russian
Compressor lubrication sk Slovak
sl Slovenian
38 ELECTRICAL SYSTEM
sv Swedish
45 PIPING AND INSTRUMENTATION SYSTEM zh Chinese
7/73 - 10/53
2 FOREWORD
The contents of this manual are considered to be proprietary and IF IN DOUBT CONSULT SUPERVISION.
confidential and should not be reproduced without the prior written
This machine has been designed and supplied for use only in the
permission of the company.
following specified conditions and applications:
Nothing contained in this document is intended to extend any promise, • Compression of normal ambient air containing no known or
warranty or representation, expressed or implied, regarding the detectable additional gases, vapours. or particles
products described herein. Any such warranties or other terms and • Operation within the ambient temperature range specified in the
conditions of sale of products shall be in accordance with the standard GENERAL INFORMATION section of this manual.
terms and conditions of sale for such products, which are available
upon request. The use of the machine in any of the situation types listed in table
1:-
This manual contains instructions and technical data to cover all a) Is not approved,
routine operation and scheduled maintenance tasks by operation and b) May impair the safety of users and other persons, and
maintenance staff. Major overhauls are outside the scope of this
c) May prejudice any claims made.
manual and should be referred to an authorised service department.
The design specification of this machine has been certified as TABLE 1

complying with EC directives. As a result:
Use of the machine to produce compressed air for:
a) Any machine modifications are strictly prohibited, and will invalidate
a) direct human consumption
EC certification.
b) indirect human consumption, without suitable filtration and purity
b) A unique specification for USA/Canada is adopted and tailored to
checks.
the territory.
Use of the machine outside the ambient temperature range
All components, accessories, pipes and connectors added to the
specified in the GENERAL INFORMATION SECTION of this
compressed air system should be:
manual.
• of good quality, procured from a reputable manufacturer and,
wherever possible, be of a type approved by the company. This machine is not intended and must not be used in potentially
• clearly rated for a pressure at least equal to the machine maximum explosive atmospheres, including situations where flammable
allowable working pressure. gases or vapours may be present.
• compatible with the compressor lubricant/coolant. Use of the machine fitted with non approved components /
• accompanied with instructions for safe installation, operation and lubricants / fluids.
maintenance.
Use of the machine with safety or control components missing or
Details of approved equipment are available from the company service disabled.
departments.
Use of the machine for storage or transportation of materials inside
The use of repair parts / lubricants / fluids other than those included or on the enclosure except when contained within the toolbox.
within the approved parts list may create hazardous conditions over
which the company has no control. Therefore the company cannot be
The company accepts no responsibility for errors in translation of this
held responsible for equipment in which non-approved repair parts are
manual from the original English version.
installed.
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
The intended uses of this machine are outlined below and examples of DOOSAN COMPANY
unapproved usage are also given, however the company cannot
anticipate every application or work situation that may arise.
7/73 - 10/53
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.
7/73 - 10/53
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.
7/73 - 10/53
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.
7/73 - 10/53
6 DECALS
Engine oil drain. Compressor oil drain.
7/73 - 10/53
DECALS 7
Look for these signs on machines shipped to markets in North America, which point out potential hazards to
the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you
do not understand, inform your supervisor.
DANGER CAUTION
Red background Yellow background
Indicates the presence of a hazard which WILL cause Indicates the presence of a hazard which WILL or can
serious injury, death or property damage, if ignored. cause injury or property damage, if ignored.
WARNING NOTICE
Orange background Blue background
Indicates the presence of a hazard which CAN cause Indicates important set-up, operating or maintenance
serious injury, death or property damage, if ignored. information.
DANGER WARNING
Trapped air pressure. Can
cause serious injury or
death.
Close service valve and

operate tool to vent trapped air
Air discharged from this machine can contain before performing any service.
carbon monoxide or other contaminants which
will cause serious injury or death.
Do not breathe this air.
WARNING WARNING
Hot pressurized fluid. Rotating Fan Blade.
Can cause serious burns. CAN cause serious injury.
Do not open radiator while Do NOT operate with guard

hot. removed.
7/73 - 10/53
8 DECALS
WARNING WARNING
Improper operation of this equipment. Trapped air pressure.
CAN cause serious injury or death. Can cause serious injury
Read Operator's Manual supplied with this machine or death.
before operation or servicing.
Close service valve and
operate tool to vent trapped
Modification or alteration of this machine.
air before performing any
CAN cause serious injury or death.
service.
Do NOT alter or modify this machine without the
express written consent of the manufacturer.
WARNING
WARNING
Disconnected Air Hoses
Whip. CAN cause
serious injury or death.
When using air tools attach
safety device (OSHA
Valve) at source of air
Falling off machine. CAN cause serious
supply for each tool.
injury or death.
Access Lifting Bail from inside machine.
WARNING
WARNING
High pressure air. Can
cause serious injury or
death.
Relieve pressure before

removing filler plugs/ Door under pressure CAN cause serious
caps, fittings or covers. injury.
Use both hands to open door when machine

is running.
7/73 - 10/53
DECALS 9
WARNING
WARNING
Collapsing propstand.
Can cause serious injury..
WARNINGExcessive Towing Speed. CAN cause
Clamp propstand securely
serious injury or death.
Excessive towing speed.
Can cause serious injury or Do NOT Tow on Highway.
death. Do NOT exceed 20 mph (32 km/h)
Do NOT exceed 65 mph (105 km/
hr)
For Highway Towable Units. For Non-Highway Towable Machines
7/73 - 10/53
10 SAFETY
Compressed air
WARNINGS
Warnings call attention to instructions which must be followed Compressed air can be dangerous if incorrectly handled. Before doing
precisely to avoid injury or death. any work on the unit, ensure that all pressure is vented from the system
and that the machine cannot be started accidentally.
CAUTIONS
Ensure that the machine is operating at the rated pressure and that the
Cautions call attention to instructions which must be followed
rated pressure is known to all relevant personnel.
precisely to avoid damaging the product, process or its surroundings.
All air pressure equipment installed in or connected to the machine
NOTES
must have safe working pressure ratings of at least the machine rated
Notes are used for supplementary information. pressure.
If more than one compressor is connected to one common

General Information downstream plant, effective check valves and isolation valves must be
fitted and controlled by work procedures, so that one machine cannot
Never operate unit without first observing all safety warnings and accidentally be pressurised / over pressurised by another.
carefully reading the operation and maintenance manual shipped from Compressed air must not be used for a direct feed to any form of
the factory with this machine. breathing apparatus or mask.
Ensure that the operator reads and understands the decals and High Pressure Air can cause serious injury or death. Relieve pressure
consults the manuals before maintenance or operation. before removing filler plugs/caps, fittings or covers.
Ensure that the Operation and Maintenance manual, and the manual Air pressure can remain trapped in air supply line which can result in
holder, are not removed permanently from the machine. serious injury or death. Always carefully vent air supply line at tool or
Ensure that maintenance personnel are adequately trained, competent vent valve before performing any service.
and have read the Maintenance Manuals. The discharged air contains a very small percentage of compressor
Ensure that ice and snow do no block the cooling air inlets. lubricating oil and care should be taken to ensure that downstream
equipment is compatible.
Use hearing protectors when the machine is running.
If the discharged air is to be ultimately released into a confined space,
Make sure that all protective covers are in place and that the canopy/ adequate ventilation must be provided.
doors are closed during operation.
When using compressed air always use appropriate personal
The specification of this machine is such that the machine is not protective equipment.
suitable for use in flammable gas risk areas. If such an application is
required then all local regulations, codes of practice and site rules must All pressure containing parts, especially flexible hoses and their
be observed. To ensure that the machine can operate in a safe and couplings, must be regularly inspected, be free from defects and be
reliable manner, additional equipment such as gas detection, exhaust replaced according to the Manual instructions.
spark arrestors, and intake (shut-off) valves may be required, Avoid bodily contact with compressed air.
dependant on local regulations or the degree of risk involved.
The safety valve located in the separator tank must be checked
A weekly visual check must be made on all fasteners/fixing screws periodically for correct operation.
securing mechanical parts. In particular, safety-related parts such as
coupling hitch, drawbar components, road-wheels, and lifting bail Whenever the machine is stopped, air will flow back into the
should be checked for total security. compressor system from devices or systems downstream of the
machine unless the service valve is closed. Install a check valve at the
All components which are loose, damaged or unserviceable, must be machine service valve to prevent reverse flow in the event of an
rectified without delay. unexpected shutdown when the service valve is open.
Air discharged from this machine may contain carbon monoxide or Disconnected air hoses whip and can cause serious injury or death.
other contaminants which will cause serious injury or death. Do not
breathe this air. Never allow the unit to sit stopped with pressure in the receiver-
separator system.
This machine produces loud noise with the doors open or service valve
vented. Extended exposure to loud noise can cause hearing loss.
Always wear hearing protection when doors are open or service valve Materials
is vented.
The following substances may be produced during the operation of this
Never inspect or service unit without first disconnecting battery
machine:
cable(s) to prevent accidental starting.
• brake lining dust
Do not use petroleum products (solvents or fuels) under high pressure • engine exhaust fumes
as this can penetrate the skin and result in serious illness. Wear eye
protection while cleaning unit with compressed air to prevent debris AVOID INHALATION
from injuring eye(s). Ensure that adequate ventilation of the cooling system and exhaust
Rotating fan blade can cause serious injury. Do not operate without gases is maintained at all times.
guard in place. The following substances are used in the manufacture of this machine
Use care to avoid contacting hot surfaces (engine exhaust manifold and may be hazardous to health if used incorrectly:
and piping, air receiver and air discharge piping, etc.). • anti-freeze
Ether is an extremely volatile, highly inflammable gas. When it is • compressor lubricant
specified as a starting aid, use sparingly. DO NOT USE ETHER IF THE • engine lubricant
MACHINE HAS GLOW PLUG STARTING AID OR ENGINE DAMAGE • preservative grease
WILL RESULT. • rust preventative
• diesel fuel
Never operate unit with guards, covers or screens removed. Keep
hands, hair, clothing, tools, blow gun tips, etc. well away from moving • battery electrolyte
parts.
7/73 - 10/53
SAFETY 11
AVOID INGESTION, SKIN CONTACT AND INHALATION OF Transport
FUMES.
When loading or transporting machines ensure that the specified lifting
Should compressor lubricant come into contact with the eyes, then
and tie down points are used and cables or chains are in safe limits.
irrigate with water for at least 5 minutes.
Should compressor lubricant come into contact with the skin, then
wash off immediately.
Consult a physician if large amounts of compressor lubricant are

ingested.
Consult a physician if compressor lubricant is inhaled.
Never give fluids or induce vomiting if the patient is unconscious or

having convulsions.
Safety data sheets for compressor and engine lubricants should be

obtained from the lubricant supplier.
Never operate the engine of this machine inside a building without

adequate ventilation. Avoid breathing exhaust fumes when working on
or near the machine.
This machine may include such materials as oil, diesel fuel, antifreeze,
brake fluid, oil/air filters and batteries which may require proper
disposal when performing maintenance and service tasks. Contact
local authorities for proper disposal of these materials.
Battery
A battery contains sulphuric acid and can give off gases which are
corrosive and potentially explosive. Avoid contact with skin, eyes and
clothing. In case of contact, flush area immediately with water.
DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY

SINCE THIS MAY CAUSE IT TO EXPLODE.
Exercise extreme caution when using booster battery. To jump battery, When loading or transporting machines ensure that the towing vehicle,
connect ends of one booster cable to the positive (+) terminal of each its size, weight, towing hitch and electrical supply are all suitable to
battery. Connect one end of other cable to the negative (-) terminal of provide safe and stable towing at speeds either, up to the legal
the booster battery and other end to a ground connection away from maximum for the country in which it is being towed or, as specified for
dead battery (to avoid a spark occurring near any explosive gases that the machine model if lower than the legal maximum.
may be present). After starting unit, always disconnect cables in Ensure that the maximum trailer weight does not exceed the maximum
reverse order. gross weight of the machine (by limiting the equipment load), limited by
the capacity of the running gear.
Radiator Note: Gross mass (on data plate) is for the basic machine and fuel
only, excluding any fitted options, tools, equipment and foreign
Hot engine coolant and steam can cause injury. Ensure that the materials.
radiator filler cap is removed with due care and attention.
Do not remove the pressure cap from a HOT radiator. Allow radiator to Before towing the machine, ensure that:
cool down before removing pressure cap.
• 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.
• the brakes and lights are functioning correctly and meet necessary
road traffic requirements.
• break–away cables/safety chains are connected to the towing
vehicle.
The machine must be towed in a level attitude (the maximum

permissible drawbar angle is between 0° and +5° from horizontal) in
order to maintain correct handling, braking and lighting functions. This
can be achieved by correct selection and adjustment of the vehicle
towing hitch and, on variable height running gear, adjustment of the
drawbar.
To ensure full braking efficiency, the front (towing eye) section must
always be set level.
When adjusting variable height running gear:-
• Ensure front (towing eye) section is set level

• When raising towing eye, set rear joint first, then front joint.
• When lowering towing eye, set front joint first, then rear joint.
After setting, fully tighten each joint by hand and then tighten further to
the next pin. Refit the pin.
7/73 - 10/53
12 SAFETY
When parking always use the handbrake and, if necessary, suitable Where brakes and safety chains are fitted:
wheel chocks.
a) Loop the chains onto the towing vehicle using the towing vehicle
Make sure wheels, tyres and tow bar connectors are in safe operating hitch as an anchorage point, or any other point of similar strength.
condition and tow bar is properly connected before towing.
b) Ensure that the effective chain length is as short as possible whilst
still allowing normal articulation of the trailer and effective operation
Safety chains / connections and their adjustment of the breakaway cable.
Where safety chains only are fitted:

The legal requirements for the joint operation of the breakaway cable
and safety chains are as yet unidentified by 71/320/EEC or UK a) Loop the chains onto the towing vehicle using the towing vehicle
regulations. Consequently we offer the following advice / instructions. hitch as an anchorage point, or any other point of similar strength.
Where brakes only are fitted: b) When adjusting the safety chains there should be sufficient free
length in the chains to allow normal articulation, whilst also being
a) Ensure that the breakaway cable is securely coupled to the short enough to prevent the towbar from touching the ground in the
handbrake lever and also to a substantial point on the towing event of an accidental separation of the towing vehicle from the
vehicle. trailer.
b) Ensure that the effective cable length is as short as possible, whilst
still allowing enough slackness for the trailer to articulate without the
handbrake being applied.
7/73 - 10/53
GENERAL INFORMATION 13
7/73 - 10/53 FIXED HEIGHT RUNNING GEAR

Braked version
7/73 - 10/53 VARIABLE HEIGHT RUNNING GEAR

Braked version
7/73 - 10/53
7/73 - 10/53 PERMANENT SKID MOUNTED

(2434 **)
1. * 10mm 1200 *
2300 *
2. ** 40mm 1019 *
1238 *
(1429 **)
265 515
378 *
125
191 *
150 * 70 (2X)
127.0 127.0
223.0
36.0 659.3 195.5 551.2
64.0
406.5
127.0
406.5
T4897_00
11/15
7/73 - 10/53 SHIPPING SKID MOUNTED
(2434 **)
1. * 10mm 2300 *
1200 *
2. ** 40mm 1019 *
1238 *
265 515
378 *
125
150 * 70 (2X)
223.0
631.0 448.6
406.5
127.0
406.5
T4898_00
11/15
7/73 - 10/53
GENERAL INFORMATION 15
7/73 - 10/53 TRUCK SKID MOUNTED

1200 * (2434 **)
1. * 10mm 2300 *
2. ** 40mm 1019 *
1274 *
(1464 **)
265 515
414 *
125
191 *
150 * 70 (2X)
127.0 127.0
36.0 659.3 195.5 551.2
223.0
64.0
406.5
127.0
406.5
T4899_00
11/15
7/73 - 10/53
COMPRESSOR - 7/73 ENGINE

Type/model. Cummins QSF 2,8
Actual free air delivery. 7,0 m3 min-1 (250 CFM)
Number of cylinders. 4
Normal operating discharge pressure. 6,9 bar (100 PSI)
Oil capacity. 7,0 litres (1,8 US GAL)
Maximum allowable pressure. 8,9 bar (129 PSI)
Speed at full load - 7/73 2450 revs min-1
Safety valve setting. 13,8 bar (200 PSI)
Speed at full load - 10/53 1900 revs min-1
Maximum pressure ratio (absolute). 7,5 : 1
Speed at idle. 1500 revs min-1
Operating ambient temperature.
CE regions -10°C TO +46°C (14°F TO 115°F) Electrical system. 12V negative earth
High ambient temp. -10°C TO +52°C (14°F TO 126°F)
Power available at 2350 revs min-1 55kW (73,7 HP)
Maximum discharge temperature. 120°C (248°F)
Fuel tank capacity 118 litres (31,2 US GAL)
Cooling system. Oil injection
Oil specification Refer engine section
Oil capacity. 10 litres (2,6 US GAL)
Coolant capacity 11,5 litres (3 US GAL)
Maximum oil system temperature. 120°C (248°F)
Maximum oil system pressure. 8,9 bar (129 PSI)
INFORMATION ON AIRBORNE NOISE (CE regions)
COMPRESSOR - 10/53 - The A-weighted emission sound pressure level
Actual free air delivery. 5,3 m3 min-1 (190 CFM) . 83 dB(A), uncertainty 1 dB(A)
Normal operating discharge pressure. 10,3 bar (150 PSI) - The A-weighted emission sound power level
Maximum allowable pressure. 12,0 bar (179 PSI) . 98 dB(A), uncertainty 1 dB(A)
Safety valve setting. 13,8 bar (200 PSI) The operating conditions of the machinery are in compliance with
ISO 3744:1995 and EN ISO 2151:2004
Maximum pressure ratio (absolute). 7,5 : 1
Operating ambient temperature.
CE regions -10°C TO +46°C (14°F TO 115°F) FIXED HEIGHT RUNNING GEAR
High ambient temp. -10°C TO +52°C (14°F TO 126°F) Braked version
Maximum discharge temperature. 120°C (248°F) Shipping weight. 1272kg (2996 lbs)
Cooling system. Oil injection Maximum weight. 1600kg (3520 lbs)
Oil capacity. 10 litres (2,6 US GAL) Maximum vertical coupling load
(nose weight). 100 kgf (220 lbs)
Maximum oil system temperature. 120°C (248°F)
Maximum oil system pressure. 8,9 bar (129 PSI)
VARIABLE HEIGHT RUNNING GEAR
Braked version
LUBRICATING OIL SPECIFICATION
Shipping weight. 1325kg (3090 lbs)
(for the specified ambient temperatures).
Maximum weight. 1600kg (3520 lbs)
ABOVE -23°C(-9°F)
Recommended: PRO-TEC Maximum vertical coupling load
(nose weight). 100 kgf (220 lbs)
Approved: SAE 10W, API CF-4/CG-4
PRO-TEC compressor fluid is factory-fitted, for use at all ambient WHEELS AND TYRES
temperatures above -23°C (-9°F). Number of wheels. 2 x 51/2 J
Tyre size. 185 R14
NOTE: Warranty may be extended only by continuous use of
PRO-TEC and Doosan oil filters and separators. Tyre pressure. 4,5 bar (65 PSI)
No other oil/fluids are compatible with PRO-TEC. Further information may be obtained by request through the
customer services department.
No other oils/fluids should be mixed with PRO-TEC because the
resulting mixture could cause damage to the airend.
In the event that PRO-TEC is not available and / or the end user
needs to use an approved single grade engine oil, the complete
system including separator / receiver, cooler and pipework must be
flushed clear of the first fill fluid and new Doosan oil filters installed.
When this has been completed, the following oils are approved:
for ambient temperatures above -23°C (-9°F),

SAE 10W, API CF-4/CG-4
Safety data sheets can be obtained on request from your Doosan

dealership.
For temperatures outside the specified ambient range, consult the
company.
7/73 - 10/53
OPERATING INSTRUCTIONS 17
COMMISSIONING Ensure that the correct fork lift truck slots or marked lifting / tie down
points are used whenever the machine is lifted or transported.
Upon receipt of the unit, and prior to putting it into service, it is
When selecting the working position of the machine ensure that there
important to adhere strictly to the instructions given below in PRIOR
is sufficient clearance for ventilation and exhaust requirements,
TO STARTING.
observing any specified minimum dimensions (to walls, floors etc.).
Ensure that the operator reads and understands the decals and
Adequate clearance needs to be allowed around and above the
consults the manuals before maintenance or operation.
machine to permit safe access for specified maintenance tasks.
Ensure that the position of the emergency stop device is known and
Ensure that the machine is positioned securely and on a stable
recognised by its markings. Ensure that it is functioning correctly and
foundation. Any risk of movement should be removed by suitable
that the method of operation is known.
means, especially to avoid strain on any rigid discharge piping.
Running gear drawbar - Machines are shipped to some areas with
Attach the battery cables to the battery(s) ensuring that they are
the drawbar removed. Fitting involves four nuts / bolts to secure the
tightened securely. Attach the negative cable before attaching the
drawbar to the axle and two bolts to fit the drawbar to the front of the
positive cable.
machine with the saddle and spacer block.
Support the front of the machine, fit the wheel chocks to stop the WARNING: All air pressure equipment installed in or connected
machine moving and attach the drawbar. Refer to the torque value to the machine must have safe working pressure ratings of at
table in the MAINTENANCE section of this manual for the correct least the machine rated pressure, and materials compatible with
torque values. the compressor lubricant (refer to the GENERAL INFORMATION
section).
CAUTION: This is a safety critical procedure. Double check the
torque settings after assembly.
WARNING: If more than one compressor is connected to one
common downstream plant, effective check valves and isolation
Fit the propstand and coupling. Remove the supports and set the valves must be fitted and controlled by work procedures, so that
machine level. one machine cannot accidentally be pressurised / over
Before towing the unit, ensure that the tyre pressures are correct (refer pressurised by another.
to the GENERAL INFORMATION section of this manual) and that the
handbrake is functioning correctly (refer to the MAINTENANCE section
WARNING: If flexible discharge hoses are to carry more than 7
of this manual). Before towing the unit during the hours of darkness,
bar pressure then it is recommended that safety retaining wires
ensure that the lights are functioning correctly (where fitted).
are used on the hoses.
Ensure that all transport and packing materials are discarded.
7/73 - 10/53
18 OPERATING INSTRUCTIONS
PRIOR TO STARTING
CAUTION: When refueling:-
• switch off the engine.
1. Place the unit in a position that is as level as possible. The design • do not smoke.
of the unit permits a 15 degree lengthways and sideways limit on • extinguish all naked lights.
out of level operation. It is the engine, not the compressor, that is • do not allow the fuel to come into contact with hot surfaces.
the limiting factor. • wear personal protective equipment.
When the unit has to be operated out of level, it is important to keep the
engine oil level near the high level mark (with the unit level). 5. Drain the fuel filter water separator of water, ensuring that any
released fuel is safely contained.
CAUTION: Do not overfill either the engine or the compressor with
6. Open the service valve(s) to ensure that all pressure is relieved
oil.
from the system. Close the service valve(s).
2. Check the engine lubrication oil in accordance with the operating 7. CAUTION: Do not operate the machine with the canopy/doors in
instructions in the Engine Operator’s Manual. the open position as this may cause overheating and operators to
3. Check the compressor oil level in the sight glass located on the be exposed to high noise levels.
separator tank.
8. Check the radiator coolant level (with the unit level).
4. Check the diesel fuel level. A good rule is to top up at the end of
each working day. This prevents condensation from occurring in the Check the air restriction indicator(s). Refer to the MAINTENANCE
tank. section of this manual.
When starting or operating the machine in temperatures below or

CAUTION: Use only a No. 2-D diesel fuel oil with a minimum octane
approaching 0°C, ensure that the operation of the regulation system,
number of 45 and a sulphur content not greater than 0,5%.
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 are clear of
ice and snow.
7/73 - 10/53
AIR HOSE RESTRAINT INSTALLATION Hoses can fail in areas other than at connecting points and require
daily inspection of the hoses for:
Safety devices such as hose restraints (whipchecks)must be used to
• Cuts, cracks or kinks
prevent hose whipping if a connection fails. Whipchecks are to be
constructed of woven stainless steel, galvanized steel wire rope or • Weakened clamps due to rust and corrosion
chain with aminimum strength adequate for the supplied pressure and
hose diameter. Whipchecks must be fastened to suitable mounting • Damaged connections
points or shackles. • Deformity
The mounts and/or shackles are to be of the same or greater strength • Incorrect or incompatible components or fittings
as the whipchecks. An engineer should be consulted about suitability
of whipchecks, mounts, mounting points, shackles and fittings as well • Any visual damage
as strength rating of materials. Whipchecks must be used at the hose
Hoses must be selected that are rated for the application as to the
origination, termination and each hose to hose connection.
maximum pressure and temperature to be encountered as well as
compatible with the materials being conveyed inside the hose. Hoses
must be compatible with the compressor oil.
7/73 - 10/53
KEY
A. Main switch H. Warning lamp, low engine oil pressure
B. High / Low pressure mode switch I. Warning lamp, high airend oil temperature
C. Service air button J. Warning lamp, dirty IQ filters (IQ filters option)
D. Air pressure gauge K. Warning lamp, high engine coolant temperature
E. Hourmeter L. Warning lamp, low engine fuel level
F. Diagnostic lamp, red M. Warning lamp, low battery voltage
G. Diagnostic lamp, yellow
7/73 - 10/53
STARTING THE MACHINE STOPPING THE MACHINE
• Close the service valve.

WARNING: Under no circumstances should volatile liquids such
as Ether be used for starting this machine. • Allow the machine to run unloaded for a short period of time to
reduce the engine temperature.
• Open the service valve fully, with no hose connected.
• Turn the start switch to the 0 (off) position.
All normal starting functions are incorporated in the key operated
• Do not turn off the battery switch (if fitted) sooner than 70 seconds
switch.
after stopping the engine.
• Turn the key switch to position 2 and hold for max 15 seconds to
allow the air inlet heater to reach working temperature. NOTE: As soon as the engine stops, the automatic blowdown valve
will relieve all pressure from the system.
• Turn the key switch to position 3 (engine start position).
• Release to position 2 when the engine starts. If the automatic blowdown valve fails to operate, then pressure must be
relieved from the system by means of the service valve(s).
• Release to position 1 when the alternator charge light is
extinguished.
CAUTION: Never allow the machine to stand idle with pressure in the
system.
WARNING: The sum of cranking time should not exceed 30
seconds within an interval of 2 minutes. If this limit is exceeded
the ECU will block cranking to protect the starter motor. Once EMERGENCY STOPPING
cranking is blocked the machine control system has to be
switched to diagnostic mode for at least 2 minutes. After this In the event that the unit has to be stopped in an emergency, TURN
interval cranking is possible. THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO
THE 0 (OFF) POSITION.
At temperatures below 0°C or is there is difficulty starting first time:
• Complete starting sequence above. RE-STARTING AFTER AN EMERGENCY
• Close service valve as soon as engine runs freely.

If the machine has been switched off because of a machine
• Do not allow machine to run for long periods with service valve malfunction, then identify and correct the fault before attempting to
open. re-start.
• Allow the engine to reach operating temperature. Then press button If the machine has been switched off for reasons of safety, then ensure
(A) when fitted. that the machine can be operated safely before re-starting.
• 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 service valve open and air is flowing from the valve.
Should any of the safety shut–down conditions occur, the unit will stop.
TWO PRESSURE MODES OF OPERATION These are:
• Low engine oil pressure.

1. The Low Pressure Mode is activated by turning the Hi/Lo Pressure
Switch to Lo. In this mode, the compressor will regulate according • High airend discharge temperature.
to the air demand, between 0 and 7,0 m3/min at 6,9 bar regulated
• High engine coolant temperature.
set pressure. The regulated set pressure of this mode can be
changed (see Pressure Regulating Adjusting Instructions) from • Alternator drive belt failure (warning message only).
5,5-6,9 bar.
• Low engine fuel level.
2. The High Pressure Mode is activated by turning the Hi/Lo Pressure
Switch to Hi. In High Pressure Mode, the compressor will regulate CAUTION: To ensure an adequate flow of oil to the compressor at
according to air demand, between 0 and 5,3 m3/min at 10,3 bar low temperature, never allow the discharge pressure to fall below 3,5
regulated set pressure. The regulated set pressure of this mode can bar.
be changed (see Pressure Regulating Adjusting Instructions) from
5,5-10,3 bar.
DECOMMISSIONING
The mode of the compressor can be changed between the Low and
High at anytime. Engine speed will be lower at the HI Pressure Mode
When the machine is to be permanently decommissioned or
setting. dismantled, it is important to ensure that all hazard risks are either
Starting and stopping are unaffected by the selection and during eliminated or notified to the recipient of the machine. In particular:-
normal running the selector switch may be safely operated. Precaution
• Do not destroy batteries or components containing asbestos
must be taken to ensure that downstream equipment is rated to suit the without containing the materials safely.
available pressure.
• Do not dispose of any pressure vessel that is not clearly marked
The pressure guage indicates which setting has been selected.
with its relevant data plate information or rendered unusable by
drilling, cutting etc.
• Do not allow lubricants or coolants to be released into land surfaces

or drains.
• Do not dispose of a complete machine without documentation

relating to instructions for its use.
7/73 - 10/53
COMPRESSOR MOUNTING Flash out of fault codes: Fault flash out mode can be entered through
the use of a diagnostic switch located next to the fault lights. To enter
Portable compressors, which are modified to remove the running gear the flash fault out mode, the keyswitch must be ON, with the engine not
and mount the compressor directly to trailers, truck beds or frames, etc. running. When a diagnostic switch is used to enter the mode, the ECM
may experience failure of the enclosure, frame, and/or other will automatically flash the first fault code after the code is turned on.
components.
The diagram below depicts the pattern of the fault code flash out
It is necessary to isolate the compressor package from the carrier scheme as indicated by the stop lamp. A blink is equavalent to the stop
basewith a flexiblemounting system. Such a system must also prevent lamp being ON for 0.5 seconds and OFF for 0.5 seconds. A pause
detachment of the package from the carrier base in the event the between fault code digits has duration of 2 seconds.
isolators fail.
Contact your Portable Power representative for flexible mounting kits. Example: Diagnostic lamp diagrams
Fault Code 244
Warranty does not cover failures attributable to mounting of the
compressor package to the carrier base unless it is a Portable Power
provided system. Yellow Red Red Red
Lamp Lamp Lamp Lamp

NOTE: The maintenance schedule in this manual describes the
service intervals that should be followed for normalapplications of this 1 Blink 2 Blink 4 Blink 4 Blink
compressor. This page may be reproduced and used as a checklist
by service personnel.
In more severe applications such as sandblasting, quarry drilling, well

drilling, and oil and gas drilling, more frequent service intervals will be
Fault Code 112
required to ensure long component life.
Dust and dirt, high humidity, and high temperatures will affect
lubricant life and service intervals for components such as inlet air Yellow Red Red Red
filters, oil separation elements and oil filters. Lamp Lamp Lamp Lamp
ONBOARD ENGINE DIAGNOSTICS 1 Blink 1 Blink 1 Blink 2 Blink
Fault lamps: If the keyswitch is turned ON, but the diagnostic switch
remains OFF, the indicator lamps will illuminate for approximately 2
seconds and then go off, one after the other, to verify they are working
and wired correctly.
In the illustration below, the indicator lamps are all on and then go off
one at at time, at an interval of 0.5 seconds each.
Fault lamp sequence
WARNING WARNING WARNING

STOP STOP
1. Diagnostics activation button

• Warning Lamp - The warning lamp provides important operator
2. Red lamp messages. These messages require timely operator attention. The
warning lamp is also used to delineate diagnostic fault codes.
3. Yellow lamp
• Stop Lamp - The stop lamp provides critical operator messages.
FAULT DETECTION These messages require immediate and decisive operator response.
The stop lamp is also used to flash out diagnostic fault codes.
7/73 - 10/53
MAINTENANCE 23
MAINTENANCE SCHEDULE
Daily Weekly Monthly 6 months 1 year or 2000 hrs
or 500 hrs 1000 hrs
Compressor Oil Level C
Engine Oil Level C
Coolant Level C
Gauges / Lamps C
Air Cleaner Service Indicators C
Fuel Tank C
Fuel / Water Separator D
Fluid Leaks C
Radiator Filler Cap C
Crankcase Breather Tube C
Air Cleaner Dust Ejector Valve 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 and Guards C
Primary Air Cleaner Elements R/WI
Seconday Air Cleaner Elements R/WI
Fuel / Water Separator Element R
Final Fuel Filter R
Engine Oil Filter R
Engine Oil R
Engine Valve Lash C/A
Compressor Oil Filter R
Compressor Oil R
Oil Separator Element R
Engine Coolant C R
NOTE: 500 and 1000 hour intervals are meant to be repeated at every
C = Check (adjust, clean or replace as necessary) 500 or 1000 hours. Other intervals only to be performed at hours
indicated.
T = Test
D = Drain NOTE: All fluid and filter intervals are valid for near perfect conditions
only. High ambient temperatures - high dust concentration - high
R = Replace humidity as well as using lower grade oils and fuels will require a
R/WI = Replace or when indicated earlier decrease in maintenance intervals.
CBT = Check before towing Contact your Doosan Infracore Portable Power dealer for more
G/C = Grease and check information or assistance in determining the optimum intervals for your
application.
C/A = Check and adjust if required
7/73 - 10/53
24 MAINTENANCE
Daily Weekly Monthly 6 months 1 year or 2000 hrs

or 500 hrs 1000 hrs
Wheels (Bearings, Seals, etc.) C
Fan Hub C
Cooling Fan Belt Tensioner C
Shutdown Switch Settings T
Scavenger Orifice & 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 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
NOTE: 500 and 1000 hour intervals are meant to be repeated at every
C = Check (adjust, clean or replace as necessary) 500 or 1000 hours. Other intervals only to be performed at hours
T = Test indicated.
D = Drain NOTE: All fluid and filter intervals are valid for near perfect conditions
only. High ambient temperatures - high dust concentration - high
R = Replace
humidity as well as using lower grade oils and fuels will require a
R/WI = Replace or when indicated earlier decrease in maintenance intervals.
CBT = Check before towing Contact your Doosan Infracore Portable Power dealer for more
G/C = Grease and check information or assistance in determining the optimum intervals for your
application.
C/A = Check and adjust if required
7/73 - 10/53
MAINTENANCE 25
ROUTINE MAINTENANCE • warning signs indicating that Maintenance Work is in Progress are
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 has to
take place. 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
maintenance for the engine, refer to the Engine Manufacturer’s • hazardous materials are effectively contained and disposed of.
Manual.
Compressed air can be dangerous if incorrectly handled. Before doing PROTECTIVE SHUTDOWN SYSTEM
any work on the unit, ensure that all pressure is vented from the system
and that the machine cannot be started accidentally. Comprises:
If the automatic blowdown fails to operate, then pressure must be • Low engine oil pressure switch.
gradually relieved by operating the manual blowdown valve. Suitable • High airend discharge temperature switch.
personal protective equipment should be worn.
• High engine coolant temperature switch.
Ensure that maintenance personnel are adequately trained, competent
and have read the Maintenance Manuals. • Alternator drive belt failure (warning message only).
Prior to attempting any maintenance work, ensure that:- • Low engine fuel level switch.
• all air pressure is fully discharged and isolated from the system. If
the automatic blowdown valve is used for this purpose, then allow Low engine oil pressure switch.
enough time for it to complete the operation.
At three month intervals, test the engine oil pressure switch circuit as
• the discharge pipe / manifold area is depressurised by opening the
follows:
discharge valve, whilst keeping clear of any airflow from it.
• Start the machine.
MINIMUM PRESSURE VALVE - WHEN FITTED
NOTE: Pressure will always remain in the part of the system between NOTE: Do not press the load button.
the minimum pressure valve and the discharge valve after operation
of the auto blowdown valve. • Remove a wire from one terminal of the switch. The machine should
shutdown.
This pressure must be relieved by carefully:
At twelve month intervals, test the engine oil pressure switch as
a) Disconnecting any downstream equipment. follows:-
b) Opening the discharge valve to atmosphere. • Remove the switch from the machine.
c) (Use hearing protection if necessary). • Connect it to an independent low pressure supply (either air or oil).
• the machine cannot be started accidentally or otherwise, by posting • The switch should operate at 1,0 bar.
warning signs and/or fitting appropriate anti-start devices. • Refit the switch.
• all residual electrical power sources (mains and battery) are
isolated. Temperature switch(es).
Prior to opening or removing panels or covers to work inside a
machine, ensure that:- At three month intervals, test the temperature switch circuit(s) as
follows:
• anyone entering the machine is aware of the reduced level of
protection and the additional hazards, including hot surfaces and • Start the machine.
intermittently moving parts.
NOTE: Do not press the load button.
• the machine cannot be started accidentally or otherwise, by posting
warning signs and/or fitting appropriate anti-start devices.
• Disconnect each switch in turn. The machine should shutdown.
Prior to attempting any maintenance work on a running machine,
• Re-connect the switch.
ensure that:-
• the work carried out is limited to only those tasks which require the
High airend discharge temperature switch(es).
machine to run.
• the work carried out with safety protection devices disabled or At twelve month intervals, test the airend discharge temperature
removed is limited to only those tasks which require the machine to switch(es) by removing it from the machine and immersing in a bath of
be running with safety protection devices disabled or removed. heated oil. The switch should operate at 120°C. Refit the switch.
• all hazards present are known (e.g. pressurised components,
electrically live components, removed panels, covers and guards, High coolant temperature switch.
extreme temperatures, inflow and outflow of air, intermittently
moving parts, safety valve discharge etc.). At twelve month intervals, test the coolant temperature switch by
• appropriate personal protective equipment is worn. removing it from the machine and immersing in a bath of heated oil.
The switch should operate at 105°C. Refit the switch.
• loose clothing, jewelry, long hair etc. is made safe.
7/73 - 10/53
26 MAINTENANCE
Alternator/drive belt failure circuit. Reassembly
Clean the filter gasket contact area and install the new element by
At twelve month intervals test the alternator drive belt failure circuit as
screwing in a clockwise direction until the gasket makes contact with
follows:
the filter housing. Tighten a further 1/2 to 3/4 of a revolution.
• Remove the drive belt from the machine.
CAUTION: Start the machine (refer to PRIOR TO STARTING and
• Turn the key switch to position 1, the alternator charge light will STARTING THE UNIT in the OPERATING INSTRUCTIONS section
illuminate. of this manual) and check for leakage before the machine is put back
• Turn the key switch to position 3 (engine start position). into service.
• The machine will start and alternator charge light / battery light will
illuminate. COMPRESSOR SPIN-ON OIL SEPARATOR FILTER ELEMENT
See Maintenance Schedule.

Low engine fuel level switch.
Removal
At three month intervals, test the low engine fuel level switch circuit as
follows: WARNING: Do not remove the filter(s) without first making sure
that the machine is stopped and the system has been
• Start the machine. completely relieved of all air pressure. (Refer to STOPPING THE
UNIT in the OPERATING INSTRUCTIONS section of this
NOTE: Do not press the load button. manual).
• Disconnect the switch, the machine should shutdown. Remove the spin-on separator element by turning the element counter-
clockwise.
• Re-connect the switch.
Reassembly
At twelve month intervals, test the low engine fuel level switch by
removing and operating the float manually. Check the spin-on filter base for contamination and clean as required.
CAUTION: Never remove or replace switches when the machine is Replace the compressor oil (refer to LUBRICATION later in this
running. section).
CAUTION: Start the machine (refer to PRIOR TO STARTING and

SCAVENGE LINE STARTING THE UNIT in the OPERATING INSTRUCTIONS section
of this manual) and check for leakage before the machine is put back
The scavenge line runs from the spin-on filter housing to the orifice into service.
fitting located in the airend.
Examine the orifice, check valve and hoses at every service or in the COMPRESSOR OIL COOLER AND ENGINE RADIATOR
event of oil carryover into the discharge air.
It is good preventative maintenance to check that the scavenge line When grease, oil and dirt accumulate on the exterior surfaces of the oil
and tube are clear of any obstruction each time the compressor cooler and radiator, the efficiency is impaired. It is recommended that
lubricant is changed as any blockage will result in oil carryover into the each month the oil cooler and radiator be cleaned by directing a jet of
discharge air. compressed air, (carrying if possible a non-flammable cleaning
solvent) over the exterior core of the cooler/radiator. This should
remove any accumulation of oil, grease and dirt from the exterior core
COMPRESSOR OIL FILTER of the cooler so that the entire cooling area can radiate the heat of the
lubricating and cooling oil/water into the air stream.
Refer to the MAINTENANCE CHART in this section for the
recommended servicing intervals. WARNING: Hot engine coolant and steam can cause injury.
When adding coolant or antifreeze solution to the engine
Removal
radiator, stop the engine at least one minute prior to releasing
the radiator filler cap. Using a cloth to protect the hand, slowly
WARNING: Do not remove the filter(s) without first making sure release the filler cap, absorbing any released fluid with the cloth.
that the machine is stopped and the system has been Do not remove the filler cap until all excess fluid is released and
completely relieved of all air pressure. (Refer to STOPPING THE the engine cooling system fully depressurised.
UNIT in the OPERATING INSTRUCTIONS section of this
manual).
WARNING: Follow the instructions provided by the antifreeze
Clean the exterior of the filter housing and remove the spin-on element supplier when adding or draining the antifreeze solution. It is
by turning it in a counter-clockwise direction. advisable to wear personal protective equipment to prevent skin
and eye contact with the antifreeze solution.
Inspection
Examine the filter element. AIR FILTER ELEMENTS
CAUTION: If there is any indication of the formation of varnishes, The air filter should be inspected regularly (refer to the SERVICE/
shellacs or lacquers on the filter element, it is a warning that the MAINTENANCE CHART) and the element replaced every 1 Year
compressor lubricating and cooling oil has deteriorated and that it (1000 hours). The dust collector box(es) should be cleaned daily (more
should be changed immediately. Refer to LUBRICATION later in this frequently in dusty operating conditions) and not allowed to become
section. more than half full.
Removal
CAUTION: Never remove and replace element(s) when the machine

is running.
7/73 - 10/53
MAINTENANCE 27
Clean the exterior of the filter housing and remove the filter element by 1. Primary fuel filter / water separator (30 microns)
releasing the nut.
2. Secondary fuel filter (10 microns)
Inspection
Check for cracks, holes or any other damage to the element by holding General Information
it up to a light source, or by passing a lamp inside.
The engine uses a dual filter system.
Check the seal at the end of the element and replace if any sign of
damage is evident. 1. The pressure-side fuel filter is used for filtration only and is
pressurised by the gear pump mounted on the fuel pump.
Reassembly
2. The suction-side fuel filter is a fuel / water separator and is located
Assemble the new element into the filter housing ensuring that the seal between the gear pump, mounted on the engine’s fuel pump, and
seats properly. the original equipment manufacturer (OEM) fuel supply tank. This
filter is not pressurised, but operates under a vacuum.
Reset the restriction indicator by depressing the rubber diaphragm.
Fuel System Priming
Assemble the dust collector box parts, ensuring that they are correctly
positioned.
Before restarting the machine, check that all clamps are tight.
VENTILATION
Always check that the air inlets and outlets are clear of debris etc.
CAUTION: NEVER clean by blowing air inwards.
COOLING FAN DRIVE
Periodically check that the fan mounting bolts in the fan hub have not
loosened. If, for any reason, it becomes necessary to remove the fan
or re-tighten the fan mounting bolts, apply a good grade of
commercially available thread locking compound to the bolt threads
and tighten 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 SYSTEM A certain amount of air becomes trapped in the fuel system when fuel
system components on the supply and/or highpressure side are
The fuel tank should be filled daily or every eight hours. To minimise serviced or replaced. Fuel system priming is accomplished using a
condensation in the fuel tank(s), it is advisable to top up after the manual priming pump. For priming procedures, see the Prime step of
machine is shut down or at the end of each working day. At six month this procedure.
intervals drain any sediment or condensate that may have
• Disconnect the batteries. See equipment manufacturer service
accumulated in the tank(s).
information.
• Clean the area around the fuel filter.

FUEL FILTER MAINTENANCE
• If required, disconnect the wiring harness from the water-in-fuel
sensor.
7/73 - 10/53
28 MAINTENANCE
Removal
CAUTION: Mechanical over-tightening can distort the threads as well

Loosen and remove the fuel filter. as damage the filter element seal or filter body.
Make sure the o-ring does not stick to the fuel filter head. Remove the
o-ring with an o-ring pick, if necessary. Install the filter on the filter head:
• Install to the point of first contact for the filter and head.
Remove the filter carefully. Use the drive feature on the bottom of the
filter to remove the canister. • Use the drive feature on the bottom. Tighten the canister.
Installation Torque value: 28 Nm (248 in lb).
• If required, connect the wiring harness to the water-in-fuel sensor.
• Connect the batteries. See equipment manufacturer service

information.
Prime
CAUTION: The system must be primed after the fuel filter is installed.
Pre-filling the pressure-side fuel filter can result in debris entering the
fuel system and damaging fuel system components.
Lubricate the fuel filter o-ring with clean lubricating oil.
WARNING: The fuel pump high-pressure lines and fuel rail

contain very high-pressure fuel. Never loosen any fittings while
the engine is running. Personal injury and property damage can
result.
7/73 - 10/53
MAINTENANCE 29
CAUTION: Do not engage the starter motor for more than 30 PRESSURE SYSTEM
seconds at a time. Allow two minutes between cranking intervals.
At 500 hour intervals it is necessary to inspect the external surfaces of
NOTE: To prevent damage to the hand pump priming seals, clean
the system (from the airend through to the discharge valve(s))
the fuel pump head and priming pump with Quick Dry Spray Cleaner,
including hoses, tubes, tube fittings and the separator tank, for visible
Part Number 3824510, or equivalent, and compressed air prior to
signs of impact damage, excessive corrosion, abrasion, tightness and
priming the fuel system.
chafing. Any suspect parts should be replaced before the machine is
put back into service.
After a filter change or running the fuel tank dry, make sure there is fuel
in the vehicle fuel tank.
TYRES/TYRE PRESSURE
NOTE: It is not necessary to vent air from the high pressure fuel
system before starting the engine. Cranking the engine will prime the See the GENERAL INFORMATION section of this manual.
fuel system.
RUNNING GEAR/WHEELS
Unlock the manual priming pump handle by turning it counter-
clockwise. Pump the primer handle until resistance is felt and the Check the wheel nut torque 20 miles (30 kilometres) after refitting the
handle can not be pumped anymore (approximately 140 to 150 strokes wheels. Refer to the TORQUE SETTING TABLE later in this section.
for dry filters, or 20 to 60 strokes for pre-filled filters).
Lifting jacks should only be used under the axle.
Lock the manual priming pump handle.
The bolts securing the running gear to the chassis should be checked
Crank the engine. If the engine does not star after 30 seconds, turn the periodically for tightness (refer to the SERVICE/MAINTENANCE
key to the OFF position. CHART for frequency) and re-tightened where necessary. Refer to the
Pump the priming pump again, repeating the previous steps until the TORQUE SETTING TABLE later in this section.
engine starts.
When the engine does start, it may operate erratically and with BRAKES
increased noise levels for a few minutes. This is a normal condition as
air is being removed from the system. Check and adjust the brake linkage at 500 miles (850Km) then every
3000 miles (5000Km) or 3 months (whichever is the sooner) to
NOTE: It is possible that Fault Code 559 may become active after compensate for any stretch of the adjustable cables. Check and adjust
fuel filter replacement, due to air introduced in the system. Ensure the wheel brakes to compensate for wear.
that the engine is run until the air is purged. Adjusting the overrun braking system (KNOTT Running Gear)
Operate the engine and check for leaks. 1. Preparation
Jack up the machine

HOSES Disengage the handbrake lever [1].
All components of the engine cooling air intake system should be Fully extend the draw bar [2] on the overrun braking system.
checked periodically to keep the engine at peak efficiency.
At the recommended intervals, (see the SERVICE/MAINTENANCE

CHART), inspect all of the intake lines to the air filter, and all flexible
hoses used for air lines, oil lines and fuel lines.
Periodically inspect all pipework for cracks, leaks, etc. and replace
immediately if damaged.
ELECTRICAL SYSTEM
WARNING: Always disconnect the battery cables before

performing any maintenance or service.
Inspect the safety shutdown system switches and the instrument panel
relay contacts for evidence of arcing and pitting. Clean where
necessary.
1. Handbrake lever
Check the mechanical action of the components.
2. Draw bar and bellows
Check the security of electrical terminals on the switches and relays i.e.
nuts or screws loose, which may cause local hot spot oxidation. 3. Handbrake lever pivot
Inspect the components and wiring for signs of overheating i.e. 4. Transmission lever
discolouration, charring of cables, deformation of parts, acrid smells 5. Brake cable
and blistered paint.
6. Breakaway Cable
BATTERY
Requirements:
Keep the battery terminals and cable clamps clean and lightly coated During the adjustment procedure always start with the wheel brakes.
with petroleum jelly to prevent corrosion.
Always rotate the wheel in the direction of forward movement.
The retaining clamp should be kept tight enough to prevent the battery
from moving. Ensure that an M10 safety screw is fitted to the handbrake pivot.
7/73 - 10/53
30 MAINTENANCE
The brake actuators must not be pre-tensioned - if necessary loosen When the brake has been adjusted accurately the actuating distance
the brake linkage [7] on the brake equalisation assembly [8]. is approximately 5-8mm on the cable [11]
Check that brake actuators and cables [11] operate smoothly. 3. Compensator assembly adjustment
Variable Height model
Fit an M10 safety screw to the handbrake pivot.
Disconnect the handbrake cable [5] at one end.
Pre-adjust brake linkage [7] lengthways (a little play is permissible) and

re-insert the cable [5], adjusting it to give a small amount of play.
Remove the M10 safety screw from the handbrake pivot.
All Models
Engage the handbrake lever [1] and check that the position of the
equaliser plate [10] is at right angles to the pulling direction. If
necessary correct the position of the equaliser plate [10] on the cables
[11].
The compression spring [9] must only be slightly pre-tensioned and

when engaged must not touch the axle tube.
7. Brake linkage
4. Brake linkage adjustment
8. Equalisation assembly
Adjust the brake linkage [7] lengthways without pre-tension and without
9. Compression spring play in the transmission lever [4].
10.Equaliser plate Readjustment
11.Cable Engage the handbrake lever [1] forcefully a number of times to set the
brake.
CAUTION: The compression spring [9] must only be lightly pre- Check the alignment of the equalisation assembly [8], this should be at
tensioned and when operating must never touch the axle tube. right angles to the pulling direction
Never adjust the brakes at the brake linkage [7].
Check the play in the brake linkage [7]
2. Brake Shoe Adjustment If necessary adjust the brake linkage [7] again without play and without
pre-tensioning
There must still be a little play in cable [5] (Variable Height Only)
Check the position of the hand brake lever [1]. The start of resistance
should be approximately 10-15mm above the horizontal position.
Check that the wheels move freely when the handbrake is disengaged.
Final test
Check the fastenings on the transmission system (cables, brake

equalisation system and linkage).
Check the handbrake cable [5] for a small amount of play and adjust if
necessary (Variable height only)
Check the compression spring [9] for pre-tensioning.
Test run
12.Adjusting screw If necessary carry out 2-3 test brake actions.
13.Cable entry Test brake action
Width across flats of adjusting screw [12] Check the play in brake linkage [7] and if necessary adjust the length
of brake linkage [7] until there is no play.
Brake size Key width
Apply the handbrake while rolling the machine forward, travel of the
160x35 / 200x50 SW 17 handbrake lever up to 2/3 of maximum is allowed.
250x40 SW 19
Re-adjusting the overrun braking system (KNOTT
300x60 SW 22 Running Gear)
Re-adjustment of the wheel brakes will compensate for brake lining
Tighten adjusting screw [12] clockwise until the wheel locks.
wear. Follow the procedure described in 2: Brake Shoe Adjustment.
Loosen adjusting screw [12] anti-clockwise (approx. ½ turn) until the
Check the play in the brake linkage [7] and re-adjust if necessary.
wheel can be moved freely.
Important
Slight dragging noises that do not impede the free movement of the
wheel are permissible. Check the brake actuators and cables [11]. The brake actuators must
not be pre-tensioned.
This adjustment procedure must be carried out as described on both
wheel brakes.
7/73 - 10/53
MAINTENANCE 31
Excessive operation of the handbrake lever, which may have been LUBRICATING OIL FILTER (SPIN-ON)
caused by worn brake linings, must not be corrected by re-adjusting
(shortening) the brake linkage [7] Removal
Re-adjustment
The handbrake lever [1] should be engaged forcefully several times to

set the braking system.
Check the setting of the brake equalisation assembly [8], which should
be at right angles to the pulling direction.
Check the play in the brake linkage [7] again, ensuring that there is no
play in the brake linkage and that it is adjusted without pre-tension
Check the position of the hand brake lever [1], cable [5] (with little play)
and the compression spring [9] (only slight pre-tension). The start of
resistance of the handbrake lever should be approximately 10-15mm
above the horizontal position.
Final test
Check the fastenings on the transmission system (cables, brake

equalisation system and linkage)
Apply the handbrake while rolling the machine forward, travel of the
handbrake lever up to 2/3 of maximum is allowed.
Check the handbrake cable [5] for a small amount of play and adjust if
necessary (Variable height only)
Check the compression spring [9] for slight pre-tensioning.
CAUTION: Check the wheel nut torque 20 miles (30 kilometres) after
refitting the wheels (Refer to the TORQUE SETTING TABLE later in
this section).
LUBRICATION
The engine is initially supplied with engine oil sufficient for a nominal
period of operation (for more information, consult the Engine section of
this manual).
CAUTION: Always check the oil levels before a new machine is put
into service.
If, for any reason, the unit has been drained, it must be re-filled with
new oil before it is put into operation.
Clean the area around the lubricating oil filter head.

ENGINE LUBRICATING OIL
Use an oil filter wrench, or a 1/2 inch drive (bottom of the oil filter) to
The engine oil should be changed at the engine manufacturer’s remove the filter.
recommended intervals. Refer to the Engine Manual supplied with this
Clean the sealing surface of the filter head.
machine.
Installation
ENGINE LUBRICATING OIL SPECIFICATION
Refer to the Engine Manual supplied with this machine.
ENGINE OIL FILTER ELEMENT
The engine oil filter element should be changed at the engine

manufacturer’s recommended intervals. Refer to the Engine Manual
supplied with this machine.
CAUTION: The lack of lubrication during the delay until the filter is
pumped full of oil at start-up can damage the engine.
7/73 - 10/53
32 MAINTENANCE
Make sure that the o-ring and two gasket seals are installed on the All filters and filter elements for air and compressor oil must be
filter, that they are clean and free of debris. Use clean lubricating oil to obtained through Portable Power to assure the proper size and
lightly lubricate the o-ring seal (1) and primary gasket seal (2) only. filtration for the compressor.
Make sure that the secondary gasket (3) remains clean and dry. Do Compressor Oil Change
not lubricate.
These compressors are normally furnished with an initial supply of oil
Fill the filter with clean lubricating oil. Use the following procedure to sufficient to allow operation until the first service interval indicated in
select the appropriate oil grade and specification. the Maintenance Schedule. If a compressor has been completely
drained of all oil, it must be refilled with new oil before it is placed in
operation. Refer to specifications in the Portable Compressor Fluid
Chart.
NOTE: Some oil types are incompatible when mixed and result in the
formation of varnishes, shellacs, or lacquers which may be insoluble.
Such deposits can cause serious troubles including clogging of the
filters.
Where possible, do NOT mix oils of different types and avoid mixing
different brands. A type or brand change is best made at the time of
a complete oil drain and refill.
If the compressor has been operated for the time/hours indicated in the
Maintenance Schedule, it should be completely drained of oil. If the
compressor has been operated under adverse conditions, or after long
periods in storage, an earlier change may be necessary as oil
deteriorates with time as well as by operating conditions.
CAUTION: In most severe applications such as sandblasting, quarry

drilling, well drilling, and oil and gas drilling, more frequent service
intervals will be required to ensure long component life.
WARNING : High pressure air can cause severe injury or death
from hot oil and flying parts. Always relieve pressure before
removing caps, plugs, covers or other parts from pressurized
air system. Ensure that the air pressure gauge reads zero (0)
pressure and ensure there is no air discharge when opening the
manual blowdown valve.
An oil change is good insurance against the accumulation of dirt,

sludge, or oxidized oil products.
CAUTION: Mechanical overtightening of the filter can distort the
threads or damage the filter element seal. Completely drain the separator tank, piping, and cooler. If the oil is
drained immediately after the compressor has been run for some time,
Install the filter on the filter head. Hand tighten the filter until the most of the sediment will be in suspension and, therefore, will drain
secondary gasket contacts the filter head surface. more readily. However, the oil will be hot and care must be taken to
avoid contact with the skin or eyes.
Use a 1/2 drive at the bottom of the filter and tighten to the following
specification: 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
Torque value: 40 Nm (30 ft lb). in the specified quantity at the filler plug. Tighten the filler plug and run
the compressor to circulate the oil. Check the oil level. DO NOT
CAUTION: If the engine does not produce oil pressure in 15 seconds OVERFILL.
after starting the engine, shut off the engine to reduce the possibility
of component damage. NOTE: Portable Power provides compressor oil specifically
formulated for Portable Compressors and requires the use of these
• Operate the engine and check for leaks. fluids in order to obtain extended limited airend warranty.
• Shut the engine off and check the oil level.
COMPRESSOR OIL FILTER ELEMENT
LUBRICATION - GENERAL INFORMATION

Refer to the SERVICE / MAINTENANCE CHART in this section for
service intervals.
Lubrication is an essential part of preventive maintenance, affecting to
a great extent the useful life of the compressor. Different lubricants are
needed and some components require more frequent lubrication than RUNNING GEAR WHEEL BEARINGS
others. Therefore, it is important that the instructions regarding types
of lubricants and the frequency of their application be explicitly Wheel bearings should be packed with grease every 6 months. The
followed. Periodic lubrication of the moving parts reduces to a type of grease used should conform to specification MIL-G-10924.
minimum the possibility of mechanical failures.
The Maintenance Schedule shows those items requiring regular ENGINE STORAGE - LONG TERM
service and the interval in which they should be performed. A regular
service program should be developed to include all items and fluids.
These intervals are based on average operating conditions. In the WARNING: Do not remove the pressure cap from a hot engine.
event of extremely severe (hot, cold, dusty or wet) operating Wait until the coolant temperature is below 50°C (120°F) before
conditions, more frequent lubrication than specified may be necessary. removing the pressure cap. Heated coolant spray or steam can
cause personal injury.
7/73 - 10/53
MAINTENANCE 33
WARNING: Coolant is toxic. Keep away from children and pets. • Install the drain plugs.
If not reused, dispose of in accordance with local environmental
regulations. CAUTION: Before starting another Internal Preservation of the Fuel
System procedure again (after passing a storage period) it is required
CAUTION: After 24 months in storage, the engine cooling system to fill the engine oil pan sump to the high mark using TectylTM 910 or
must be drained and flushed with a suitable solvent or a hot, equivalent engine preservative oil.
lightweight mineral oil. Repeat flushing procedure a second time
before being put back into service.
• If the engine is being stored as a loose engine, drain the engine
coolant and cover all cooling system openings with plastic and tape.
This procedure describes the proper method for the long-term (more
than 6 months) storage of an engine that is currently in running • If the engine is not being removed from chassis and the engine has
condition. This procedure applies to this engine either remaining in an extended life coolant with rust inhibitor, then coolant does not
chassis -or being removed out of chassis upon completion of the steps need to be drained.
below.
• If the engine will remain in storage for over 24 months, the engine
Prepare the Engine for Long Term Storage cooling system must be drained and flushed with a suitable solvent
or a hot, lightweight mineral oil. Repeat after each 24-month period.
• Operate the engine at high idle until the coolant temperature is 70°C
[158°F]. • Remove the intake and exhaust manifolds.
• Turn the engine off. • Spray preservative oil into the intake and exhaust ports in the
cylinder heads and in the exhaust manifolds only. Do not use
• Drain the oil. preservative oil on the intake manifold or any fuel system
• Install the drain plugs. components as this may permanently damage sensors or valves.
• Fill the engine oil pan sump to the high mark using TectylTM 910 or • Spray preservative oil in the inlet port on the air compressor (if
equivalent engine preservative oil. This will provide long term applicable).
engine rust protection. The oil must meet military specification MIL- • Remove the rocker lever covers.
PRF-21260, Type P-10, Grade 2, SAE 30.
• Spray the rocker levers, the valve stems, the springs, the valve
Internal Preservation of the Fuel System with Mechanically and guides, the crossheads, and the push rods with preservative oil.
Electronically Actuated Injectors
• Install the rocker lever covers, intake and exhaust manifolds.
CAUTION: DO NOT use diesel fuel containing bio components for
• Brush or spray the preservative oil on all the exposed metal
internal preservation of fuel system for engine storage. Fuel
surfaces that are not painted. Preservative oil should not be
properties degradation may cause damages and lead to premature
applied to any plastic, rubber, or similar surfaces. Make sure to coat
failure of fuel system components.
the flywheel, flywheel housing and all other unpainted machined
surfaces with this preservative oil. Use a rust preservative oil
• Disconnect the fuel lines to the engine fuel filter and the injector compound that meets military specification MIL-C-16173C, type P-
return line. 2, Grade 1 or 2.
• Use Diesel Pump and Injector calibration fluid that meets ISO 4113 • For components containing exposed bearings that are not easily
standard, SAE J967d standard and Bosch VS 15665-0L standard. accessible e.g. Fan Hubs, remove the component to aid access.
Brush or spray preservative oil on all surfaces that are not painted
NOTE: Using calibration fluid allows storage for up to 12 months. and refit the component. Use a rust preservative oil compound that
After 12 months the engine fuel system must be drained and flushed meets military specification, MIL-C-16173C, type P-2, Grade 1 or 2.
again with fresh calibration fluid. Repeat after each 12-month period.
• Cover all the openings (engine and components) with heavy paper
and tape to prevent dirt and moisture from entering the engine.
Alternatively you can use the diesel fuel with 0 percent bio components
Cover the entire engine with plastic.
content for Internal Preservation of the Fuel System.
• Put a warning tag on the engine. The tag must indicate:
NOTE: Using diesel fuel with 0 percent bio components content
allows storage for up to 6 months. After 6 months, the engine fuel
- Do not operate the engine.
system must be drained and be flushed again with fresh diesel fuel - Do not bar the crankshaft.
with 0 percent bio components content. Repeat after each 6-month
period. - The engine has been treated with preservatives.
- The coolant has been removed.
• Start the engine.
- The date of treatment.
• After the engine is operating smoothly, transfer the fuel supply line
to the container of calibration fluid or the container of diesel fuel with - The date of the 6 week inspection if required.
0 percent bio components content.
CAUTION: The engine must be stored in an area that is dry and has
• Let the engine run for approximately 25 minutes at low idle in order uniform temperature.
to ensure that the engine preservative oil (TectylTM 910 E or
equivalent) is distributed around the engine and its internal
• Remove any external drive belts to prevent localized stretching and
components and that the calibration fluid or the diesel fuel with 0
deformation.
percent bio components content flows out of the injector return line.
• If the engine can be stored inside a designated storage facility
• Turn the engine "OFF".
isolated from the external environment, ignore the following step.
• Connect the fuel lines to the fuel filter and the injector return line.
• Excluding the crankshaft, ensure that all external dynamic engine
• Drain all the preservative oil from the engine oil pan sump, the air components are rotated every 6 weeks. Ensure parts are free from
compressor (if applicable), and drain all the oil filters and all the fuel corrosion, debris and water ingress. Record and date this on the
filters. engine tag created.
7/73 - 10/53
34 MAINTENANCE
Remove the Engine from Long Term Storage DECOMMISSIONING
To remove the engine from long term storage, follow the following
When the machine is to be permanently decommissioned or
steps:
dismantled, it is important to ensure that all hazard risks are either
eliminated or notified to the recipient of the machine. In particular:-
CAUTION: To reduce the possibility of personal injury, avoid direct
contact of hot oil with your skin. • Do not destroy batteries or components containing asbestos
without containing the materials safely.
• Flush the engine preservative oil out of the engine by removing the
• Do not dispose of any pressure vessel that is not clearly marked
plug from the main engine oil rifle and pumping a hot, lightweight
with its relevant data plate information or rendered unusable by
mineral oil through it. Make sure that the engine crankshaft is barred
drilling, cutting etc.
at least three to four revolutions during this flushing procedure.
• Do not allow lubricants or coolants to be released into land surfaces
• Drain all the mineral oil that was used to flush the engine clean of
or drains.
the engine preservative oil.
• Do not dispose of a complete machine without documentation
• Install the drain plugs.
relating to instructions for its use.
• Install new oil, fuel and coolant filters.
• Fill the engine to the high mark with engine oil. LONG TERM STORAGE RECOMMENDATIONS
(6 months or more)
• If the engine has been in storage for less than 24 months and if the
cooling system was drained, fill the cooling system with coolant. Spare Airends
See the Coolant Recommendations and Specifications procedure
in Section V of the corresponding owners and/or operation and • Long-term storage of airends should include filling the airend with
maintenance manual for antifreeze, water, and SCA specifications. the standard compressor fluid, PRO-TEC, XHP605 or XHP405.
Upon installation of the airend, drain the storage oil from the airend
• If the engine has been in storage for 24 months, every 24 months and proceed with the installation, assuring fresh oil is poured into
the engine cooling system must be drained and flushed with a the intake prior to start up.
suitable solvent or a hot, lightweight mineral oil. Fill the cooling
system with coolant. See the Coolant Recommendations and Portable Compressors
Specifications procedure in Section V of the corresponding owners
• Airend – Remove the intake connection and pour the airend intake
and/or operation and maintenance manual for antifreeze, water,
full with Doosan compressor fluid PRO-TEC, XHP605 or XHP405.
and SCA specifications.
Reconnect the intake connection.
• If the engine has been in storage for less than 24 months and the
• Engine cooling system – Treat with rust inhibitor and drain.
engine has an extended life coolant with a rust inhibitor, drain the
Checkwith engine dealer for further recommendations.
cooling system. Fill the cooling system with coolant. See the
Coolant Recommendations and Specifications procedure in • Compressor Oil Filter/s- fill with Doosan compressor fluid PROTEC,
Section V of the corresponding owners and/or operation and XHP605 or XHP405.
maintenance manual for antifreeze, water, and SCA specifications.
• Seal all opening with waterproof tape.
• Adjust the engine brake (if applicable) and valve clearances.
Reference the Overhead Set procedure in the corresponding base • Place a desiccant in the exhaust pipes, engine and compressor air
Troubleshooting and Repair Manual or Service Manual for the intake pipes.
engine being serviced. • Loosen tension on belts, fan, airend, etc.
• Tighten the intake and exhaust manifold mounting capscrews. • Block axles so tyres are off ground and do not support any weight.
• Prime the lubricating system. • Disconnect battery cables.
• Reinstall any external drive belts that were removed. • Drain fuel system.
• Replace all spark plugs. Reference the Spark Plugs procedure in
the corresponding base Troubleshooting and Repair Manual or SHORT TERM STORAGE
Service Manual for engine being serviced (if applicable).
• Make sure all fuel lines are securely tightened and all fuel shutoff Machines that stand idle for extended periods of time greater than
valves are open prior to attempting to start the engine. 30 days:
• Start the engine. • Start and operate the machine every 30 days. Operate long enough
to allow the engine and compressor to reach operating
Note that it might take multiple cranking attempts to start the engine. temperature.
Do not crank the engine more than 30 seconds at a time as this • Open and close the service valve to exercise machine from full load
might cause the starter to overheat and fail. to idle RPM.
• Drain fuel tank to remove any water.

Note that the engine might run rough until the fuel system is
• Drain water from fuel water separator.
completely primed or until all residual fuel system preservative oil is
completely flushed out of the fuel system (if the fuel has been
treated with fuel system preservative oil). COMPRESSOR MOUNTING
• Install the exhaust aftertreatment components (if applicable). Portable compressors, which are modified to remove the running gear
and mount the compressor directly to trailers, truck beds or frames, etc.
• Force an active regeneration (if applicable).
may experience failure of the enclosure, frame, and/or other
components.
7/73 - 10/53
MAINTENANCE 35
It is necessary to isolate the compressor package from the carrier base Before Starting
with a flexible mounting system. Such a system must also prevent
detachment of the package from the carrier base in the event the 1. Select Low Pressure Mode by turning HI/LO Pressure Switch on
control panel.
isolators fail.
2. At the Low Pressure Regulator (A), pull the plastic cap upwards to
Contact your Portable Power representative for flexible mounting kits.
unlock and turn counter clockwise until tension is relieved. Proceed
Warranty does not cover failures attributable to mounting of the to turn the cap clockwise one full turn.
compressor package to the carrier base unless it is a Portable Power
3. If high pressure regulation needs adjustment, repeat Step 2 at High
provided system.
Pressure Regulator (B).
NOTE: The maintenance schedule in this manual describes the 4. Close Service Valves.
service intervals that should be followed for “normal” applications of
this compressor. This page may be reproduced and used as a After Starting Unit
checklist by service personnel. 5. Push the Service Air Button on the Control Panel. The unit should
speed up and then unload (and drop back to IDLE). With the unit
In more severe applications such as sandblasting, quarry drilling, well unloaded, turn the adjusting cap on the Low Pressure Regulator (A)
drilling, and oil and gas drilling, more frequent service intervals will be clockwise until the discharge pressure gauge indicates 8,6-9 bar.
required to ensure long component life. Push the plastic cap downwards to lock.
Dust and dirt, high humidity, and high temperatures will affect 6. To adjust the high pressure regulation, repeat Step 5 on High
lubricant life and service intervals for components such as inlet air Pressure Regulator (B) except adjust pressure at idle to 12,1-12,4
filters, oil separation elements and oil filters. bar while in High Pressure Mode.
NOTE: The High Pressure Regulator (B) must be set at a higher

SPEED AND PRESSURE REGULATION ADJUSTMENT pressure than the Low Pressure Regulator (A).
Normally, regulation requires no adjusting, but if correct adjustment is

lost, proceed as follows:
7/73 - 10/53
36 MAINTENANCE
TORQUE VALUES
Part ft. lbf N.m Part ft. lbf N.m
Airend (main body) to engine 29-34 39-47 Discharge hose to Airend- 158-167 214-226
Separator (-24 JIC)
Coupling element to engine 35-38 48-52

flywheel Fan clutch to adapter on engine 1033-1047 1400-1420
Air filters to brackets 18-21 24-28 Lifting bail to frame 63-70 85-95
Cooling baffle to frame 18-21 24-28 Oil Hose Separator-Airend (-12 JIC) 71-88 96-119
Exhaust clamps to baffle 18-21 24-28 Radiator/cooler to baffle 18-21 24-28
Discharge manifold to frame 35-38 48-52 Radiator/cooler to baffle 18-21 24-28
Engine to brackets 63-70 85-95 Running gear to chasis 60-69 82-93
Engine brackets to silentblocks 35-38 48-52 Separator tank to frame 35-38 48-52
Engine silentblock to frame 18-21 24-28 Pipe, Separator-Spin-on manifold 127-133 172-180
(-20 JIC)
Airend to bracket 153-156 207-212

Pipe, Spin-on manifold-Service 127-133 172-180
manifold (-20 JIC)
Airend bracket to frame 18-21 24-28
Wheel nuts 63-70 85-95

Fan guards 18-21 24-28
7/73 - 10/53
MAINTENANCE 37
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 consult
oxidization inhibitors, consult
factory
factory
designed for air
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.
7/73 - 10/53
elec
7/73 - 10/53
ELECTRICAL SYSTEM 39
KEY
J99 Fan, Full Speed

K5 Switch, Oil Pressure
K6 Switch, Water Temperature
K9 Switch, Water Temperature
L1 Valve, Start / Run Solenoid
L3 Valve, Hi / Lo Pressure Solenoid
PS2 IQ Filter Restriction
PT2 Sensor, Regulation System Pressure (0-30 PSI)
RT5 Sensor, Discharge Oil Temperature
S1 Keyswitch
S3 Button, Warm-Up
S4 Switch, Hi / Lo
TS1 Switch, Airend Temperature
TS2 Switch, Airend Temperature
U1 Fuel Level
1 Airend Temperature
2 Engine Oil Pressure
3 Engine Temperature
4 Low Fuel
5 No Charge
6 IQ Filter Restriction
7/73 - 10/53
7/73 - 10/53
KEY
BDS1 Switch, Battery Disconnect (Option)

BT1 Battery System, 12VDC
B1 Starter, Engine
C5B Sensor, Water-In-Fuel
FB1 Centre, Fuse / Relay
FC1 Clutch, Fan
F11 Fuse, Alternator
F12 Fuse, Engine Intake Air Heater
G1 Alternator, Engine
HR1 Heater, Engine Intake Air
HR5 Heater, Fuel
J2 Connector,
Cummins QSF2.8 S3B CM2880B ECM OEM 94 PIN
J11 Sensor, Coolant Level
J5A Connector, Engine ECM Service
K1 Relay, Engine Starter
K2 Relay, Engine Intake Air Heater
K7 Relay, Service Mode
P18 Connector, IQ Heaters (Option)
RT4 Sensor, Temperature CAC
S8 Switch, Diag.
S12 Switch, Engine Overspeed Valve (Option)
S13 Switch, Aftercooler
TR1 Resistor, Terminating J1939 CAN BUSS
TR2 Resistor, Terminating J1939 CAN BUSS
FUSE DEVICE
F1 Mini Controller
F2 Starter
F3 Not Used
F4 Temperature Switch
F5 Regulation Heaters
F6 Engine ECM
F7 Engine COMMS.
F8 Fuel Heater
F9 Fan
F10 Fan
K11 Starter Lockout
K12 Regaultion Heaters Relay
K13 Warm-Up Relay
7/73 - 10/53
KEY
B2 Fan, Electric
B3 Fan, Electric
CS Cold Start (Option)
C33 Connector, TBAP Engine Harness
C34 Sensor, TBAP
K3 Relay, Electric Fans
7/73 - 10/53
SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM - 7 PINS
KEY
IL LH Indicator light - left hand B Black

IL RH Indicator light - right hand G Green
FL Fog light K Pink
SL LH Stop light - left hand N Brown
SL RH Stop light - right hand O Orange
TL LH Tail light - left hand P Purple
TL RH Tail light - right hand R Red
PL Plug S Grey
U Blue
W White
Y Yellow
7/73 - 10/53
SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM - 13 PINS REVERSE LIGHT
KEY
IL LH Indicator light - left hand B Black

IL RH Indicator light - right hand G Green
FL Fog light K Pink
RL Reverse light N Brown
SL LH Stop light - left hand O Orange
SL RH Stop light - right hand P Purple
TL LH Tail light - left hand R Red
TL RH Tail light - right hand S Grey
PL Plug U Blue
W White
Y Yellow
7/73 - 10/53
PIPING AND INSTRUMENTATION SYSTEM 45
KEY
1 Air discharge Air

2 Sonic orifice (restricts flow) Oil
3 Pressure gauge Air/oil
4 Separator tank
5 Safety valve
6 Compressor
7 Engine
8 Oil cooler
9 Oil filter
10 Thermostatic valve (when fitted)
11 Separator filter assembly (spin-on)
7/73 - 10/53
46 FAULT FINDING
FAULT CAUSE REMEDY

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.
Engine control not in ’run’ position. Check the pressure transducer.

Engine starts but stalls Electrical fault Test the electrical circuits.
when the switch
returns to position I. Low engine oil pressure. Check the oil level and the oil filter(s).
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. Reduced cooling air from fan. Check the fan and the drive belts. Check for any obstruction inside the cowl.
Engine speed too high. Faulty regulator valve. Check the regulation system.
Engine speed too low. Incorrect throttle arm setting. Check the throttle setting.
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 pressure transducer.
Excessive vibration. Engine speed too low. See ”Engine speed too low”
Refer also to the engine section of this manual and the engine diagnostic codes.
7/73 - 10/53
FAULT FINDING 47
FAULT CAUSE REMEDY

Air discharge capacity Engine speed too low. Check the pressure transducer 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.
Recirculation of cooling air. Move the machine to avoid recirculation.
Faulty temperature switch. Check the operation of the switch and replace if necessary.
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).
Faulty discharge check valve. Remove the valve from the discharge pipe and check the operation.
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.
Machine fails to load Faulty load solenoid. Replace the solenoid. Check the electrical circuit by feeling for movement
when the load button is whilst depressing the load button.
pressed.
7/73 - 10/53
48 FAULT FINDING
DIAGNOSTIC CODES
Fault Code J1939 SPN J1939 FMI Lamp Colour Cummins Description
111 629 12 Stop (Solid) Engine Control Module Critical Internal Failure - Bad intelligent device or
component.
115 612 2 Stop (Solid) Engine Magnetic Speed/Position Lost Both of Two Signals - Data erratic,
intermittent or incorrect.
122 102 3 Warning (Solid) Intake Manifold 1 Pressure Sensor Circuit - Voltage above normal, or
shorted to high source.
123 102 4 Warning (Solid) Intake Manifold 1 Pressure Sensor Circuit - Voltage below normal, or
shorted to low source.
131 91 3 Stop (Solid) Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage above
normal, or shorted to high source.
132 91 4 Stop (Solid) Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage below
normal, or shorted to low source.
133 974 3 Stop (Solid) Remote Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage
above normal, or shorted to high source.
134 974 4 Stop (Solid) Remote Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage
below normal, or shorted to low source.
143 100 18 Warning (Solid) Engine Oil Rifle Pressure - Data Valid But Below Normal Operating
Range - Moderately Severe Level.
144 110 3 Warning (Solid) Engine Coolant Temperature 1 Sensor Circuit - Voltage above normal, or
145 110 4 Warning (Solid) Engine Coolant Temperature 1 Sensor Circuit - Voltage below normal, or
146 110 16 Warning (Solid) Engine Coolant Temperature - Data Valid But Above Normal Operating
Range - Moderately Severe Level.
147 91 1 Stop (Solid) Accelerator Pedal or Lever Position 1 Sensor Circuit Frequency - Data
valid but below normal operational range - Most Severe Level.
148 91 0 Stop (Solid) Accelerator Pedal or Lever Position Sensor 1 - Data valid but above
normal operational range - Most Severe Level.
151 110 0 Stop (Solid) Engine Coolant Temperature - Data valid but above normal operational
range - Most Severe Level.
153 105 3 Warning (Solid) Intake Manifold 1 Temperature Sensor Circuit - Voltage above normal, or
154 105 4 Warning (Solid) Intake Manifold 1 Temperature Sensor Circuit - Voltage below normal, or
155 105 0 Stop (Solid) Intake Manifold 1 Temperature - Data valid but above normal operational
range - Most Severe Level.
187 3510 4 Warning (Solid) Sensor Supply 2 Circuit - Voltage below normal, or shorted to low source.
195 111 3 Warning (Solid) Coolant Level Sensor 1 Circuit - Voltage above normal, or shorted to high
source.
196 111 4 Warning (Solid) Coolant Level Sensor 1 Circuit - Voltage below normal, or shorted to low
source.
197 111 18 Warning (Solid) Coolant Level - Data Valid But Below Normal Operating Range -
Moderately Severe Level.
221 108 3 Warning (Solid) Barometric Pressure Sensor Circuit - Voltage above normal, or shorted
to high source.
222 108 4 Warning (Solid) Barometric Pressure Sensor Circuit - Voltage below normal, or shorted to
low source.
227 3510 3 Warning (Solid) Sensor Supply 2 Circuit - Voltage above normal, or shorted to high
source.
234 190 0 Stop (Solid) Engine Crankshaft Speed/Position - Data valid but above normal
operational range - Most Severe Level.
7/73 - 10/53
FAULT FINDING 49
235 111 1 Stop (Solid) Coolant Level - Data valid but below normal operational range - Most
Severe Level.
source.
241 84 2 Warning (Solid) Wheel-Based Vehicle Speed - Data erratic, intermittent or incorrect.
242 84 10 Warning (Solid) Wheel-Based Vehicle Speed Sensor Circuit tampering has been
detected - Abnormal rate of change.
245 647 4 Warning (Solid) Fan Control Circuit - Voltage below normal, or shorted to low source.
271 1347 4 Warning (Solid) Engine Fuel Pump Pressurizing Assembly 1 Circuit - Voltage below
272 1347 3 Warning (Solid) Engine Fuel Pump Pressurizing Assembly 1 Circuit - Voltage above
281 1347 7 Warning (Solid) Engine Fuel Pump Pressurizing Assembly 1 - Mechanical system not
responding or out of adjustment.
285 639 9 Warning (Solid) SAE J1939 Multiplexing PGN Timeout Error - Abnormal update rate.
286 639 13 Warning (Solid) SAE J1939 Multiplexing Configuration Error - Out of Calibration.
288 974 19 Stop (Solid) SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Position
Sensor System - Received Network Data In Error.
292 441 14 Stop (Solid) Auxiliary Temperature Sensor Input 1 - Special Instructions.
293 441 3 Warning (Solid) Auxiliary Temperature Sensor Input 1 Circuit - Voltage above normal, or
294 441 4 Warning (Solid) Auxiliary Temperature Sensor Input 1 Circuit - Voltage below normal, or
296 1388 14 Stop (Solid) Auxiliary Pressure Sensor Input 2 - Special Instructions.
322 651 5 Warning (Solid) Injector Solenoid Driver Cylinder 1 Circuit - Current below normal or open
circuit.
circuit.
circuit.
circuit.
343 629 12 Warning (Solid) Engine Control Module Warning Internal Hardware Failure - Bad
intelligent device or component.
351 3597 12 Warning (Solid) Injector Power Supply - Bad intelligent device or component.
415 100 1 Stop (Solid) Engine Oil Rifle Pressure - Data valid but below normal operational range
- Most Severe Level.
418 97 3 Warning (Solid) Water in Fuel Indicator Sensor Circuit - Voltage above normal, or shorted
to high source.
429 97 4 Warning (Solid) Water in Fuel Indicator Sensor Circuit - Voltage below normal, or shorted
to low source.
431 558 2 Warning (Solid) Accelerator Pedal or Lever Idle Validation Switch - Data erratic,
432 558 13 Stop (Solid) Accelerator Pedal or Lever Idle Validation Switch Circuit - Out of
Calibration.
435 100 2 Warning (Solid) Engine Oil Rifle Pressure - Data erratic, intermittent or incorrect.
441 168 18 Warning (Solid) Battery 1 Voltage - Data Valid But Below Normal Operating Range -
442 168 16 Warning (Solid) Battery 1 Voltage - Data Valid But Above Normal Operating Range -
7/73 - 10/53
50 FAULT FINDING
449 157 0 Stop (Solid) Injector Metering Rail 1 Pressure - Data valid but above normal
operational range - Most Severe Level.
451 157 3 Warning (Solid) Injector Metering Rail 1 Pressure Sensor Circuit - Voltage above normal,
or shorted to high source.
452 157 4 Warning (Solid) Injector Metering Rail 1 Pressure Sensor Circuit - Voltage below normal,
or shorted to low source.
523 611 2 Warning (Solid) Auxiliary Intermediate (PTO) Speed Switch Validation - Data erratic,
527 702 3 Warning (Solid) Auxiliary Input/Output 2 Circuit - Voltage above normal, or shorted to high
source.
528 93 2 Warning (Solid) Auxiliary Alternate Torque Validation Switch - Data erratic, intermittent or
incorrect.
529 703 3 Warning (Solid) Auxiliary Input/Output 3 Circuit - Voltage above normal, or shorted to high
source.
553 157 16 Warning (Solid) Injector Metering Rail 1 Pressure - Data Valid But Above Normal
Operating Range - Moderately Severe Level.
559 157 18 Warning (Solid) Injector Metering Rail 1 Pressure - Data Valid But Below Normal
584 677 3 Warning (Solid) Starter Relay Driver Circuit - Voltage above normal, or shorted to high
source.
585 677 4 Warning (Solid) Starter Relay Driver Circuit - Voltage below normal, or shorted to low
source.
599 640 14 Stop (Solid) Auxiliary Commanded Dual Output Shutdown - Special Instructions.
649 1378 31 Warning (Blinking) Engine Oil Change Interval - Condition Exists.
689 190 2 Warning (Solid) Engine Crankshaft Speed/Position - Data erratic, intermittent or incorrect.
691 1172 3 Warning (Solid) Turbocharger 1 Compressor Intake Temperature Circuit - Voltage above
692 1172 4 Warning (Solid) Turbocharger 1 Compressor Intake Temperature Circuit - Voltage below
697 1136 3 Warning (Solid) Engine ECU Temperature Sensor Circuit - Voltage above normal, or
698 1136 4 Warning (Solid) Engine ECU Temperature Sensor Circuit - Voltage below normal, or
731 723 7 Warning (Solid) Engine Speed / Position Camshaft and Crankshaft Misalignment -
Mechanical system not responding or out of adjustment.
778 723 2 Warning (Solid) Engine Camshaft Speed / Position Sensor - Data erratic, intermittent or
incorrect.
778 723 2 Warning (Solid) Engine Camshaft Speed / Position Sensor - Data erratic, intermittent or
incorrect.
1117 3597 2 None Power Supply Lost With Ignition On - Data erratic, intermittent or
incorrect.
1239 2623 3 Warning (Solid) Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage above
1241 2623 4 Warning (Solid) Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage below
1242 91 2 Stop (Solid) Accelerator Pedal or Lever Position Sensor 1 - Data erratic, intermittent
or incorrect.
1515 91 19 Stop (Solid) SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor System -
Received Network Data In Error.
1539 1387 3 Warning (Solid) Auxiliary Pressure Sensor Input 1 Circuit - Voltage above normal, or
1621 1387 4 Warning (Solid) Auxiliary Pressure Sensor Input 1 Circuit - Voltage below normal, or
1695 3513 3 Warning (Solid) Sensor Supply 5 - Voltage above normal, or shorted to high source.
7/73 - 10/53
FAULT FINDING 51
1696 3513 4 Warning (Solid) Sensor Supply 5 - Voltage below normal, or shorted to low source.
1852 97 16 Warning (Solid) Water in Fuel Indicator - Data Valid But Above Normal Operating Range
- Moderately Severe Level.
1866 411 2 Warning (Solid) Exhaust Gas Recirculation Differential Pressure - Data erratic.
1893 2791 9 Warning (Solid) EGR Valve Control Circuit - Abnormal update rate.
1896 2791 13 Warning (Solid) EGR Valve Controller - Out of Calibration.
2182 1072 3 Warning (Solid) Engine Brake Actuator Driver 1 Circuit - Voltage above normal, or shorted
to high source.
2183 1072 4 Warning (Solid) Engine Brake Actuator Driver 1 Circuit - Voltage below normal, or shorted
to low source.
source.
2271 27 3 Warning (Solid) EGR Valve Position Circuit - Voltage above normal, or shorted to high
source.
2272 27 4 Warning (Solid) EGR Valve Position Circuit - Voltage below normal, or shorted to low
source.
2273 411 3 Warning (Solid) Exhaust Gas Recirculation Differential Pressure Sensor Circuit - Voltage
above normal, or shorted to high source.
2274 411 4 Warning (Solid) Exhaust Gas Recirculation Differential Pressure Sensor Circuit - Voltage
below normal, or shorted to low source.
2311 633 31 Warning (Solid) Electronic Fuel Injection Control Valve Circuit - Condition Exists.
2321 190 2 None Engine Crankshaft Speed/Position - Data erratic, intermittent or incorrect.
2322 723 2 None Engine Camshaft Speed / Position Sensor - Data erratic, intermittent or
incorrect.
2351 2791 4 Warning (Solid) EGR Valve Control Circuit - Voltage below normal, or shorted to low
source.
2352 2791 3 Warning (Solid) EGR Valve Control Circuit - Voltage above normal, or shorted to high
source.
2375 412 3 Warning (Solid) Exhaust Gas Recirculation Temperature Sensor Circuit - Voltage above
2376 412 4 Warning (Solid) Exhaust Gas Recirculation Temperature Sensor Circuit - Voltage below
2377 647 3 Warning (Solid) Fan Control Circuit - Voltage above normal, or shorted to high source.
2442 651 13 Warning (Solid) Injector Solenoid Driver Cylinder 1 - Out of Calibration.
2448 111 17 Warning (Blinking) Coolant Level - Data Valid But Below Normal Operating Range - Least
Severe Level.
2555 729 3 Warning (Solid) Engine Intake Air Heater 1 Circuit - Voltage above normal, or shorted to
high source.
2556 729 4 Warning (Solid) Engine Intake Air Heater 1 Circuit - Voltage below normal, or shorted to
low source.
2557 697 3 Warning (Solid) Auxiliary PWM Driver 1 Circuit - Voltage above normal, or shorted to high
source.
2558 697 4 Warning (Solid) Auxiliary PWM Driver 1 Circuit - Voltage below normal, or shorted to low
source.
2961 412 15 None Exhaust Gas Recirculation Temperature - Data Valid But Above Normal
Operating Range - Least Severe Level.
7/73 - 10/53
52 FAULT FINDING
2962 412 16 Warning (Solid) Exhaust Gas Recirculation Temperature - Data Valid But Above Normal
2963 110 15 None Engine Coolant Temperature - Data Valid But Above Normal Operating
Range - Least Severe Level.
2964 105 15 None Intake Manifold 1 Temperature - Data Valid But Above Normal Operating
Range - Least Severe Level.
3136 5019 3 Warning (Solid) Engine Exhaust Gas Recirculation Outlet Pressure Sensor Circuit -
Voltage above normal, or shorted to high source.
3137 5019 4 Warning (Solid) Engine Exhaust Gas Recirculation Outlet Pressure Sensor Circuit -
Voltage below normal, or shorted to low source.
3186 1623 9 Warning (Solid) Tachograph Output Shaft Speed - Abnormal update rate.
3213 1623 19 Warning (Solid) Tachograph Output Shaft Speed - Received Network Data In Error.
3326 91 9 Stop (Solid) SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor System -
Abnormal update rate.
3328 191 9 Warning (Solid) Transmission Output Shaft Speed - Abnormal update rate.
3418 191 19 Warning (Solid) Transmission Output Shaft Speed - Received Network Data In Error.
3525 84 19 Warning (Solid) Wheel-Based Vehicle Speed - Received Network Data In Error.
3526 84 9 Warning (Solid) Wheel-Based Vehicle Speed - Abnormal update rate.
3527 558 19 Stop (Solid) Accelerator Pedal or Lever Idle Validation Switch - Received Network
Data In Error.
3528 558 9 Stop (Solid) Accelerator Pedal or Lever Idle Validation Switch - Abnormal update rate.
3555 1081 9 Warning (Solid) Engine Wait to Start Lamp - Abnormal update rate.
3613 111 9 Warning (Solid) Coolant Level Sensor - Abnormal update rate.
3614 111 19 Warning (Solid) Coolant Level Sensor - Received Network Data In Error.
3641 748 9 Warning (Solid) Transmission Output Retarder - Abnormal update rate.
3697 630 12 Stop (Solid) Engine Control Module Calibration Memory - Bad intelligent device or
component.
3727 5571 7 None High Pressure Common Rail Fuel Pressure Relief Valve - Mechanical
system not responding or out of adjustment.
3741 5571 0 Warning (Solid) High Pressure Common Rail Fuel Pressure Relief Valve - Data valid but
above normal operational range - Most Severe Level.
4642 97 0 Stop (Solid) Water in Fuel Indicator - Data Valid But Above Normal Operating Range
- Most Severe Level.
4734 701 14 Stop (Solid) Auxiliary Input/Output 1 - Special Instructions.
4734 701 14 Stop (Solid) Auxiliary Input/Output 1 - Special Instructions.
4789 1639 0 Warning (Solid) Fan Speed - Data Valid but Above Normal Operational Range - Most
Severe Level.
4791 1639 1 Warning (Solid) Fan Speed - Data Valid but Below Normal Operational Range - Most
Severe Level.
7/73 - 10/53
OPTIONS 53
PRIMARY AND SECONDARY FILTER MAINTENANCE
OPTION - AFTERCOOLER AND WATER SEPARATOR
FIGURE 1.
DESCRIPTION
The compressed air exits the separator tank through the top cover
piping, and will then travel into the aftercooler inlet side.
The aftercooler is cooled by the incoming compressor package air.
The compressed air and condensate (water with a small amount of

compressor lubricant) exits the aftercooler and enters the moisture
separator, where most of the condensate is removed.
At the bottom of the moisture separator a strainer and constant-bleed

orifice is fitted, which are sized to allow the maximum flow of
FIGURE 2.
condensate while minimising compressed air loss.
A second condensate drain valve is mounted on the aftercooler body,

this valve will open on machine shutdown thereby allowing any
remaining condensate in the aftercooler to drain. This is to prevent
cooler damage at freezing temperatures.
These drains are plugged through the compressor frame and will expel
condensation to atmosphere. Should site contamination by this
condensate be prohibited, the user can connect an additional section
of drain hose and route into an allowed drain point.
MAINTENANCE
Daily Maintenance:
Verify, during full-load (maximum compressed air delivery) that

condensate can be seen to drain from the water separator drain hose.
Weekly Maintenance:
• Verify that the piping from the orifice purge points are not clogged.
• Clean the inside of the water separator housing.
Water separator maintenance:

FIGURE 3.
• With engine stopped, ensure pressure is relieved from air system.
• Remove any hose connected to the water separator housing.
Inspect fittings and hoses for any blockage. Clean if necessary.
• Remove and clean the water separator float.
7/73 - 10/53
54 OPTIONS
WATER SEPARATOR MAINTENANCE
FIGURE 4.
FIGURE 1.
FIGURE 5.
FIGURE 2.
FIGURE 3.
7/73 - 10/53
OPTIONS 55
FIGURE 4. FIGURE 7.
FIGURE 5. FIGURE 8.
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.
FIGURE 6. NOTE: Do not operate at temperatures less that 2°C (35°F).
7/73 - 10/53
56 OPTIONS
DRAIN LOCATIONS
OPTION - BUNDED BASE
DESCRIPTION
This machine can be fitted with bund equipment to contain leakages

and spillages, which occur within the machine enclosure.
The bund will contain all fluids normally installed in the machine, plus
an additional 10%.
OPERATING INSTRUCTIONS
When fitted with bund, the machine must only be operated when level.
Drains for engine coolant, engine oil, compressor oil and fuel tank are
located on the left rear side of the machine.
The bunded base drain is located at the right rear side of the machine.
Bunded base must be drained daily.
DRAINING OF CONTAMINATED FLUIDS
Contaminated fluid must be removed by authorized personnel only.
Captured fluids can be drained from the bund by removing the plug or
uncoupling the flexible pipe secured at the right side of the machine.
The plug must be re-sealed after draining. The flexible pipe must be
re-secured after draining.
DRAINING OF MACHINE FLUIDS
During maintenance operations, drain machine fluids using the drain

ports indicated.
WARNING: Major leakages or spillages must be drained before

the machine is towed.
1. Fuel tank drain.
2. Compressor coolant drain.
3. Engine oil drain.
4. Separator tank drain.
5. Engine coolant drain.
6. Bunded base drain.
7/73 - 10/53
OPTIONS 57
DRAIN LOCATIONS
OPTION - CENTRAL DRAINS
DESCRIPTION
This machine can be fitted with a central drains option. When this
option is fitted, all drain ports are routed to one easily accessible point.
Each drain port consists of a valve, a safety plug and an identification

decal.
The draining procedure is the same as on the standard unit.
Identify the correct port to be drained.
Remove the plug, connect the enclosed hose with coupling to the
valve, then open valve and drain all volume of fluid into an appropriate
container.
Repeat the procedure on each drain as required.
Close the valves and replace plugs before new fluid is filled.
Check all ports for leakage.
1. Fuel tank drain.
2. Compressor coolant drain.
3. Engine oil drain.
4. Separator tank drain.
5. Engine coolant drain.
7/73 - 10/53
58 OPTIONS
OPTION - CHALWYN VALVE (Air intake shutdown valve) NOTES:

Turbocharged Engines - When setting up a valve on a
turbocharged engine using the preceding method, it may be found
DESCRIPTION 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
Chalwyn valves provide emergency overspeed shutdown protection half turn clockwise should be made until the problem is eliminated.
for diesel engines and are the most effective way of preventing a
runaway situation. The valves completely block the engine air intake Jammed Valve - If in the course of adjusting the valve it jams on its
system, cutting off an uncontrolled external fuel source and the air seat, release by turning CLOCKWISE viewed from adjuster end of
required to keep the engine running. valve.
OPERATING INSTRUCTIONS MAINTENANCE
Three monthly
1. Disconnect intake pipework and release the valve from any support
brackets etc. to allow it to be removed.
2. Inspect the valve internally for cleanliness. If necessary, clean in

paraffin or white spirit taking normal precautions. Dry the valve
thoroughly.
3. Check there is no excessive wear and that the valve moves

smoothly over its complete operating stroke. DO NOT LUBRICATE.
4. Refit valve. Check valve setting based on the ’Adjustment’

instructions given herein.
NOTE: The three monthly routine maintenance period requirement is

dependent on the operating conditions to which the equipment is
exposed and, by experience, may need to be varied.
A. Adjuster
B. Locknut
C. Hold with spanner when adjusting
D. Air flow
Once the Chalwyn valve is installed, adjustment of the overspeed trip

setting is carried out using the adjuster and locknut (refer to diagram).
Basically rotating the adjuster clockwise will increase the engine speed
at which automatic shut down occurs.
1. Start engine. Slowly accelerate. Note speed at which shut down

occurs.
2. Remove hose at air inlet to Chalwyn valve to expose the adjuster

and locknut (see diagram).
3. Release locknut. Turn adjuster clockwise one turn. Tighten locknut.
4. Refit inlet hose to Chalwyn valve.
5. Start engine. Slowly accelerate. Note speed at which shut down

occurs.
6. Repeat the above steps ’2’ to ’5’ until the first setting at which the
engine does not shut down at high idle speed (i.e. maximum
throttle, no load).
Then either:
a) Use the results of shut down speed versus adjuster setting as a

calibration check to make a final adjustment to give the required setting
(typically 10% to 15% over high idle).
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).
7/73 - 10/53
OPTIONS 59
GENERAL INFORMATION
OPTION - LUBRICATOR
Oil capacity: 2 litres
Oil specification: Refer to the Tool Manufacturer’s Manual.
COMMISSIONING
Check the lubricator oil level and fill as necessary.
PRIOR TO STARTING
Check the lubricator oil level and replenish as necessary.
MAINTENANCE
Check the lubricator oil level and replenish as necessary.
FAULT FINDING
FAULT CAUSE REMEDY

No oil flow. Incorrect Reverse the nylon tube
connection. connections to the lubricator.
DESCRIPTION
The internal air line lubricator is used to release a lubricant into the
internal compressed air piping before it exits the compressor, from
there the air/oil mixture will flow to the compressed air operated
appliance; one that requires an external source of pneumatic oil for
proper operation.
SAFETY
WARNING: Ensure that the lubricator filler cap is re-tightened

correctly after replenishing with oil.
WARNING: Do not replenish the lubricator oil, or service the

lubricator without first making sure that the machine is stopped
and the system has been completely relieved of all air pressure
(Refer to STOPPING THE UNIT in the OPERATING
INSTRUCTIONS section of this manual).
CAUTION: If the nylon tubes to the lubricator are disconnected then

ensure that each tube is re-connected in its original location.
7/73 - 10/53
60 OPTIONS
MAINTENANCE
OPTION - SPARK ARRESTOR
Daily:
Examine the spark arrestor for any sign of gas leakage, cracks or
significant areas of damage, i.e. dents of more than a few millimetres
in depth.
Three Monthly:
Remove spark arrestor. Tap with a soft mallet to loosen any internal
deposits and shake out. Also by shaking check for any loose internal
baffles.
Six Monthly (or 1500 hours operation, whichever is sooner):
Examine the exhaust discharge in darkness whilst repeatedly loading

and accelerating the engine. If any sparks are observed, the spark
arrestor is not suitable for further use.
DESCRIPTION
WARNING: Ensure adequate ventilation if this check is carried
Diesel Engine exhaust spark arrestors are a key safety feature for both out in an enclosed area.
hazardous area and lower risk diesel engine applications where a stray
spark may cause ignition of combustible material. Virtually all
WARNING: The engine must not be put back into service until
legislation regarding the operation of a diesel engine in a hazardous
any problems identified by the above checks are rectified.
area includes a mandatory requirement to fit a tested and approved
exhaust spark arrestor.
7/73 - 10/53
PARTS ORDERING 61
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 unit. All of the compressor parts, listed in the b. Locate the area or system of the compressor in which the desired
part is used and find illustration page number.
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 unit serial number for assistance In order that all avoidable errors may be eliminated, the following
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 unit as shown on the
general data decal attached to the unit.
The illustrated parts breakdown illustrates and lists the various b. Always specify the serial number of the unit. THIS IS
assemblies, subassemblies and detailed parts which make up this IMPORTANT. The serial number of the unit will be found stamped
particular machine. This covers the standard models and the more on a plate attached to the unit. (The serial number on the unit is
popular options that are available. also permanently stamped in the metal of the frame side rail.)
A series of illustrations show each part distinctly and in location relative
c. Always specify the number of the parts list publication.
to the other parts in the assembly. The part number, the description of
the part and the quantity of parts required are shown on each d. Always specify the quantity of parts required.
illustration or on adjacent page. The quantities specified are the
number of parts used per one assembly and are not necessarily the e. Always specify the part number, as well as the description of the
total number of parts used in the machine. Where no quantity is part, or parts, exactly as it is given on the parts list illustration.
specified the quantity is assumed to be one. In the event parts are being returned to your nearest sales office,
Each description of a part is based upon the "noun first" method, i.e., autonomous company or authorised distributor, for inspection or
the identifying noun or item name is always the first part of the repair, it is important to include the serial number of the unit from which
description. The noun name is generally followed by a single the parts were removed.
descriptive modifier. The descriptive modifier may be followed by
words or abbreviations such as upper, lower, inner, outer, front, rear, TERMS AND CONDITIONS ON PARTS ORDERS
RH, LH, etc. when they are essential.
In referring to the rear, the front or to either side of the unit, always Acceptance: Acceptance of an offer is expressly limited to the exact
consider the drawbar end of the unit as the front. Standing at the rear terms contained herein. If purchaser's order form is used for
of the unit facing the drawbar (front) will determine the right and left acceptance of an offer, it is expressly understood and agreed that the
sides. terms and conditions of such order form shall not apply unless
expressly agreed to by Doosan Company ("Company") in writing. No
FASTENERS 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 Taxes: Any tax or other governmental charge now or hereafter levied
assembly of these units. In the disassembly and reassembly of parts, upon the production, sale, use or shipment of material and equipment
extreme care must be taken to avoid damaging threads by the use of ordered or sold is not included in the Company's price and will be
wrong fasteners. In order to clarify the proper usage and for exact charged to and paid for by the Purchaser.
replacement parts, all standard fasteners have been identified by part Shipping dates shall be extended for delays due to acts of God, acts of
number, size and description. This will enable a customer to obtain Purchaser, acts of Government, fires, floods, strikes, riot, war,
fasteners locally rather than ordering from the factory. These parts are embargo, transportation shortages, delay or default on the part of the
identified in tables that will be found at the rear of the parts illustrations. Company's vendors, or any other cause beyond the Company's
Any fastener that has not been identified by both part number and size reasonable control.
is a specially engineered part that must be ordered by part number to
obtain the exact replacement part. Should Purchaser request special shipping instruction, such as
exclusive use of shipping facilities, including air freight when common
carrier has been quoted and before change order to purchase order
MARKINGS AND DECALS
can be received by the Company, the additional charges will be
honoured by the Purchaser.
NOTICE
Warranty: The Company warrants that parts manufactured by it will be
Do not paint over safety warnings or instructional decals. If safety as specified and will be free from defects in materials and
warning decals become illegible, immediately order replacements workmanship. The Company's liability under this warranty shall be
from the factory. limited to the repair or replacement of any part which was defective at
the time of shipment provided Purchaser notifies the Company of any
Part numbers for original individual decals and their mounting
such defect promptly upon discovery, but in no event later than three
locations are shown within Parts List Section. These are available
(3) months from the date of shipment of such part by the Company.
as long as a particular model is in production.
The only exception to the previous statement is the extended warranty
as it applies to the special airend exchange program.
7/73 - 10/53
62 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
7/73 - 10/53
Doosan Bobcat EMEA s.r.o
U Kodetky 1810
263 12 Dobříš
Czech Republic www.doosanportablepower.eu

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7/73 - 10/53

OPERATION AND MAINTENANCE MANUAL

This manual contains

7/20 17,5 96LWA 97LWA 7/124-10/104 97

CPN 46552199 rev P

The design specification of this machine has been certified as TABLE 1

The company reserves the right to make changes and improvements

Prohibition / Mandatory Information / Instructions Warning

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

Compressor oil filling. Diesel fuel. Parking brake.

Prohibition: Do not start Start and stop device. Mandatory action:

Diesel fuel drain. Engine coolant drain. Compressor oil drain.

Engine oil drain. Compressor oil drain.

Close service valve and

Do not open radiator while Do NOT operate with guard

Access Lifting Bail from inside machine.

Relieve pressure before

Use both hands to open door when machine

For Highway Towable Units. For Non-Highway Towable Machines

If more than one compressor is connected to one common

Consult a physician if large amounts of compressor lubricant are

Consult a physician if compressor lubricant is inhaled.

Never give fluids or induce vomiting if the patient is unconscious or

Safety data sheets for compressor and engine lubricants should be

Never operate the engine of this machine inside a building without

DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY

The machine must be towed in a level attitude (the maximum

When adjusting variable height running gear:-

• Ensure front (towing eye) section is set level

Where safety chains only are fitted:

7/73 - 10/53 FIXED HEIGHT RUNNING GEAR

7/73 - 10/53 VARIABLE HEIGHT RUNNING GEAR

7/73 - 10/53 PERMANENT SKID MOUNTED

7/73 - 10/53 SHIPPING SKID MOUNTED

7/73 - 10/53 TRUCK SKID MOUNTED

COMPRESSOR - 7/73 ENGINE

for ambient temperatures above -23°C (-9°F),

Safety data sheets can be obtained on request from your Doosan

When starting or operating the machine in temperatures below or

A. Main switch H. Warning lamp, low engine oil pressure

D. Air pressure gauge K. Warning lamp, high engine coolant temperature

E. Hourmeter L. Warning lamp, low engine fuel level

F. Diagnostic lamp, red M. Warning lamp, low battery voltage

G. Diagnostic lamp, yellow

• Close the service valve.

• Complete starting sequence above. RE-STARTING AFTER AN EMERGENCY

• Close service valve as soon as engine runs freely.

• Low engine oil pressure.

• Do not allow lubricants or coolants to be released into land surfaces

• Do not dispose of a complete machine without documentation

Lamp Lamp Lamp Lamp

In more severe applications such as sandblasting, quarry drilling, well

ONBOARD ENGINE DIAGNOSTICS 1 Blink 1 Blink 1 Blink 2 Blink

WARNING WARNING WARNING

1. Diagnostics activation button

Daily Weekly Monthly 6 months 1 year or 2000 hrs

See Maintenance Schedule.

CAUTION: Start the machine (refer to PRIOR TO STARTING and

Examine the filter element. AIR FILTER ELEMENTS