Orca Share Media1670890579278 7008223040228773626

9/270, 9/300, 12/235, 17/235, 21/215
9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA

OPERATION AND MAINTENANCE MANUAL
Original Instruction
This manual contains

important safety information
and must be made available to
9/270, 9/300 SERIAL No : 893000 ->
personnel who operate and
10/300, 12/235
maintain this machine.
17/235, SERIAL No : 881500 ->
21/215
22839567 _en_E_10/15
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:
SAMPLE
CONTENTS & ABBREVIATIONS 1
1 CONTENTS ABBREVIATIONS & SYMBOLS
2 FOREWORD #### Contact the company for serial number

->#### Up to Serial No.
3 WARRANTY
####-> From Serial No.
6 ISO SYMBOLS * Not illustrated
† Option
9 SAFETY
WDG Generator option
11 GENERAL INFORMATION AR As required
Dimensions HA High ambient machine
Data S.R.G. Site running gear
H.R.G. High speed running gear
14 OPERATING INSTRUCTIONS
Commissioning
Prior to starting
bg Bulgarian
Starting
cs Czech
Stopping
da Danish
Emergency stopping
de German
Re-starting
el Greek
Monitoring during operation
en English
Decommissioning
es Spanish
et Estonian
23 MAINTENANCE
fi Finnish
Routine maintenance
fr French
Lubrication
hu Hungarian
Speed & pressure regulation
it Italian
Torque settings table
lt Lithuanian
Compressor lubrication
lv Latvian, Lettish
mt Maltese
35 MACHINE SYSTEMS
nl Dutch
Electrical system
no Norwegian
Piping & instrumentation system
pl Polish
pt Portuguese
39 FAULT FINDING
ro Romanian
ru Russian
41 OPTIONS
sk Slovak
sl Slovenian
43 ENGINE INSTRUCTION MANUAL
sv Swedish
zh Chinese
62 PARTS ORDERING
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
2 FOREWORD
The contents of this manual are considered to be proprietary and The intended uses of this machine are outlined below and
confidential to and should not be reproduced without the prior written examples of unapproved usage are also given, however the company
permission of the company. cannot anticipate every application or work situation that may arise.
Nothing contained in this document is intended to extend any IF IN DOUBT CONSULT SUPERVISION.
promise, warranty or representation, expressed or implied, regarding
This machine has been designed and supplied for use only in the
the products described herein. Any such warranties or other terms and
following specified conditions and applications:
conditions of sale of products shall be in accordance with the standard
terms and conditions of sale for such products, which are available • Compression of normal ambient air containing no known or
upon request. detectable additional gases, vapours. or particles
• Operation within the ambient temperature range specified in the
This manual contains instructions and technical data to cover all GENERAL INFORMATION section of this manual.
routine operation and scheduled maintenance tasks by operation and The use of the machine in any of the situation types listed in
maintenance staff. Major overhauls are outside the scope of this table 1:-
manual and should be referred to an authorised service department.
a Is not approved,
The design specification of this machine has been certified as b) May impair the safety of users and other persons, and
complying with EC directives. As a result: c) May prejudice any claims made against the company.
a) Any machine modifications are strictly prohibited, and will invalidate
EC certification. TABLE 1
b) A unique specification for USA/Canada is adopted and tailored to
Use of the machine to produce compressed air for:
the territory.
a) direct human consumption
All components, accessories, pipes and connectors added to the b) indirect human consumption, without suitable filtration and purity
compressed air system should be: checks.
• of good quality, procured from a reputable manufacturer and,
Use of the machine outside the ambient temperature range
wherever possible, be of a type approved by the company.
specified in the GENERAL INFORMATION SECTION of this
• clearly rated for a pressure at least equal to the machine maximum manual.
allowable working pressure.
• compatible with the compressor lubricant/coolant. This machine is not intended and must not be used in potentially
• accompanied with instructions for safe installation, operation and explosive atmospheres, including situations where flammable
maintenance. gases or vapours may be present.
Details of approved equipment are available from the company Use of the machine fitted with non approved components /
Service departments. lubricants / fluids.
The use of repair parts / lubricants / fluids other than those included Use of the machine with safety or control components missing or
within the approved parts list may create hazardous conditions over disabled.
which the company has no control. Therefore the company cannot be
held responsible for equipment in which non-approved repair parts are The company accepts no responsibility for errors in translation of
installed. this manual from the original English version.
The company reserves the right to make changes and
improvements to products without notice and without incurring any
obligation to make such changes or add such improvements to
products sold previously. © COPYRIGHT 2011
DOOSAN COMPANY
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
WARRANTY 3
The company, through its distributor, warrants that each item of F. Platinum Drive Train Extended Warranty - Platinum drive train
equipment manufactured by it and delivered hereunder to the initial warranty is available for the following compressor types.
user will be free of defects in material and workmanship for a period of
European built
three (3) months from initial operation or six (6) months from the date
of shipment to the initial user, whichever occurs first. 7/20-7/26E-7/31E-7/41-7/51-7/71-12/56-P65-P90
7/120-9/110-14/85-10/105-14/115-10/125-7/170-12/150
With respect to the following types of equipment, the warranty period
enumerated below will apply in lieu of the foregoing warranty period. USA built
Model Serial Code**
A. Aftercoolers - The earlier of nine (9) months from date of
shipment to or six (6) months from start up by initial user. P185WJD-T4I D75
P185WYM-T4I D76
B. Portable Compressors, Portable Generator Sets -
C185WKUB-T2 D80
9 Kva through to 550 Kva, Portable Light Towers and Air
Dryers - The earlier of twelve (12) months from shipment to or the P250WJD-T3 D81
accumulation of 2,000 hours of service by the initial user. P260/HP220WYM-T3 D82
C185SKUB-T2 E04
2.5 Kva Through to 8 Kva - The earlier of twelve (12) months
from shipment to or the accumulation of 2,000 hours of operation C185WKUB-T4I D95
by the initial user.
P425-XP375-HP350-P600-HP450-VHP400 WIR (John Deere engines
The company will provide a new part or repaired part, at it’s sole only)
discretion, in place of any part which is found to be defective in 1. The original airend is returned assembled and unopened.
material or workmanship during the period described above.
Labor cost to replace the part is the responsibility of the initial 2. Continued use of genuine Doosan parts, fluids, oil and filters
user.
3. Maintenance is performed at prescribed intervals by
C. Portable Compressor Air Ends - The earlier of twenty-four (24) authorized and properly trained service engineers.
months from shipment to or the accumulation of 4,000 hours of
The company shall be provided with such information as it
service by the initial user. For Air Ends, the warranty against
requires to confirm that these conditions have been complied with.
defects will include replacement of the complete Air End, provided
the original Air End is returned assembled and all original seals G. Construction Tools, (Portable Power range only) - Twelve (12)
are intact. months from shipment to initial user. The company will provide a
new part or repaired part, at it’s sole discretion, in place of any part
C1. Portable Compressor Airend Limited Extended Warranty -
which is found to be defective in material or workmanship during
The earlier of sixty (60) months from shipment to or the
the period described above. Labour cost to replace the part is the
accumulation of 10,000 hours of operation by the initial user. This
responsibility of the initial user.
extended warranty is limited to defects in design or defective
material or workmanship in rotors, housings, bearings and gears H. Spare Parts - Six (6) months from date of shipment to the initial
and provided all the following conditions are met: user.
The original air end is returned assembled and all original seals The company will provide a new part or repaired part, at its sole
are intact. discretion, in place of any part that is found to be defective in material
and workmanship during the period described above. Such parts will
Continued use of genuine Doosan parts, fluids, oils and filters.
be repaired or replaced without charge to the initial user during normal
Maintenance is performed at prescribed intervals by authorized working hours at the place of business of a distributor authorized to sell
and properly trained service engineers. the type of equipment involved or other establishment authorized. User
must present proof of purchase at the time of exercising warranty.
D. Generator Alternator - 9 Kva through to 550 Kva. The earlier of
twenty-four (24) months from shipment to or the accumulation of The above warranties do not apply to failures occurring as a result of
4,000 hours of operation by the initial user. abuse; misuse, negligent repairs, corrosion, erosion and normal wear
and tear, alterations or modifications made to the product without
2.5 Kva Through to 8 Kva - The earlier of twelve (12) months
express written consent; or failure to follow the recommended
from shipment to or the accumulation of 2,000 hours of operation operating practices and maintenance procedures as provided in the
by the initial user. product’s operating and maintenance publications.
E. Portable Light Tower Alternator - The earlier of twelve (12)
Accessories or equipment furnished by the company, but
months from shipment to or the accumulation of 2,000 hours of manufactured by others, including, but not limited to, engines, tires,
operation by the initial user. Light Source model only, the earlier batteries, engine electrical equipment, hydraulic transmissions,
of twenty-four (24) months from shipment to or the accumulation
carriers, shall carry only the manufacturers warranty, which the
of 4,000 hours of operation by the initial user. company can lawfully assign to the initial user.
THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTHER

WARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT OF
TITLE), AND THERE ARE NO WARRANTIES OF
MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
4 WARRANTY
GENERAL WARRANTY INFORMATION - ESA
COMMENTS
PORTABLE COMPRESSOR PACKAGE 12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,
HOURS RADIATOR, OIL COOLER, RECEIVER, PIPEWORK,
ELECTRICAL CIRCUIT ETC.
AIREND 24 MONTHS / 4,000 60 MONTHS / 10,000 HOURS. EXTENDED LIMITED
HOURS WARRANTY AVAILABLE ON MAJOR COMPONENTS.
REFER TO OPERATOR’S MANUAL.
ENGINE SEE BELOW
2.5kVA - 8kVA PACKAGE 12 MONTHS / 2,000 CONTACT THE COMPANY NETWORK FOR WARRANTY
GENERATORS HOURS (PARTS ONLY NO LABOUR).
ALTERNATOR 12 MONTHS / 2,000 CONTACT THE COMPANY NETWORK FOR WARRANTY
HOURS (PARTS ONLY NO LABOUR).
ENGINE SEE BELOW
9kVA - 550kVA PACKAGE 12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,
GENERATORS HOURS ELECTRICAL CIRCUIT ETC.
ALTERNATOR 24 MONTHS / 4,000 CONTACT THE COMPANY FOR WARRANTY.
HOURS
ENGINE SEE BELOW
LIGHT TOWER PACKAGE 12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,
HOURS ELECTRICAL CIRCUIT ETC.
ALTERNATOR 12 MONTHS / 2,000 EXTENDED WARRANTY OF 24 MONTHS / 4,000 HRS.
HOURS FOR LIGHTSOURCE INTRODUCED 8/16/99.
ENGINE SEE BELOW
ENGINES
MONTHS HOURS COMMENTS
CATERPILLAR 12 UNLIMITED EXTENDED WARRANTY PROVIDED VIA ENGINE
SUPPLIER’S OWN APPROVED NETWORK AT TIME OF
PURCHASE.
CUMMINS 24 2,000 EXTENDED WARRANTY PROVIDED VIA ENGINE
SUPPLIER’S OWN APPROVED NETWORK AT TIME OF
PURCHASE.
JOHN DEERE 24 2,000
(IN COMPRESSORS)
(IN GENERATORS) 24 2,000 24 MONTHS / 4,000 HRS. AVAILABLE FROM THE
COMPANY WITH USE OF GENUINE DOOSAN PARTS
AND OILS AT PRESCRIBED SERVICE INTERVALS.
CONTACT THE COMPANY NETWORK.
KUBOTA 24 2,000 EXTENDED WARRANTY OF 36 MONTHS / 3,000 HRS.
(North America only) ON MAJOR COMPONENTS, PARTS ONLY, AVAILABLE
FROM KUBOTA.
(Western Europe and Oceania) 24 2,000 NO EXTENDED WARRANTY AVAILABLE.
(Central and South America, Asia, 12 1,000 NO EXTENDED WARRANTY AVAILABLE.
Middle East and Africa)
PARTS
DOOSAN 6 UNLIMITED PARTS ONLY AVAILABLE FROM THE COMPANY
NETWORK.
AIREND EXCHANGE
AIREND 12 2,000 60 MONTHS/10.000 HOURS AVAILABLE UNDER
CONDITIONS.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
WARRANTY 5
CONSTRUCTION TOOLS
CONSTRUCTION TOOLS 12 N/A
NOTE: Actual warranty times may change.
Consult the Manufacturer’s warranty policy as shipped with each

new product.
Extended Limited Airend Warranty

All machines have the standard airend warranty, - The earlier of 24 months from shipment to, or the accumulation of 4000 hours of service by
the initial user.
The warranty against defects will include replacement of the complete Airend, provided the original Airend is returned assembled and unopened.
The optional limited warranty is the earlier of 60 months from shipment to, or the accumulation of 10,000 hours of service. The optional warranty
is limited to defects in major components (rotors, housings, gears and bearings), and is automatically available when the following conditions are
met:
1. The original airend is returned assembled and unopened.
2. Submissions of proof that Doosan fluid, filters and separators have been used. Refer to the Operation and Parts manual for the correct fluids,
filters and separator elements required.
3. Submissions of proof that maintenance intervals have been followed.
WARRANTY TIME *BARE AIREND **AIREND COMPONENTS

STANDARD 2YRS / 4,000HRS 100% PARTS & LABOUR 100% PARTS & LABOUR
OPTIONAL 5YRS / 10,000HRS 100% PARTS & LABOUR 0%
*BARE AIREND - pertains to major airend parts (rotors, housings, gears and bearings).
**AIREND COMPONENTS - pertains to auxiliary attachments to the bare airend (seals, pumps, valves, tubes, hoses, fittings and filter housing).
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
6 ISO SYMBOLS
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory Information / Instructions Warning
WARNING: Electrical shock risk WARNING - Pressurised component or WARNING - Hot surface.
system.
WARNING - Pressure control. WARNING - Corrosion risk. WARNING - Air/gas flow or Air discharge.
WARNING - Pressurised vessel. WARNING - Hot and harmful exhaust gas. WARNING - Flammable liquid.
WARNING - Maintain correct tyre pressure. WARNING - Before connecting the tow bar WARNING - For operating temperature
(Refer to the GENERAL INFORMATION or commencing to tow consult the below 0°C, consult the operation and
section of this manual). operation and maintenance manual. maintenance manual.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
ISO SYMBOLS 7
WARNING - Do not undertake any WARNING - Consult the operation and Do not breathe the compressed air from this
maintenance on this machine until the maintenance manual before commencing machine.
electrical supply is disconnected and the air any maintenance.
pressure is totally relieved.
Do not remove the Operating and Maintenance Do not stack. Do not operate the machine without the guard
manual and manual holder from this machine. being fitted.
Do not stand on any service valve or other parts Do not operate with the doors or enclosure Do not use fork lift truck from this side.
of the pressure system. open.
Do not exceed the trailer speed limit. No naked lights. Do not open the service valve before the
airhose is attached.
Use fork lift truck from this side only. Emergency stop. Tie down point
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
8 ISO SYMBOLS
Lifting point. On (power). Off (power).
Read the Operation and Maintenance manual When parking use prop stand, handbrake and Compressor oil filling
before operation or maintenance of this wheel chocks.
machine is undertaken.
FREE SAFETY DECALS!

Safety Decals are available free of charge.
Decal part numbers are on the bottom of each decal and are also listed in the
compressor's parts manual. Submit orders for Safety Decals to the Doosan
Portable Power EMEA Aftermarket Department. The no charge order
should contain only Safety Decals. Help promote product safety! Assure that
decals are present on the machines. Replace decals that are not readable.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
SAFETY 9
The safety valve located in the separator tank must be checked
WARNINGS
periodically for correct operation.
Warnings call attention to instructions which must be followed
precisely to avoid injury or death.
Materials
CAUTIONS
The following substances may be produced during the operation of
Cautions call attention to instructions which must be followed
this machine:
precisely to avoid damaging the product, process or its surroundings.
• brake lining dust
NOTES • engine exhaust fumes
Notes are used for supplementary information. AVOID INHALATION
Ensure that adequate ventilation of the cooling system and exhaust

General Information gases is maintained at all times.
The following substances are used in the manufacture of this

Ensure that the operator reads and understands the decals and
machine and may be hazardous to health if used incorrectly:
consults the manuals before maintenance or operation.
• anti-freeze
Ensure that the Operation and Maintenance manual, and the
• compressor lubricant
manual holder, are not removed permanently from the machine.
• engine lubricant
Ensure that maintenance personnel are adequately trained, • preservative grease
competent and have read the Maintenance Manuals. • rust preventative
Make sure that all protective covers are in place and that the • diesel fuel
canopy/doors are closed during operation. • battery electrolyte
The specification of this machine is such that the machine is not AVOID INGESTION, SKIN CONTACT AND INHALATION OF
suitable for use in flammable gas risk areas. If such an application is FUMES.
required then all local regulations, codes of practice and site rules must
Should compressor lubricant come into contact with the eyes, then
be observed. To ensure that the machine can operate in a safe and
irrigate with water for at least 5 minutes.
reliable manner, additional equipment such as gas detection, exhaust
spark arrestors, and intake (shut-off) valves may be required, Should compressor lubricant come into contact with the skin, then
dependant on local regulations or the degree of risk involved. wash off immediately.
A weekly visual check must be made on all fasteners/fixing screws Consult a physician if large amounts of compressor lubricant are
securing mechanical parts. In particular, safety-related parts such as ingested.
coupling hitch, drawbar components, road-wheels, and lifting bail
should be checked for total security. Consult a physician if compressor lubricant is inhaled.
All components which are loose, damaged or unserviceable, must Never give fluids or induce vomiting if the patient is unconscious or
be rectified without delay. having convulsions.
Safety data sheets for compressor and engine lubricants should be

Compressed air obtained from the lubricant supplier.
Compressed air can be dangerous if incorrectly handled. Before Battery

doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally. Batteries contain corrosive liquid and produce explosive gas. Do
Ensure that the machine is operating at the rated pressure and that not expose to naked lights. Always wear personal protective clothing
the rated pressure is known to all relevant personnel. when handling. When starting the machine from a slave battery ensure
that the correct polarity is observed and that connections are secure.
All air pressure equipment installed in or connected to the machine
must have safe working pressure ratings of at least the machine rated DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY
pressure. SINCE THIS MAY CAUSE IT TO EXPLODE.
If more than one compressor is connected to one common

downstream plant, effective check valves and isolation valves must be Radiator
fitted and controlled by work procedures, so that one machine cannot
accidentally be pressurised / over pressurised by another. Hot engine coolant and steam can cause injury. Ensure that the
radiator filler cap is removed with due care and attention.
Compressed air must not be used for a direct feed to any form of
breathing apparatus or mask.
Engine starting fluid (ether)
The discharged air contains a very small percentage of compressor
lubricating oil and care should be taken to ensure that downstream Use and recharge system only with suppliers instructions and
equipment is compatible. replacement parts.
If the discharged air is to be ultimately released into a confined Some machines are fitted with an ether cold starting aid.
space, adequate ventilation must be provided.
Do NOT use on engines which are provided with inlet heaters.
When using compressed air always use appropriate personal
protective equipment. AVOID INGESTION, INHALATION, HOT SURFACES AND NAKED
LIGHTS.
All pressure containing parts, especially flexible hoses and their
couplings, must be regularly inspected, be free from defects and be
replaced according to the Manual instructions. Transport
Avoid bodily contact with compressed air.

When loading or transporting machines ensure that the specified
lifting and tie down points are used.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
10 SAFETY
When loading or transporting machines ensure that the towing • the tyres and towing hitch are in a serviceable condition.
vehicle, its size, weight, towing hitch and electrical supply are all • the canopy is secure.
suitable to provide safe and stable towing at speeds either, up to the • all ancillary equipment is stored in a safe and secure manner.
legal maximum for the country in which it is being towed or, as specified
for the machine model if lower than the legal maximum.
When parking always use the handbrake and, if necessary, suitable
Before towing the machine, ensure that:- wheel chocks.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
GENERAL INFORMATION - ESA (CE/HA) 11
‘CE’
‘HA’
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
12 GENERAL INFORMATION - ESA (CE/HA)
MODEL 12/235 9/270 9/300 10/300 21/215 17/235
COMPRESSOR
Actual free air delivery. m3/min/ 23,3/ 27,0/ 29,9/ 29,9/ 21,5/ 23,3/
cfm 825 950 1060 1060 750 825
Normal operating discharge psi/bar/ 175/12/ 125/8,6/ 125/8,6/ 145/10/ 300/21/ 250/17,2/
pressure. kPa 1200 860 860 1000 2100 1724
Maximum allowable pressure psi/bar/ 200/13,8/ 150/10,3/ 150/10,3/ 170/11,7/ 325/22,4/ 275/19/
kPa 1380 1030 1030 1170 2240 1900
Safety valve setting psi/bar/ 217/15/ 217/15/ 217/15/ 217/15/ 362/25/ 362/25/
kPa 1500 1500 1500 1500 2500 2500
Maximum pressure ratio 8:1 8:1 8:1 8:1 18:9:1 18:9:1
(absolute)
Operating ambient temperature °C -10/+50 -10/+50 -10/+50 -10/+50 -10/+50 -10/+50
range
Maximum discharge temperature °C 120 120 120 120 120 120
COMPRESSOR
Cooling system. Oil Injection
Oil capacity. Litre 70 70 70 70 75 75
Maximum oil system temperature °C 120 120 120 120 120 120
Maximum oil system pressure psi/bar/ 217/15/ 217/15/ 217/15/ 217/15/ 362/25/ 362/25/
kPa 1500 1500 1500 1500 2500 2500
LUBRICATING OIL
SPECIFICATION (for the SEE NOTE - 1
specified ambient temperatures).
MODEL 12/235 9/270 9/300 10/300 21/215 17/235
ENGINE QSL (300hp) QSL (300hp) QSL (340hp) QSL (340hp) QSL (340hp) QSL (340hp)
Number of cylinders / /Litre 6/8,9 6/8,9 6/8,9 6/8,9 6/8,9 6/8,9
Displacement
Oil capacity. Litre 24 24 24 24 24 24
Speed at full load. Rev min-1 1800 1800 1800 1800 1800 1800
Speed at idle. Rev min -1 1200 1200 1200 1200 1350 1350
Electrical system. V DC 24 24 24 24 24 24
Power available at rated speed KW 224 224 255 255 255 255
Fuel tank capacity. Litre 550 550 550 550 550 550
Coolant capacity Litre 48 48 48 48 48 48
Max. gross weight kg 5125 5125 5125 5125 5125 5125
Shipping weight kg 4665 4665 4665 4665 4665 4665
NOTE - 1 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
ABOVE -23°C(-9°F) flushed clear of the first fill fluid and new Doosan oil filters installed.
Recommended: PRO-TEC or XHP605 When this has been completed, the following oils are approved:
Approved: SAE 10W, API CF-4/CG-4 for ambient temperatures above -23°C(-9°F),
PRO-TEC compressor fluid is factory-fitted, for use at all ambient SAE 10W, API CF-4/CG-4
temperatures above -23°C(-9°F).
Safety data sheets can be obtained on request from your Doosan
NOTE: Warranty may be extended only by continuous use of PRO- dealership.
TEC and Doosan oil filters and separators.
No other oil/fluids are compatible with PRO-TEC
No other oils/fluids should be mixed with PRO-TEC because the
resulting mixture could cause damage to the airend.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
GENERAL INFORMATION - ESA (CE/HA) 13
INFORMATION ON AIRBORNE NOISE (CE regions) WHEELS AND TYRES - SITE RUNNING GEAR
- The A-weighted emission sound pressure level Number of wheels. 4
. 83 dB(A), uncertainty 1 dB(A) Tyre size. 750 x 16 x 6PR
- The A-weighted emission sound power level Tyre pressure. 3,5 bar (50 lbf in-2)
. 100 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with TOWING SPEED
ISO 3744:1995 and EN ISO 2151:2004
Maximum towing speed. 30 km h-1
(20 mile h-1)
WEIGHT
Shipping weight 4665 kg
Further information may be obtained by request through the
Maximum weight 5725 kg customer services department.
Maximum horizontal towing force 5012 kgf Estimated
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
COMMISSIONING Adequate clearance needs to be allowed around and above the
machine to permit safe access for specified maintenance tasks.
Upon receipt of the unit, and prior to putting it into service, it is
Ensure that the machine is positioned securely and on a stable
important to adhere strictly to the instructions given below in PRIOR
foundation. Any risk of movement should be removed by suitable
TO STARTING.
means, especially to avoid strain on any rigid discharge piping.
Ensure that the operator reads and understands the decals and
Attach the battery cables to the battery(s) ensuring that they are
consults the manuals before maintenance or operation.
tightened securely. Attach the negative cable before attaching the
Ensure that the position of the emergency stop device is known and positive cable.
recognised by its markings. Ensure that it is functioning correctly and
that the method of operation is known. WARNING: All air pressure equipment installed in or connected
to the machine must have safe working pressure ratings of at
Before towing the unit, ensure that the tyre pressures are correct least the machine rated pressure, and materials compatible with
(refer to the GENERAL INFORMATION section of this manual) and the compressor lubricant (refer to the GENERAL INFORMATION
that the handbrake is functioning correctly (refer to the section).
MAINTENANCE section of this manual). Before towing the unit during
the hours of darkness, ensure that the lights are functioning correctly
(where fitted). WARNING: If more than one compressor is connected to one
common downstream plant, effective check valves and isolation
Ensure that all transport and packing materials are discarded.
valves must be fitted and controlled by work procedures, so that
Ensure that the correct fork lift truck slots or marked lifting / tie down one machine cannot accidentally be pressurised / over pressu-
points are used whenever the machine is lifted or transported. rised by another.
When selecting the working position of the machine ensure that

there is sufficient clearance for ventilation and exhaust requirements, WARNING: If flexible discharge hoses are to carry more than 7
observing any specified minimum dimensions (to walls, floors etc.). bar pressure then it is recommended that safety retaining wires
are used on the hoses.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
OPERATING INSTRUCTIONS 15
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. Check the radiator coolant level (with the unit level).
oil.
7. Open the service valve(s) to ensure that all pressure is relieved
2. Check the engine lubrication oil in accordance with the operating from the system. Close the service valve(s).
instructions in the Engine Operator’s Manual.
8. CAUTION: Do not operate the machine with the canopy/doors in
3. Check the compressor oil level in the sight glass located on the the open position as this may cause overheating and operators to
separator tank. be exposed to high noise levels.
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 9. Check the emergency stop. Rotate knob as indicated to release.
tank.
10.Close the manual relief valve inside the service door near the
emergency stop.
CAUTION: Use only a No. 2-D diesel fuel oil with a minimum octane
number of 45 and a sulphur content not greater than 0,5%. When starting or operating the machine in temperatures below or
approaching 0°C, ensure that the operation of the regulation system,
the unloader valve, the safety valve, and the engine are not impaired
by ice or snow, and that all inlet and outlet pipes and ducts are clear of
ice and snow.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
5. Restricted Air Filter: Alarm indicator lamp. Indicates engine/
compressor air inlet filters need service.
6. High Engine Coolant Temp: Fault indicator lamp. Indicates

shutdown due to high engine water temperature.
7. Restricted IQ Air Filters: Fault indicator lamp. Indicates

shutdown due to high pressure in ”IQ” air filters (if equipped).
8. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to

low fuel level. Lamp blinks at low fuel warning.
9. Compressor Malfunction: Fault indicator lamp. Indicates

shutdown due to compressor system fault. Refer to Fault Code
List.
10. Low Battery Voltage: Alarm indicator lamp. Indicates battery or

charging system requires service.
11. Engine Malfunction: Engine Fault code. Refer to service card or

engine manual for codes and service requirements.
12. Malfunction Code (4 Digit): Compressor or engine fault. Refer

to manual for list of codes and service requirements.
13. Inlet Heater / Wait to Start Lamp: Indicates engine manifold pre
heater is energized. Wait until lamp extinguishes before engaging
starter.
14. Panel Light Switch: Controls panel lamp # 1.
15. Service Air Switch: Momentary contact switch. Allows engine to

warm up at low compressor pressure.
16. ON/OFF Start Switch: Main Power Control Switch.
17. Heater Switch: ON/OFF Power Switch for regulation and IQ

heaters. Prevents freeze up in cold weather.
18. Hourmeter: Indicates machine operating hours.
19. E-STOP: Emergency Stop Push Button (ESA units only). Push to
stop, turn to release.
OPERATING CONTROLS AND INSTRUMENTS
20. Discharge Air Pressure Gage: Indicates pressure in receiver
tank, normally from 0 psi(kPa) to the rated pressure of the
The operating controls and instruments are arranged on the control machine.
panel as shown above. A description of each panel device is as
follows: 21. Engine Tachometer: Indicates engine speed in RPM from 0
when stopped to full speed.
1. Panel Light: Illuminates the instrument control panel controlled
by Switch 14. 22. Fuel Level Gage: Indicate fuel level in tank.
2. High Compressor Temp: Fault indicator lamp. Indicates 23. Engine Water Temp Gage
shutdown due to high compressor temperature.
24. Compressor Oil Temp Gage
3. Low Radiator Coolant Level: Alarm indicator lamp. Indicates
25. Engine Oil Pressure Gage
engine coolant needs service.
26. Battery Voltage Gage
4. Low Engine Oil Pressure: Fault indicator lamp. Indicates
shutdown due to low engine oil pressure.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
Wedge Diagnostic Display Codes
If the fault indicator lamp is illuminated, refer to the Alert/Shutdown list below.
If the fault indicator lamp is illuminated, refer to the Engine diagnostic list below.
ALERT/SHUTDOWN CONDITIONS
ALERT SHUTDOWN
CONDITION CODE LIGHT BLINKS CODE LIGHT STEADY DELAY
(sec)
Engine Speed < Min. RPM 1 CPRSR 30
Malfunction.
Engine Speed > Max. RPM 2 CPRSR 30
Malfunction.
Engine Crank Time Exceeded 3 CPRSR 0
Malfunction.
High Engine Oil Temperature 5 CPRSR
Malfunction.
High Intake Manifold 6 CPRSR
Temperature Malfunction.
Water In Fuel 8 CPRSR
Malfunction.
Engine Not Responding To 10 CPRSR
Throttle command Malfunction.
Too Many Start Attempts 11 CPRSR 0
During Autostart Malfunction.
Engine Shut Itself Down: 29 CPRSR 0
reason unknown Malfunction.
Low AE Oil Pressure 31 CPRSR 20
Malfunction.
Disch. Temp (RT2) 32 CPRSR 10
Sensor Fault Malfunction.
Sep. Tank Pressure (PT1) 33 CPRSR
Seperator Tank Pressure >20 34 CPRSR 0
PSI During Start Attempt Malfunction.
(Engine Will Not Crank)
Machine Over Pressure 35 CPRSR 1
Malfunction.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
ALERT SHUTDOWN
CONDITION CODE LIGHT BLINKS CODE LIGHT STEADY DELAY
(sec)
Safety Valve Open 36 CPRSR 2
Malfunction.
Seperator Tank Temp > (247 50 CPRSR 3
deg.F) Malfunction.
Machine ID Not Valid 51 CPRSR 0
Malfunction.
Sep. Tank Temp (RT1) 53 CPRSR 10
Reg. System Pressure (PT2) 54 CPRSR
Estop Button Pushed 55 CPRSR 55 CPRSR 3
Malfunction. Malfunction.
Minimum Pressure Not Met 56 CPRSR
Malfunction.
Serial Comm. Problem 70 CPRSR
Malfunction.
CAN Bus Problem 71 CPRSR
Malfunction.
Auto Start/Stop Module Failure 73 CPRSR
- No Comm. for 17 sec. Malfunction.
Dedicated Lights:
Low Fuel Level Fuel Level Fuel Level 3

Air Filter Restriction Soiled Filter
Low Battery Voltage Battery Charging
Condition
Low Engine Oil Pressure Low Engine Oil
Pressure
Low Coolant Level Engine Coolant
Level
High Engine Coolant High Engine High Engine 10
Temperature Temp. Temp.
IQ Filter Restriction IQ Filt. Rest 3
High Discharge Temp. High Comp Temp. 3
(RT2>247 deg. F)
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
ENGINE DIAGNOSTIC CODES
Displayed Code Definition
111 Engine Control Module - Critical Internal Failure
115 Engine Speed/Position Sensor Circuit - Lost Both of Two Signals
122 Intake Manifold Pressure Sensor Circuit - Voltage Above Normal, or Shorted High
123 Intake Manifold Pressure Sensor Circuit - Voltage Below Normal, or Shorted Low
135 Engine Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted High
141 Engine Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted Low
143 Engine Oil Pressure Low - Warning
144 Engine Coolant Temperature Sensor Circuit - Voltage Above Normal, or Shorted High
145 Engine Coolant Temperature Sensor Circuit - Voltage Below Normal, or Shorted Low
146 Engine Coolant Temperature High - Warning
147 Frequency Throttle Signal - Abnormal Frequency, Pulse Width, or Period
148 Frequency Throttle Signal - Abnormal Frequency, Pulse Width, or Period
151 Engine Coolant Temperature High - Critical
153 Intake Manifold Temperature Sensor Circuit - Voltage Above Normal, or Shorted High
154 Intake Manifold Temperature Sensor Circuit - Voltage Below Normal, or Shorted Low
155 Intake Manifold Air Temperature High - Critical
187 Sensor Supply Voltage #2 Circuit - Voltage Below Normal, or Shorted Low
195 Engine Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted High
196 Engine Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted Low
197 Engine Coolant Level Low - Warning
212 Engine Oil Temperature Sensor 1 Circuit - Voltage Above Normal, or Shorted High
213 Engine Oil Temperature Sensor 1 Circuit - Voltage Below Normal, or Shorted Low
214 Engine Oil Temperature High - Critical
221 Barometric Pressure Sensor Circuit - Voltage Above Normal, or Shorted High
222 Barometric Pressure Sensor Circuit - Voltage Below Normal, or Shorted Low
227 Sensor Supply Voltage #2 Circuit - Voltage Above Normal, or Shorted High
231 Engine Coolant Pressure Sensor Circuit - Voltage Above Normal, or Shorted High
232 Engine Coolant Pressure Sensor Circuit - Voltage Below Normal, or Shorted Low
233 Engine Coolant Pressure Low - Warning
234 Engine Speed High - Cricital
235 Engine Coolant Level Low - Critical
249 Ambient Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted High
256 Ambient Air Temperature Sensor Circuit - Voltage Below Normal, or Shorted Low
261 Engine Fuel Temperature High - Warning
263 Engine Fuel Temperature Sensor 1 Circuit - Voltage Above Normal, or Shorted High
265 Engine Fuel Temperature Sensor 1 Circuit - Voltage Below Normal, or Shorted Low
268 Fuel Pressure Sensor Circuit - Data Incorrect
271 High Fuel Pressure Solenoid Valve Circuit - Voltage Below Normal, or Shorted Low
272 High Fuel Pressure Solenoid Valve Circuit - Voltage Above Normal, or Shorted High
275 Fuel Pumping Element (Front) - Mechanical System Malfunction
281 High Fuel Pressure Solenoid Valve - Mechanical System Malfunction
284 Engine Speed/Position Sensor (Crankshaft) Circuit - Voltage Below Normal, or Shorted Low
285 SAE J1939 Multiplexing PGN Timeout Error
286 SAE J1939 Multiplexing Configuration Error
287 SAE J1939 Multiplexing Throttle Error
295 Barometric Pressure Sensor Circuit - Data Incorrect
319 Real Time Clock Power Interrupt- Data Incorrect
322 Injector Solenoid Cylinder #1 Circuit - Current Below Normal, or Open Circuit
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
334 Engine Coolant Temperature Sensor Circuit - Data Incorrect
342 Electronic Calibration Code Incompatibility - Out of Calibration
351 Injector Power Supply - Bad Intelligent Device or Component
352 Sensor Supply Voltage #1 Circuit - Voltage Below Normal or Shorted Low
386 Sensor Supply Voltage #1 Circuit - Voltage Above Normal or Shorted High
415 Engine Oil Pressure Low - Critical
418 Water in Fuel Indicator High - Maintenance
422 Engine Coolant Level - Data Incorrect
425 Engine Oil Temperature - Data Incorrect
428 Water in Fuel Sensor Circuit - Voltage Above Normal or Shorted High
429 Water in Fuel Sensor Circuit - Voltage Below Normal or Shorted Low
433 Intake Manifold Pressure Sensor Circuit - Data Incorrect
435 Engine Oil Pressure Sensor Circuit - Data Incorrect
441 Battery Voltage Low - Warning
442 Battery Voltage High - Warning
449 Fuel Pressure High - Warning
451 Injector Metering Rail Pressure Sensor Circuit - Voltage Above Normal or Shorted High
452 Injector Metering Rail Pressure Sensor Circuit - Voltage Below Normal or Shorted Low
488 Intake Manifold Air Temperature High - Warning
553 Injector Metering Rail Pressure High - Warning
554 Fuel Pressure Sensor Error - Data Incorrect
559 Injector Metering Rail Pressure Low - Warning
595 Turbocharger Speed High - Warning
596 Electrical Charging System Voltage High - Warning
597 Electrical Charging System Voltage Low - Warning
598 Electrical Charging System Voltage Low - Critical
687 Turbocharger Speed Low - Warning
689 Primary Engine Speed Sensor Error - Data Incorrect
691 Turbocharger Compressor Inlet Temperature Sensor Circuit - Voltage Above Normal or Shorted High
692 Turbocharger Compressor Inlet Temperature Sensor Circuit - Voltage Below Normal or Shorted Low
697 ECM Internal Temperature Sensor Circuit - Voltage Above Normal or Shorted High
698 ECM Internal Temperature Sensor Circuit - Voltage Below Normal or Shorted Low
719 Extended Crankcase Blow-by Pressure Circuit - Voltage Above Normal or Shorted High
729 Extended Crankcase Blow-by Pressure Circuit - Voltage Below Normal or Shorted Low
731 Engine Speed/Position #2 Mechanical Misalignment - Mechanical SystemMalfunction
753 Engine Speed/Position #2 Camshaft Sync Error - Data Incorrect
778 Engine Speed Sensor (Camshaft) Error - Data Incorrect
951 Cylinder Power Imbalance Between Cylinders - Data Incorrect
1139 Injector Cylinder #1 - Mechanical System Malfunction
1911 Injector Metering Rail Pressure High - Critical
2111 Engine Coolant Temperature 2 Sensor Circuit - Voltage Above Normal, or Shorted High
2112 Engine Coolant Temperature 2 Senor Circuit - Voltage Below Normal, or Shorted Low
2113 Engine Coolant Temperature 2 High - Warning
2114 Engine Coolant Temperature 2 High - Critical
2115 Engine Coolant Pressure 2 Circuit - Voltage Above Normal, or Shorted High
2116 Engine Coolant Pressure 2 Circuit - Voltage Below Normal, or Shorted Low
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
2117 Engine Coolant Pressure 2 Low - Warning
2185 Sensor Supply Voltage #4 Circuit - Voltage Above Normal, or Shorted High
2215 Fuel Pump Delivery Pressure Low - Warning
2216 Fuel Pump Delivery Pressure High - Warning
2249 Injector Metering Rail Pressure Low - Critical
2265 Fuel Priming Pump Control Signal Circuit - Voltage Above Normal, or Shorted High
2266 Fuel Priming Pump Control Signal Circuit - Voltage Below Normal, or Shorted Low
2292 Fuel Inlet Meter Device - High - Warning
2293 Fuel Inlet Meter Device - Low - Warning
2311 Fueling Actuator #1 Circuit Error - Condition Exists
2321 Engine Speed/Position Sensor #1 - Data Incorrect
2322 Engine Speed/Position Sensor #2 - Data Incorrect
2345 Turbocharger Speed - Abnormal Rate of Change
2555 Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted High
2556 Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted Low
2963 EngineCoolant Temperature High - Alert
2964 Intake Manifold Air Temperature High - Alert
2973 Intake Manifold Pressure Sensor Circuit - Date Incorrect
STARTING THE MACHINE

NOTE: In order to allow the machine to start at a reduced load, a
valve, which is operated by a service air switch located on the
Ensure emergency stop button is reset. instrument panel, is incorporated in the regulation system. (The valve
automatically returns to the start position when the machine is
WARNING: Under no circumstances should volitile fluids such switched off and air pressure relieved from the system).
as ether be used for starting this machine.
• Allow the engine to reach its operating temperature - then press the
All normal starting functions are incorporated in the key operated pressure control button 15.
switch.
• At this point in the operation of the machine it is safe to apply full
load to the engine.
CAUTION: If the engine does not start, repeat the above procedure
after waiting for a minimum of one minute.
If the engine fails to start, refer to the MAINTENANCE section of this

manual, and to the ENGINE MANUFACTURER’S MANUAL..
STOPPING THE MACHINE
• Close the service valve.
• Allow the machine to run unloaded for a short period of time to

Turn the keyswitch to position 1; reduce the engine temperature.
- The auxillary start compressor will operate to close the inlet valve. • Turn the ON/OFF start switch to the 0 (off) position.
- The wedge controller will execute a lamp test.
NOTE: As soon as the engine stops, the automatic blowdown valve
- The low engine oil pressure and low battery lamps will flash indicating will relieve all pressure from the system,except for the discharge pipe
proper communication between wedge and engine ECM. / manifold area. This area should be depressurised by opening the
discharge valve, keeping clear of any airflow from it.
Inlet heater / Wait to start light
• Turn the key switch to on position 1 until the inlet heater warning If the automatic blowdown valve fails to operate, then pressure
light 13 extinguishes. must be relieved from the system by means of the service valve(s).
NOTE: Position 2 is not used WARNING: When relieving system pressure by means of the
service valve(s), a small amount of pressure will remain in the
system. No maintenance work should be carried out whilst this
• Turn the key switch to crank position 3 (engine start position).
situation exists. This pressure may be relieved by slowly oper-
• Release to on position 1 when the engine starts. The engine will ating the manual blowdown valve.
now be running at a reduced speed.
• During warm up, the engine will idle at 1500RPM. After warm up the CAUTION: Never allow the machine to stand idle with pressure in the
engine will idle at a lower speed. system.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
EMERGENCY STOPPING Refer to the wedge diagnostic display codes table for a listing of
shutdown conditions.
In the event that the unit has to be stopped in an emergency,
PRESS THE EMERGENCY STOP SWITCH ON THE FRONT OF THE CAUTION: To ensure an adequate flow of oil to the compressor at
MACHINE AND ENSURE THAT IT ENGAGES IN DEPRESSED low temperature, never allow the discharge pressure to fall below 3,5
POSITION. (IF FITTED) bar.
If the unit is not fitted with an emergency stop switch, rotate the start
switch to the (0) off position. DECOMMISSIONING
When the machine is to be permanently decommissioned or

RE-STARTING AFTER AN EMERGENCY
dismantled, it is important to ensure that all hazard risks are either
eliminated or notified to the recipient of the machine. In particular:-
Disengage emergency stop control from engaged (depressed)
position. (IF FITTED) • Do not destroy batteries or components containing asbestos
without containing the materials safely.
If the machine has been switched off because of a machine
malfunction, then identify and correct the fault before attempting to re- • Do not dispose of any pressure vessel that is not clearly marked
start. with its relevant data plate information or rendered unusable by drilling,
cutting etc.
If the machine has been switched off for reasons of safety, then
ensure that the machine can be operated safely before re-starting. • Do not allow lubricants or coolants to be released into land surfaces
or drains.
Refer to the PRIOR TO STARTING and STARTING THE UNIT
instructions earlier in this section before re-starting the machine. • Do not dispose of a complete machine without documentation
relating to instructions for its use.
MONITORING DURING OPERATION
Should any of the safety shut–down conditions occur, the unit will
stop.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
MAINTENANCE 23
MAINTENANCE
Initial 500 Daily Weekly Monthly 3 Monthly. 6 Monthly.
miles 500 hrs. 1000 hrs
/850 km
Compressor Oil Level C
Engine Oil Level C
*Radiator Coolant Level C
Gauges/Lamps C
*Air Cleaner Service Indicators C
Fuel Tank (Fill at end of day) C D
*Fuel/Water Separator Drain C
Oil Leaks C
Fuel Leaks C
Drain Water From Fuel Filters D
Coolant Leaks C
Radiator Filler Cap C
Air Cleaner Precleaner Dumps C
Fan/Alternator Belts C
Battery Connections/Electrolyte C
Tire Pressure and Surface C
*Wheel Lug Nuts C
Hoses (Oil, Air, Intake, etc.) C
Automatic Shutdown System C
Air Cleaner System C
Compressor Oil Cooler Exterior C
*Engine Rad/Oil Cooler Exterior C
Fasteners, Guards C
Air Cleaner Elements R/WI
*Disregard if not appropriate for this particular machine. D = Drain

(1) or 3000 miles/5000km whichever is the sooner G = Grease
(2) or as defined by local or national legislation R = Replace
C = Check (adjust, clean or replace as necessary) T = Test
CBT =check before towing. W I =or when indicated if earlier.
CR = Check and report Refer to specific sections of the operator’s manual for more
information.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
24 MAINTENANCE
Initial 500 Daily Monthly 3 Monthly. 6 Monthly. 12 Monthly. 12 Monthly.

miles 500 hrs. 1000 hrs 1500 hrs 2000 hrs
/850 km
*Fuel/Water Separator Element R
Compressor Oil Filter Element R
Compressor Oil R
Engine Oil Change R
Engine Oil Filter R
*Water Pump Grease. R
*Wheels (Bearings, Seals, etc.) C
*Engine Coolant C R
Fuel Filter Element R
*Injection Nozzle Check C
Shutdown Switch Settings T
Scavenger Orifice & Related Parts C
Oil Separator Element R
*Feed Pump Strainer Cleaning. C
*Valve Clearance Check C
Lights (running, brake, & turn) CBT
Pintle Eye Bolts CBT
*Brakes CBT C
*Brake linkage C
Emergency stop T
Fasteners C
Running gear linkage G
Safety valve C
Running gear bolts(1) C

information.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
MAINTENANCE 25
Initial 500 Daily Weekly 3 Monthly. 6 Monthly. 12 Monthly.

miles 500 hrs. 1000 hrs 2000 hrs
/850 km
Scavenge line C
Pressure system C
Engine breather element C
Separator tank (2) exterior CR
Lubricator (Fill) C
2 Yrs 4 Yrs 6 Yrs

Safety valve C
Hoses R
Separator tank (2) interior C

information.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
26 MAINTENANCE
ROUTINE MAINTENANCE • all guards and safety protection devices are refitted.
• all panels are replaced, canopy and doors closed.

This section refers to the various components which require
periodic maintenance and replacement. • hazardous materials are effectively contained and disposed of.
The SERVICE/MAINTENANCE CHART indicates the various
components’ descriptions and the intervals when maintenance has to PROTECTIVE SHUTDOWN SYSTEM
take place. Oil capacities, etc., can be found in the GENERAL
INFORMATION section of this manual. Refer to the Wedge diagnostic display codes table for a listing of
shutdown conditions.
For any specification or specific requirement on service or
preventative maintenance for the engine, refer to the Engine
Manufacturer’s Manual. Low engine oil pressure switch.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the At three month intervals, test the engine oil pressure switch circuit as
system and that the machine cannot be started accidentally. follows:
If the automatic blowdown fails to operate, then pressure must be • Start the machine.
gradually relieved by operating the manual blowdown valve. Suitable
personal protective equipment should be worn. NOTE: Do not press the load button.
Ensure that maintenance personnel are adequately trained,

• Disconnect the switch, the machine should shutdown.
competent and have read the Maintenance Manuals.
• Re-connect the switch.
Prior to attempting any maintenance work, ensure that:-
At twelve month intervals, test the low engine fuel level switch by
• all air pressure is fully discharged and isolated from the system. If
removing and operating the float manually.
the automatic blowdown valve is used for this purpose, then allow
enough time for it to complete the operation.
CAUTION: Never remove or replace switches when the machine is
running.
NOTE: Pressure will always remain in the part of the system between
the minimum pressure valve and the discharge valve after operation
of the auto blowdown valve. SCAVENGE LINE
THIS PRESSURE MUST BE RELIEVED BY CAREFULLY: The scavenge line runs from the combined orifice/drop tube in the
separator tank, to the orifice fitting located in the airend.
(a) DISCONNECTING ANY DOWNSTREAM EQUIPMENT.
Examine the orifice, check valve and hoses at every service or in
(b) OPENING THE DISCHARGE VALVE TO ATMOSPHERE. the event of oil carryover into the discharge air.
(USE HEARING PROTECTION IF NECESSARY). It is good preventative maintenance to check that the scavenge line
• the machine cannot be started accidentally or otherwise, by posting and tube are clear of any obstruction each time the compressor
warning signs and/or fitting appropriate anti-start devices. lubricant is changed as any blockage will result in oil carryover into the
discharge air.
• all residual electrical power sources (mains and battery) are
isolated.
COMPRESSOR OIL FILTER
Prior to opening or removing panels or covers to work inside a
machine, ensure that:- Refer to the MAINTENANCE CHART in this section for the
• anyone entering the machine is aware of the reduced level of recommended servicing intervals.
protection and the additional hazards, including hot surfaces and Removal
intermittently moving parts.
• the machine cannot be started accidentally or otherwise, by posting WARNING: Do not remove the filter(s) without first making sure
warning signs and/or fitting appropriate anti-start devices. that the machine is stopped and the system has been
completely relieved of all air pressure. (Refer to STOPPING THE
Prior to attempting any maintenance work on a running machine, UNIT in the OPERATING INSTRUCTIONS section of this manual).
ensure that:-
• the work carried out is limited to only those tasks which require the Clean the exterior of the filter housing and remove the spin-on
machine to run. element by turning it in a counter-clockwise direction.
• the work carried out with safety protection devices disabled or Inspection
removed is limited to only those tasks which require the machine to Examine the filter element.
be running with safety protection devices disabled or removed.
• all hazards present are known (e.g. pressurised components, CAUTION: If there is any indication of the formation of varnishes,
electrically live components, removed panels, covers and guards, shellacs or lacquers on the filter element, it is a warning that the
extreme temperatures, inflow and outflow of air, intermittently compressor lubricating and cooling oil has deteriorated and that it
moving parts, safety valve discharge etc.). should be changed immediately. Refer to LUBRICATION later in this
section.
• appropriate personal protective equipment is worn.
• loose clothing, jewelry, long hair etc. is made safe. Reassembly
• warning signs indicating that Maintenance Work is in Progress are Clean the filter gasket contact area and install the new element by
posted in a position that can be clearly seen. screwing in a clockwise direction until the gasket makes contact with
the filter housing. Tighten a further 1/2 to 3/4 of a revolution.
Upon completion of maintenance tasks and prior to returning the
machine into service, ensure that:-
• the machine is suitably tested.

9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
MAINTENANCE 27
CAUTION: Start the machine (refer to PRIOR TO STARTING and WARNING: Follow the instructions provided by the antifreeze
STARTING THE UNIT in the OPERATING INSTRUCTIONS section supplier when adding or draining the antifreeze solution. It is
of this manual) and check for leakage before the machine is put back advisable to wear personal protective equipment to prevent skin
into service. and eye contact with the antifreeze solution.
COMPRESSOR OIL SEPARATOR ELEMENT AIR FILTER ELEMENT
Refer to the SERVICE / MAINTENANCE CHART in this section for The air filter should be inspected regularly (refer to the SERVICE/
service intervals. MAINTENANCE CHART) and the element replaced when the
restriction indicator lamp illuminates. The dust collector box(es) should
Removal
be cleaned daily (more frequently in dusty operating conditions) and
not allowed to become more than half full.
WARNING: Do not remove the filter(s) without first making sure
that the machine is stopped and the system has been The safety element should be renewed every 3000 hours or every
completely relieved of all air pressure. (Refer to STOPPING THE third change of the main element, whichever comes first.
UNIT in the OPERATING INSTRUCTIONS section of this manual).
Removal
Disconnect all hoses and tubes from the separator tank cover plate. CAUTION: Never remove and replace element(s) when the machine
Remove the drop-tube from the separator tank cover plate and then
is running.
remove the cover plate. Remove the separator element.
Inspection Clean the exterior of the filter housing and remove the filter element
by releasing the nut.
Examine the filter element. Examine all hoses and tubes, and
replace if necessary. If the safety element is to be renewed, thoroughly clean the interior
of the filter housing prior to removing the safety element.
Reassembly
Inspection
Thoroughly clean the orifice/drop tube and filter gasket contact
area before reassembly. Install the new element. Check for cracks, holes or any other damage to the element by
holding it up to a light source, or by passing a lamp inside.
WARNING: Do not remove the staple from the anti-static gasket
on the separator element since it serves to ground any possible CAUTION: If inspection reveals damage to the main element, the
static build-up. Do not use gasket sealant since this will affect safety element must be replaced.
electrical conductance.
Check the seal at the end of the element and replace if any sign of
Reposition the cover plate, taking care not to damage the gasket, damage is evident.
and replace the cover plate screws tightening in a criss-cross pattern
to the recommended torque (refer to the TORQUE SETTING TABLE Reassembly
later in this section). Assemble the new element into the filter housing ensuring that the
seal seats properly.
Replace the drop-tube and reconnect all hoses and tubes to the
separator tank cover plate. Secure the element in the housing by hand tightening the nut.
Replace the compressor oil (refer to LUBRICATION later in this Assemble the dust collector box parts, ensuring that they are
section). correctly positioned.
CAUTION: Start the machine (refer to PRIOR TO STARTING and Before restarting the machine, check that all clamps are tight.
STARTING THE UNIT in the OPERATING INSTRUCTIONS section
of this manual) and check for leakage before the machine is put back NOTE: In the event that a new filter element is not readily available,
into service. the element can be re-used after cleaning. In this case the following
procedure must be carried out:
COMPRESSOR OIL COOLER AND ENGINE RADIATOR AIR Clean the element by directing a jet of clean, dry compressed air,
CHARGE COOLER no more than 5 bar, at an angle of 45 degrees to the outside of the
element. Carefully blow any dust from each fold of the element.
When grease, oil and dirt accumulate on the exterior surfaces of the
oil cooler and radiator, the efficiency is impaired. It is recommended Compressed air cleaning is only recommended when a new
that each month the oil cooler and radiator be cleaned by directing a jet element is not available.
of compressed air, (carrying if possible a non-flammable cleaning
solvent) over the exterior core of the cooler/radiator. This should CAUTION: Safety elements must not be cleaned and re-used.
remove any accumulation of oil, grease and dirt from the exterior core
of the cooler so that the entire cooling area can radiate the heat of the
VENTILATION
lubricating and cooling oil/water into the air stream.
WARNING: Hot engine coolant and steam can cause injury. Always check that the air inlets and outlets are clear of debris etc.
When adding coolant or antifreeze solution to the engine
radiator, stop the engine at least one minute prior to releasing CAUTION: NEVER clean by blowing air inwards.
the radiator filler cap. Using a cloth to protect the hand, slowly
release the filler cap, absorbing any released fluid with the cloth.
Do not remove the filler cap until all excess fluid is released and
the engine cooling system fully depressurised.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
28 MAINTENANCE
COOLING FAN DRIVE PRESSURE SYSTEM
Periodically check that the fan mounting bolt in the fan hub has not At 3 month intervals it is necessary to inspect the external surfaces
loosened. If, for any reason, it becomes necessary to remove the fan of the system (from the airend through to the discharge valve(s))
or re-tighten the fan mounting bolt, apply a good grade of commercially including hoses, tubes, tube fittings and the separator tank, for visible
available thread locking compound to the bolt threads and tighten to signs of impact damage, excessive corrosion, abrasion, tightness and
the torque value shown in the TORQUE SETTING TABLE later in this chafing. Any suspect parts should be replaced before the machine is
section. put back into service.
The fan belt(s) should be checked regularly for wear and correct
tensioning. TYRES/TYRE PRESSURE
See the GENERAL INFORMATION section of this manual.

FUEL SYSTEM
The fuel tank should be filled daily or every eight hours. To minimise RUNNING GEAR/WHEELS
condensation in the fuel tank(s), it is advisable to top up after the
machine is shut down or at the end of each working day. At six month Check the wheel nut torque 20 miles (30 kilometres) after refitting
intervals drain any sediment or condensate that may have the wheels. Refer to the TORQUE SETTING TABLE later in this
accumulated in the tank(s). section.
The bolts securing the running gear to the chassis should be

FUEL FILTER WATER SEPARATOR checked periodically for tightness (refer to the SERVICE/
MAINTENANCE CHART for frequency) and re-tightened where
The fuel filter water separator contains a filter element which should necessary. Refer to the TORQUE SETTING TABLE later in this
be replaced at regular intervals (see the SERVICE/MAINTENANCE section.
CHART).
LUBRICATION
CHARGE COOLER PIPEWORK:-
The engine is initially supplied with engine oil sufficient for a nominal
Inspect all hoses and clips on the charge cooler pipe work. period of operation (for more information, consult The Engine
Manufacturer's Manual).
Engine damage will occur if the charge cooling system leaks.
CAUTION: Always check the oil levels before a new machine is put
HOSES into service.
All components of the engine cooling air intake system should be If, for any reason, the unit has been drained, it must be re-filled with
checked periodically to keep the engine at peak efficiency. new oil before it is put into operation.
At the recommended intervals, (see the SERVICE/MAINTENANCE

CHART), inspect all of the intake lines to the air filter, and all flexible ENGINE LUBRICATING OIL
hoses used for air lines, oil lines and fuel lines.
The engine oil should be changed at the engine manufacturer's
Periodically inspect all pipework for cracks, leaks, etc. and replace
recommended intervals. Refer to the SERVICE / MAINTENANCE
immediately if damaged.
CHART.
ELECTRICAL SYSTEM
ENGINE LUBRICATING OIL SPECIFICATION
WARNING: Always disconnect the battery cables before Refer to the Engine Manufacturer's Manual or Lubrication
performing any maintenance or service. Specification list.
Inspect the safety shutdown system switches and the instrument

ENGINE OIL FILTER ELEMENT
panel relay contacts for evidence of arcing and pitting. Clean where
necessary.
The engine oil filter element should be changed at the engine
Check the mechanical action of the components. manufacturer's recommended intervals. Refer to the SERVICE /
MAINTENANCE CHART..
Check the security of electrical terminals on the switches and relays
i.e. nuts or screws loose, which may cause local hot spot oxidation.
COMPRESSOR LUBRICATING OIL
Inspect the components and wiring for signs of overheating i.e.
discolouration, charring of cables, deformation of parts, acrid smells
Refer to the SERVICE/MAINTENANCE CHART in this section for
and blistered paint.
service intervals.
BATTERY NOTE: If the machine has been operating under adverse conditions,
or has suffered long shutdown periods, then more frequent service
Keep the battery terminals and cable clamps clean and lightly intervals will be required.
coated with petroleum jelly to prevent corrosion.
The retaining clamp should be kept tight enough to prevent the WARNING: DO NOT, under any circumstances, remove any
battery from moving. drain plugs or the oil filler plug from the compressor lubricating
and cooling system 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).
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
MAINTENANCE 29
Completely drain the receiver/separator system including the piping
CAUTION: Some oil mixtures are incompatible and result in the
and oil cooler by removing the drain plug(s) and collecting the used oil
formation of varnishes, shellacs or lacquers which may be insoluble.
in a suitable container.
Replace the drain plug(s) ensuring that each one is secure.

NOTE: Always specify PRO-TEC oil for use at all ambient
temperatures above -23°C.
NOTE: If the oil is drained immediately after the machine has been
running, then most of the sediment will be in suspension and will
therefore drain more readily. RUNNING GEAR WHEEL BEARINGS
Wheel bearings should be packed with grease every 6 months. The

type of grease used should conform to specification MIL-G-10924.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
30 MAINTENANCE
9/230 9/230HA 9/270 9/270HA 9/300 9/300HA 10/300HA 12/235 12/235HA
KEY
A Adjusting screw E Orifice I Separator tank

B Mini compressor F Regulation pressure transducer J Manual blowdown valve
C Auto blowdown valve G Start/Run solenoid K Unloader
D Unloader solenoid H Panel pressure gauge
SPEED AND PRESSURE REGULATION ADJUSTMENT Adjust the service valve on the outside of the machine to maintain
normal operating discharge pressure (refer to GENERAL
Normally, regulation requires no adjusting, but if correct adjustment INFORMATION) and full speed position. If the tachometer moves away
is lost, proceed as follows: from the full speed position before normal operating discharge
pressure is attained, then turn the adjusting screw 'A' clockwise to
Refer to the diagram above. increase the pressure. Optimum adjustment is achieved when the
A: Adjusting screw throttle just moves from its full speed position and the pressure
increases slightly.
Start the machine (Refer to STARTING INSTRUCTIONS in the
OPERATING INSTRUCTIONS section of this manual). Close the service valve. The engine will slow to idle speed.
CAUTION: Never allow the idle pressure to exceed maximum

allowable pressure (refer to GENERAL INFORMATION).
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
MAINTENANCE 31
17/235 21/215
KEY
1 Air cylinder 7 Regulation pressure transducer 13 Pressure transducer

2 Butterfly valve 8 Start/Run solenoid 14 Minimum pressure valve
3 Mini compressor 9 Pressure regulator 15 Separator tank
4 Unloader Solenoid 10 Panel pressure guage 16 Auto blowdown valve
5 Relief valve 11 Manual blowdown valve 17 HR2 Airend
6 Orifice 12 Temperature sensor 18 Air inlet
SPEED AND PRESSURE REGULATION ADJUSTMENT Allow the cylinder to return to its extended position and reconnect
17/235 21/215 the ballast spring 'A'.
Normally, regulation requires no adjusting, but if correct adjustment IMPORTANT: Ensure all components are aligned and move freely.
is lost, proceed as follows:
Start engine: Note receiver pressure. Warm up pressure should be
Refer to the diagram above.
3,5-5,0 bar (50-70 p.s.i.).
With the unit stopped, disconnect ballast spring 'A' from the
To increase the warm up pressure, turn the air cylinder rod in an
butterfly lever. Loosen the two screws securing bracket 'C' to main
anti-clockwise direction to open the butterfly valve.
bracket 'J'.
To reduce warm up pressure, turn air cylinder rod in clockwise
Loosen screw 'D' and rotate the butterfly valve pivot shaft 'K' fully
direction to close butterfly valve.
clockwise until the valve is closed. Position lever 'L' approximately 10°
after vertical and tighten screw 'D'. When the engine is warmed up, press the service air switch on the
control panel to commence normal regulation.
Keep the butterfly lever in the closed position and with the the air
cylinder fully contracted tighten the screws holding bracket 'C' to the Set pressure by adjusting the screw 'E' on the pressure regulator
main bracket 'J'. 'F'. Turn the screw clockwise to increase pressure and anticlocwise to
reduce pressure.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
32 MAINTENANCE
TORQUE VALUES
TABLE 1 INCH FASTENERS

NOMINAL DESIGN TORQUE
8AE J249 8AE J249

GRADE 5 GRADE 8
(HEAD MARKING) (HEAD MARKING)
TYPICAL RECTANGULAR TORQUE PATTERN
CAPSCREW
OR NUT
THREAD SIZE
AND PITCH
TYPICAL SQUARE TORQUE PATTERN
(Nm.) (FT-LBF) (Nm.) (FT-LBF)
1/4 - 20 11 8 16 12
5/16 - 18 24 17 33 25
3/8 - 16 42 31 59 44
7/16 - 14 67 49 95 70
1/2 - 13 102 75 144 106
9/16 - 12 148 109 208 154 TYPICAL CIRCULAR TORQUE PATTERN

5/8 - 11 203 150 287 212
3/4 - 10 361 266 509 376
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
MAINTENANCE 33
TABLE 2 METRIC FASTENERS

NOMINAL DESIGN TORQUE
PROPERTY PROPERTY PROPERTY

GRADE 8.8 GRADE 10.9 GRADE 12.9
(HEAD MARKING) (HEAD MARKING) (HEAD MARKING)
TYPICAL RECTANGULAR TORQUE
PATTERN
CAPSCREW
OR NUT
THREAD SIZE
AND PITCH
TYPICAL SQUARE TORQUE PATTERN
(Nm.) (FT-LBF) (Nm.) (FT-LBF) (Nm.) (FT-LBF)
M6 X 1.0 11 8 15 11 18 13
M8 X 1.25 26 19 36 27 43 31
M10 X 1.5 52 38 72 53 84 62
M12 X 1.75 91 67 126 93 147 109
M14 X 2 145 107 200 148 234 173
M16 X 2 226 166 313 231 365 270

TYPICAL CIRCULAR TORQUE PATTERN
M20 X 2.5 441 325 610 450 713 526
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
34 MAINTENANCE
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 cunsumption) may be greater

with the use of alternative fluids.
Design Operating Ambient Specification

Pressure Temperature
100 psi to 300 psi -10°F to 125°F Preferred:
(-23°C to 52°C) PRO-TEC
Alternate:
ISO Viscosity Grade
46 with rust and consult
consult factory
factory
oxidisation inhibitors,
designed for air
compressor service.
350 psi -10°F to 125°F Preferred:
(-23°C to 52°C) XHP 605
Alternate:
XHP 405 Preferred Doosan Fluids - 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 oxidisation representative.
inhibitors, designed
for air compressor
service.
65°F to 125°F Preferred:
(18°C to 52°C) XHP 605
XHP 1001
Doosan Preferred Fluids 19.0 Litre 208.2 Litre 836 Litre

PRO-TEC 89292973 89292981 22082598
XHP 605 22252076 22252050 22252068
XHP 1001 35612738 35300516 -
XHP 405 22252126 22252100 22252118
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
MACHINE SYSTEMS 35
KEY
BAT Battery RT1 Thermistor, seperator tank temperature -30 - 255°F

CO RS232C comms RT2 Thermistor, Thermistor, airend discharge temperature -30 -
255°F
ECON Engine controller
S7 Emergency stop
ES Engine speed
SC Start compressor
FT Frequency throttle.
Range = 150Hz(1200 RPM) to 375Hz(1800 RPM) at 24VDC SI Switch inputs
G2 Fly wheel SS Starter solenoid
POUT1 Engine key switch SW1 IQ filter restriction
POUT2 Solenoid, start/run -L1 SW2 Alert, low fuel
POUT3 Low fuel warning beacon (option) SW3 Low fuel shutdown
POUT4 Spare SW4 Switch, service air
POUT5 Start relay SW5 Air filter rest (option)
POUT6 Start compressor SW6 Switch, airend oil pressure (12PSI N.O.)
POUT7 Hour meter SW7 ESTOP Sense
POUT8 Solenoid, unloader -L2 SW8 Switch, start
PT1 Pressure trancducer, separator tank. SWB Switch batery disconnect
0-225 PSIG - 9/235, 9/270, 9/300, 10/300, 12/235. TE Transducer exitation
0-500 PSIG - 21/215, 17/235.
WCON Wedge controller
PT2 Pressure trancducer, regulation system 0-100 PSIG
RS Relay-spst
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
36 MACHINE SYSTEMS
WEDGE TO ENGINE INTERFACE
CAN HI
CAN LO
CAN SHLD
ENGINE
ECM WEDGE
CONTROLLER
FREQ THT+
RANGE = 150Hz (1200rpm) to 375Hz (1800rpm) at 24 VDC
KEYSWITCH
HARNESS SYSTEM SCHEMATIC
CONTROL PANEL
SWITCHES 24VDC HEATERS SOLENOID VALVES
CONTROLL PANEL HARNESS
SPEED SENSOR
ENGINE ECM
HOURMETER DIAGNOSTIC FUEL LEVEL SWITCH
WEDGE INTERFACE
CONTROLLER
PRESSURE
TRANSDUCER
GUAGES ESTOP SWITCHES TEMPERATURE

SENSOR
BATTERY STARTING AND

CHARGING SYSTEM
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
MACHINE SYSTEMS 37
EMU 6IRQ9AE LOW PRESSURE ELECTRICAL PARTS 9/235, 12/235, 9/270, 9/300, 10/300
PART NUMBERS DESCRIPTION QTY PER

MACHINE
22162572 IQ HARNESS OPTION 1
36899599 IQ FILTER SWITCH 1
54474572 COOLANT LEVEL SWITCH 1
36896975 SW MASTER DISCONNECT 1
36920825 0-100 PRESSURE TRANS 1
36892362 24V SEALED RELAY 2
36785319 MAG SPEED SENSOR 1
36898922 THERMISTOR PROBE 1
36840481 SOLENOID VALVE L1, L2 2
36847838 AIR FILTER RESTRICTION INDICATOR SWITCH 2
36870608 ENGIINE OIL PRESSURE SENDER 1
36841138 COMPRESSOR AND ENGIINE TEMPERATURE SENDER 2
36757581 COMPRESSOR OIL PRESSURE SWITCH 1
36850691 COMPRESSOR MOTOR 1
35577873 RELAY, MAGNETIC 24V K1 1
36841526 CONTROL HEATER 2
26854677 REGULATOR HEATER 1
54658323 NEGATIVE BATTERY CABLE 1
54658331 POSITIVE BATTERY CABLE 1
54511282 POSITIVE JUMPER BATTERY CABLE 1
35128982 BATTERY JUMPER 1
22132153 FRAME GROUND STRAP 1
22132153 ENGINE GROUND STRAP 1
22094759 FUEL LEVEL SENDER 1
22173579 WEDGE CONTROLLER 1
22781249 W1 CHASSIS HARNESS 1
22101968 INLET HEATER, 120 AMPS 1
36853521 INLET HEATER RELAY 1
89303127 EMERGENCY STOP OPERATOR 1
89303135 NC E-STOP CONTACT BLOCK 2
22817829 WW CONTROL PANEL HARNESS 1
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
38 MACHINE SYSTEMS
EMU 6IRQ9AE HIGH PRESSURE ELECTRICAL PARTS 21/215, 17/235
PART NUMBERS DESCRIPTION QTY PER

MACHINE
22162572 IQ HARNESS OPTION 1
54474572 COOLANT LEVEL SWITCH 1
36896975 SW MASTER DISCONNECT 1
36892362 24V SEALED RELAY 2
36785319 MAG SPEED SENSOR 1
36898922 THERMISTOR PROBE 1
36842300 START/RUN SOLENOID VALVE L1 1
36842318 COMPRESSOR SOLENOID VALVE 1
36847838 AIR FILTER RESTRICTION INDICATOR SWITCH 2
36870608 ENGIINE OIL PRESSURE SENDER 1
36841138 COMPRESSOR AND ENGIINE TEMPERATURE SENDER 2
36757581 COMPRESSOR OIL PRESSURE SWITCH 1
36850691 COMPRESSOR MOTOR 1
35577873 RELAY, MAGNETIC 24V K1 1
36841526 CONTROL HEATER 2
54658323 NEGATIVE BATTERY CABLE 1
54658331 POSITIVE BATTERY CABLE 1
54511282 POSITIVE JUMPER BATTERY CABLE 1
35128982 BATTERY JUMPER 1
22132153 FRAME GROUND STRAP 1
22132153 ENGINE GROUND STRAP 1
22094759 FUEL LEVEL SENDER 1
22173579 WEDGE CONTROLLER 1
22781249 W1 CHASSIS HARNESS 1
22101968 INLET HEATER, 120 AMPS 1
36853521 INLET HEATER RELAY 1
89303127 EMERGENCY STOP OPERATOR 1
89303135 NC E-STOP CONTACT BLOCK 2
22817829 WW CONTROL PANEL HARNESS 1
36842318 SOLENOID, UNLOADER L2 1
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
FAULT FINDING 39
FAULT CAUSE REMEDY

No reaction from Emergency stop actuated. Reset emergency stop button.
instrument panel when
key turned to (I) Batteries not connected. Connect batteries.
position.
Fuse at starter motor ‘blown’. Replace fuse.
Engine fails to start. Low battery charge. Check the fan belt tension, battery and cable connections.
Bad earth connection. Check the earth cables, clean as required.
Loose connection. Locate and make the connection good.
Fuel starvation. Check the fuel level and fuel system components. Replace the fuel filter if
necessary.
Relay failed. Replace the relay.
Faulty stop solenoid Check the stop solenoid.
Engine stops while in Low fuel level. Fill fuel tank and bleed air from fuel system if necessary. (Refer to
service or is reluctant MAINTENANCE SECTION).
to start.
Safety shut–down system in Check the safety shut–down switches.
operation.
Engine starts but stalls Electrical fault Test the electrical circuits.
when the switch
returns to position I. Low engine oil pressure. Check the oil level and the oil filter(s).
Low water level Check if the low water lamp is extinguished.
Faulty relay Check the relays.
Faulty key-switch Check the key-switch.
Engine starts but will Electrical fault. Test the electrical circuits.
not run or engine shuts
down prematurely. Low engine oil pressure. Check the oil level and oil filter(s).
Safety shut–down system in Check the safety shut–down switches.

operation.
Fuel starvation. Check the fuel level and fuel system components. Replace the fuel filter if
necessary.
Switch failure. Test the switches.
High compressor oil temperature. Check the compressor oil level and oil cooler. Check the fan drive.
Water present in fuel system. Check the water separator and clean if required.
Faulty relay. Check the relay in the holder and replace if necessary.
Engine Overheats. Low water level Check the level and replenish if necessary.
Blocked radiator. Stop the machine and clean the cooling fins with compressed air or steam.
Use reduced pressure for cleaning the fins.
Reduced cooling air from fan. Check the fan and the drive belts. Check for any obstruction inside the cowl.
Faulty thermostat Check the thermostat and replace if necessary.
Engine speed too low. Blocked fuel filter. Check and replace if necessary.
Blocked air filter. Check and replace the element if necessary.
Faulty regulator valve. Check the regulation system.
Premature unloading. Check the regulation and the operation of the air cylinder.
Excessive vibration. Engine speed too low. See ”Engine speed too low”
Leaking oil seal Improperly fitted oil seal. Replace the oil seal
Refer also to the Engine Manufacturer’s Manual.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
40 FAULT FINDING
FAULT CAUSE REMEDY

Air discharge capacity Engine speed too low. Check the air cylinder and air filter(s).
too low.
Blocked air cleaner. Check the restriction indicators and replace the element(s) if necessary.
High pressure air escaping. Check for leaks.
Incorrectly set regulation system. Reset the regulation system. Refer to SPEED AND PRESSURE
REGULATION ADJUSTMENT in the MAINTENANCE section of this
manual.
Compressor overheats. Low oil level. Top up the oil level and check for leaks.
Dirty or blocked oil cooler. Clean the oil cooler fins.
Incorrect grade of oil. Use Doosan recommended oil.
Defective by–pass valve. Check the operation of the element and replace if necessary.
Recirculation of cooling air. Move the machine to avoid recirculation.
Reduced cooling air from fan. Check the fan and the drive belts. Check for any obstruction inside the fan
cowl.
Excessive oil present Blocked scavenge line. Check the scavenge line, drop tube and orifice. Clean and replace.
in the discharge air.
Perforated separator element. Replace the separator element.
Pressure in the system is too low. Check the minimum pressure valve or sonic orifice.
Safety valve operates. Operating pressure too high. Check the setting and operation of the regulator valve piping.
Incorrect setting of the regulator. Adjust the regulator.
Faulty regulator. Replace the regulator.
Inlet valve set incorrectly. Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in the
MAINTENANCE section of this manual.
Loose pipe/hose connections. Check all pipe/hose connections.
Faulty safety valve. Check the relieving pressure. Replace the safety valve if faulty. DO NOT
ATTEMPT A REPAIR.
Oil is forced back into Incorrect stopping procedure used Always employ the correct stopping procedure. Close the discharge valve
the air filter. and allow the machine to run on idle before stopping.
Faulty inlet valve. Check for free operation of the inlet valve(s).
Machine goes to full Inlet valve set incorrectly. (17/235, Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in the
pressure when started. 21/215) MAINTENANCE section of this manual. (17/235, 21/215)
Faulty load valve. Replace the valve.
Machine fails to load Faulty load solenoid. Replace the valve.

when the load button is
pressed.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
OPTIONS 41
IQ SYSTEM OPERATING INSTRUCTIONS - 1
KEY
1 Three way valve 5 Filters

2 Ball valve 11/4” 6 Aftercooler
3 Ball valve 2” 7 Minimum pressure valve
4 Safety valve 8 Separator tank
IQ SYSTEM IQ SYSTEM OPERATING INSTRUCTIONS - 2
The IQ System is a complete, self-contained system which provides The compressed air exits the separator tank through the top cover
cooler, cleaner air than from a standard portable compressor. The piping, and can then travel along one of two paths, selectable via
system utilizes an integral aftercooler, high-efficiency filtration, and a manual valving.
patented condensate disposal system to provide the cool, clean air.
One path allows Standard Operation, which bypasses the IQ
The condensate disposal system injects all liquid condensed from the
System, and delivers air quality equivalent to a standard oil-flooded
moisture separator and filters into the engine exhaust system where it
is vaporized by heat. This eliminates the need for collecting the portable compressor. If the IQ System is enabled by proper setting of
the selector valve, the compressed air first enters the aftercooler.
condensate, and the added cost of disposing of the condensate, which
is often regulated by local, state, and/or federal regulations. The aftercooler is cooled by the incoming compressor package air,
which is controlled by movable louvers mounted on the aftercooler (if
When equipped with the low ambient feature, the IQ System
equipped with low ambient option). At most conditions, the louvers are
automatically adjusts movable louvers to control airflow through the
fully open, and maximum aftercooling is available. The compressed air
aftercooler, ensuring that the compressed air temperature always
and condensate (water with a small amount of compressor lubricant)
remains above freezing temperatures (typically 45°F) at any ambient
exits the aftercooler and enters the moisture separator, where most of
temperature down to -20°F. This prevents the need for 120V AC heat
the condensate is removed. The compressed air then flows through
tracing systems, or any manual adjustment to prevent freezing of the
two stages of filtration, where the aerosol water and oil is removed
compressed air system. All drain points for the condensate handling
down to approximately 0.01 ppm, and all particulates are removed
system are heated with 24VDC heaters, which are integral to the
down to 0.01 micron.
compressor heater system.
At the bottom of the moisture separator and both filters are strainers
Standard Non-Louvered configuration not to be operated below
and constant-bleed orifices, which are sized to allow the maximum flow
freezing.
of condensate while minimizing compressed air loss.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
42 OPTIONS
The condensate lines are then piped together, and the condensate Yearly Maintenance:
is injected at a single point into the engine exhaust piping. The
The normal maintenance interval on the primary and secondary IQ
compressed air then travels through the minimum pressure valve, and
System filters is one year, or earlier if pressure drop becomes
out through the service air valve. The air pressure gauge on the
excessive. Restriction indicators for the filters are mounted on the filter
instrument panel indicates the pressure inside the separator tank. A
support inside the front door, and will shut down the compressor if
service air pressure gauge is located inside the front door of the
restriction exceeds recommended values.
compressor on the filter support.
Filter Replacement
If the IQ System is bypassed (Standard Operation selected), the
delivered air pressure will be approximately equal to the separator tank • With engine stopped, ensure pressure is relieved from air system.
pressure. If the IQ System operation is selected, the delivered air
pressure will be slightly less, depending on the restriction of the filters. • Remove all wires and hoses connected to drains on bottom of each
filter housing. Inspect fittings and hoses for any blockage. Clean if
Low Ambient Option Operation necessary.
When the ambient temperature falls to the point that the aftercooler • Using a chain wrench or similar tool, loosen the housing. The
outlet temperature is approaching 45°F, the Temperature Control Unit housing should be removed by hand after loosening, taking care to
(TCU), mounted on the rear of the control panel, will automatically prevent the housing from falling to the floor panel.
adjust the louvers to control the cooling airflow through the aftercooler.
• Lower the housing to floor panel and lean it against the airend.
In the event that the unit is operating under abnormal conditions Remove and replace the filter element, being careful not to damage
(i.e., an enclosure door open) which would cause excessive cooling of outer wrap.
the aftercooler, a temperature sensor in the aftercooler outlet header
will signal the TCU to further close the louvers if the compressed air Verify the part number of new element vs. old element, as the two
temperature falls to approximately 36°F or lower. IQ filters are of different media.
There are no user selectable or serviceable components in the

TCU. Contact Doosan Service if any abnormal operation of the freeze OPTIONS - IQ SYSTEM
protection control system occurs.
MAINTENANCE
SAFETY
Daily Maintenance:
Verify, during full-load (maximum compressed air delivery) that the CAUTION: The compressor regulation system is adjusted to
IQ System filter restriction indicators do not show excessive restriction. maintain regulated pressure at the separator tank. DO NOT adjust
Restriction indicators for the filters are mounted inside the control regulation to provide full regulation pressure at the service valve
panel, and will shut down the compressor if restriction exceeds when the IQ System is enabled. This will result inC operation at
recommended values. excessive horsepower levels, causing overheating, reduced engine
life, and reduced airend life.
Weekly Maintenance:
CAUTION: Excessively restricted filter elements may cause an
• Remove Y-strainer screens at the bottom of the moisture separator increase in the amount of aerosol water and oil carryover, which
and both filters and clean out any residue. could result in damage to downstream equipment. Normal service
intervals should not be exceeded.
• Verify that the orifices below the Y-strainers are not clogged.
CAUTION: Blockage of the condensate will result in flooding of the
• Verify that the piping from the orifice purge points to the exhaust vessels. If flooding occurs, excessive condensate may enter the air
system is not clogged. stream and could result in damage to downstream equipment.
NOTICE:
Do not operate at temperatures less that 2°C (35°F) unless equipped
with low ambient IQ option.
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ENGINE INSTRUCTION MANUAL 43
CONTENTS
44 FOREWORD
45 EXTERNAL VIEW
46 GENERAL INFORMATION
Main data and specifications
Engine identification
After sales support
47 FUEL, LUBRICANT, AND COOLANT

Fuel
Lubricant
Coolant
49 OPERATION
Check before operation
Check and operation after start- up
Operation and care of a new engine
52 PERIODICAL INSPECTION AND

MAINTENANCE
Lubricating system
Cooling system
Fuel system
Air intake system
Routine maintenance
56 COLD WEATHER OPERATION
57 MAINTENANCE SCHEDULE
59 TROUBLESHOOTING
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44 FOREWORD
In order to get the fullest use and benefit from your engine, it is important that you operate and maintain it correctly. This Manual is designed to help
you do this.
Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of trouble-free and
economical engine operation.
Should your engine require servicing, please contact your nearest branch or distributor.
All information, illustrations, and specifications contained in this Manual are based on the latest product information available at the time of
publication.
The company reserves the right to make changes in this Manual at any time without prior notice.
The pictures contained within are for guidance only and might not reflect
the physical characteristics of each individual engine covered.
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EXTERNAL VIEWS 45
DIESEL ENGINE Engine External View
Fig 1 (Left-hand Side) Fig 2 (Right-hand Side)
(1) Engine air inlet. (19) High-pressure fuel lines.
(2) Intake manifold pressure sensor. (20) injection pump.
(3) Intake manifold temperature sensor. (21) Intake air heater.
(4) M10 (STOR) fuel pressure after-lift pump. (22) 1/2-inch (NPTF) coolant taps.
(5) M10 (STOR) fuel pressure before-lift pump. (23) Turbocharger wastegate actuator.
3
(6) Magnetic pickup location /4 -16UNF. (24) Oil filler cap.
(7) Fuel return connection. (25) Coolant outlet.
(8) Fuel inlet connection. (26) Front engine lifting bracket.
(9) Fuel lift pump. (27) Coolant temperature sensor.
(10) Starter mounting flange. (28) Coolant heater port.
(11) Oil pressure sensor. (29) Coolant inlet.
(12) Fuel filter. (30) Lubricating oil cooler.
(13) Electronic control module (ECM). (31) Oil drain plug.
(14) Dipstick location. (32) Lubricating oil filter.
(15) M10 (STOR) oil pressure port. (33) Dipstick location.
(16) Engine position sensor (EPS) - (inboard). (34) Coolant filter.
(17) Engine speed sensor (ESS) - (outboard). (35) Injector drain fuel outlet connection.
(18) Engine dataplate.
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46 GENERAL INFORMATION
EPA CERTIFIED ENGINE DATA and SPECIFICATIONS
Engine model name QSL
Engine type Water-Cooled, four cycle, in-line overhead valve type

Combustion type Direct injection
No. of cylinders - bore x stroke. mm (in) 6-114 x 144,5 (4.49 x 5.69)
Engine displacement L (cid) 8,9 (543)
Compression ratio 16,6:1
Firing order 1-5-3-6-2-4
Exhaust emission control system Engine modification
Governor Electronic type
Specified fuel Diesel fuel (ASTM D975 No. 2-D)
Starter (V-kW) 24 - 2.4
Alternator (V-A) 24 - 55
Specified engine oil (API grade) 15W-40 - CI-4
Coolant volume (Engine only) L (qts) 11,1 (11.7)
Engine dry weight kg (lb) 706 (1556)
Overall length mm (in) TBA
Engine dimensions Overall width mm (in) TBA
Overall height mm (in) TBA
Valve clearance (cold) mm (in) Intake 0,305 (.012) Exhaust 0,559 (.022)
ENGINE IDENTIFICATION
Serial No Location
The engine serial number is stamped on a plate.
Fig. 4
Confirmation of Engine Number

It is advisable to quote the engine serial number together with the
machine serial number, as it is required when you contact the Doosan
branch or distributor for repair, service or parts ordering.
CAUTION: Conduct confirmation of engine serial number with the
engine stopped. To avoid being injured, do not check it, while the
engine is still hot.
Fig. 3
ENGINE AFTER SERVICE
A. Engine serial number Please feel free to contact your dealer for periodical inspection and
maintenance.
Electronic control module is located on the mid-left hand side of
engine. Doosan Genuine Parts
Note: Serial number (SN) and (ECM CODE) Genuine Doosan parts are identical with those used in the engine
production, and accordingly, they are warranted by Doosan.
Genuine Doosan parts are supplied by your Doosan branch or
distributor.
Please ensure that only genuine Doosan parts, lubricants and fluids
are used for service and/or repair.
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FUEL, LUBRICANTS, AND COOLANT 47
FUEL NOTICE: Do not use home heating oil or gasoline in your diesel
Fuel Selection engine; either may cause engine damage.
The following properties are required of the diesel fuel.
Handling of the Fuel.
Must be free from minute dust particles.
Any fuel containing dust particles or water might cause engine failure.
Must have adequate viscosity.
Therefore, the following must be observed.
Must have high cetane value.
Take care to protect the fuel from ingress of dust particles or water
Must have high fluidity at low temperature. when filling the fuel tank.
Must have low sulphur content. If refuelling is done from an oil drum directly, ensure that it has been
kept stationary to allow any dust, sediment or water to settle at the
Must have little residual carbon. bottom. Do not draw fuel direct from the bottom of the drum to prevent
It is strongly advisable to use ASTM D975 No. 2D (the general pick-up of any settled foreign material.
automotive diesel engine purpose fuel oil) or equivalent which fully Always fully fill the fuel tank. Drain the sedimented particles in the fuel
meets the above requirements. tank frequently.
Applicable Standard Recommendation Water in Fuel
JIS (Japanese Industrial Standard) NO. 2 During refuelling, it is possible for water (and other contaminants) to be
pumped into your fuel tank along with the diesel fuel. This can happen
DIN (DEUTSCHE INDUSTRIE NORMEN) DIN 51601
if a fuel provider does not regularly inspect and clean its fuel tanks, or
SAE (Society of Automotive Engineers) NO. 2-D receives contaminated fuel from its supplier(s). To protect your engine
Based on SAE-J-313C from contaminated fuel, there is a fuel filter system on the engine which
BS (BRITISH STANDARD) Based on BS/ Class A-1 allows you to drain excess water.
2869-1970
CAUTION: The water/diesel fuel mixture is flammable, and could be
EURONORM EN590 hot. To avoid personal injury and/or property damage, do not touch
the fuel coming from the drain valve, and do not expose the fuel to
FUEL REQUIREMENTS open flames or sparks.
Notice: the fuel injection pump, injector or other parts of the fuel system
and engine can be damaged if you use any fuel or fuel additive other Be sure you do not overfill the fuel tank. Heat (such as from the engine)
than those specifically recommended by Doosan. can cause the fuel to expand. If the tank is too full, fuel could be forced
out. This could lead to a fire and the risk of personal injury and/or
NOTE: If any fuel other than the one specified is used, engine oper- equipment damage.
ation will be impaired. Engine failure or malfunction resulting from
use of such improper fuel will not be warranted by Doosan. Biocides
In warm or humid weather, fungus and/or bacteria may form in diesel
To help avoid fuel system or engine damage, please read the following: fuel if there is water in the fuel.
Do not use diesel fuel which has been contaminated with engine oil. NOTICE: Fungus or bacteria can cause fuel system damage by
Besides causing engine damage, such fuel can also affect emission plugging the fuel lines, fuel filters or injector. They can also cause fuel
control. Before using any diesel fuel, check with the fuel supplier to see system corrosion.
if the fuel has been mixed with engine oil.
Your engine is designed to use either Number 1-D or Number 2-D If fungus or bacteria has caused fuel system problems, you should
diesel fuel. However, for better fuel economy, use Number 2-D diesel have your authorized dealer correct these problems. Then, use a
fuel whenever possible. At temperatures less than -7°C, (20°F), diesel fuel biocide to sterilize the fuel system (follow the biocide
Number 2-D fuel may pose operating problems (see "Cold Weather manufacturer's instructions). Biocides are available from your dealer,
Operation" which follows). At colder temperatures, use Number 1-D service stations, parts stores and other automotive places. See your
fuel (if available) or use a "winterized" Number 2-D (a blend of Number authorized dealer for advice on using biocides in your area and for
1-D and Number 2-D). This blended fuel is usually called Number 2-D recommendations on which biocides you should use.
also, but can be used in colder temperatures than Number 2-D fuel
Smoke Suppressants
which has not been "winterized."
The use of a smoke suppressant additive is not allowed because of the
Check with the fuel supplier to be sure you get the properly blended greater possibility of stuck rings and valve failure, resulting from
fuel. excessive ash deposits.
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48 FUEL, LUBRICANTS, AND COOLANT
LUBRICANT. NOTE
Use of unsuitable engine oil will result in piston ring, piston and cylinder
Using a mixture of different brands or quality of oils will adversely af-
seizure and accelerate surface wear causing increased oil
fect the original oil quality; therefore, never mix different brand or dif-
consumption, lowered output and, finally engine failure. To avoid this,
ferent type oils.
use the specified engine oil.
Do not use API, CA, CB grade and reconstituted engine oil
1) Engine Oil Selection
Engine damage due to improper maintenance, or using oil of the im-
PRO-TEC proper quality and/or viscosity, is not covered by the warranty.
2) Oil Viscosity
Engine oil viscosity affects engine startability, performance, oil

consumption, wear and the potential for seizure, etc. Always ensure
that lubricants with the correct viscosity for the operating temperature
are used. Refer to fig 5.
Fig. 5
A. (Single - grade)
B. Ambient Temperature
C. (Multi - grade)
COOLANT
All Doosan portable compressor engines are factory filled with a 50/50
Ethylene glycol base antifreeze/water mix. which provides protection to
-33°C (-27°F)
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ENGINE OPERATION Check the fan belt for tension and abnormalities.
A loose belt will cause belt slippage which may result in a damaged
Engine Exhaust Gas Caution (Carbon Monoxide)
belt, abnormal noise, poor battery charging and engine overheating.
CAUTION
Do not breathe exhaust gas because it contains carbon monoxide,

which by itself has no color or odor. Carbon monoxide is a dangerous
gas. It can cause unconsciousness and can be lethal.
Do not run the engine in confined areas (such as garages or next to a

building). Keep the exhaust tailpipe area clear of snow and other
material to help reduce the buildup of exhaust gases under the
equipment. This is particularly important when parked in blizzard
conditions.
CHECK BEFORE OPERATION
CAUTION: For safety reasons, conduct the inspection with the engine
stopped.
Engine Oil Level.
Place the engine or the machine on a level surface.
Remove the dipstick, wipe it with a cloth. Insert it fully and take it out
gently again.
Check the oil level against the marks on the dipstick. The oil level must
be between the ‘H’ level mark and the ‘L’ level mark as illustrated.
Fig. 7
Use of Genuine Doosan Fan Belt.
Always use Genuine Doosan fan belts as they provide high driving
ability and long operating durability. Use of non-Doosan fan belts could
result in premature belt wear or belt elongation leading to engine
overheating or excessive belt noise.
Coolant Level Check
Check and ensure that the level is correct.

Fig. 6
CAUTION: When removing the radiator filler cap, while the engine is
Also check the sample oil on the dipstick for contamination and still hot, cover the cap with cloth, then turn it slowly to gradually release
viscosity. the internal steam pressure. this will prevent anyone from being
scalded by hot steam spurting out from the filler neck.
Take care not to add too much engine oil
Add coolant mixed to the correct ratio: 50/50 ethylene glycol/water.
Oil can be poured either through the oil filler at the front of the cylinder
head cover or through the oil filler on the right side of the timing gear Radiator Cap Condition
case.
After the replenishment of the coolant, install the radiator filler cap.
A certain period of time is required before the engine oil completely Make sure the cap is securely installed.
flows down from the oil filler to the crankcase. Wait at least ten minutes
Crankcase Breather
before checking the oil level.
Check and clean the breather tube daily during cold weather.
NOTE: Take care to avoid engine oil being splashed on the fan drive
belt because it causes belt slippage or slackness. Battery Cable Connection
CAUTION: When adding oil, take care not to spill it. If you spill oil on Check the battery cable connections for looseness or corrosion. A
the engine or equipment, wipe it properly, to prevent the risk of fire and loosened cable connection will result in hard engine starting or
personal injury and/or equipment damage. insufficient battery charge. The battery cables must be tightened
securely. Never reverse “+” and “-” terminals when reconnecting
Fan and Belt Check
cables after disconnection. Even a short period of reverse connection
The engine is fitted with an automatic belt tensioner will damage the electrical parts.
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Coolant leakage -
Check the radiator and water pump hose connections and the water
drain cock on the cylinder block for leakage.
Exhaust smoke or gas leakage
Checking coolant level
The coolant level could drop because any mixed air is expelled in about
5 minutes after the engine started.
Stop the engine, remove radiator cap, and add coolant.
CAUTION: Hot steam can rush out and you could get burnt if the
Fig. 8
radiator cap is removed when the engine is hot. Cover the radiator cap
with a thick cloth and loosen the cap slowly to reduce the pressure,
A. Battery cable then remove the cap.
B. Connections
Battery Electrolyte level OPERATION AND CARE OF A NEW ENGINE.

The amount of electrolyte in the batteries will be reduced after repeated
discharge and recharge. Check the electrolyte level in the batteries, Your engine is carefully tested and adjusted in the factory, however,
replenish with a commercially available electrolyte such as distilled further run-in is necessary. Avoid any harsh engine operation within the
water, if necessary. The battery electrolyte level checking procedure initial 100 operating hours.
will vary with battery type. NOTICE: Do not replenish with dilute sulfuric Do not operate the unit at full load until the engine is warmed-up.
acid in the daily service.
Do not allow the engine to run unloaded for extended periods so as to
CAUTION: minimise the risk of cylinder bore glazing.
When inspecting the batteries, be sure to stop the engine first. During operation, pay attention to the following points if the engine
As dilute sulphuric acid is used as electrolyte, be careful not to shows any sign of abnormalities.
contaminate your eyes, hands, clothes, and metals with the electrolyte. (1) Engine Oil Pressure -
If it gets in your eye, wash with a large amount of water at once, then
seek medical advice. The engine oil pressure is monitored by a switch that will stop the
engine if the pressure falls below a pre-set value.
As highly flammable hydrogen gas is released from the batteries, do
not create a spark or allow any naked flame near the batteries. If the oil pressure gauge shows below 30 psi or if the reading fluctuates
continually, stop the engine and check the oil level. If the level is
When handling such metallic articles as tools near the batteries, be correct, contact your local Doosan branch or dealer to establish the
sure not to contact the “+” terminal because the compressor body is “- cause.
” and a dangerous short circuit might result.
(2) Coolant Temperature -
When disconnecting the terminals, start with “-” terminal. When
connecting them, connect the “-” terminal last. The engine performance will be adversely affected if engine coolant
temperature is too hot or too cold. The normal coolant temperature is
75 to 85°C (167 to 185°F).
CHECKS AND OPERATION AFTER START-UP
Overheating
Check after the Engine Start-up
CAUTION: If you see or hear escaping steam or have other reason
Check the following items in the engine warming-up operation. to suspect there is a serious overheat condition, stop the engine
Engine oil pressure - immediately.
The engine oil pressure gauge readings (where fitted) may vary If the Engine Coolant Temperature gage (where fitted) shows an
depending on ambient temperature and type of oil. The gauge should overheat condition, or you have reason to suspect the engine may be
register around 55 to 85 psi in the warming-up period. overheating, take the following steps:
Engine noise and exhaust smoke color - • Close the service valve to reduce the load.
Listen to the engine and, if any abnormal noise is heard, check to • Let the engine run at normal idle speed for two or three minutes. If
determine the cause. the engine coolant temperature does not start to drop, turn off the
Check the fuel combustion condition by observing the exhaust smoke engine and proceed as follows:
color. The exhaust smoke color after engine warm-up and at no-load
condition should be colorless or light blue. CAUTION: To help avoid being burned -
Black or white smoke indicates incorrect combustion. • Do not open the canopy or door if you see or hear steam or engine
coolant escaping. Wait until no steam or engine coolant can be seen
Note: After start-up from cold the engine might be noisier and the or heard before opening the engine canopy or door.
exhaust smoke color darker than when it has warmed up. However this
condition will disappear after warm up. Do not remove the radiator filler cap if the engine coolant in the
reserve tank is boiling. Also do not remove the radiator filler cap while
Leakage in the systems - the engine and radiator are still hot. Scalding fluid and steam can be
Check the following items: blown out under pressure if either cap is taken off too soon.
Lubrication oil leakage - If no steam or engine coolant can be seen or heard, open the canopy
Check the engine for oil leaks, paying particular attention to oil filter and or door. If the engine coolant is boiling, wait until it stops before
oil pipe joints. proceeding. The engine coolant level should be between the “MAX
COLD” and “MIN” marks on the reserve tank.
Fuel leakage -
Check the fuel injection pump, fuel lines and fuel filter for leakage.
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Make sure the fan belt is not broken, or off the pulley, and that the fan (4) Liquid and Exhaust Smoke Leakage
turns when the engine is started. If the engine coolant level in the
reserve tank is low, look for leaks at the radiator hoses and Make regular checks for lubricant, fuel, coolant and exhaust smoke
leakage.
connections, radiator, and water pump. If you find major leaks, do not
run the engine until these problems have been corrected. If you do not (5) Abnormal Engine Noise
find a leak or other problem, WAIT UNTIL THE ENGINE HAS
COOLED DOWN then carefully add engine coolant to the reserve tank. In the event of any abnormal engine noise, please consult your local
Doosan branch or dealer.
(Engine coolant is a mixture of ethylene glycol antifreeze and water.
See “Engine Care in cold season” for the proper antifreeze and (6) State of the Exhaust Smoke
mixture.)
Check for any abnormal exhaust smoke color.
CAUTION: To avoid being burned, do not spill antifreeze or engine

coolant on the exhaust system or hot engine parts. Under some ENGINE STOPPING
conditions the ethylene glycol in engine coolant is combustible.
(1) Close service valves.
If the engine coolant level in the reserve tank is at the correct level but
(2) Before stopping the engine, cool down the engine by operating it at
there is still an indication of an overheat condition and no cause was
reduced load about three minutes. In this period, check the engine
found, please consult your local Doosan branch or dealer.
noise for abnormalities and the engine oil pressure (where a gage is
Overcooling fitted) for abnormalities.
Operating the engine at low coolant temperature will not only increase
the oil and fuel consumption but also will lead to premature parts wear LONG TERM STORAGE
which may result in engine failure. Ensure that the engine reaches
normal operating temperature 75 to 85°C (167 to 185°F) within ten If the equipment is to be out of operation for an extended period, it
minutes of starting. should be started at least once per week and run on load for about 15
minutes after it has reached normal operating temperature.
(3) Hourmeter
This meter indicates the machine operation hours. Make sure that the
meter is always working during engine operation. Periodical machine
maintenance is scheduled on the operation hours indicated on the
hourmeter.
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52 PERIODICAL INSPECTION AND MAINTENANCE
LUBRICATING SYSTEM. Oil filter element installation -
Lightly apply engine oil to the O-ring.

Servicing of the engine oil and oil filter element will affect the engine
performance as well as the engine life. Change the engine oil and the
oil filter in accordance with the recommended service intervals.
Engine Oil and Oil Filter Element Change.
Engine Oil Change and Oil Filter Element Change must be made
simultaneously according to the following change schedule.
Change intervals: Refer to maintenance schedule section.
Engine Oil draining -
CAUTION: To help avoid the risk of being burned, do not drain oil
while the engine is still hot.
Fig. 11
Wipe clean around the oil filler cap taking care so that no foreign Screw in the new cartridge hand tight as the O-ring comes in contact
articles enter. Remove the filler cap. with the engine block. Tighten a further 3/4 to 11/4 turns. DO NOT
It is advisable that draining be done while the engine is warm to overtighten.
minimize the draining time. Engine oil refilling.
Remove the oil pan drain plug and drain the engine oil completely. Reinstall the drain plug.
NOTICE: Use a receptacle to catch the drained oil so that the engine Fill with new engine oil via the most convenient oil filler port.
and equipment will not be contaminated.
Wait at least ten minutes until the oil drains down to the oil pan. Then
check the oil level with the dipstick.
Check after Oil and Filter Changes.
Oil leakage check:
Run the unit for five to ten minutes, then visually check for oil leakage.
Oil level recheck:
Stop the engine for at least ten minutes.
Fig. 9 Use the dipstick to recheck the oil level. If necessary replenish with
engine oil to the specified level
Remove drain plug arrowed to drain the engine oil completely.
NOTE: When the engine is started, the oil level will slightly drop from
Oil filter element removal
the initial level as the oil fills the entire oil circuit.
Engine Oil Additives.
Engine oils contain a variety of additives. Your engine should not need
any extra additives if you use the recommended oil quality and change
intervals.
Used Oil Disposal - Do not dispose of used engine oil (or any other
oil) in a careless manner such as pouring it on the ground, into sewers,
or into streams or bodies of water. Instead, recycle it by taking it to a
used oil collection facility which may be found in your community. If you
have a problem disposing of your used oil, it is suggested that you
contact your local Doosan branch or dealer. This also applies to diesel
fuel which is contaminated with water.
Used Engine Oil.
CAUTION: Used engine oil contains harmful contaminants that have

Fig. 10 caused skin cancer in laboratory animals. Avoid prolonged skin con-
A Cartridge tact. Clean skin and nails thoroughly using soap and water -not min-
eral oil, fuels, or solvents. Launder or discard clothing, shoes, or rags
containing used engine oil.
Discard used engine oil and other oils properly.
COOLING SYSTEM
Coolant Change.
The coolant must be changed at intervals of 1000 hours or twelve

months, whichever come first.
If the coolant becomes sludged up it will lead to engine overheating or

coolant blow-off from the radiator.
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PERIODICAL INSPECTION AND MAINTENANCE 53
Coolant draining.
WARNING: Hot engine coolant and steam can cause injury.

When adding to or draining coolant or antifreeze solution from
the engine radiator, stop the engine at least one minute prior to
releasing the radiator filler cap. Using a cloth to protect the
hand, slowly release the filler cap, absorbing any released fluid
with the cloth. Do not remove the filler cap until all excess fluid
is released and the engine cooling system fully depressurised.
WARNING: Follow the instructions provided by the antifreeze

supplier when adding or draining the antifreeze solution. It is ad-
visable to wear personal protective equipment to prevent skin
and eye contact with the antifreeze solution.
Remove the radiator cap. Fig. 14
Slacken the bottom radiator hose clamp to drain the coolant from the Filling with coolant
radiator. Ensure that the engine is cool.
Close the coolant drain plug and tighten the bottom hose clamp.
Use clean water mixed 50/50 with antifreeze as a coolant.
Fill slowly to prevent air entering the cooling system.
For Coolant volume, refer to "General Information section"
When the system has been filled, operate the engine about five
minutes at a low idle speed, then as the air contained in the coolant
circuit is bled off the coolant level will drop.
Stop the engine and replenish with the correct coolant mix.
Cleaning outside of Radiator, Oil cooler and Charge Air Cooler
Debris, mud or dried grass caught between radiator fins will block the
air flow, resulting in lower cooling efficiency. Clean the radiator fins with
steam or low pressure (< 5 Bar) compressed air every 250 hours or 3
Fig. 12 months (whichever comes first) or more frequently in adverse
operating conditions.
A Cylinder block water drain valve
Cooling System Circuit Cleaning
Coolant Filter Replacement
When the cooling system circuit is contaminated with water scales or
sludge particles, cooling efficiency will be lowered. Periodically clean
the circuit interior with a suitable cleaner.
Clean the cooling system circuit every 1000 operating hours or 12

months, whichever comes first.
Fig. 13
Rotate clockwise to close shut-off valve. Remove and replace coolant

filter. Open shut-off valve
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
54 PERIODICAL INSPECTION AND MAINTENANCE
FUEL SYSTEM Discard the old element into a suitable container.
Using a clean cloth, wipe the sealing face of the filter/separator head
The fuel injection pump and injector nozzles are precisely
to ensure correct seating of the sealing ring.
manufactured, and therefore, using fuel which contains water or dust
particles will result in either injection pump plunger seizure or injector Fill the element/bowl assembly with clean fuel oil then apply a light coat
nozzle seizure. A fuel filter element blocked with sludge or dust of clean engine oil to the new element seal ring.
particles will lead to reduced engine output.
Screw the new element onto the head firmly by hand.
Perform inspection and maintenance periodically as follows:
The engine has a self priming system that purges air from the fuel
system.
AIR INTAKE SYSTEM
Air cleaner
Engine performance and life vary with the air intake conditions.
A dirty air cleaner element reduces the amount of intake air, causing
reduced engine output and possible engine damage.
Also, a damaged element leads to abrasion of cylinders and valves,

resulting in increased oil consumption, reduced output and shortened
engine life.
The filter element should be changed at 500 hours or 6 months,

whichever comes first, or sooner if the restriction indicator shows red.
Fig. 15 See below.
A Filter element
B Drain valve
Draining Water from Fuel Filter/separator.
The fuel filter/separator is provided to allow water to be drained from

the fuel system. Water is heavier than fuel so any water contained in
the system will collect in the bottom of the bowl.
Place a suitable container under the separator to prevent any spillage

inside the machine.
Slacken the drain valve 'B' until water drains from the vent tube.
When all the water has been evacuated, tighten the drain valve 'B'.
Fuel filter/separator element change.
NOTE: The cartridge and bowl contain fuel. Take care not to spill it
during disassembly and reassembly. Fig. 17
The fuel filter/separator also provides primary filtration and the element A Normal
'A' should be changed every 500 operating hours or 6 months, B Clogged
whichever comes first.
C Indicator
Change procedure:
D Red signal
Disconnect fuel sensor (where fitted). Loosen drain plug B and empty
fuel into suitable container Air cleaner with dust indicator
This indicator is attached to the air cleaner. When the air cleaner
element is clogged, air intake resistance becomes greater and the dust
indicator signal turns to red indicating the element needs to be
changed.
When the signal turns to red, replace the element. Then press the dust
indicator button to reset the indication.
Fig. 16
Unscrew the element 'A' from the head taking care not to spill fuel
inside the machine. Remove fuel sensor (where fitted) and re-fit to new
filter element.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
PERIODICAL INSPECTION AND MAINTENANCE 55
Air Intake Piping Never reverse "+" and "-" terminals when reconnecting cables after
removal. Even a short period of reverse connection will damage the
Inspect air intake and charge air cooling pipes and connections for electrical parts.
damage or loose fitting. Replace or re-fit as necessary.
Cleaning of Battery
When the battery terminals are fouled clean them with clean tepid
water and wipe with a dry cloth to remove the water. Apply a light coat
of vaseline or a grease.
Alternator Servicing
The polarity of the alternator is negative (-) grounding type.
Do not reverse the polarity connection, otherwise a short circuit will

occur resulting in alternator failure.
Do not put water directly on the alternator. Entry of water into the
alternator creates electrolytic corrosion causing failure.
When the battery is charged from an external source, be sure to

disconnect the battery cables.
Fig. 18
Wiring Connections
ENGINE ELECTRICAL Check all of the electric wiring connections for looseness and damage
on a regular basis.
The engine uses a 24 volt system and a negative grounding for the
electrical system.
SERVICE AND MAINTENANCE
Battery Servicing
Please refer to the engine maintenance schedule.
Battery terminal connections
For continued trouble free engine operation throughout its life, the
Check the battery cable connections for looseness or corrosion. Poor
service procedures marked with an asterisk (*) need to be carried out
cable connections will result in difficult engine starting or insufficient
by a skilled and trained technician.
battery charge.
Please consult your local Doosan branch or dealer when these
The battery cables must be tightened securely.
procedures become due.
Please also read the note refering to the service items marked with the
star symbol.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
56 COLD WEATHER OPERATION
FUEL SELECTION ENGINE OIL
In cold weather, the fuel might freeze resulting in difficult engine At low ambient temperatures, engine oil viscocity can affect engine
starting; therefore, select a suitable fuel for such engine operation. starting. It is important to use the correct grade of oil as recommended
in fig 4.
Use ASTM 975 No. 2-D fuel if you expect temperature above 20°F (-
7°C). Try to position the compressor where it will not be affected by cold
winds when not running.
Use Number 1-D if you expect temperatures below 20°F (-7°C).
If Number 1-D is not available, a "winter" blend of 1-D and 2-D is BATTERY
available in some areas during the winter months.
Check with your fuel supplier to be sure you get the correct blended (1) Always ensure that the batteries are kept fully charged in the cold
fuel. season. This takes a longer period of running than in warm weather
operation.
COOLANT The electrolyte in a partly discharged battery will freeze easier than
when it is fully charged. Try to keep the batterys fully charged and
Where the ambient temperature falls below freezing point, the cooling warm in cold weather operation.
system should be drained after engine operation, but to eliminate the (2) Top up the battery with distilled water immediately before starting
need for repeated draining, refilling and to provide all year protection
the engine.
against corrosion, the use of anti-freeze solution throughout the year is
highly recommended.
COLD STARTING
All Doosan portable compressor engines are factory filled with a 50/50
Ethylene glycol base antifreeze/water mix. which provides protection to
When operating in cold ambient conditions, or when starting from cold.
-33°C (-27°F)
If the engine does not start at the first attempt, allow the battery to
Concentrations over about 65% adversely affect freeze protection, recover for at least 30 seconds.
heat transfer rates, and silicate stability which may cause water pump
Observe the following procedures:
leakage.
In order to protect the starter, do not engage for longer than 10 seconds
CAUTION: during any attempt.
Never exceed a 60/40 antifreeze/water mix. (which provides
protection to about -50°C (-58°F). If during cranking, the starter motor repeatedly engages and
disengages the battery power could be low. Either recharge the battery
or replace it with one that is fully charged.
NOTE:
NOTICE: Do not use starting "aids" in the air intake system. Such aids
Methyl alcohol base antifreeze is not recommended because of its
can cause immediate engine damage.
effect on the non-metallic components of the cooling system and
because of its low boiling point.
NOTE:
High silicate antifreeze is not recommended because of causing
serious silica gelation problems.
NOTE:
Usage and mixing ratio etc. should be followed to the antifreeze
manufacture's recommendations.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
ENGINE MAINTENANCE SCHEDULE 57
When performing the following items, the daily inspection items should also be carried out.
Description of check and (operation hours) Remark

No Daily
maintenance 250 500 750 1000 1250 1500
1 Oil level O
2 Oil leakage O
3 Oil pressure gage reading (where fitted) O
4 Oil pressure warning lamp (where fitted) O
5 Engine oil replacement O O O
6 Oil filter element replacement O O O
7 Fuel leakage O
8 Draining water in fuel filter/separator O
9 Fuel filter element replacement O O O
10 Injection nozzle check (*) O
11 Coolant level O
12 Coolant leakage check O
13 Radiator filler cap fitting condition O
14 Fan and belt check O O
15 Coolant temperature gage reading
O
(where fitted)
16 Coolant replacement O
See “EXPLANATION OF
17 Coolant filter replacement O MAINTENANCE SCHEDULE”
18 Radiator external face cleaning O O O O O O
19 Cooling system circuit cleaning O
20 Radiator filler cap function check (*) O O O
21 Electrolyte level check O
22 Battery cleaning O
23 Battery charge lamp O
24 Starter and alternator check and
O
cleaning (*)
25 Wiring and connection check O O O
26 Air cleaner element replace O O O
27 Air intake piping O
28 Engine starting conditions and noise
O
conditions
29 Exhaust smoke condition O
30 Cylinder compression pressure (*) O
31 Valve clearance check (*) O
32 Positive crankcase ventilation valve
O O
cleaning
Note:
1. After every 1500 hours of operation, the service intervals should be repeated in accordance with this check and maintenance schedule.
2. When servicing on the asterisked (*) items is necessary, consult your local Doosan branch or distributor.
Note:
This is a recommended maintenance. The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior
to the completion engine useful life. Doosan, urges that recommended maintenance service is performed at the indicated intervals.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
58 ENGINE MAINTENANCE SCHEDULE
EXPLANATION OF MAINTENANCE SCHEDULE
The following is a brief explanation of the services listed in the preceding Engine Maintenance schedule.
1. Oil level. Check that the oil level is within cross hatch area (ref fig. 6)
Fill or drain as necessary.
2. Oil leakage check Replace any damaged or malfunctioning parts which could cause leakage.
3. Oil pressure gauge Normal oil pressure is 30 to 85 psi. Check and repair the lubrication system if it is abnormal.
4. Oil pressure warning lamp If it stays on whilst running check and repair the lamp and/or lubrication system.
5. Engine oil replacement Change at 500 hours or 6 months, whichever comes first.
6. Oil filter element Change at 500 hours or 6 months, whichever comes first.
replacement
7. Fuel leakage Replace any damaged or malfunctioning parts which could cause leakage.
8. Draining water in fuel filter/ Drain off water in the fuel filter/separator bowl.
separator.
9. Fuel filter element Replace both primary (filter/separator) and secondary elements at 500 hours or 6 months whichever come
replacement first.
10. Injection nozzle check Check injection opening pressure and spray condition. (This is a recommended maintenance item ). Consult
your local branch or distributor.
11. Coolant level. Check coolant level and add coolant if necessary.
12. Coolant leakage check Replace any damaged or malfunctioning parts which could cause leakage.
13. Radiator filler cap fitting The radiator cap must be installed tightly and sealing correctly.
condition
14. Fan and belt check Look for cracks, fraying and wear. Replace if necessary
15. Coolant temperature Normal running temperature is 75 to 85°C (167 to 185°F). Check and repair the cooling system if temperature
is abnormal.
16. Coolant replacement Change coolant at intervals of 1000 hours or 12 months, whichever comes first.
17. Coolant filter replacement Replace filter at 500 hours
18. Radiator external face Check monthly. Clean at intervals of 250 hours or 3 months, whichever comes first. In very dusty
cleaning environments, more frequent cleaning might be necessary.
19. Cooling system circuit Clean at intervals of 1000 hours or 12 months, whichever comes first.
cleaning
20. Radiator filling cap function Check radiator pressure cap periodically for proper operation. Consult your local branch or distributor.
check
21. Battery electrolyte level Replenish with distilled water if necessary.
check
22. Battery cleaning Clean the terminals.
23. Battery charge condition If the lamp stays on while engine is running, check charging circuit.
24. Starter and generator check Check wear condition of brush and commutator. Consult your local branch or distributor.
and cleaning
25. Wiring and connection Check for loose terminals/connections and integrity of insulation.
check
26. Air cleaner element replace Change element at 500 hours or 6 months, whichever come first, or sooner if the restriction indicator shows
red.
27. Air intake piping Check pipes and connections for damage or loose fitting
28. Engine starting condition Check engine stability and noise.
and noise condition
29. Exhaust smoke condition Check exhaust smoke color.
30. Cylinder compression Consult your local Ibranch or distributor.
pressure
31. Valve clearance check Incorrect valve clearance will result in increased engine noise and lower engine output thereby adversely
affecting engine performance. Check and adjust every 1000 hours. Consult your local branch or distributor.
32. Positive crankcase Check and clean the breather tube daily during cold weather. Check according to the equipment specifications.
ventilation valve cleaning Perform the adjustment, cleaning, repair or replacement every 1500 hours. (This is a recommended
maintenance item). Consult your local branch or distributor.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
ENGINE TROUBLESHOOTING 59
This item contains a simple troubleshooting. When a failure takes place on your engine, diagnose the cause referring this troubleshooting. Should
the cause of failure not be detected or you are unable to manage the failure, consult your machine supply source or nearest company engine service
outlet.
Engine does not start Battery discharged
Bad cable connections.

Starter does not turn.
Starter or starter switch failure.
Safety relay failure.
Engine stop solenoid malfunction.
No fuel in the fuel tank.

No fuel injection.
Clogged fuel filter element.
Air in the fuel system.

Starter turns but engine does not
fire. Incorrect preheating operation.
Glow plug malfunction.

Fuel is injected but engine does
not fire. Incorrect injection timing.
Low cylinder compression

pressure.
Engine fires but stalls

Air in the fuel system.
immediately.
Unstable engine running Crack in injection pipe.
Unstable low idling Injection nozzle failure.
Uneven compression pressure between cylinders.
Air in the fuel system
Clogged fuel filter element

Insufficient fuel supply.
Piping failure (squeezed/restricted
Engine malfunction in high speed etc.)
range.
Uneven fuel injection amount between cylinders.
Incorrect valve clearance adjustment.
Deteriorated valve spring.
Engine speed stuck at high idle.
Engine overheat Insufficient coolant volume.
Fan belt slippage.
Thermostat malfunction.
Cooling system defect
Radiator filler cap malfunction.
Cooling system interior fouled.
Radiator clogged.
Engine over-loaded.
Air cleaner element clogged.

Improper servicing
Insufficient airflow/restriction.
Restricted coolant flow (high concentration of antifreeze, etc.)
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
60 ENGINE TROUBLESHOOTING
Low oil pressure Oil leakage

Lack of oil
High oil consumption
Wrong oil Wrong type and viscosity.
High coolant temperature. Over heat.
Clogged filter and strainer.
Worn bearings and oil pump.
Faulty relief valve.
Low engine output Incorrect valve clearance

adjustment.
Cylinder compression leakage
Injector nozzle misalignment.
Low cylinder compression
pressure Cylinder bore wear.
Air cleaner clogged.

Insufficient air intake volume.
Restricted air flow.
Excessive oil consumption Wrong selection of type and viscosity.

Incorrect oil
Too much oil quantity.
Faulty piston rings/damaged cylinder bores.

Engine burning oil
Faulty valve stem seal.
Damaged seal / Damaged turbocharger seal
Oil leakage Loose joints/gaskets.
Improper installation of filter and piping.
Excessive fuel consumption Damaged seals.

Fuel leakage
Improper component installation or tightening.
Excessive injection volume. Injection pump defective.
Excessive mechanical loads
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
ENGINE TROUBLESHOOTING 61
Improper exhaust Clogged air cleaner.
Damaged injector nozzle.
Wrong injector nozzle.

Excessive black smoke
Injection timing incorrect.
Excessive injection volume.
Incorrect fuel.
Water mixing in fuel
Low compression pressure.
Excessive white smoke Injection timing incorrect.
Low coolant temperature
Faulty turbocharger
Battery over discharge Crack in battery body.

Low electrolyte level
Natural consumption.
Loose or damaged belt.
Charging failure Faulty alternator.
Damaged wiring or contact failure.
Excessive electrical loads Insufficient battery capacity for the application.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
62 PARTS ORDERING
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 authorized 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 authorized 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
honored by the Purchaser.
NOTICE
Warranty: The Company warrants that parts manufactured by it will
Do not paint over safety warnings or instructional decals. If be as specified and will be free from defects in materials and
safety warning decals become illegible, immediately order workmanship. The Company's liability under this warranty shall be
replacements 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
Afterwards, service sets of exterior decals and current production as it applies to the special airend exchange program.
safety warning decals are available. Contact the Product Support
Group at Mocksville for your particular needs and availability.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
PARTS ORDERING 63
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 Purchaser for service interruption whether or not such loss or damage
best efforts to ship by the dates specified; however, the Company shall is based on contract, warranty, negligence, indemnity, strict liability or
not be liable for any delay or failure in the estimated delivery or otherwise.
shipment 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.
On the airend exchange program the exchange price is determined by
Limitation of Liability: the age and condition of the airend.
The remedies of the Purchaser set forth herein are exclusive, and the Your nearest sales office, autonomous company or authorized
total liability of the Company with respect to this order whether based distributor must first contact the Parts Service Department at the
on contract, warranty, negligence, indemnity, strict liability or factory at which your portable air compressor was manufactured for an
otherwise, shall not exceed the purchase price of the part upon which airend exchange number. The airend must be tagged with this
such liability is based. preassigned number and returned to the factory prepaid. The airend
must be intact, with no excluded parts, otherwise the exchange
agreement may be cancelled. The warranty on an exchange or factory
rebuilt airend is 365 days.
Airends being returned to the factory in connection with a WARRANTY
CLAIM must be processed through the Customer Service Department.
If returned without a Warranty MRR (Material Return Request)
Number, no warranty claim will be considered.
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
64 PARTS ORDERING
For parts, service or information regarding your local U.S, Latin America or Asia Pacific distributor, please contact:
Facility: Telephone: Fax:

Doosan International USA, Inc 800-633-5206 (US & Canada) 336-751-1579 (US & Canada)
1293 Glenway Drive 305-222-0835 (Latin America) 336-751-4325 (Latin America)
Statesville 65-860-6863 (Asia Pacific) 336-751-4325 (Asia Pacific)
North Carolina 28625-9218
Office hours: Monday - Friday 8:00 a.m. to 5:30 p.m. (EST)
For information on how to order parts or information regarding your local distributor
(Europe, Middle East, Africa) please contact:
Doosan Portable Power EMEA Aftermarket

Drève Richelle 167
B-1410 Waterloo
Belgium
Telephone: +32 (2) 404 0811

Fax: +32 (2) 371 6915
For Service information contact: service_emea@dii.doosan.com
For Parts information contact: parts_emea@dii.doosan.com
Operating hours: Monday to Friday 8:30 a.m. to 5:15 p.m. (GMT)
9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA

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9/270, 9/300, 12/235, 17/235, 21/215

9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA

This manual contains

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

THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTHER

GENERAL WARRANTY INFORMATION - ESA

NOTE: Actual warranty times may change.

Consult the Manufacturer’s warranty policy as shipped with each

Extended Limited Airend Warranty

1. The original airend is returned assembled and unopened.

3. Submissions of proof that maintenance intervals have been followed.

WARRANTY TIME *BARE AIREND **AIREND COMPONENTS

Prohibition / Mandatory Information / Instructions Warning

Lifting point. On (power). Off (power).

FREE SAFETY DECALS!

Ensure that adequate ventilation of the cooling system and exhaust

The following substances are used in the manufacture of this

Safety data sheets for compressor and engine lubricants should be

Compressed air can be dangerous if incorrectly handled. Before Battery

If more than one compressor is connected to one common

Avoid bodily contact with compressed air.

MODEL 12/235 9/270 9/300 10/300 21/215 17/235

MODEL 12/235 9/270 9/300 10/300 21/215 17/235

When selecting the working position of the machine ensure that

6. High Engine Coolant Temp: Fault indicator lamp. Indicates

7. Restricted IQ Air Filters: Fault indicator lamp. Indicates

8. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to

9. Compressor Malfunction: Fault indicator lamp. Indicates

10. Low Battery Voltage: Alarm indicator lamp. Indicates battery or

11. Engine Malfunction: Engine Fault code. Refer to service card or

12. Malfunction Code (4 Digit): Compressor or engine fault. Refer

14. Panel Light Switch: Controls panel lamp # 1.

15. Service Air Switch: Momentary contact switch. Allows engine to

16. ON/OFF Start Switch: Main Power Control Switch.

17. Heater Switch: ON/OFF Power Switch for regulation and IQ

18. Hourmeter: Indicates machine operating hours.

Wedge Diagnostic Display Codes

Low Fuel Level Fuel Level Fuel Level 3

STARTING THE MACHINE

If the engine fails to start, refer to the MAINTENANCE section of this

STOPPING THE MACHINE

• Close the service valve.

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

When the machine is to be permanently decommissioned or

MONITORING DURING OPERATION

*Disregard if not appropriate for this particular machine. D = Drain

Initial 500 Daily Monthly 3 Monthly. 6 Monthly. 12 Monthly. 12 Monthly.

*Disregard if not appropriate for this particular machine. D = Drain

Initial 500 Daily Weekly 3 Monthly. 6 Monthly. 12 Monthly.

2 Yrs 4 Yrs 6 Yrs

*Disregard if not appropriate for this particular machine. D = Drain

• all panels are replaced, canopy and doors closed.

Ensure that maintenance personnel are adequately trained,

• loose clothing, jewelry, long hair etc. is made safe. Reassembly

• the machine is suitably tested.

COMPRESSOR OIL SEPARATOR ELEMENT AIR FILTER ELEMENT

See the GENERAL INFORMATION section of this manual.

The bolts securing the running gear to the chassis should be

At the recommended intervals, (see the SERVICE/MAINTENANCE