9/270, 9/300, 12/235, 17/235, 21/215 9/270HA, 9/300HA, 12 ... · Continued use of genuine Doosan...

22839567_en_D_10/11

9/270, 9/300, 12/235, 17/235, 21/2159/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HAOPERATION AND MAINTENANCE MANUALOriginal Instruction

9/270,9/300, −>SERIAL No : 893000

17/235 −>SERIAL No : 881500

12/335

21/215

This manual containsimportant safety informationand must be made available topersonnel who operate andmaintain this machine.

Machine models represented in this manual may be used in various locations world−wide. Machines sold and shippedinto European Union Territories require that the machine display the CE Mark and conform to various directives. Insuch cases, the design specification of this machine has been certified as complying with EC directives. Anymodification to any part is absolutely prohibited and would result in the CE Certification and marking being renderedinvalid. A declaration of that conformity follows:

SAMPLE

CONTENTS & ABBREVIATIONS 1

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

CONTENTS

1 CONTENTS

2 FOREWORD

3 WARRANTY

6 ISO SYMBOLS

9 SAFETY

11 GENERAL INFORMATIONDimensionsData

14 OPERATING INSTRUCTIONSCommissioningPrior to startingStartingStoppingEmergency stoppingRe−startingMonitoring during operationDecommissioning

24 MAINTENANCERoutine maintenanceLubricationSpeed & pressure regulationTorque settings tableCompressor lubrication

36 MACHINE SYSTEMSElectrical systemPiping & instrumentation system

40 FAULT FINDING

42 OPTIONS

44 ENGINE INSTRUCTION MANUAL

65 PARTS ORDERING

ABBREVIATIONS & SYMBOLS

#### Contact the company for serial number

−>#### Up to Serial No.####−> From Serial No.

* Not illustrated

† Option

WDG Generator option

AR As required

HA High ambient machine

S.R.G. Site running gear

H.R.G. High speed running gear

bg Bulgariancs Czechda Danishde Germanel Greeken Englishes Spanishet Estonianfi Finnishfr Frenchhu Hungarianit Italianlt Lithuanianlv Latvian, Lettishmt Maltesenl Dutchno Norwegianpl Polishpt Portuguesero Romanianru Russiansk Slovaksl Sloveniansv Swedishzh Chinese

FOREWORD2

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

The contents of this manual are considered to be proprietary andconfidential and should not be reproduced without the prior writtenpermission of the company.

Nothing contained in this document is intended to extend anypromise, warranty or representation, expressed or implied, regardingthe products described herein. Any such warranties or other terms andconditions of sale of products shall be in accordance with the standardterms and conditions of sale for such products, which are availableupon request.

This manual contains instructions and technical data to cover allroutine operation and scheduled maintenance tasks by operation andmaintenance staff. Major overhauls are outside the scope of thismanual and should be referred to an authorised service department.

The design specification of this machine has been certified ascomplying with EC directives. As a result:

(a) Any machine modifications are strictly prohibited, and will invalidateEC certification.

(b) This machine may be used in USA / Canada, when configured withcomponents bearing the appropriate certification. (Where ASMEcertification is valid).

All components, accessories, pipes and connectors added to thecompressed air system should be:. of good quality, procured from a reputable manufacturer and,wherever possible, be of a type approved by the company.. clearly rated for a pressure at least equal to the machine maximumallowable working pressure.. compatible with the compressor lubricant/coolant.. accompanied with instructions for safe installation, operation andmaintenance.

Details of approved equipment are available from the company servicedepartments.

The use of repair parts / lubricants / fluids other than those includedwithin the approved parts list may create hazardous conditions overwhich the company has no control. Therefore the company cannot beheld responsible for equipment in which non−approved repair parts areinstalled.

The company reserves the right to make changes andimprovements to products without notice and without incurring anyobligation to make such changes or add such improvements toproducts sold previously.

The intended uses of this machine are outlined below and examplesof unapproved usage are also given, however the company cannotanticipate every application or work situation that may arise.

IF IN DOUBT CONSULT SUPERVISION.

This machine has been designed and supplied for use only in thefollowing specified conditions and applications:. Compression of normal ambient air containing no known ordetectable additional gases, vapours. or particles. Operation within the ambient temperature range specified in theGENERAL INFORMATION section of this manual.

The use of the machine in any of the situation types listed intable 1:−a) Is not approved,b) May impair the safety of users and other persons, andc) May prejudice any claims made.

TABLE 1

Use of the machine to produce compressed air for:a) direct human consumptionb) indirect human consumption, without suitable filtration and puritychecks.

Use of the machine outside the ambient temperature rangespecified in the GENERAL INFORMATION SECTION of this manual.

THIS MACHINE IS NOT INTENDED AND MUST NOT BEUSED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,INCLUDING SITUATIONS WHERE FLAMMABLE GASES ORVAPOURS MAY BE PRESENT.

Use of the machine fitted with non approved components /lubricants / fluids.

Use of the machine with safety or control components missing ordisabled.

The company accepts no responsibility for errors in translation ofthis manual from the original English version.

© COPYRIGHT 2011DOOSAN COMPANY

WARRANTY 3

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

The company, through its distributor, warrants that each item of equip-ment manufactured by it and delivered hereunder to the initial user willbe free of defects in material and workmanship for a period of three (3)months from initial operation or six (6) months from the date of shipmentto the initial user, whichever occurs first.

With respect to the following types of equipment, the warranty periodenumerated below will apply in lieu of the foregoing warranty period.

A. Aftercoolers − The earlier of nine (9) months from date ofshipment to or six (6) months from start up by initial user.

B. Portable Compressors, Portable Generator Sets −9 Kva through to 550 Kva, Portable Light Towers and AirDryers − The earlier of twelve (12) months from shipment to orthe accumulation of 2,000 hours of service by the initial user.

2.5 Kva Through to 8 Kva − The earlier of twelve (12) monthsfrom shipment to or the accumulation of 2,000 hours of operationby the initial user.

The company will provide a new part or repaired part, at it’s solediscretion, in place of any part which is found to be defective inmaterial or workmanship during the period described above.Labor cost to replace the part is the responsibility of the initialuser.

C. Portable Compressor Air Ends − The earlier of twenty−four(24) months from shipment to or the accumulation of 4,000 hoursof service by the initial user. For Air Ends, the warranty againstdefects will include replacement of the complete Air End,provided the original Air End is returned assembled and alloriginal seals are intact.

C1. Portable Compressor Airend Limited Extended Warranty −The earlier of sixty (60) months from shipment to or theaccumulation of 10,000 hours of operation by the initial user. Thisextended warranty is limited to defects in design or defectivematerial or workmanship in rotors, housings, bearings and gearsand provided all the following conditions are met:

The original air end is returned assembled and all original sealsare intact.

Continued use of genuine Doosan parts, fluids, oils and filters.

Maintenance is performed at prescribed intervals by authorizedand properly trained service engineers.

D. Generator Alternator − 9 Kva through to 550 Kva. The earlierof twenty−four (24) months from shipment to or the accumulationof 4,000 hours of operation by the initial user.

2.5 Kva Through to 8 Kva − The earlier of twelve (12) monthsfrom shipment to or the accumulation of 2,000 hours of operationby the initial user.

E. Portable Light Tower Alternator − The earlier of twelve (12)months from shipment to or the accumulation of 2,000 hours ofoperation by the initial user. Light Source model only, the earlierof twenty−four (24) months from shipment to or the accumulationof 4,000 hours of operation by the initial user.

F. Platinum Drive Train Extended Warranty − Platinum drive trainwarranty is available for the following compressor types.

European built7/20−7/26E−7/31E−7/41−7/51−7/71−12/56−P65−P907/120−9/110−14/85−10/105−14/115−10/125−7/170−12/150

USA builtModel Serial Code**P185WJD−T4I D75P185WYM−T4I D76C185WKUB−T2 D80P250WJD−T3 D81P260/HP220WYM−T3 D82C185SKUB−T2 E04C185WKUB−T4I D95

P425−XP375−HP350−P600−HP450−VHP400 WIR (John Deereengines only)

1. The original airend is returned assembled and unopened.

2. Continued use of genuine Doosan parts, fluids, oil and filters.

3. Maintenance is performed at prescribed intervals byauthorized and properly trained service engineers.

The company shall be provided with such information as itrequires to confirm that these conditions have been compliedwith.

G. Construction Tools, (Portable Power range only) − Twelve(12) months from shipment to initial user. The company willprovide a new part or repaired part, at it’s sole discretion, in placeof any part which is found to be defective in material orworkmanship during the period described above. Labour cost toreplace the part is the responsibility of the initial user.

H. Spare Parts − Six (6) months from date of shipment to the initialuser.

The company will provide a new part or repaired part, at its solediscretion, in place of any part that is found to be defective in materialand workmanship during the period described above. Such parts willbe repaired or replaced without charge to the initial user during normalworking hours at the place of business of a distributor authorized to sellthe type of equipment involved or other establishment authorized. Usermust present proof of purchase at the time of exercising warranty.

The above warranties do not apply to failures occurring as a result ofabuse; misuse, negligent repairs, corrosion, erosion and normal wearand tear, alterations or modifications made to the product withoutexpress written consent; or failure to follow the recommendedoperating practices and maintenance procedures as provided in theproduct’s operating and maintenance publications.

Accessories or equipment furnished by the company, butmanufactured by others, including, but not limited to, engines, tires,batteries, engine electrical equipment, hydraulic transmissions,carriers, shall carry only the manufacturers warranty, which thecompany can lawfully assign to the initial user.

THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTHERWARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT OFTITLE), AND THERE ARE NO WARRANTIES OFMERCHANTABILITY OR OF FITNESS FOR A PARTICULARPURPOSE.

WARRANTY4

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

GENERAL WARRANTY INFORMATION − ESA

COMMENTS

PORTABLE COMPRESSOR PACKAGE 12 MONTHS / 2,000HOURS

COVERS CONTROLS, SWITCHES, SHEET METAL,RADIATOR, OIL COOLER, RECEIVER, PIPEWORK,ELECTRICAL CIRCUIT ETC.

AIREND 24 MONTHS / 4,000HOURS

60 MONTHS / 10,000 HOURS. EXTENDED LIMITEDWARRANTY AVAILABLE ON MAJOR COMPONENTS.REFER TO OPERATOR’S MANUAL.

ENGINE SEE BELOW

2.5kVA − 8kVAGENERATORS

PACKAGE 12 MONTHS / 2,000HOURS

CONTACT THE COMPANY FOR WARRANTY (PARTSONLY NO LABOUR).

ALTERNATOR 12 MONTHS / 2,000HOURS

CONTACT THE COMPANY FOR WARRANTY (PARTSONLY NO LABOUR).

ENGINE SEE BELOW

9kVA − 550kVAGENERATORS

PACKAGE 12 MONTHS / 2,000HOURS

COVERS CONTROLS, SWITCHES, SHEET METAL,ELECTRICAL CIRCUIT ETC.


CONTACT THE COMPANY FOR WARRANTY.

ENGINE SEE BELOW

LIGHT TOWER PACKAGE 12 MONTHS / 2,000HOURS

COVERS CONTROLS, SWITCHES, SHEET METAL,ELECTRICAL CIRCUIT ETC.


EXTENDED WARRANTY OF 24 MONTHS / 4,000 HRS.FOR LIGHTSOURCE INTRODUCED 8/16/99.

ENGINE SEE BELOW

ENGINES

MONTHS HOURS COMMENTS

CATERPILLAR 12 UNLIMITED EXTENDED WARRANTY PROVIDED VIA ENGINESUPPLIER’S OWN APPROVED NETWORK AT TIME OFPURCHASE.

CUMMINS 24 2,000 EXTENDED WARRANTY PROVIDED VIA ENGINESUPPLIER’S OWN APPROVED NETWORK AT TIME OFPURCHASE.

JOHN DEERE(IN COMPRESSORS)

24 2,000

(IN GENERATORS) 24 2,000 24 MONTHS / 4,000 HRS. AVAILABLE FROM THECOMPANY WITH USE OF GENUINE DOOSAN PARTSAND OILS AT PRESCRIBED SERVICE INTERVALS.CONTACT THE COMPANY NETWORK.

KUBOTA(North America only)

24 2,000 EXTENDED WARRANTY OF 36 MONTHS / 3,000 HRS.ON MAJOR COMPONENTS, PARTS ONLY, AVAILABLEFROM KUBOTA.

(Western Europe and Oceania) 24 2,000 NO EXTENDED WARRANTY AVAILABLE.

(Central and South America, Asia,Middle East and Africa)

12 1,000 NO EXTENDED WARRANTY AVAILABLE.

PARTS


DOOSAN 6 UNLIMITED PARTS ONLY AVAILABLE FROM THE COMPANYNETWORK.

WARRANTY 5

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

AIREND EXCHANGE


AIREND 24 4,000 60 MONTHS / 10,000 HRS. AVAILABLE UNDERCONDITIONS.

CONSTRUCTION TOOLS


CONSTRUCTION TOOLS 12 N/A

NOTE: Actual warranty times may change.Consult the Manufacturer’s warranty policy as shipped with eachnew product.

Extended Limited Airend WarrantyAll 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 warrantyis 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, filtersand 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).

ISO SYMBOLS6

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

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING − Pressurised component orsystem.

WARNING − Hot surface.

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.

X,XBAR

0�C

WARNING − Maintain correct tyre pressure.(Refer to the GENERAL INFORMATION

section of this manual).

WARNING − Before connecting the tow baror commencing to tow consult the

operation and maintenance manual.

WARNING − For operating temperaturebelow 0�C, consult the operation and

maintenance manual.

ISO SYMBOLS 7

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

WARNING − Do not undertake anymaintenance on this machine until the

electrical supply is disconnected and the airpressure is totally relieved.

WARNING − Consult the operation andmaintenance manual before commencing

any maintenance.

Do not breathe the compressed air from thismachine.

Do not remove the Operating and Maintenancemanual and manual holder from this machine. Do not stack. Do not operate the machine without the guard

being fitted.

Do not stand on any service valve or otherparts of the pressure system.

Do not operate with the doors or enclosureopen. Do not use fork lift truck from this side.

XXkm/h

Do not exceed the trailer speed limit. No naked lights. Do not open the service valve before theairhose is attached.

Use fork lift truck from this side only. Emergency stop. Tie down point

ISO SYMBOLS8

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

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

Read the Operation and Maintenance manualbefore operation or maintenance of this

machine is undertaken.

When parking use prop stand, handrake andwheel chocks. Compressor oil filling

Diesel fuelNo open flame. Parking brake. Rough Service Designation.

Wet Location Operation.

Replace any cracked protective shield. Oil drain.

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 thecompressor’s parts manual. Submit orders for Safety Decals to the Doosan PortablePower EMEA Aftermarket Department. The no charge order should contain onlySafety Decals. Help promote product safety! Assure that decals are present on themachines. Replace decals that are not readable.

SAFETY 9

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

WARNINGSWarnings call attention to instructions which must be followed

precisely to avoid injury or death.

CAUTIONSCautions call attention to instructions which must be followed

precisely to avoid damaging the product, process or its surroundings.

NOTESNotes are used for supplementary information.

General Information

Ensure that the operator reads and understands the decals andconsults the manuals before maintenance or operation.

Ensure that the Operation and Maintenance manual, and themanual holder, are not removed permanently from the machine.

Ensure that maintenance personnel are adequately trained,competent and have read the Maintenance Manuals.

Make sure that all protective covers are in place and that thecanopy/doors are closed during operation.

The specification of this machine is such that the machine is notsuitable for use in flammable gas risk areas. If such an application isrequired then all local regulations, codes of practice and site rules mustbe observed. To ensure that the machine can operate in a safe andreliable manner, additional equipment such as gas detection, exhaustspark arrestors, and intake (shut−off) valves may be required,dependant on local regulations or the degree of risk involved.

A weekly visual check must be made on all fasteners/fixing screwssecuring mechanical parts. In particular, safety−related parts such ascoupling hitch, drawbar components, road−wheels, and lifting bail

should be checked for total security.

All components which are loose, damaged or unserviceable, must

be rectified without delay.

Compressed air

Compressed air can be dangerous if incorrectly handled. Beforedoing any work on the unit, ensure that all pressure is vented from thesystem and that the machine cannot be started accidentally.

Ensure that the machine is operating at the rated pressure and thatthe rated pressure is known to all relevant personnel.

All air pressure equipment installed in or connected to the machinemust have safe working pressure ratings of at least the machine ratedpressure.

If more than one compressor is connected to one commondownstream plant, effective check valves and isolation valves must befitted and controlled by work procedures, so that one machine cannotaccidently be pressurised / over pressurised by another.

Compressed air must not be used for a direct feed to any form ofbreathing apparatus or mask.

The discharged air contains a very small percentage of compressorlubricating oil and care should be taken to ensure that downstreamequipment is compatible.

If the discharged air is to be ultimately released into a confinedspace, adequate ventilation must be provided.

When using compressed air always use appropriate personalprotective equipment.

All pressure containing parts, especially flexible hoses and theircouplings, must be regularly inspected, be free from defects and bereplaced according to the Manual instructions.

Avoid bodily contact with compressed air.

The safety valve located in the separator tank must be checkedperiodically for correct operation.

Materials

The following substances may be produced during the operation ofthis machine:. brake lining dust. engine exhaust fumes

AVOID INHALATION

Ensure that adequate ventilation of the cooling system and exhaustgases is maintained at all times.

The following substances are used in the manufacture of thismachine and may be hazardous to health if used incorrectly:

. anti−freeze

. compressor lubricant

. engine lubricant

. preservative grease

. rust preventative

. diesel fuel

. battery electrolyte

AVOID INGESTION, SKIN CONTACT AND INHALATION OFFUMES

Should compressor lubricant come into contact with the eyes, thenirrigate with water for at least 5 minutes.

Should compressor lubricant come into contact with the skin, thenwash off immediately.

Consult a physician if large amounts of compressor lubricant areingested.

Consult a physician if compressor lubricant is inhaled.

Never give fluids or induce vomiting if the patient is unconscious orhaving convulsions.

Safety data sheets for compressor and engine lubricants should beobtained from the lubricant supplier.

Battery

Batteries contain corrosive liquid and produce explosive gas. Donot expose to naked lights. Always wear personal protective clothingwhen handling. When starting the machine from a slave battery ensurethat the correct polarity is observed and that connections are secure.

DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERYSINCE THIS MAY CAUSE IT TO EXPLODE.

Radiator

Hot engine coolant and steam can cause injury. Ensure that theradiator filler cap is removed with due care and attention.

Engine starting fluid (ether)

Use and recharge system only with suppliers instructions andreplacement parts.

Some machines are fitted with an ether cold starting aid.

SAFETY 10

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

Do NOT use on engines which are provided with inlet heaters.

AVOID INGESTION, INHALATION, HOT SURFACES AND NAKEDLIGHTS

Transport

When loading or transporting machines ensure that the specifiedlifting and tie down points are used.

When loading or transporting machines ensure that the towingvehicle, its size, weight, towing hitch and electrical supply are allsuitable to provide safe and stable towing at speeds either, up to thelegal maximum for the country in which it is being towed or, as specifiedfor the machine model if lower than the legal maximum.

Before towing the machine, ensure that:−

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

. the canopy is secure.

. all ancillary equipment is stored in a safe and secure manner.

When parking always use the handbrake and, if necessary, suitablewheel chocks.

GENERAL INFORMATION − ESA (CE/HA) 11

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

‘CE’

‘HA’

GENERAL INFORMATION − ESA (CE/HA)12

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

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

COMPRESSOR

Actual free air delivery. m3/min/cfm

23,3/825

27,0/950

29,9/1060

21,5/750

23,3/825

Normal operating dischargepressure.

psi/bar/kPa

175/12/1200

125/8,6/860

125/8,6/860

300/21/2100

250/17,2/1724

Maximum allowable pressure psi/bar/kPa

200/13,8/1380

150/10,3/1030

150/10,3/1030

325/22,4/2240

275/19/1900

Safety valve setting psi/bar/kPa

217/15/1500

217/15/1500

217/15/1500

362/25/2500

362/25/2500

Maximum pressure ratio(absolute)

8:1 8:1 8:1 18:9:1 18:9:1

Operating ambient temperaturerange

°C −10/+50 −10/+50 −10/+50 −10/+50 −10/+50

Maximum discharge temperature °C 120 120 120 120 120

COMPRESSOR

Cooling system. Oil Injection

Oil capacity. Litre 70 70 70 75 75

Maximum oil system temperature °C 120 120 120 120 120

Maximum oil system pressure psi/bar/kPa

217/15/1500

217/15/1500

217/15/1500

362/25/2500

362/25/2500

LUBRICATING OILSPECIFICATION (for thespecified ambient temperatures)

SEE NOTE − 1specified ambient temperatures).

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

ENGINE QSL (300HP) QSL (300HP) QSL (340HP) QSL (340HP) QSL (340HP)

Number of cylinders /Displacement

/Litre 6/8,9 6/8,9 6/8,9 6/8,9 6/8,9

Oil capacity. Litre 24 24 24 24 24

Speed at full load. Rev min−1 1800 1800 1800 1800 1800

Speed at idle. Rev min−1 1200 1200 1200 1350 1350

Electrical system. V DC 24 24 24 24 24

Power available at rated speed KW 224 224 255 255 255

Fuel tank capacity. Litre 550 550 550 550 550

Coolant capacity Litre 48 48 48 48 48

Max. gross weight kg 5125 5125 5125 5125 5125

Shipping weight kg 4665 4665 4665 4665 4665

NOTE − 1

ABOVE −23�C(−9�F)Recommended: PRO−TEC or XHP 605Approved: SAE 10W, API CF−4/CG−4

PRO−TEC compressor fluid is factory−fitted, for use at all ambienttemperatures above −23�C(−9�F).

NOTE: Warranty may be extended only by continuous use ofPRO−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 theresulting mixture could cause damage to the airend.

In the event that PRO−TEC is not available and / or the end userneeds to use an approved single grade engine oil, the complete systemincluding separator / receiver, cooler and pipework must be flushedclear of the first fill fluid and new Doosan oil filters installed.When this has been completed, the following oils are approved:

for ambient temperatures above −23�C(−9�F),SAE 10W, API CF−4/CG−4

Safety data sheets can be obtained on request from your Doosandealership.

INFORMATION ON AIRBORNE NOISE (CE regions)

− The A−weighted emission sound pressure level

. 83 dB(A), uncertainty 1 dB(A)

− The A−weighted emission sound power level

. 100 dB(A), uncertainty 1 dB(A)

The operating conditions of the machinery are in compliance with ISO3744:1995 and EN ISO 2151:2004

GENERAL INFORMATION − ESA (CE/HA) 13

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

WEIGHT

Shipping weight. 4665 kg

Maximum weight. 5725 kg

Maximum horizontal towing force. 5012 kgf Estimated

WHEELS AND TYRES − SITE RUNNING GEAR

Number of wheels. 4

Tyre size. 750x16x6PR

Tyre pressure. 3,5 bar (50 lbf in−2)

TOWING SPEED

Maximum towing speed 30 km h−1

(20 mile h−1)

Further information may be obtained by request through thecustomer services department.

OPERATING INSTRUCTIONS14

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

COMMISSIONING

Upon receipt of the unit, and prior to putting it into service, it isimportant to adhere strictly to the instructions given below in PRIOR TOSTARTING.

Ensure that the operator reads and understands the decals andconsults the manuals before maintenance or operation.

Ensure that the position of the emergency stop device is known andrecognised by its markings. Ensure that it is functioning correctly andthat the method of operation is known.

Before towing the unit, ensure that the tyre pressures are correct(refer to the GENERAL INFORMATION section of this manual) andthat the handbrake is functioning correctly (refer to theMAINTENANCE section of this manual). Before towing the unit duringthe hours of darkness, ensure that the lights are functioning correctly(where fitted).

Ensure that all transport and packing materials are discarded.

Ensure that the correct fork lift truck slots or marked lifting / tie downpoints are used whenever the machine is lifted or transported.

When selecting the working position of the machine ensure thatthere is sufficient clearance for ventilation and exhaust requirements,observing any specified minimum dimensions (to walls, floors etc.).

Adequate clearance needs to be allowed around and above themachine to permit safe access for specified maintenance tasks.

Ensure that the machine is positioned securely and on a stablefoundation. Any risk of movement should be removed by suitablemeans, especially to avoid strain on any rigid discharge piping.

Attach the battery cables to the battery(s) ensuring that they aretightened securely. Attach the negative cable bofore attaching thepositive cable

WARNING: All air pressure equipment installed in or connectedto the machine must have safe working pressure ratings of at leastthe machine rated pressure, and materials compatible with thecompressor lubricant (refer to the GENERAL INFORMATIONsection).

WARNING: If more than one compressor is connected to onecommon downstream plant, effective check valves and isolationvalves must be fitted and controlled by work procedures, so thatone machine cannot accidently be pressurised / over pressurisedby another.

WARNING: If flexible discharge hoses are to carry more than 7 barpressure then it is recommended that safety retaining wires areused on the hoses.

OPERATING INSTRUCTIONS 15

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

PRIOR TO STARTING

1. Place the unit in a position that is as level as possible. The designof the unit permits a 15 degree lengthways and sideways limit on outof level operation. It is the engine, not the compressor, that is the limitingfactor.

When the unit has to be operated out of level, it is important to keepthe engine oil level near the high level mark (with the unit level).

CAUTION: Do not overfill either the engine or the compressor with oil.

2. Check the engine lubrication oil in accordance with the operatinginstructions in the Engine Operator’s Manual.

3. Check the compressor oil level in the sight glass located on theseparator tank.

4. Check the diesel fuel level. A good rule is to top up at the end of eachworking day. This prevents condensation from occurring in the tank.

CAUTION: Use only a No. 2−D diesel fuel oil with a minimum octanenumber of 45 and a sulphur content not greater than 0,5%.

CAUTION: When refuelling:−. switch off the engine.. do not smoke.. extinguish all naked lights.. do not allow the fuel to come into contact with hot surfaces.. wear personal protective equipment.

5 Drain fuel filter water separator of water ensuring that anyreleased fuel is safely contained.

6. Check the radiator coolant level (with the unit level).

7. Open the service valve(s) to ensure that all pressure is relievedfrom the system. Close the service valve(s).

8. CAUTION: Do not operate the machine with the canopy/doors inthe open position as this may cause overheating and operators to beexposed to high noise levels.

9. Check the emergency stop. Rotate knob as indicated to release.

10.Close the manual relief valve inside the service door near theemergency stop.

When starting or operating the machine in temperatures below orapproaching 0�C, ensure that the operation of the regulation system,the unloader valve, the safety valve, and the engine are not impairedby ice or snow, and that all inlet and outlet pipes and ducts are clear ofice and snow.


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

OPERATING CONTROLS AND INSTRUMENTS

The operating controls and instruments are arrangedon the control panel as shown above. A description ofeach panel device is as follows:

1. Panel Light: Illuminates the instrumentcontrol panel controlled by Switch 14.

2. High Compressor Temp: Fault indicatorlamp. Indicates shutdown due to highcompressor temperature.

3. Low Radiator Coolant Level: Alarm indicatorlamp. Indicates engine coolant needs service.

4. Low Engine Oil Pressure: Fault indicatorlamp. Indicates shutdown due to low engine oilpressure.

5. Restricted Air Filter: Alarm indicator lamp.Indicates engine/compressor air inlet filtersneed service.

6. High Engine Coolant Temp: Fault indicatorlamp. Indicates shutdown due to high enginewater temperature.

7. Restricted IQ Air Filters: Fault indicatorlamp. Indicates shutdown due to high pressurein ”IQ” air filters (if equipped).

8. Low Fuel Level: Fault indicator lamp.Indicates shutdown due to low fuel level. Lampblinks at low fuel warning.

9. Compressor Malfunction: Fault indicatorlamp. Indicates shutdown due to compressorsystem fault. Refer to Fault Code List.

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

11. Engine Malfunction: Engine Fault code.Refer to service card or engine manual forcodes and service requirements.

12. Malfunction Code (4 Digit): Compressor orengine fault. Refer to manual for list of codesand service requirements.

13. Inlet Heater / Wait to Start Lamp: Indicatesengine manifold pre heater is energized. Waituntil lamp extinguishes before engagingstarter.

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

15. Service Air Switch: Momentary contactswitch. Allows engine to warm up at lowcompressor pressure.

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

17. Heater Switch: ON/OFF Power Switch forregulation and IQ heaters. Prevents freeze upin cold weather.

18. Hourmeter: Indicates machine operatinghours.

19. E−STOP: Emergency Stop Push Button (ESAunits only). Push to stop, turn to release.

20. Discharge Air Pressure Gage: Indicatespressure in receiver tank, normally from 0psi(kPa) to the rated pressure of the machine.

21. Engine Tachometer: Indicates engine speedin RPM from 0 when stopped to full speed.

22. Fuel Level Gage: Indicate fuel level in tank.

23. Engine Water Temp Gage

24. Compressor Oil Temp Gage

25. Engine Oil Pressure Gage

26. Battery Voltage Gage


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

CONDITIONALERT SHUTDOWN

CONDITION CODE LIGHTBLINKS

CODE LIGHTSTEADY

DELAY(sec)

Engine Speed < Min. RPM 1 CPRSRMalfunction.

30

Engine Speed > Max. RPM 2 CPRSRMalfunction.

30

Engine Crank Time Exceeded 3 CPRSRMalfunction.

0

High Engine Oil Temperature 5 CPRSRMalfunction.

High Intake ManifoldTemperature

6 CPRSRMalfunction.

Water In Fuel 8 CPRSRMalfunction.

Engine Not Responding ToThrottle command

10 CPRSRMalfunction.

Too Many Start AttemptsDuring Autostart


0

Engine Shut Itself Down:reason unknown


0

Low AE Oil Pressure 31 CPRSRMalfunction.

20

Disch. Temp (RT2)Sensor Fault


10

Sep. Tank Pressure (PT1)Sensor Fault


Seperator Tank Pressure >20PSI During Start Attempt(Engine Will Not Crank)


0


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

ALERT SHUTDOWN

CODE LIGHTBLINKS

CODE LIGHTSTEADY

DELAY(sec)

Machine Over Pressure 35 CPRSRMalfunction.

1

Safety Valve Open 36 CPRSRMalfunction.

2

Seperator Tank Temp > (247deg.F)


3

Machine ID Not Valid 51 CPRSRMalfunction.

0

Sep. Tank Temp (RT1)Sensor Fault


10

Reg. System Pressure (PT2)Sensor Fault


Estop Button Pushed 55 CPRSRMalfunction.


3

Minimum Pressure Not Met 56 CPRSRMalfunction.

Serial Comm. Problem 70 CPRSRMalfunction.

CAN Bus Problem 71 CPRSRMalfunction.

Auto Start/Stop ModuleFailure − No Comm. for 17sec.


Dedicated Lights:

Low Fuel Level Fuel Level Fuel Level 3

Air Filter Restriction Soiled Filter

Low Battery Voltage Battery ChargingCondition

Low Engine Oil Pressure Low Engine OilPressure

Low Coolant Level Engine CoolantLevel

High Engine CoolantTemperature

High EngineTemp.

High EngineTemp.

10

IQ Filter Restriction IQ Filt. Rest 3

High Discharge Temp.(RT2>247 deg. F)

High CompTemp.

3


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


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


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






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


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


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

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


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

STARTING THE MACHINE

Ensure emergency stop button is reset.

WARNING: Under no circumstances should volitile fluids suchas ether be used for starting this machine.

All normal starting functions are incorporated in the key operatedswitch.

1

3

2

Turn the keyswitch to position 1;

− The auxillary start compressor will operate to close the inlet valve.

− The wedge controller will execute a lamp test.

− The low engine oil pressure and low battery lamps will flashindicating proper communication between wedge and engine ECM.

Inlet heater / Wait to start light. Turn the key switch to on position 1 until the inlet heater warninglight 13 extinguishes.

NOTE: Position 2 is not used

. Turn the key switch to crank position 3 (engine start position).

. Release to on position 1 when the engine starts. The engine will nowbe running at a reduced speed.

. During warm up, the engine will idle at 1500RPM. After warm upthe engine will idle at a lower speed.

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 instrumentpanel, is incorporated in the regulation system. (The valveautomatically returns to the start position when the machine is switchedoff and air pressure relieved from the system).

. Allow the engine to reach its operating temperature − then press thepressure control button 15.

. At this point in the operation of the machine it is safe to apply full loadto the engine.

CAUTION: If the engine does not start, repeat the above procedureafter waiting for a minimum of one minute.

If the engine fails to start, refer to the MAINTENANCE section of thismanual, 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 toreduce the engine temperature.

. Turn the ON/OFF start switch to the 0 (off) position.

NOTE: As soon as the engine stops, the automatic blowdown valve willrelieve all pressure from the system,except for the discharge pipe /manifold area. This area should be depressurised by opening thedischarge valve, keeping clear of any airflow from it.

If the automatic blowdown valve fails to operate, then pressure mustbe relieved from the system by means of the service valve(s).

WARNING: When relieving system pressure by means of theservice valve(s), a small amount of pressure will remain in thesystem. No maintenance work should be carried out whilst thissituation exists. This pressure may be relieved by slowlyoperating the manual blowdown valve.

CAUTION: Never allow the machine to stand idle with pressure in thesystem.

EMERGENCY STOPPING

In the event that the unit has to be stopped in an emergency,PRESS THE EMERGENCY STOP SWITCH ON THE FRONT OFTHE MACHINE AND ENSURE THAT IT ENGAGES INDEPRESSED POSITION. (IF FITTED)

If the unit is not fitted with an emergency stop switch, rotate the startswitch to the (0) off position.

RE−STARTING AFTER AN EMERGENCY

Disengage emergency stop control from engaged (depressed)position. (IF FITTED)

If the machine has been switched off because of a machinemalfunction, then identify and correct the fault before attempting tore−start.

If the machine has been switched off for reasons of safety, thenensure that the machine can be operated safely before re−starting.

Refer to the PRIOR TO STARTING and STARTING THE UNITinstructions earlier in this section before re−starting the machine.

MONITORING DURING OPERATION

Should any of the safety shut-down conditions occur, the unit willstop. These are:

Refer to the wedge diagnostic display codes table for a listing ofshutdown conditions.

CAUTION: To ensure an adequate flow of oil to the compressor at lowtemperature, never allow the discharge pressure to fall below 3,5 bar.


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

DECOMMISSIONING

When the machine is to be permanently decommissioned ordismantled, it is important to ensure that all hazard risks are eithereliminated or notified to the recipient of the machine. In particular:−

. Do not destroy batteries or components containing asbestoswithout containing the materials safely.

. Do not dispose of any pressure vessel that is not clearly markedwith its relevant data plate information or rendered unusable by drilling,cutting etc.

. Do not allow lubricants or coolants to be released into land surfacesor drains.

. Do not dispose of a complete machine without documentationrelating to instructions for its use.

MAINTENANCE24

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

MAINTENANCEInitial 500

miles/850 km

Daily Weekly Monthly 3 Monthly.

500 hrs.

6 Monthly.

1000 hrs

12 Monthly.

2000 hrs

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 heat exchanger exterior C

* Engine heat exchanger exterior C

Fasteners, Guards C

Air Cleaner Elements R/WI

*Disregard if not appropriate for this particular machine.

(1) or 3000 miles/5000km whichever is the sooner

(2) or as defined by local or national legislation

C = Check (adjust, clean or replace as necessary)

CBT =check before towing.

CR = Check and report

D = Drain

G = Grease

R=Replace

T = Test

W I =or when indicated if earlier.

Refer to specific sections of the operator’s manual for more

information.

MAINTENANCE 25

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

Initial 500miles

/850 km


500 hrs.

6 Monthly.

1000 hrs

12

Monthly.

1500 hrs

12

Monthly.

2000 hrs

*Fuel/Water Separator Element RCompressor Oil Filter Element RCompressor Oil REngine Oil Change REngine Oil Filter R*Water Pump Grease. R*Wheels (Bearings, Seals, etc.) C*Engine Coolant C RFuel Filter Element R*Injection Nozzle Check CShutdown Switch Settings TScavenger Orifice & Related Parts COil Separator Element R*Feed Pump Strainer Cleaning. C*Valve Clearance Check CLights (running, brake, & turn) CBT

Pintle Eye Bolts CBT

*Brakes CBT C*Brake linkage CEmergency stop TFasteners CRunning gear linkage GSafety valve CRunning gear bolts(1) C







D = Drain

G = Grease

R=Replace

T = Test



information.

MAINTENANCE26

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

Initial 500miles

/850 km


500 hrs.

6 Monthly.

1000 hrs

12 Monthly.

2000 hrs

Scavenge line CPressure system CEngine breather element CSeparator tank (2) exterior CRLubricator (Fill) C

2 Yrs 4 Yrs 6 Yrs

Safety valve CHoses RSeparator tank (2) interior C







D = Drain

G = Grease

R=Replace

T = Test



information.

MAINTENANCE 27

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

ROUTINE MAINTENANCE

This section refers to the various components which requireperiodic maintenance and replacement.

The SERVICE/MAINTENANCE CHART indicates the variouscomponents’ descriptions and the intervals when maintenance has totake place. Oil capacities, etc., can be found in the GENERALINFORMATION section of this manual.

For any specification or specific requirement on service orpreventative maintenance for the engine, refer to the EngineManufacturer’s Manual.

Compressed air can be dangerous if incorrectly handled. Beforedoing any work on the unit, ensure that all pressure is vented from thesystem and that the machine cannot be started accidentally.

If the automatic blowdown fails to operate, then pressure must begradually relieved by operating the manual blowdown valve. Suitablepersonal protective equipment should be worn.

Ensure that maintenance personnel are adequately trained,competent and have read the Maintenance Manuals.

Prior to attempting any maintenance work, ensure that:−

. all air pressure is fully discharged and isolated from the system. Ifthe automatic blowdown valve is used for this purpose, then allowenough time for it to complete the operation.

NOTE: Pressure will always remain in the part of the system betweenthe minimum pressure valve and the discharge valve after operation ofthe auto blowdown valve.

THIS PRESSURE MUST BE RELIEVED BY CAREFULLY:

(a) DISCONNECTING ANY DOWNSTREAM EQUIPMENT.

(b) OPENING THE DISCHARGE VALVE TO ATMOSPHERE.

(USE HEARING PROTECTION IF NECESSARY).

. the machine cannot be started accidently or otherwise, by postingwarning signs and/or fitting appropriate anti−start devices.

. all residual electrical power sources (mains and battery) areisolated.

Prior to opening or removing panels or covers to work insidea machine, ensure that:−

. anyone entering the machine is aware of the reduced level ofprotection and the additional hazards, including hot surfaces andintermittently moving parts.

. the machine cannot be started accidently or otherwise, by postingwarning signs and/or fitting appropriate anti−start devices.

Prior to attempting any maintenance work on a runningmachine, ensure that:−

. the work carried out is limited to only those tasks which require themachine to run.

. the work carried out with safety protection devices disabled orremoved is limited to only those tasks which require the machine to berunning with safety protection devices disabled or removed.

. all hazards present are known (e.g. pressurised components,electrically live components, removed panels, covers and guards,extreme temperatures, inflow and outflow of air, intermittently movingparts, safety valve discharge etc.).

. appropriate personal protective equipment is worn.

. loose clothing, jewellery, long hair etc. is made safe.

. warning signs indicating that Maintenance Work is in Progress areposted in a position that can be clearly seen.

Upon completion of maintenance tasks and prior to returningthe machine into service, ensure that:−

. the machine is suitably tested.

. all guards and safety protection devices are refitted.

. all panels are replaced, canopy and doors closed.

. hazardous materials are effectively contained and disposed of.

PROTECTIVE SHUTDOWN SYSTEM

Refer to the Wedge diagnostic display codes table for a listing ofshutdown conditions.

Low engine fuel level switch.

At three month intervals, test the low engine fuel level switch circuitas follows:

. Start the machine.

Note: Do not press the load button.

. Disconnect the switch, the machine should shutdown.

. Re−connect the switch.

At twelve month intervals, test the low engine fuel level switch byremoving and operating the float manually.

CAUTION: Never remove or replace switches when the machineis running.

SCAVENGE LINE

The scavenge line runs from the combined orifice/drop tube in theseparator tank, to the orifice fitting located in the airend.

Examine the orifice, check valve and hoses at every service or inthe event of oil carryover into the discharge air.

It is good preventative maintenance to check that the scavenge lineand tube are clear of any obstruction each time the compressorlubricant is changed as any blockage will result in oil carryover into thedischarge air.

COMPRESSOR OIL FILTER

Refer to the MAINTENANCE CHART in this section for therecommended servicing intervals.

Removal

WARNING: Do not remove the filter(s) without first making surethat the machine is stopped and the system has been completelyrelieved of all air pressure. (Refer to STOPPING THE UNIT in theOPERATING INSTRUCTIONS section of this manual).

MAINTENANCE28

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

Clean the exterior of the filter housing and remove the spin−onelement by turning it in a counter−clockwise direction.

Inspection

Examine the filter element.

CAUTION: If there is any indication of the formation of varnishes,shellacs or lacquers on the filter element, it is a warning that thecompressor lubricating and cooling oil has deteriorated and that itshould be changed immediately. Refer to LUBRICATION later in thissection.

Reassembly

Clean the filter gasket contact area and install the new element byscrewing in a clockwise direction until the gasket makes contact withthe filter housing. Tighten a further 1/2 to 3/4 of a revolution.

CAUTION: Start the machine (refer to PRIOR TO STARTING andSTARTING THE UNIT in the OPERATING INSTRUCTIONS sectionof this manual) and check for leakage before the machine is put backinto service.

COMPRESSOR OIL SEPARATOR ELEMENT

Refer to the SERVICE / MAINTENANCE CHART in this section forservice intervals.

Removal

WARNING: Do not remove the filter(s) without first making surethat the machine is stopped and the system has been completelyrelieved of all air pressure. (Refer to STOPPING THE UNIT in theOPERATING INSTRUCTIONS section of this manual).

Disconnect all hoses and tubes from the separator tank cover plate.Remove the drop−tube from the separator tank cover plate and thenremove the cover plate. Remove the separator element.

Inspection

Examine the filter element. Examine all hoses and tubes, andreplace if necessary.

Reassembly

Thoroughly clean the orifice/drop tube and filter gasket contact areabefore reassembly. Install the new element.

WARNINGDo not remove the staple from the anti−static gasket on the

separator element since it serves to ground any possible staticbuild−up. Do not use gasket sealant since this will affect electricalconductance.

Reposition the cover plate, taking care not to damage the gasket,and replace the cover plate screws tightening in a criss−cross patternto the recommended torque (refer to the TORQUE SETTING TABLElater in this section).

Replace the drop−tube and reconnect all hoses and tubes to theseparator tank cover plate.

Replace the compressor oil (refer to LUBRICATION later in thissection).

CAUTION: Start the machine (refer to PRIOR TO STARTING andSTARTING THE UNIT in the OPERATING INSTRUCTIONS sectionof this manual) and check for leakage before the machine is put backinto service.

COMPRESSOR OIL COOLER AND ENGINE RADIATOR AIRCHARGE COOLER

When grease, oil and dirt accumulate on the exterior surfaces of theoil cooler and radiator, the efficiency is impaired. It is recommended thateach month the oil cooler and radiator be cleaned by directing a jet ofcompressed air, (carrying if possible a non−flammable cleaningsolvent) over the exterior core of the cooler/radiator. This shouldremove any accumulation of oil, grease and dirt from the exterior coreof the cooler so that the entire cooling area can radiate the heat of thelubricating and cooling oil/water into the air stream.

WARNING: Hot engine coolant and steam can cause injury. Whenadding coolant or antifreeze solution to the engine radiator, stopthe engine at least one minute prior to releasing the radiator fillercap. Using a cloth to protect the hand, slowly release the filler cap,absorbing any released fluid with the cloth. Do not remove thefiller cap until all excess fluid is released and the engine coolingsystem fully depressurised.

WARNING: Follow the instructions provided by the antifreezesupplier when adding or draining the antifreeze solution. It isadvisable to wear personal protective equipment to prevent skinand eye contact with the antifreeze solution.

AIR FILTER ELEMENT

The air filter should be inspected regularly (refer to theSERVICE/MAINTENANCE CHART) and the element replaced whenthe restriction indicator lamp illuminates. The dust collector box(es)should be cleaned daily (more frequently in dusty operatingconditions) and not allowed to become more than half full.

The safety element should be renewed every 3000 hours or everythird change of the main element, whichever comes first.

Removal

CAUTION: Never remove and replace element(s) when the machineis running.

Clean the exterior of the filter housing and remove the filter elementby releasing the nut.

If the safety element is to be renewed, thoroughly clean the interiorof the filter housing prior to removing the safety element.

Inspection

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

MAINTENANCE 29

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

CAUTION: If inspection reveals damage to the main element, thesafety element must be replaced.

Check the seal at the end of the element and replace if any sign ofdamage is evident.

Reassembly

Assemble the new element into the filter housing ensuring that theseal seats properly.

Secure the element in the housing by hand tightening the nut.

Assemble the dust collector box parts, ensuring that they arecorrectly positioned.

Before restarting the machine, check that all clamps are tight.

NOTE: In the event that a new filter element is not readily available, theelement can be re−used after cleaning. In this case the followingprocedure must be carried out:

Clean the element by directing a jet of clean, dry compressed air,no more than 5 bar, at an angle of 45 degrees to the outside of theelement. Carefully blow any dust from each fold of the element.

Compressed air cleaning is only recommended when a newelement is not available.

CAUTION: Safety elements must not be cleaned and re−used.

VENTILATION

Always check that the air inlets and outlets are clear of debris etc.

CAUTION: NEVER clean by blowing air inwards.

COOLING FAN DRIVE

Periodically check that the fan mounting bolt in the fan hub has notloosened. If, for any reason, it becomes necessary to remove the fanor re−tighten the fan mounting bolt, apply a good grade of commerciallyavailable thread locking compound to the bolt threads and tighten to thetorque value shown in the TORQUE SETTING TABLE later in thissection.

The fan belt(s) should be checked regularly for wear and correcttensioning.

FUEL SYSTEM

The fuel tank should be filled daily or every eight hours. To minimisecondensation in the fuel tank(s), it is advisable to top up after themachine is shut down or at the end of each working day. At six monthintervals drain any sediment or condensate that may haveaccumulated in the tank(s).

FUEL FILTER WATER SEPARATOR

The fuel filter water separator contains a filter element which shouldbe replaced at regular intervals (see the SERVICE/MAINTENANCECHART).

CHARGE COOLER PIPEWORK:−

Inspect all hoses and clips on the charge cooler pipe work.

Engine damage will occur if the charge cooling system leaks.

HOSES

All components of the engine cooling air intake system should bechecked periodically to keep the engine at peak efficiency.

At the recommended intervals, (see theSERVICE/MAINTENANCE CHART), inspect all of the intake lines tothe air filter, and all flexible hoses used for air lines, oil lines and fuellines.

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

ELECTRICAL SYSTEM

WARNING: Always disconnect the battery cables beforeperforming any maintenance or service.

Inspect the safety shutdown system switches and the instrumentpanel relay contacts for evidence of arcing and pitting. Clean wherenecessary.

Check the mechanical action of the components.

Check the security of electrical terminals on the switches and relaysi.e. nuts or screws loose, which may cause local hot spot oxidation.

Inspect the components and wiring for signs of overheating i.e.discolouration, charring of cables, deformation of parts, acrid smellsand blistered paint.

BATTERY

Keep the battery terminals and cable clamps clean and lightlycoated with petroleum jelly to prevent corrosion.

The retaining clamp should be kept tight enough to prevent thebattery from moving.

PRESSURE SYSTEM

At 3 month intervals it is necessary to inspect the externalsurfaces of the system (from the airend through to the dischargevalve(s)) including hoses, tubes, tube fittings and the separator tank,for visible signs of impact damage, excessive corrosion, abrasion,tightness and chafing. Any suspect parts should be replaced beforethe machine is put back into service.

TYRES/TYRE PRESSURE

See the GENERAL INFORMATION section of this manual.

RUNNING GEAR/WHEELS

Check the wheel nut torque 20 miles (30 kilometres) after refittingthe wheels. Refer to the TORQUE SETTING TABLE later in thissection.

The bolts securing the running gear to the chassis should bechecked periodically for tightness (refer to theSERVICE/MAINTENANCE CHART for frequency) and re−tightenedwhere necessary. Refer to the TORQUE SETTING TABLE later in thissection.

MAINTENANCE30

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

LUBRICATION

The engine is initially supplied with engine oil sufficient for a nominalperiod of operation (for more information, consult The EngineManufacturer’s Manual).

CAUTION: Always check the oil levels before a new machine is put intoservice.

If, for any reason, the unit has been drained, it must be re−filled withnew oil before it is put into operation.

ENGINE LUBRICATING OIL

The engine oil should be changed at the engine manufacturer’srecommended intervals. Refer to the SERVICE / MAINTENANCECHART.

ENGINE LUBRICATING OIL SPECIFICATION

Refer to the Engine Manufacturer’s Manual or LubricationSpecification list.

ENGINE OIL FILTER ELEMENT

The engine oil filter element should be changed at the enginemanufacturer’s recommended intervals. Refer to the SERVICE /MAINTENANCE CHART..

COMPRESSOR LUBRICATING OIL

Refer to the SERVICE/MAINTENANCE CHART in this section forservice intervals.

NOTE: If the machine has been operating under adverse conditions,or has suffered long shutdown periods, then more frequent serviceintervals will be required.

WARNING: DO NOT, under any circumstances, remove any drainplugs or the oil filler plug from the compressor lubricating andcooling system without first making sure that the machine isstopped and the system has been completely relieved of all airpressure (refer to STOPPING THE UNIT in the OPERATINGINSTRUCTIONS section of this manual).

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

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

NOTE: If the oil is drained immediately after the machine has beenrunning, then most of the sediment will be in suspension and willtherefore drain more readily.

CAUTION: Some oil mixtures are incompatible and result in theformation of varnishes, shellacs or lacquers which may be insoluble.

NOTE: Always specify PRO−TEC oil for use at all ambienttemperatures above −23�C.

RUNNING GEAR WHEEL BEARINGS

Wheel bearings should be packed with grease every 6 months. Thetype of grease used should conform to specification MIL−G−10924.

MAINTENANCE 31

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

9/230 9/230HA 9/270 9/270HA 9/300 9/300HA 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

Normally, regulation requires no adjusting, but if correct adjustmentis lost, proceed as follows:

Refer to the diagram above.

A Adjusting screw

Start the machine (Refer to STARTING INSTRUCTIONS in theOPERATING INSTRUCTIONS section of this manual).

Adjust the service valve on the outside of the machine to maintainnormal operating discharge pressure (refer to GENERALINFORMATION) and full speed position. If the tachometer moves awayfrom the full speed position before normal operating dischargepressure is attained, then turn the adjusting screw ‘A’ clockwise toincrease the pressure. Optimum adjustment is achieved when thethrottle just moves from its full speed position and the pressureincreases slightly.

Close the service valve. The engine will slow to idle speed.

CAUTION: Never allow the idle pressure to exceed maximumallowable pressure (refer to GENERAL INFORMATION).

MAINTENANCE32

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

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 ADJUSTMENT17/235 21/215

Normally, regulation requires no adjusting, but if correct adjustmentis lost, proceed as follows:

Refer to the diagram above.

With the unit stopped, disconnect ballast spring ‘A’ from the butterflylever. Loosen the two screws securing bracket ‘C’ to main bracket ‘J‘.

Loosen screw ‘D‘ and rotate the butterfly valve pivot shaft ‘K‘ fullyclockwise until the valve is closed. Position lever ‘L‘ approximately 10°after vertical and tighten screw ‘D‘.

Keep the butterfly lever in the closed position and with the the aircylinder fully contracted tighten the screws holding bracket ‘C’ to themain bracket ‘J‘.

Allow the cylinder to return to its extended position and reconnectthe ballast spring ‘A‘.

IMPORTANT: Ensure all components are aligned and move freely.

Start engine: Note receiver pressure. Warm up pressure should be3,5−5,0 bar (50−70 p.s.i.).

To increase the warm up pressure, turn the air cylinder rod in ananti−clockwise direction to open the butterfly valve.

To reduce warm up pressure, turn air cylinder rod in clockwisedirection to close butterfly valve.

When the engine is warmed up, press the service air switch onthe control panel to commence normal regulation.

Set pressure by adjusting the screw ‘E’ on the pressure regulator‘F’. Turn the screw clockwise to increase pressure and anticlocwise toreduce pressure.

MAINTENANCE 33

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

TORQUE VALUES

TABLE 1 INCH FASTENERS

NOMINAL DESIGN TORQUE

8AE J249GRADE 5

(HEAD MARKING)

8AE J249GRADE 8

(HEAD MARKING)TYPICAL RECTANGULAR TORQUE

PATTERN

CAPSCREWOR NUT

THREAD SIZEAND PITCH

TYPICAL SQUARE TORQUEPATTERN

(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

5/8 − 11 203 150 287 212TYPICAL CIRCULAR TORQUE

3/4 − 10 361 266 509 376

TYPICAL CIRCULAR TORQUEPATTERN

MAINTENANCE34

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

TABLE 2 METRIC FASTENERS

NOMINAL DESIGN TORQUE

PROPERTYGRADE 8.8

(HEAD MARKING)

PROPERTYGRADE 10.9

(HEAD MARKING)

PROPERTYGRADE 12.9

(HEAD MARKING)

TYPICAL RECTANGULAR TORQUEPATTERN

CAPSCREWOR NUT

THREAD SIZEAND PITCH

TYPICAL SQUARE TORQUEPATTERN

(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 270TYPICAL CIRCULAR TORQUE

PATTERN

M20 X 2.5 441 325 610 450 713 526

MAINTENANCE 35

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

COMPRESSOR LUBRICATION

Portable Compressor Fluid Chart

Refer to these charts for correct compressor fluid required. Notethat the selection of fluid is dependent on the design operatingpressure of the machine and the ambient temperature expected tobe encountered before the next oil change.

Note: Fluids listed as “preferred” are required for extendedwarranty.

Compressor oil carryover (oil consumption) may be greaterwith the use of alternative fluids.

Design OperatingPressure

AmbientTemperature

Specification

100 psi to 300 psi −10�F to 125�F

(−23�C to 52�C)

Preferred:PRO−TECAlternate:ISO Viscosity Grade46 with rust andoxidation inhibitors,designed for aircompressor service

350 psi −10�F to 125�F

(−23�C to 52�C)

Preferred:XHP 605Alternate:XHP 405ISO Viscosity Grade68 Group 3 or 5 withrust and oxidationinhibitors designedfor air compressorservice.

65�F to 125�F

(18�C to 52�C)

Preferred:

XHP 605XHP1001

XHP605

PRO−TEC

100 − 300 PSI

RATED OPERATING PRESSURE

350 PSI

XHP 1001

10�F

125�F50�C

40�C

30�C

20�C

10�C

0�C

−10�C

−20�C

−30�C

−40�C

104�F

86�F

65�F

50�F

32�F

14�F

−10�F−22�F

−40�F

consult factory

XHP405

consultfactory

Preferred Doosan Fluids − Use of these fluids with original Doosanbranded filters can extend airend warranty. Refer to operator’smanual warranty section for details or contact your Portable Powerrepresentative.

Doosan Preferred Fluids 1 gal.(3.8 Litre)

5 gal.(19.0 Litre)

55 gal.(208.2Litre)

220 gal.(836 litre)

PRO−TEC − 89292973 89292981 22082598

XHP 605 − 22252076 22252050 22252068

XHP 1001 − 35612738 35300516 −

XHP 405 − 22252126 22252100 22252118

MACHINE SYSTEMS36

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

KEY

BAT Battery

CO RS232C comms

ECON Engine controller

ES Engine speed

FT Frequency throttle.Range = 150Hz(1200 RPM) to 375Hz(1800 RPM) at 24VDC

G2 Fly wheel

POUT1 Engine key switch

POUT2 Solenoid, start/run −L1

POUT3 Low fuel warning beacon (option)

POUT4 Spare

POUT5 Start relay

POUT6 Start compressor

POUT7 Hour meter

POUT8 Solenoid, unloader −L2

PT1 Pressure trancducer, separator tank.

0−225 PSIG − 9/235, 9/270, 9/300, 12/235.

0−500 PSIG − 21/215, 17/235

PT2 Pressure trancducer, regulation system 0−100 PSIG

RS Relay−spst

RT1 Thermistor, seperator tank temperature −30 − 255�F

RT2 Thermistor, Thermistor, airend discharge temperature −30 −

255�F

S7 Emergency stop

SC Start compressor

SI Switch inputs

SS Starter solenoid

SW1 IQ filter restriction

SW2 Alert, low fuel

SW3 Low fuel shutdown

SW4 Switch, service air

SW5 Air filter rest (option)

SW6 Switch, airend oil pressure (12PSI N.O.)

SW7 ESTOP Sense

SW8 Switch, start

SWB Switch batery disconnect

TE Transducer exitation

WCON Wedge controller

MACHINE SYSTEMS 37

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

CAN HI

CAN LO

CAN SHLD

RANGE = 150Hz (1200rpm) to 375Hz (1800rpm) at 24 VDC

WEDGECONTROLLER

FREQ THT+

ENGINEECM

WEDGE TO ENGINE INTERFACE

KEYSWITCH

ENGINE ECMDIAGNOSTIC INTERFACE

CO

NT

RO

LL P

AN

EL

HA

RN

ES

S

SOLENOID VALVES24VDC HEATERS

GUAGES

HOURMETER

CONTROL PANELSWITCHES

WEDGECONTROLLER

SPEED SENSOR

FUEL LEVEL SWITCH

PRESSURETRANSDUCER

TEMPERATURE SENSOR

BATTERY STARTING ANDCHARGING SYSTEM

ESTOP SWITCHES

HARNESS SYSTEM SCHEMATIC

MACHINE SYSTEMS38

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

EMU LOW PRESSURE ELECTRICAL PARTS 9/235, 12/235, 9/270, 9/300

PART NUMBERS DESCRIPTION QTY PERMACHINE

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

MACHINE SYSTEMS 39

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

EMU HIGH PRESSURE ELECTRICAL PARTS 21/215, 17/235

PART NUMBERS DESCRIPTION QTY PERMACHINE

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

FAULT FINDING40

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

FAULT CAUSE REMEDYNo reaction from instrumentpanel when key turned to (I)

Emergency stop actuated. Reset emergency stop button.panel when key turned to (I)position. 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 ifnecessary.

Relay failed. Replace the relay.

Faulty stop solenoid Check the stop solenoid

Engine stops while inservice or is reluctant tostart

Low fuel level. Fill fuel tank and bleed air from fuel system if necessary. (Refer toMAINTENANCE SECTION).

start.Safety shut-down system inoperation.

Check the safety shut-down switches.

Engine starts but stallswhen the switch returns to

Electrical fault Test the electrical circuits.when the switch returns toposition I. Low engine oil pressure. Check the oil level and the oil filter(s).position I.

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 notrun or engine shuts down

Electrical fault. Test the electrical circuits.run or engine shuts downprematurely. Low engine oil pressure. Check the oil level and oil filter(s).prematurely.

Safety shut-down system inoperation.

Check the safety shut-down switches.

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

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. Usereduced 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.

FAULT FINDING 41

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

FAULT CAUSE REMEDYAir discharge capacity toolow

Engine speed too low. Check the air cylinder and air filter(s).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 PRESSUREREGULATION 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 fancowl.

Excessive oil present in thedischarge air

Blocked scavenge line. Check the scavenge line, drop tube and orifice. Clean and replace.discharge air.

Perforated separator element. Replace the separator element.

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

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 theMAINTENANCE 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 NOTATTEMPT A REPAIR.

Oil is forced back into theair filter.

Incorrect stopping procedure used Always employ the correct stopping procedure. Close the discharge valve andallow the machine to run on idle before stopping.

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

Machine goes to fullpressure when started.

Inlet valve set incorrectly. (17/235,21/215)

Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in theMAINTENANCE section of this manual. (17/235, 21/215)

Faulty load valve. Replace the valve.

Machine fails to load whenthe load button is pressed.

Faulty load valve. Replace the valve.

OPTIONS42

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

IQ SYSTEM OPERATING INSTRUCTIONS − 1

KEY

1 Three way valve

2 Ball valve11/4”

3 Ball valve2”

4 Safety valve

5 Filters

6 Aftercooler

7 Minimum pressure valve

8 Separator tank

IQ SYSTEM

The IQ System is a complete, self−contained system whichprovides cooler, cleaner air than from a standard portable compressor.The system utilizes an integral aftercooler, high−efficiency filtration,and a patented condensate disposal system to provide the cool, cleanair. The condensate disposal system injects all liquid condensed fromthe moisture separator and filters into the engine exhaust systemwhere it is vaporized by heat. This eliminates the need for collectingthe condensate, and the added cost of disposing of the condensate,which is often regulated by local, state, and/or federal regulations.

When equipped with the low ambient feature, the IQ Systemautomatically adjusts movable louvers to control airflow through theaftercooler, ensuring that the compressed air temperature alwaysremains above freezing temperatures (typically 45�F) at any ambienttemperature down to −20�F. This prevents the need for 120V AC heattracing systems, or any manual adjustment to prevent freezing of thecompressed air system. All drain points for the condensate handlingsystem are heated with 24VDC heaters, which are integral to thecompressor heater system.Standard Non−Louvered configuration not to be operated belowfreezing.

OPTIONS 43

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

IQ SYSTEM OPERATING INSTRUCTIONS − 2

The compressed air exits the separator tank through the top coverpiping, and can then travel along one of two paths, selectable viamanual valving.

One path allows Standard Operation, which bypasses the IQSystem, and delivers air quality equivalent to a standard oil−floodedportable compressor. If the IQ System is enabled by proper setting ofthe selector valve, the compressed air first enters the aftercooler.

The aftercooler is cooled by the incoming compressor package air,which is controlled by movable louvers mounted on the aftercooler (ifequipped with low ambient option). At most conditions, the louvers arefully open, and maximum aftercooling is available. The compressed airand condensate (water with a small amount of compressor lubricant)exits the aftercooler and enters the moisture separator, where most ofthe condensate is removed. The compressed air then flows throughtwo stages of filtration, where the aerosol water and oil is removeddown to approximately 0.01 ppm, and all particulates are removeddown to 0.01 micron.

At the bottom of the moisture separator and both filters are strainersand constant−bleed orifices, which are sized to allow the maximum flowof condensate while minimizing compressed air loss.

The condensate lines are then piped together, and the condensateis injected at a single point into the engine exhaust piping. Thecompressed air then travels through the minimum pressure valve, andout through the service air valve. The air pressure gauge on theinstrument panel indicates the pressure inside the separator tank. Aservice air pressure gauge is located inside the front door of thecompressor on the filter support.

If the IQ System is bypassed (Standard Operation selected), thedelivered air pressure will be approximately equal to the separator tankpressure. If the IQ System operation is selected, the delivered airpressure will be slightly less, depending on the restriction of the filters.

Low Ambient Option Operation

When the ambient temperature falls to the point that the aftercooleroutlet temperature is approaching 45�F, the Temperature Control Unit(TCU), mounted on the rear of the control panel, will automaticallyadjust the louvers to control the cooling airflow through the aftercooler.

In the event that the unit is operating under abnormal conditions(i.e., an enclosure door open) which would cause excessive cooling ofthe aftercooler, a temperature sensor in the aftercooler outlet headerwill signal the TCU to further close the louvers if the compressed airtemperature falls to approximately 36�F or lower.

There are no user selectable or serviceable components in theTCU. Contact Doosan Service if any abnormal operation of the freezeprotection control system occurs.

MAINTENANCE

Daily Maintenance:

Verify, during full−load (maximum compressed air delivery) that theIQ System filter restriction indicators do not show excessive restriction.Restriction indicators for the filters are mounted inside the controlpanel, and will shut down the compressor if restriction exceedsrecommended values.

Weekly Maintenance:

� Remove Y−strainer screens at the bottom of the moisture separatorand both filters and clean out any residue.

� Verify that the orifices below the Y−strainers are not clogged.

� Verify that the piping from the orifice purge points to the exhaustsystem is not clogged.

Yearly Maintenance:

The normal maintenance interval on the primary and secondary IQSystem filters is one year, or earlier if pressure drop becomesexcessive. Restriction indicators for the filters are mounted on the filtersupport inside the front door, and will shut down the compressor ifrestriction exceeds recommended values.

Filter Replacement

� With engine stopped, ensure pressure is relieved from air system.

� Remove all wires and hoses connected to drains on bottom of eachfilter housing. Inspect fittings and hoses for any blockage. Clean ifnecessary.

� Using a chain wrench or similar tool, loosen the housing. Thehousing should be removed by hand after loosening, taking care toprevent the housing from falling to the floor panel.

� Lower the housing to floor panel and lean it against the airend.Remove and replace the filter element, being careful not to damageouter wrap.

Verify the part number of new element vs. old element, as the twoIQ filters are of different media.

OPTIONS − IQ SYSTEM

SAFETY

CAUTION: The compressor regulation system is adjusted to maintainregulated pressure at the separator tank. DO NOT adjust regulation toprovide full regulation pressure at the service valve when the IQSystem is enabled. This will result inC operation at excessivehorsepower levels, causing overheating, reduced engine life, andreduced airend life.

CAUTION: Excessively restricted filter elements may cause anincrease in the amount of aerosol water and oil carryover, which couldresult in damage to downstream equipment. Normal service intervalsshould not be exceeded.

CAUTION: Blockage of the condensate will result in flooding of thevessels. If flooding occurs, excessive condensate may enter the airstream and could result in damage to downstream equipment.

NOTICE:Do not operate at temperatures less that 2�C (35�F) unless equippedwith low ambient IQ option.

ENGINE INSTRUCTION MANUAL44

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA,

12/235HA, 17/235HA, 21/215HA

CONTENTS

45 FOREWORD

46 EXTERNAL VIEWS

GENERAL INFORMATION

Main data and specifications

Engine identification

After sales support

EMISSION CONTROL LABEL

48 FUEL, LUBRICANT, AND COOLANT

Fuel

Lubricant

Coolant

50 OPERATION

Check before operation

Check and operation after start− up

Operation and care of a new engine

53 PERIODICAL INSPECTION AND MAINTENANCE

Lubricating system

Cooling system

Fuel system

Air intake system

Routine maintenance

57 COLD WEATHER OPERATION

58 MAINTENANCE SCHEDULE

61 TROUBLESHOOTING

FOREWORD 45

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

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 helpyou do this.

Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of trouble−free andeconomical 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 ofpublication.

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 notreflect the physical characteristics of each individual engine covered.

46 EXTERNAL VIEWS

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA,

12/235HA, 17/235HA, 21/215HA

DIESEL ENGINE Engine External View

Fig. 1 (Left−hand Side) Fig. 2 (Right−hand Side)

(1) Engine air inlet.

(2) Intake manifold pressure sensor.

(3) Intake manifold temperature sensor.

(4) M10 (STOR) fuel pressure after−lift pump.

(5) M10 (STOR) fuel pressure before−lift pump.

(6) Magnetic pickup location 3/4−16UNF.

(7) Fuel return connection.

(8) Fuel inlet connection.

(9) Fuel lift pump.

(10) Starter mounting flange.

(11) Oil pressure sensor.

(12) Fuel filter

(13) Electronic control module (ECM).

(14) Dipstick location.

(15) M10 (STOR) oil pressure port.

(16) Engine position sensor (EPS) − (inboard).

(17) Engine speed sensor (ESS) − (outboard).

(18) Engine dataplate.

(19) High−pressure fuel lines.

(20) injection pump

(21) Intake air heater.

(22) 1/2−inch (NPTF) coolant taps.

(23) Turbocharger wastegate actuator.

(24) Oil filler cap.

(25) Coolant outlet.

(26) Front engine lifting bracket.

(27) Coolant temperature sensor.

(28) Coolant heater port.

(29) Coolant inlet.

(30) Lubricating oil cooler.

(31) Oil drain plug.

(32) Lubricating oil filter.

(33) Dipstick location.

(34) Coolant filter.

(35) Injector drain fuel outlet connection.

47GENERAL INFORMATION

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

EPA CERTIFIED ENGINE DATA and SPECIFICATIONS

Engine model name QSLEngine 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. 3

A. Engine serial number

Electronic control module is located on the mid−left hand side of engine.Note: Serial number (SN) and (ECM CODE)

Fig. 4

Confirmation of Engine Number

It is advisable to quote the engine serial number together with themachine serial number, as it is required when you contact the Doosanbranch or distributor for repair, service or parts ordering.

CAUTION: Conduct confirmation of engine serial number with theengine stopped. To avoid being injured, do not check it, while the engineis still hot.

ENGINE AFTER SERVICE

Please feel free to contact your dealer for periodical inspection andmaintenance.

Doosan Genuine Parts

Genuine Doosan parts are identical with those used in the engineproduction, and accordingly, they are warranted.

Genuine Doosan parts are supplied by your branch or distributor.

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

48 FUEL, LUBRICANTS, AND COOLANT

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

FUEL

Fuel Selection

The following properties are required of the diesel fuel.

Must be free from minute dust particles.

Must have adequate viscosity.

Must have high cetane value.

Must have high fluidity at low temperature.

Must have low sulphur content.

Must have little residual carbon.

It is strongly advisable to use ASTM D975 No. 2D (the generalautomotive diesel engine purpose fuel oil) or equivalent which fullymeets the above requirements.

Applicable Standard Recommendation

JIS (Japanese Industrial Standard) NO. 2

DIN (DEUTSCHE INDUSTRIE NORMEN) DIN 51601

SAE (Society of Automotive Engineers) Basedon SAE−J−313C

NO. 2−D

BS (BRITISH STANDARD) Based onBS/2869−1970

Class A−1

EURONORM EN590

FUEL REQUIREMENTS

Notice: The fuel injection pump, injector or other parts of the fuelsystem and engine can be damaged if you use any fuel or fuel additiveother than those specifically recommended by Doosan.

NOTE: If any fuel other than the one specified is used, engine operationwill be impaired. Engine failure or malfunction resulting from use of suchimproper fuel will not be warranted by Doosan.

To help avoid fuel system or engine damage, please read the following:

Do not use diesel fuel which has been contaminated with engine oil.Besides causing engine damage, such fuel can also affect emissioncontrol. Before using any diesel fuel, check with the fuel supplier to seeif the fuel has been mixed with engine oil.

Your engine is designed to use either Number 1−D or Number 2−Ddiesel fuel. However, for better fuel economy, use Number 2−D dieselfuel whenever possible. At temperatures less than −7�C, (20�F),Number 2−D fuel may pose operating problems (see “Cold WeatherOperation” which follows). At colder temperatures, use Number 1−Dfuel (if available) or use a “winterized” Number 2−D (a blend of Number1−D and Number 2−D). This blended fuel is usually called Number 2−Dalso, but can be used in colder temperatures than Number 2−D fuelwhich has not been “winterized.”

Check with the fuel supplier to be sure you get the properly blendedfuel.

NOTICE: Do not use home heating oil or gasoline in your diesel engine;either may cause engine damage.

Handling of the Fuel.

Any fuel containing dust particles or water might cause enginefailure .

Therefore, the following must be observed.

Take care to protect the fuel from ingress of dust particles or waterwhen filling the fuel tank.

If refuelling is done from an oil drum directly, ensure that it has beenkept stationary to allow any dust, sediment or water to settle at thebottom. Do not draw fuel direct from the bottom of the drum to preventpickup of any settled foreign material.

Always fully fill the fuel tank. Drain the sedimented particles in thefuel tank frequently.

Water in Fuel

During refueling, it is possible for water (and other contaminants) to bepumped into your fuel tank along with the diesel fuel. This can happenif a fuel provider does not regularly inspect and clean its fuel tanks, orreceives contaminated fuel from its supplier(s). To protect your enginefrom contaminated fuel, there is a fuel filter system on the engine whichallows you to drain excess water.

CAUTION: The water/diesel fuel mixture is flammable, and could behot. To avoid personal injury and/or property damage, do not touch thefuel coming from the drain valve, and do not expose the fuel to openflames or sparks.

Be sure you do not overfill the fuel tank. Heat (such as from the engine)can cause the fuel to expand. If the tank is too full, fuel could be forcedout. This could lead to a fire and the risk of personal injury and/orequipment damage.

BiocidesIn warm or humid weather, fungus and/or bacteria may form in dieselfuel if there is water in the fuel.

NOTICE: Fungus or bacteria can cause fuel system damage byplugging the fuel lines, fuel filters or injector. They can also cause fuelsystem corrosion.

If fungus or bacteria has caused fuel system problems, you shouldhave your authorized dealer correct these problems. Then, use a dieselfuel biocide to sterilize the fuel system (follow the biocidemanufacturer‘s instructions). Biocides are available from your dealer,service stations, parts stores and other automotive places. See yourauthorized dealer for advice on using biocides in your area and forrecommendations on which biocides you should use.

Smoke Suppressants

The use of a smoke suppressant additive is not allowed because of thegreater possibility of stuck rings and valve failure, resulting fromexcessive ash deposits.

49FUEL, LUBRICANTS, AND COOLANT

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

LUBRICANT.

Use of unsuitable engine oil will result in piston ring, piston andcylinder seizure and accelerate surface wear causing increased oilconsumption, lowered output and, finally engine failure. To avoid this,use the specified engine oil.

1) Engine Oil SelectionPRO−TEC

2) Oil Viscosity

Engine oil viscosity affects engine startability, performance, oilconsumption, wear and the potential for seizure, etc. Always ensurethat lubricants with the correct viscosity for the operating temperatureare used. Refer to fig 5.

NOTE

Using a mixture of different brands or quality of oils will adversely affectthe original oil quality; therefore, never mix different brand or differenttype oils.

Do not use API, CA, CB grade and reconstituted engine oil.

Engine damage due to improper maintenance, or using oil of theimproper quality and/or viscosity, is not covered by the warranty.

Fig. 5

A. (Single − grade)

B. Ambient Temperature

C. (Multi − grade)

COOLANT

All Doosan portable compressor engines are factory filled with a50/50 Ethylene glycol base antifreeze/water mix. which providesprotection to −33�C (−27�F).

50 OPERATION

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

ENGINE OPERATION

Engine Exhaust Gas Caution (Carbon Monoxide)

CAUTION

Do not breathe exhaust gas because it contains carbon monoxide,which by itself has no color or odor. Carbon monoxide is a dangerousgas. It can cause unconsciousness and can be lethal.

Do not run the engine in confined areas (such as garages or next to abuilding). Keep the exhaust tailpipe area clear of snow and othermaterial to help reduce the buildup of exhaust gases under theequipment. This is particularly important when parked in blizzardconditions.

CHECK BEFORE OPERATION

CAUTION: For safety reasons, conduct the inspection with the enginestopped.

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 outgently again.

Check the oil level against the marks on the dipstick. The oil levelmust be between the ”H” level mark and the ”L” level mark asillustrated

Fig. 6

Also check the sample oil on the dipstick for contamination andviscosity.Take care not to add too much engine oil

Oil can be poured either through the oil filler at the front of the cylinderhead cover or through the oil filler on the right side of the timing gearcase.

A certain period of time is required before the engine oil completelyflows down from the oil filler to the crankcase. Wait at least ten minutesbefore checking the oil level.

NOTE:Take care to avoid engine oil being splashed on the fan drivebelt because it causes belt slippage or slackness.

CAUTION: When adding oil, take care not to spill it. If you spill oil onthe engine or equipment, wipe it properly, to prevent the risk of fire andpersonal injury and/or equipment damage.

Fan and Belt Check

The engine is fitted with an automatic belt tensioner

Check the fan belt for tension and abnormalities.

A loose belt will cause belt slippage which may result in a damaged belt,abnormal noise, poor battery charging and engine overheating.

Fig. 7

Use of genuine Doosan fan belt

Always use genuine Doosan fan belts as they provide high drivingability and long operating durability. Use of non−Doosan fan belts couldresult in premature belt wear or belt elongation leading to engineoverheating or excessive belt noise.

Coolant Level Check

Check and ensure that the level is correct.

CAUTION: When removing the radiator filler cap, while the engine isstill hot, cover the cap with cloth, then turn it slowly to gradually releasethe internal steam pressure. this will prevent anyone from beingscalded by hot steam spurting out from the filler neck.

Add coolant mixed to the correct ratio: 50/50 ethylene glycol/water.

Radiator Cap Condition

After the replenishment of the coolant, install the radiator filler cap.Make sure the cap is securely installed.

Crankcase Breather

Check and clean the breather tube daily during cold weather.

Battery Cable Connection

Check the battery cable connections for looseness or corrosion. Aloosened cable connection will result in hard engine starting orinsufficient battery charge. The battery cables must be tightenedsecurely. Never reverse “+” and “−” terminals when reconnectingcables after disconnection. Even a short period of reverse connectionwill damage the electrical parts.

51OPERATION

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

Fig. 8

A Battery cable

B Connections

Battery Electrolyte level

The amount of electrolyte in the batteries will be reduced after repeateddischarge and recharge. Check the electrolyte level in the batteries,replenish with a commercially available electrolyte such as distilledwater, if necessary. The battery electrolyte level checking procedurewill vary with battery type. NOTICE: Do not replenish with dilute sulfuricacid in the daily service.

CAUTION:

When inspecting the batteries, be sure to stop the engine first.

As dilute sulphuric acid is used as electrolyte, be careful not tocontaminate your eyes, hands, clothes, and metals with the electrolyte.If it gets in your eye, wash with a large amount of water at once, thenseek medical advice.

As highly flammable hydrogen gas is released from the batteries, do notcreate a spark or allow any naked flame near the batteries.

When handling such metallic articles as tools near the batteries, besure not to contact the “+” terminal because the compressor body is “−”and a dangerous short circuit might result.

When disconnecting the terminals, start with “−” terminal. Whenconnecting them, connect the “−” terminal last.

CHECKS AND OPERATION AFTER START−UP

Check after the Engine Start−up

Check the following items in the engine warming−up operation.

Engine oil pressure −

The engine oil pressure gauge readings (where fitted) may varydepending on ambient temperature and type of oil. The gauge shouldregister around 55 to 85 psi in the warming−up period.

Engine noise and exhaust smoke color −

Listen to the engine and, if any abnormal noise is heard, check todetermine the cause.

Check the fuel combustion condition by observing the exhaust smokecolor. The exhaust smoke color after engine warm−up and at no−loadcondition should be colorless or light blue.

Black or white smoke indicates incorrect combustion.

Note: After start−up from cold the engine might be noisier and theexhaust smoke color darker than when it has warmed up. However thiscondition will disappear after warm up.

Leakage in the systems −

Check the following items:

Lubrication oil leakage −

Check the engine for oil leaks, paying particular attention to oil filter andoil pipe joints.

Fuel leakage −

Check the fuel injection pump, fuel lines and fuel filter for leakage.

Coolant leakage − Check the radiator and water pump hoseconnections 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 about5 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 theradiator cap is removed when the engine is hot. Cover the radiator capwith a thick cloth and loosen the cap slowly to reduce the pressure, thenremove the cap.

52 OPERATION

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

OPERATION AND CARE OF A NEW ENGINE.

Your engine is carefully tested and adjusted in the factory, however,further run−in is necessary. Avoid any harsh engine operation withinthe initial 100 operating hours.

Do not operate the unit at full load until the engine is warmed−up.

Do not allow the engine to run unloaded for extended periods so as tominimise the risk of cylinder bore glazing.

During operation, pay attention to the following points if the engineshows any sign of abnormalities.

(1) Engine Oil Pressure − The engine oil pressure is monitored by aswitch that will stop the engine if the pressure falls below a pre−setvalue.If the oil pressure gauge shows below 30 psi or if the reading fluctuatescontinually, stop the engine and check the oil level. If the level is correct,contact your local Doosan branch or dealer to establish the cause.

(2) Coolant Temperature − The engine performance will be adverselyaffected if engine coolant temperature is too hot or too cold. The normalcoolant temperature is 75 to 85�C (167 to 185�F).

Overheating

CAUTION:

If you see or hear escaping steam or have other reason to suspectthere is a serious overheat condition, stop the engine immediately.

If the Engine Coolant Temperature gage (where fitted) shows anoverheat condition, or you have reason to suspect the engine may beoverheating, take the following step:

� Close the service valve to reduce the load.

� Let the engine run at normal idle speed for two or three minutes. Ifthe engine coolant temperature does not start to drop, turn off theengine and proceed as follows:

CAUTION: To help avoid being burned −

� Do not open the canopy or door if you see or hear steam or enginecoolant escaping. Wait until no steam or engine coolant can be seen orheard before opening the engine canopy or door.

� Do not remove the radiator filler cap if the engine coolant in thereserve tank is boiling. Also do not remove the radiator filler cap whilethe engine and radiator are still hot. Scalding fluid and steam can beblown out under pressure if either cap is taken off too soon.

If no steam or engine coolant can be seen or heard, open the canopyor door. If the engine coolant is boiling, wait until it stops beforeproceeding. The engine coolant level should be between the “MAXCOLD” and “MIN” marks on the reserve tank.

Make sure the fan belt is not broken, or off the pulley, and that the fanturns when the engine is started. If the engine coolant level in thereserve tank is low, look for leaks at the radiator hoses andconnections, radiator, and water pump. If you find major leaks, do notrun the engine until these problems have been corrected. If you do notfind a leak or other problem, WAIT UNTIL THE ENGINE HAS COOLEDDOWN then carefully add engine coolant to the reserve tank.

(Engine coolant is a mixture of ethylene glycol antifreeze and water.See “Engine Care in cold season” for the proper antifreeze andmixture.)

CAUTION: To avoid being burned, do not spill antifreeze or enginecoolant on the exhaust system or hot engine parts. Under someconditions the ethylene glycol in engine coolant is combustible.

If the engine coolant level in the reserve tank is at the correct level butthere is still an indication of an overheat condition and no cause wasfound, please consult your local Doosan branch or dealer.

Overcooling

Operating the engine at low coolant temperature will not only increasethe oil and fuel consumption but also will lead to premature parts wearwhich may result in engine failure. Ensure that the engine reachesnormal operating temperature 75 to 85�C (167 to 185�F) within tenminutes of starting.

(3) Hourmeter

This meter indicates the machine operation hours. Make sure that themeter is always working during engine operation. Periodical machinemaintenance is scheduled on the operation hours indicated on thehourmeter.

(4) Liquid and Exhaust Smoke Leakage

Make regular checks for lubricant, fuel, coolant and exhaust smokeleakage.

(5) Abnormal Engine Noise

In the event of any abnormal engine noise, please consult your localDoosan branch or dealer.

(6) State of the Exhaust Smoke

Check for any abnormal exhaust smoke color.

ENGINE STOPPING

(1) Close service valves.

(2) Before stopping the engine, cool down the engine by operating it atreduced load about three minutes. In this period, check the enginenoise and the engine oil pressure (where a gage is fitted) forabnormalities.

LONG TERM STORAGE

If the equipment is to be out of operation for an extended period, itshould be started at least once per week and run on load for about 15minutes after it has reached normal operating temperature.

53PERIODICAL INSPECTION AND MAINTENANCE.

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

LUBRICATING SYSTEM.

Servicing of the engine oil and oil filter element will affect the engineperformance as well as the engine life. Change the engine oil and theoil 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 madesimultaneously 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 whilethe engine is still hot.

Wipe clean around the oil filler cap taking care so that no foreign articlesenter. Remove the filler cap.

It is advisable that draining be done while the engine is warm tominimize the draining time.

Remove the oil pan drain plug and drain the engine oil completely.

NOTICE: Use a receptacle to catch the drained oil so that the engineand equipment will not be contaminated.

Fig. 9

Remove drain plug arrowed to drain the engine oil completely.

Oil filter element removal

Fig. 10

A Cartridge

Oil filter element installation −

Lightly apply engine oil to the O−ring.

Fig. 11

Screw in the new cartridge hand tight as the O−ring comes in contactwith the engine block. Tighten a further 3/4 to 11/4 turns. DO NOTovertighten.

Engine oil refilling.

Reinstall the drain plug.

Fill with new engine oil via the most convenient oil filler port.

Wait at least ten minutes until the oil drains down to the oil pan. Thencheck 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.

Use the dipstick to recheck the oil level. If necessary replenish withengine oil to the specified level

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

Engine Oil Additives

Engine oils contain a variety of additives. Your engine should not needany extra additives if you use the recommended oil quality and changeintervals.

Used Oil Disposal − Do not dispose of used engine oil (or any otheroil) 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 aused oil collection facility which may be found in your community. If youhave a problem disposing of your used oil, it is suggested that youcontact your local Doosan branch or dealer. This also applies to dieselfuel which is contaminated with water.

Used Engine Oil

CAUTION: Used engine oil contains harmful contaminants that havecaused skin cancer in laboratory animals. Avoid prolonged skincontact. Clean skin and nails thoroughly using soap and water −notmineral oil, fuels, or solvents. Launder or discard clothing, shoes, orrags containing used engine oil.

Discard used engine oil and other oils properly.

54 PERIODICAL INSPECTION AND MAINTENANCE.

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

COOLING SYSTEM

Coolant Change

The coolant must be changed at intervals of 1000 hours or twelvemonths, whichever come first.

If the coolant becomes sludged up it will lead to engine overheating orcoolant blow−off from the radiator.

Coolant draining.

WARNING: Hot engine coolant and steam can cause injury. Whenadding to or draining coolant or antifreeze solution from the en-gine radiator, stop the engine at least one minute prior to releasingthe radiator filler cap. Using a cloth to protect the hand, slowly re-lease the filler cap, absorbing any released fluid with the cloth. Donot remove the filler cap until all excess fluid is released and theengine cooling system fully depressurised.

WARNING: Follow the instructions provided by the antifreezesupplier when adding or draining the antifreeze solution. It isadvisable to wear personal protective equipment to prevent skinand eye contact with the antifreeze solution.

Remove the radiator cap.

Slacken the bottom radiator hose clamp to drain the coolant from theradiator.

Fig. 12

A Cylinder block water drain valve

Coolant Filter Replacement

Fig. 13

Rotate clockwise to close shut−off valve. Remove and replacecoolant filter. Open shut−off valve

Fig. 14

Filling with coolant

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 minutesat a low idle speed, then as the air contained in the coolant circuit is bledoff 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 theair flow, resulting in lower cooling efficiency. Clean the radiator fins withsteam or low pressure (< 5 Bar) compressed air every 250 hours or 3months (whichever comes first) or more frequently in adverseoperating conditions.

Cooling System Circuit Cleaning

When the cooling system circuit is contaminated with water scales orsludge particles, cooling efficiency will be lowered. Periodically cleanthe circuit interior with a suitable cleaner.

Clean the cooling system circuit every 1000 operating hours or 12months, whichever comes first.

55PERIODICAL INSPECTION AND MAINTENANCE.

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

FUEL SYSTEM

The fuel injection pump and injector nozzles are preciselymanufactured, and therefore, using fuel which contains water or dustparticles will result in either injection pump plunger seizure or injectornozzle seizure. A fuel filter element blocked with sludge or dustparticles will lead to reduced engine output.

Perform inspection and maintenance periodically as follows:

Fig. 15

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

Place a suitable container under the separator to prevent any spillageinside 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 duringdisassembly and reassembly.

The fuel filter/separator also provides primary filtration and the element‘A’ should be changed every 500 operating hours or 6 months,whichever comes first.

Change procedure:

Disconnect fuel sensor (where fitted). Loosen drain plug B andempty fuel into suitable container

Fig. 16

Unscrew the element ‘A’ from the head taking care not to spill fuelinside the machine. Remove fuel sensor (where fitted) and re−fit tonew filter element

Discard the old element into a suitable container.

Using a clean cloth, wipe the sealing face of the filter/separator headto ensure correct seating of the sealing ring.

Fill the element/bowl assembly with clean fuel oil then apply a light coatof clean engine oil to the new element seal ring.

Screw the new element onto the head firmly by hand.

The engine has a self priming system that purges air from the fuelsystem.

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, causingreduced 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 shortenedengine life.

The filter element should be changed at 500 hours or 6 months,whichever comes first, or sooner if the restriction indicator shows red.See below.

Fig. 17

A Normal

B Clogged

C Indicator

D Red signal

56 PERIODICAL INSPECTION AND MAINTENANCE.

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

Air cleaner with dust indicator

This indicator is attached to the air cleaner. When the air cleanerelement is clogged, air intake resistance becomes greater and the dustindicator signal turns to red indicating the element needs to bechanged.

When the signal turns to red, replace the element. Then press the dustindicator button to reset the indication.

Air Intake Piping

Inspect air intake and charge air cooling pipes and connections fordamage or loose fitting. Replace or re−fit as necessary.

Fig. 18

ENGINE ELECTRICAL

The engine uses a 24 volt system and a negative grounding for theelectrical system.

Battery Servicing

Battery terminal connections

Check the battery cable connections for looseness or corrosion.Poor cable connections will result in difficult engine starting orinsufficient battery charge.

The battery cables must be tightened securely.

Never reverse “+” and “−” terminals when reconnecting cables afterremoval. Even a short period of reverse connection will damage theelectrical parts.

Cleaning of Battery

When the battery terminals are fouled clean them with clean tepid waterand wipe with a dry cloth to remove the water. Apply a light coat ofvaseline or a grease.

Alternator Servicing

The polarity of the alternator is negative (−) grounding type.

Do not reverse the polarity connection, otherwise a short circuit willoccur resulting in alternator failure.

Do not put water directly on the alternator. Entry of water into thealternator creates electrolytic corrosion causing failure.

When the battery is charged from an external source, be sure todisconnect the battery cables.

Wiring Connections

Check all of the electric wiring connections for looseness and damageon a regular basis.

SERVICE AND MAINTENANCE

Please refer to the engine maintenance schedule.

For continued trouble free engine operation throughout its life, theservice procedures marked with an asterisk (*) need to be carried outby a skilled and trained technician.

Please consult your local Doosan branch or dealer when theseprocedures become due.

Please also read the note refering to the service items marked with thestar � symbol.

57COLD WEATHER OPERATION

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FUEL SELECTION

In cold weather, the fuel might freeze resulting in difficult enginestarting; therefore, select a suitable fuel for such engine operation.Use ASTM 975 No. 2−D fuel if you expect temperature above 20�F(−7�C).

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 isavailable in some areas during the winter months.

Check with your fuel supplier to be sure you get the correct blendedfuel.

COOLANT

Where the ambient temperature falls below freezing point, thecooling system should be drained after engine operation, but toeliminate the need for repeated draining, refilling and to provide all yearprotection against corrosion, the use of anti−freeze solution throughoutthe year is highly recommended.

All Doosan portable compressor engines are factory filled with a50/50 Ethylene glycol base antifreeze/water mix. which providesprotection to −33�C (−27�F).

Concentrations over about 65% adversely affect freeze protection,heat transfer rates, and silicate stability which may cause water pumpleakage.

CAUTION:

Never exceed a 60/40 antifreeze/water mix.(which provides protection to about−50�C (−58�F).

NOTE:

Methyl alcohol base antifreeze is not recommended because of itseffect on the non−metallic components of the cooling system andbecause of its low boiling point.

NOTE:

High silicate antifreeze is not recommended because of causingserious silica gelation problems.

NOTE:

Usage and mixing ratio etc. should be followed to the antifreezemanufacture’s recommendations.

ENGINE OIL

At low ambient temperatures, engine oil viscocity can affect enginestarting. It is important to use the correct grade of oil as recommendedin fig 4.

Try to position the compressor where it will not be affected by coldwinds when not running.

BATTERY

(1) Always ensure that the batteries are kept fully charged in the coldseason. This takes a longer period of running than in warm weatheroperation.

The electrolyte in a partly discharged battery will freeze easier thanwhen it is fully charged. Try to keep the batterys fully charged and warmin cold weather operation.

(2) Top up the battery with distilled water immediately before startingthe engine.

COLD STARTING

When operating in cold ambient conditions, or when starting from cold.If the engine does not start at the first attempt, allow the battery torecover for at least 30 seconds.Observe the following procedures:

In order to protect the starter, do not engage for longer than 10 secondsduring any attempt.

If during cranking, the starter motor repeatedly engages anddisengages the battery power could be low. Either recharge the batteryor replace it with one that is fully charged.

NOTICE: Do not use starting “aids” in the air intake system. Such aidscan cause immediate engine damage.

58 ENGINE MAINTENANCE SCHEDULE

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When performing the following items, the daily inspection items should also be carried out.

NoDescription of check

d i t Daily(operation hours) Remark

Nop

and maintenance Daily250 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� See “EXPLANATION OFMAINTENANCE SCHEDULE”

11 Coolant level OMAINTENANCE SCHEDULE”

12 Coolant leakage check O

13 Radiator filler cap fittingcondition O

14 Fan and belt check O O

15 Coolant temperature gage reading(where fitted) O

16 Coolant replacement O

17 Coolant filter replacement O

18 Radiator external face cleaning O O O O O O

19 Cooling system circuitcleaning O

20 Radiator filler capfunction check (*) O O O

21 Electrolyte level check O

22 Battery cleaning O

23 Battery charge lamp O

24 Starter and alternator check andcleaning (*) O

25 Wiring and connectioncheck O O O

26 Air cleaner elementreplace O O O

27 Air intake piping O

28 Engine starting conditions and noiseconditions O

29 Exhaust smoke condition O

30 Cylinder compressionpressure (*) O

31 Valve clearance check (*) O

32 Positive crankcase ventilation valvecleaning O O�

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 priorto the completion engine useful life. Doosan, however, urges that recommended maintenance service is performed at the indicated intervals.

59ENGINE MAINTENANCE SCHEDULE

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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 elementreplacement

Change at 500 hours or 6 months, whichever comes first.

7. Fuel leakage Replace any damaged or malfunctioning parts which could cause leakage.

8. Draining water in fuelfilter/separator.

Drain off water in the fuel filter/separator bowl.

9. Fuel filter elementreplacement

Replace both primary (filter/separator) and secondary elements at 500 hours or 6 months whichever come first.

10. Injection nozzle check Check injection opening pressure and spray condition. (This is a recommended maintenance item �). Consultyour 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 fittingcondition

The radiator cap must be installed tightly and sealing correctly.

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 temperatureis 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 facecleaning

Check monthly. Clean at intervals of 250 hours or 3 months, whichever comes first. In very dusty environments,more frequent cleaning might be necessary.

19. Cooling system circuitcleaning

Clean at intervals of 1000 hours or 12 months, whichever comes first.

20. Radiator filling capfunction check

Check radiator pressure cap periodically for proper operation. Consult your local branch or distributor.

21. Battery electrolyte levelcheck

Replenish with distilled water if necessary.

60 ENGINE MAINTENANCE SCHEDULE

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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 generatorcheck and cleaning

Check wear condition of brush and commutator. Consult your local branch or distributor.

25. Wiring and connectioncheck

Check for loose terminals/connections and integrity of insulation.

26. Air cleaner elementreplace

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 conditionand noise condition

Check engine stability and noise.

29. Exhaust smoke condition Check exhaust smoke color.

30. Cylinder compressionpressure

Consult your dealer or distributor

31. Valve clearance check Check wear condition of brush and commutator. Consult your local branch or distributor.

Incorrect valve clearance will result in increased engine noise and lower engine output thereby adverselyaffecting engine performance. Check and adjust every 1000 hours. Consult your local branch or distributor.

32. Positive crankcaseventilation valve cleaning

Check and clean the breather tube daily during cold weather. Check according to the equipment specifications.Perform the adjustment, cleaning, repair or replacement every 1500 hours. (This is a recommended maintenanceitem �). Consult your local branch or distributor.

61ENGINE TROUBLESHOOTING

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

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

Engine does not start Battery discharged

Starter does not turn. Bad cable connections.

Starter or starter switch failure.

Safety relay failure.

Engine stop solenoid malfunction.

No fuel in the fuel tank.

No fuel injection. Clogged fuel filter element.

Starter turns but engine does notfire.

Air in the fuel system.

Incorrect preheating operation.

Glow plug malfunction.

Fuel is injected but engine does notfire.

Incorrect injection timing.

Low cylinder compressionpressure.

Engine fires but stalls immediately. Air in the fuel system.

62 ENGINE TROUBLESHOOTING

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Unstable engine running Crack in injection pipe.

Unstable low idling Injection nozzle failure.

Uneven compression pressure between cylinders.

Air in the fuel system

Insufficient fuel supply. Clogged fuel filter element

Piping failure (squeezed/restrictedetc.)

Engine malfunction in high speedrange.

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.

Cooling system defect Thermostat malfunction.

Radiator filler cap malfunction.

Cooling system interior fouled.

Radiator clogged.

Engine over−loaded.

Improper servicing Air cleaner element clogged.

Insufficient airflow/restriction.

Restricted coolant flow (high concentration of antifreeze, etc.)

Low oil pressure Lack of oil Oil leakage

High oil consumption

Wrong oil Wrong type and viscocity.

High coolant temperature. Over heat.

Clogged filter and strainer.

Worn bearings and oil pump.

Faulty relief valve.

63ENGINE TROUBLESHOOTING

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

Incorrect valve clearanceadjustment.

Cylinder compression leakage Injector nozzle misalignment.

Low engine output Low cylinder compression pressure Cylinder bore wear.

Insufficient air intake volume. Air cleaner clogged.

Restricted air flow.

Excessive oil consumption Incorrect oil Wrong selection of type and viscosity.

Too much oil quantity.

Engine burning oil Faulty piston rings/damaged cylinder bores.

Faulty valve stem seal.

Damaged seal / Damaged turbocharger seal

Oil leakage Loose joints/gaskets.

Improper installation of filter and piping.

Fuel leakage Damaged seals.

Excessive fuel consumption Improper component installation or tightening.

Excessive injection volume. Injection pump defective.

Excessive mechanical loads

64 ENGINE TROUBLESHOOTING

9/230, 9/270, 9/300, 12/235, 17/235, 21/215, 9/230HA, 9/270HA, 9/300HA, 12/235HA, 17/235HA, 21/215HA

Improper exhaust Clogged air cleaner.

Damaged injector nozzle.

Excessive black smoke Wrong injector nozzle.

Injection timing incorrect.

Excessive injection volume.

Incorrect fuel.

Water mixing in fuel

Excessive white smoke Low compression pressure.

Injection timing incorrect.

Low coolant temperature

Faulty turbocharger

Battery overdischarge Low electrolyte level Crack in battery body.

Natural consumption.

Charging failure Loose or damaged belt.

Faulty alternator.

Damaged wiring or contact failure.

Excessive electrical loads Insufficient battery capacity for the application.

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GENERALThis publication, which contains an illustrated partsbreakdown, has been prepared as an aid in locatingthose parts which may be required in the maintenanceof the unit. All of the compressor parts, listed in theparts breakdown, are manufactured with the sameprecision as the original equipment. For the greatestprotection always insist on genuine Doosan parts foryour compressor.

NOTICEDoosan can bear no responsibility for injury or damagesresulting directly from the use of non−approved repairparts.

Doosan Infracore service facilities and parts areavailable worldwide.There are Authorised Distributors or Company Salesoffices in principal cities of many countries.

Special order parts may not be included in the manual.Contact Doosan Parts Department with the unit serialnumber for assistance with these special parts.

DESCRIPTIONThe illustrated parts breakdown illustrates and lists thevarious assemblies, subassemblies and detailed partswhich make up this particular machine. This covers thestandard models and the more popular options that areavailable.

A series of illustrations show each part distinctly and inlocation relative to the other parts in the assembly. Thepart number, the description of the part and the quantityof parts required are shown on each illustration or onadjacent page. The quantities specified are the numberof parts used per one assembly and are not necessarilythe total number of parts used in the machine. Whereno quantity is specified the quantity is assumed to beone.

Each description of a part is based upon the “noun first”method, i.e., the identifying noun or item name isalways the first part of the description. The noun nameis generally followed by a single descriptive modifier.The descriptive modifier may be followed by words orabbreviations such as upper, lower, inner, outer, front,rear, RH, LH, etc. when they are essential.

In referring to the rear, the front or to either side of theunit, always consider the drawbar end of the unit as thefront. Standing at the rear of the unit facing thedrawbar (front) will determine the right and left sides.

FASTENERSBoth SAE/inch, ISO/metric hardware have been usedin the design and assembly of these units. In thedisassembly and reassembly of parts, extreme caremust be taken to avoid damaging threads by the use ofwrong fasteners. In order to clarify the proper usageand for exact replacement parts, all standard fastenershave been identified by part number, size anddescription. This will enable a customer to obtainfasteners locally rather than ordering from the factory.These parts are identified in tables that will be found atthe rear of the parts illustrations. Any fastener that hasnot been identified by both part number and size is aspecially engineered part that must be ordered by partnumber to obtain the exact replacement part.

PARTS ORDERING66

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MARKINGS AND DECALS

NOTICEDo not paint over safety warnings or instructionaldecals. If safety warning decals become illegible,immediately order replacements from the factory.

Part numbers for original individual decals andtheir mounting locations are shown within PartsList Section. These are available as long as aparticular model is in production.

Afterwards, service sets of exterior decals and currentproduction safety warning decals are available.Contact the Product Support Group at Mocksville foryour particular needs and availability.

HOW TO USE PARTS LISTa. Turn to Parts List.

b. Locate the area or system of the compressor inwhich the desired part is used and find illustrationpage number.

c. Locate the desired part on the illustration by visualidentification and make note of part number anddescription.

HOW TO ORDERThe satisfactory ordering of parts by a purchaser isgreatly dependent upon the proper use of all availableinformation. By supplying your nearest sales office,autonomous company or authorized distributor, withcomplete information, you will enable them to fill yourorder correctly and to avoid any unnecessary delays.

In order that all avoidable errors may be eliminated, thefollowing instructions are offered as a guide to thepurchaser when ordering replacement parts:

a. Always specify the model number of the unit asshown on the general data decal attached to theunit.

b. Always specify the serial number of the unit. THISIS IMPORTANT. The serial number of the unit willbe found stamped on a plate attached to the unit.(The serial number on the unit is also permanentlystamped in the metal of the frame side rail.)

c. Always specify the number of the parts listpublication.

d. Always specify the quantity of parts required.

e. Always specify the part number, as well as thedescription of the part, or parts, exactly as it isgiven on the parts list illustration.

In the event parts are being returned to your nearestsales office, autonomous company or authorizeddistributor, for inspection or repair, it is important toinclude the serial number of the unit from which theparts were removed.

TERMS AND CONDITIONS ON PARTSORDERS

Acceptance: Acceptance of an offer is expresslylimited to the exact terms contained herein. Ifpurchaser’s order form is used for acceptance of anoffer, it is expressly understood and agreed that theterms and conditions of such order form shall not applyunless expressly agreed to by Doosan Company(“Company”) in writing. No additional or contrary termswill be binding upon the Company unless expresslyagreed to in writing.

Taxes: Any tax or other governmental charge now orhereafter levied upon the production, sale, use orshipment of material and equipment ordered or sold isnot included in the Company’s price and will be chargedto and paid for by the Purchaser.

Shipping dates shall be extended for delays due to actsof God, acts of Purchaser, acts of Government, fires,floods, strikes, riot, war, embargo, transportationshortages, delay or default on the part of theCompany’s vendors, or any other cause beyond theCompany’s reasonable control.

Should Purchaser request special shipping instruction,such as exclusive use of shipping facilities, including airfreight when common carrier has been quoted andbefore change order to purchase order can be receivedby the Company, the additional charges will be honoredby the Purchaser.

Warranty: The Company warrants that partsmanufactured by it will be as specified and will be freefrom defects in materials and workmanship. TheCompany’s liability under this warranty shall be limitedto the repair or replacement of any part which wasdefective at the time of shipment provided Purchasernotifies the Company of any such defect promptly upondiscovery, but in no event later than three (3) monthsfrom the date of shipment of such part by the Company.The only exception to the previous statement is theextended warranty as it applies to the special airendexchange program.

Repairs and replacements shall be made by theCompany F.O.B. point of shipment. The Company shallnot be responsible for costs of transportation, removalor installation.

Warranties applicable to material and equipmentsupplied by the Company but wholly manufactured byothers shall be limited to the warranties extended to theCompany by the manufacturer which are able to beconveyed to the Purchaser.

Delivery: Shipping dates are approximate. TheCompany will use best efforts to ship by the datesspecified; however, the Company shall not be liable forany delay or failure in the estimated delivery orshipment of material and equipment or for anydamages suffered by reason thereof.

PARTS ORDERING 67

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The company makes no other warranty orrepresentation of any kind whatsoever, expressed orimplied, except that of title, and all implied warranties,including any warranty of merchantability and fitness fora particular purpose, are hereby disclaimed.

Limitation of Liability: The remedies of the Purchaser set forth herein areexclusive, and the total liability of the Company withrespect to this order whether based on contract,warranty, negligence, indemnity, strict liability orotherwise, shall not exceed the purchase price of thepart upon which such liability is based.

The Company shall in no event be liable to thePurchaser, any successors in interest or anybeneficiary of this order for any consequential,incidental, indirect, special or punitive damages arisingout of this order or any breach thereof, or any defect in,or failure of, or malfunction of the parts hereunder,whether based upon loss of use, lost profits or revenue,interest, lost goodwill, work stoppage, impairment ofother goods, loss by reason of shutdown or non−operation, increased expenses of operation or claims ofcustomers of Purchaser for service interruptionwhether or not such loss or damage is based oncontract, warranty, negligence, indemnity, strict liabilityor otherwise.

AIREND EXCHANGE PROGRAMDoosan offers an airend exchange program to benefitportable compressor users.

On the airend exchange program the exchange price isdetermined by the age and condition of the airend.

Your nearest sales office, autonomous company orauthorized distributor must first contact the PartsService Department at the factory at which yourportable air compressor was manufactured for anairend exchange number. The airend must be taggedwith this preassigned number and returned to thefactory prepaid. The airend must be intact, with noexcluded parts, otherwise the exchange agreementmay be cancelled. The warranty on an exchange orfactory rebuilt airend is 365 days.Airends being returned to the factory in connection witha WARRANTY CLAIM must be processed through theCustomer Service Department. If returned without aWarranty MRR (Material Return Request) Number, nowarranty claim will be considered.

PARTS ORDERING68

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For parts, service or information regarding your local U.S, Latin America or Asia Pacific distributor, please contact:

Doosan International USA, Inc

1293 Glenway Drive

Statesville

North Carolina 28625−9218Telephone:

800−633−5206 (US & Canada)

305−222−0835 (Latin America)

65−860−6863 (Asia Pacific)

Fax:

336−751−1579 (US & Canada)

336−751−4325 (Latin America)

336−751−4325 (Asia Pacific)

Facility:

Office hours: Monday − Friday 8:00 a.m. to 5:30 p.m. (EST)

Facility:

For information on how to order parts or information regarding your local distributor (Europe, Middle East, Africa) please contact:

Doosan Portable Power EMEA Aftermarket ESADréve Richelle 167B−1410 Waterloo, Belgium

Telephone: +32 (2) 404 0811

Fax: +32 (2) 371 6915

For Service Information contact − [email protected]

For Parts Information contact − [email protected]

Operating hours: Monday − Friday 8:30 a.m. to 5:15 p.m. (GMT)

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