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9/270, 9/300, 12/235, 17/235, 21/215
9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA
OPERATION AND MAINTENANCE MANUAL
Original Instruction
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
22839567 _en_E_10/15
9/270, 9/300
SERIAL No :
10/300, 12/235
17/235,
SERIAL No :
21/215
893000 ->
881500 ->

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Summary of Contents for Doosan 9/270

  • Page 1 9/270, 9/300, 12/235, 17/235, 21/215 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA OPERATION AND MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to 9/270, 9/300 SERIAL No : 893000 -> personnel who operate and 10/300, 12/235 maintain this machine.
  • Page 2 Machine models represented in this manual may be used in various locations world-wide. Machines sold and shipped into European Union Territories require that the machine display the CE Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives.
  • Page 4: Table Of Contents

    Latvian, Lettish Maltese MACHINE SYSTEMS Dutch Electrical system Norwegian Piping & instrumentation system Polish Portuguese FAULT FINDING Romanian Russian OPTIONS Slovak Slovenian ENGINE INSTRUCTION MANUAL Swedish Chinese PARTS ORDERING 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 5: Foreword

    The company reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to © COPYRIGHT 2011 products sold previously. DOOSAN COMPANY 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 6: Warranty

    THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT OF TITLE), THERE WARRANTIES MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 7 Middle East and Africa) PARTS MONTHS HOURS COMMENTS DOOSAN UNLIMITED PARTS ONLY AVAILABLE FROM THE COMPANY NETWORK. AIREND EXCHANGE MONTHS HOURS COMMENTS AIREND 2,000 60 MONTHS/10.000 HOURS AVAILABLE UNDER CONDITIONS. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 8 1. The original airend is returned assembled and unopened. 2. Submissions of proof that Doosan fluid, filters and separators have been used. Refer to the Operation and Parts manual for the correct fluids, filters and separator elements required. 3. Submissions of proof that maintenance intervals have been followed.
  • Page 9 WARNING - For operating temperature (Refer to the GENERAL INFORMATION or commencing to tow consult the below 0°C, consult the operation and section of this manual). operation and maintenance manual. maintenance manual. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 10 Do not exceed the trailer speed limit. No naked lights. Do not open the service valve before the airhose is attached. Use fork lift truck from this side only. Emergency stop. Tie down point 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 11 Portable Power EMEA Aftermarket Department. The no charge order should contain only Safety Decals. Help promote product safety! Assure that decals are present on the machines. Replace decals that are not readable. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 12: Safety

    Manual instructions. Transport Avoid bodily contact with compressed air. When loading or transporting machines ensure that the specified lifting and tie down points are used. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 13 When parking always use the handbrake and, if necessary, suitable Before towing the machine, ensure that:- wheel chocks. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 14 GENERAL INFORMATION - ESA (CE/HA) ‘CE’ ‘HA’ 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 15 / receiver, cooler and pipework must be flushed clear of the first fill fluid and new Doosan oil filters installed. ABOVE -23°C(-9°F) When this has been completed, the following oils are approved:...
  • Page 16: General Information

    (20 mile h WEIGHT Shipping weight 4665 kg Further information may be obtained by request through the Maximum weight 5725 kg customer services department. Maximum horizontal towing force 5012 kgf Estimated 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 17: Operating Instructions

    (to walls, floors etc.). bar pressure then it is recommended that safety retaining wires are used on the hoses. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 18: Prior To Starting

    9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 19 Low Radiator Coolant Level: Alarm indicator lamp. Indicates 25. Engine Oil Pressure Gage engine coolant needs service. 26. Battery Voltage Gage Low Engine Oil Pressure: Fault indicator lamp. Indicates shutdown due to low engine oil pressure. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 20 Sensor Fault Malfunction. Sep. Tank Pressure (PT1) CPRSR Sensor Fault Malfunction. Seperator Tank Pressure >20 CPRSR PSI During Start Attempt Malfunction. (Engine Will Not Crank) Machine Over Pressure CPRSR Malfunction. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 21 Low Coolant Level Engine Coolant Level High Engine Coolant High Engine High Engine Temperature Temp. Temp. IQ Filter Restriction IQ Filt. Rest High Discharge Temp. High Comp Temp. (RT2>247 deg. F) 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 22 Injector Solenoid Cylinder #5 Circuit - Current Below Normal, or Open Circuit Injector Solenoid Cylinder #3 Circuit - Current Below Normal, or Open Circuit Injector Solenoid Cylinder #6 Circuit - Current Below Normal, or Open Circuit 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 23 Engine Coolant Temperature 2 High - Critical 2115 Engine Coolant Pressure 2 Circuit - Voltage Above Normal, or Shorted High 2116 Engine Coolant Pressure 2 Circuit - Voltage Below Normal, or Shorted Low 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 24 During warm up, the engine will idle at 1500RPM. After warm up the CAUTION: Never allow the machine to stand idle with pressure in the engine will idle at a lower speed. system. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 25: Emergency Stopping

    Do not dispose of a complete machine without documentation relating to instructions for its use. MONITORING DURING OPERATION Should any of the safety shut–down conditions occur, the unit will stop. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 26: Maintenance

    = Check (adjust, clean or replace as necessary) = Test =check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 27 = Check (adjust, clean or replace as necessary) = Test =check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 28 = Check (adjust, clean or replace as necessary) = Test =check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 29: Routine Maintenance

    Tighten a further of a revolution. Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:- • the machine is suitably tested. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 30 Do not remove the filler cap until all excess fluid is released and the engine cooling system fully depressurised. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 31: Lubrication

    (refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual). 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 32 RUNNING GEAR WHEEL BEARINGS Wheel bearings should be packed with grease every 6 months. The type of grease used should conform to specification MIL-G-10924. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 33 Close the service valve. The engine will slow to idle speed. OPERATING INSTRUCTIONS section of this manual). CAUTION: Never allow the idle pressure to exceed maximum allowable pressure (refer to GENERAL INFORMATION). 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 34 'C' to the Set pressure by adjusting the screw 'E' on the pressure regulator main bracket 'J'. 'F'. Turn the screw clockwise to increase pressure and anticlocwise to reduce pressure. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 35 (FT-LBF) 1/4 - 20 5/16 - 18 3/8 - 16 7/16 - 14 1/2 - 13 9/16 - 12 TYPICAL CIRCULAR TORQUE PATTERN 5/8 - 11 3/4 - 10 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 36 (Nm.) (FT-LBF) (Nm.) (FT-LBF) M6 X 1.0 M8 X 1.25 M10 X 1.5 M12 X 1.75 M14 X 2 M16 X 2 TYPICAL CIRCULAR TORQUE PATTERN M20 X 2.5 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 37: Compressor Lubrication

    XHP 1001 Doosan Preferred Fluids 19.0 Litre 208.2 Litre 836 Litre PRO-TEC 89292973 89292981 22082598 XHP 605 22252076 22252050 22252068 XHP 1001 35612738 35300516 XHP 405 22252126 22252100 22252118 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 38: Machine Systems

    Pressure trancducer, separator tank. Switch batery disconnect 0-225 PSIG - 9/235, 9/270, 9/300, 10/300, 12/235. Transducer exitation 0-500 PSIG - 21/215, 17/235. WCON Wedge controller Pressure trancducer, regulation system 0-100 PSIG Relay-spst 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 39 24VDC HEATERS SOLENOID VALVES SWITCHES SPEED SENSOR ENGINE ECM HOURMETER FUEL LEVEL SWITCH DIAGNOSTIC WEDGE INTERFACE CONTROLLER PRESSURE TRANSDUCER GUAGES ESTOP SWITCHES TEMPERATURE SENSOR BATTERY STARTING AND CHARGING SYSTEM 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 40 MACHINE SYSTEMS EMU 6IRQ9AE LOW PRESSURE ELECTRICAL PARTS 9/235, 12/235, 9/270, 9/300, 10/300 PART NUMBERS DESCRIPTION QTY PER MACHINE 22162572 IQ HARNESS OPTION 36899599 IQ FILTER SWITCH 36899615 IQ FILTER SWITCH 54474572 COOLANT LEVEL SWITCH 36896975 SW MASTER DISCONNECT 36920825...
  • Page 41 W1 CHASSIS HARNESS 22101968 INLET HEATER, 120 AMPS 36853521 INLET HEATER RELAY 89303127 EMERGENCY STOP OPERATOR 89303135 NC E-STOP CONTACT BLOCK 22817829 WW CONTROL PANEL HARNESS 36842318 SOLENOID, UNLOADER L2 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 42: Fault Finding

    Excessive vibration. Engine speed too low. See ”Engine speed too low” Leaking oil seal Improperly fitted oil seal. Replace the oil seal Refer also to the Engine Manufacturer’s Manual. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 43 MAINTENANCE section of this manual. (17/235, 21/215) Faulty load valve. Replace the valve. Machine fails to load Faulty load solenoid. Replace the valve. when the load button is pressed. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 44: Options

    At the bottom of the moisture separator and both filters are strainers Standard Non-Louvered configuration not to be operated below and constant-bleed orifices, which are sized to allow the maximum flow freezing. of condensate while minimizing compressed air loss. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 45 NOTICE: Do not operate at temperatures less that 2° C (35° F) unless equipped with low ambient IQ option. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 46: Engine Instruction Manual

    Check and operation after start- up Operation and care of a new engine PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance COLD WEATHER OPERATION MAINTENANCE SCHEDULE TROUBLESHOOTING 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 47 The company reserves the right to make changes in this Manual at any time without prior notice. The pictures contained within are for guidance only and might not reflect the physical characteristics of each individual engine covered. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 48 (33) Dipstick location. (16) Engine position sensor (EPS) - (inboard). (34) Coolant filter. (17) Engine speed sensor (ESS) - (outboard). (35) Injector drain fuel outlet connection. (18) Engine dataplate. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 49 Confirmation of Engine Number It is advisable to quote the engine serial number together with the machine serial number, as it is required when you contact the Doosan branch or distributor for repair, service or parts ordering. Conduct confirmation of engine serial number with the CAUTION: engine stopped.
  • Page 50 The use of a smoke suppressant additive is not allowed because of the Check with the fuel supplier to be sure you get the properly blended greater possibility of stuck rings and valve failure, resulting from fuel. excessive ash deposits. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 51 C. (Multi - grade) COOLANT All Doosan portable compressor engines are factory filled with a 50/50 Ethylene glycol base antifreeze/water mix. which provides protection to -33° C (-27° F) 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 52 Never reverse “+” and “-” terminals when reconnecting Fan and Belt Check cables after disconnection. Even a short period of reverse connection will damage the electrical parts. The engine is fitted with an automatic belt tensioner 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 53 The engine coolant level should be between the “MAX COLD” and “MIN” marks on the reserve tank. Fuel leakage - Check the fuel injection pump, fuel lines and fuel filter for leakage. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 54 This meter indicates the machine operation hours. Make sure that the meter is always working during engine operation. Periodical machine maintenance is scheduled on the operation hours indicated on the hourmeter. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 55 If you have a problem disposing of your used oil, it is suggested that you contact your local Doosan branch or dealer. This also applies to diesel fuel which is contaminated with water.
  • Page 56 Clean the cooling system circuit every 1000 operating hours or 12 months, whichever comes first. Fig. 13 Rotate clockwise to close shut-off valve. Remove and replace coolant filter. Open shut-off valve 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 57 Fig. 16 Unscrew the element 'A' from the head taking care not to spill fuel inside the machine. Remove fuel sensor (where fitted) and re-fit to new filter element. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 58 Please consult your local Doosan branch or dealer when these The battery cables must be tightened securely. procedures become due. Please also read the note refering to the service items marked with the star symbol. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 59 NOTE: High silicate antifreeze is not recommended because of causing serious silica gelation problems. NOTE: Usage and mixing ratio etc. should be followed to the antifreeze manufacture's recommendations. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 60 This is a recommended maintenance. The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion engine useful life. Doosan, urges that recommended maintenance service is performed at the indicated intervals.
  • Page 61 Check and clean the breather tube daily during cold weather. Check according to the equipment specifications. ventilation valve cleaning Perform the adjustment, cleaning, repair or replacement every 1500 hours. (This is a recommended maintenance item ). Consult your local branch or distributor. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 62 Cooling system defect Radiator filler cap malfunction. Cooling system interior fouled. Radiator clogged. Engine over-loaded. Air cleaner element clogged. Improper servicing Insufficient airflow/restriction. Restricted coolant flow (high concentration of antifreeze, etc.) 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 63 Loose joints/gaskets. Improper installation of filter and piping. Excessive fuel consumption Damaged seals. Fuel leakage Improper component installation or tightening. Excessive injection volume. Injection pump defective. Excessive mechanical loads 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 64 Crack in battery body. Low electrolyte level Natural consumption. Loose or damaged belt. Charging failure Faulty alternator. Damaged wiring or contact failure. Excessive electrical loads Insufficient battery capacity for the application. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 65: Parts Ordering

    Afterwards, service sets of exterior decals and current production safety warning decals are available. Contact the Product Support Group at Mocksville for your particular needs and availability. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 66 Airends being returned to the factory in connection with a WARRANTY CLAIM must be processed through the Customer Service Department. If returned without a Warranty MRR (Material Return Request) Number, no warranty claim will be considered. 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...
  • Page 67 Telephone: +32 (2) 404 0811 Fax: +32 (2) 371 6915 For Service information contact: service_emea@dii.doosan.com For Parts information contact: parts_emea@dii.doosan.com Operating hours: Monday to Friday 8:30 a.m. to 5:15 p.m. (GMT) 9/270, 9/300, 12/235, 17/235, 21/215, 9/270HA, 9/300HA, 10/300HA, 12/235HA, 17/235HA, 21/215HA...

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