Doosan HP450WJD T3 Operation & Maintenance Manual Download Page 115

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Service Tools

Operating & Maintenance Manual

Book: 23252059 (08-2010) Rev B

115

DT-RT1

Crimp Tool for Deutsh pins
Crimp

Available from: Ladd

Industries (800-223-1236)

54729710

Electrical Contact Cleaner

54729728

PDA Service Tool

54699616

Deutsch Terminal Removal
Tool

22073886

Packard Crimp Tool

22073878

Thermistor Simulator

Summary of Contents for HP450WJD T3

Page 1: ...UAL COMPRESSOR MODELS P600WJD T3 7 170 C54 D18 HP450WJD T3 10 125 C55 D19 VHP400WJD T3 14 115 C56 D20 Revised 10 12 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Rand Company in this manual is historical or nominative in nature and is ...

Page 2: ...2 ...

Page 3: ... Systems 25 C Acoustic Materials 25 D Fasteners 26 E Enclosure Panels 26 F Air Intake and Engine Exhaust 26 G Cooling Systems 26 H Isolation Mounts 26 I Engine Operation 26 J Fuels and Lubricants 26 SAFETY 29 Safety 30 General Information 30 Compressed Air 31 Materials 32 Battery 32 Radiator 32 Transport 33 Safety Chains Connections and Their Adjustment 33 GENERAL ARRANGEMENT 35 General Arrangemen...

Page 4: ... Diesel Engine Coolant 58 Supplemental Coolant Additives 59 Coolant Drain Intervals 59 Operating in Warm Temperature Climates 60 LUBRICATION 61 Lubrication 62 Lubrication and Maintenance Service Interval Chart 62 Lubrication Maintenance Daily 63 Daily Pre starting Checks 63 Changing Engine Oil and Replacing Filter 63 To change engine oil and oil filter 64 Cleaning Crankcase Vent Tube 65 Replacing ...

Page 5: ...tification Label 81 MAINTENANCE 83 Maintenance 84 Routine Maintenance 89 Productive Shutdown System 91 Scavenge Line 91 Compressor Oil Filter 92 Compressor Oil Separator Element 93 Compressor Oil Cooler and Engine Radiator 94 Air Filter Elements 95 Ventilation 95 Cooling Fan Drive 95 Fuel System 96 Fuel Filter Water Separator 96 Charge Air Cooler Pipework 96 Hoses 96 Electrical System 96 Battery 9...

Page 6: ...ons Lubricator 124 Safety 124 General Information 124 Operating Instructions 124 Commissioning 124 Prior to Starting 125 Maintenance 125 Fault Finding 125 Options Dual Pressure 125 Safety 125 Operating instructions 125 Commissioning 125 Starting and Use 125 Options IQ System 126 Safety 126 Operating Instructions 127 Maintenance 128 Daily maintenance 128 Weekly Maintenance 128 Yearly Maintenance 12...

Page 7: ...7 TABLE OF CONTENTS Operating Maintenance Manual TITLE PAGE ...

Page 8: ...8 ...

Page 9: ...Book 23252059 08 2010 Rev B 9 Foreword ...

Page 10: ... A unique specification for USA Canada is adopted and tailored to the territory All components accessories pipes and connectors added to the compressed air system should be of good quality procured from a reputable manufacturer and wherever possible be of a type approved by Portable Power clearly rated for a pressure at least equal to the machine maximum allowable working pressure compatible with ...

Page 11: ...om the original English version TABLE 1 Use of the machine to produce compressed air for a direct human consumption b indirect human consumption without suitable filtration and purity checks Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION of this manual This machine is not intended and must not be used in potentially explosive atmospheres inclu...

Page 12: ...12 Book 23252059 08 2010 Rev B ...

Page 13: ...Book 23252059 08 2010 Rev B 13 Decals ...

Page 14: ...ook for these signs on machines manufactured in Europe which point out potential hazards to the safety of you and others Read and understand thoroughly Heed warnings and follow instructions If you do not understand inform your supervisor GRAPHIC FORM AND MEANING OF ISO SYMBOLS ...

Page 15: ...Decals Operating Maintenance Manual Book 23252059 08 2010 Rev B 15 ...

Page 16: ...Operating Maintenance Manual Decals 16 Book 23252059 08 2010 Rev B ...

Page 17: ...Decals Operating Maintenance Manual Book 23252059 08 2010 Rev B 17 ...

Page 18: ...and inform your DANGER WARNING CAUTION NOTICE Indicates the presence of a hazard which WILL cause serious injury death or property damage if ignored Indicates the presence of a hazard which CAN cause serious injury death or property damage if ignored Indicates the presence of a hazard which WILL or can cause injury or property damage if ignored Indicates important set up operating or maintenance i...

Page 19: ...Decals Operating Maintenance Manual Book 23252059 08 2010 Rev B 19 ...

Page 20: ...Operating Maintenance Manual Decals 20 Book 23252059 08 2010 Rev B ...

Page 21: ...rts thereof b the air intake system or parts thereof c enclosure or parts thereof 2 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 3 Operation of the compressor with any of the enclosure doors open Compressor Noise Emission Control Information A The removal or rendering inoperative other than for the purpose of maintenance repair or replacement of any n...

Page 22: ...22 22442578 ...

Page 23: ...Book 23252059 08 2010 Rev B 23 Noise Emission ...

Page 24: ...arrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed built and equipped to conform at the time of sale to the first retail purchaser with all applicable U S EPA Noise Control Regulations This warranty is not limited to any particular part component or system of the air compressor Defects in the design assembly or in any part component or system of t...

Page 25: ...n immediately and correct the leak s B Safety and Control Systems Repair or replace all safety and control systems or circuits as malfunction occurs No compressor should be operated with either system bypassed disabled or nonfunctional C Acoustic Materials In daily inspections observe these materials Maintain all acoustic material as nearly as possible in its original condition Repair or replace a...

Page 26: ...xhaust systems should be inspected after each 100 hours of operation for loose damaged or deteriorated components Repairs or replacements should be made before the next period of use G Cooling Systems All components of the cooling system for engine water and compressor oil should be inspected every 250 hours of use Any discrepancies found should be corrected before placing the unit back in operati...

Page 27: ...ntenance Manual Book 23252059 08 2010 Rev B 27 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK OR COMMENTS HOURMETER READING MAINT INSPECT DATE LOCATION CITY STATE WORK DONE BY NAME ...

Page 28: ...28 22442578 ...

Page 29: ...Book 23252059 08 2010 Rev B 29 Safety ...

Page 30: ...l protective covers are in place and that the canopy doors are closed during operation The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas If such an application is required then all local regulations codes of practice and site rules must be observed To ensure that the machine can operate in a safe and reliable manner additional equipment ...

Page 31: ...tted and controlled by work procedures so that one machine cannot accidently be pressurized over pressurized by another Compressed air must not be used for a direct feed to any form of breathing apparatus or mask High pressure Air can cause serious injury or death Relieve pressure before removing filler plugs caps fittings or covers Air pressure can remain trapped in air supply line which can resu...

Page 32: ...the lubricant supplier Never operate the engine of this machine inside a building without adequate ventilation Avoid breathing exhaust fumes when working on or near the machine This machine may include such materials as oil diesel fuel antifreeze brake fluid oil air filters and batteries which may require proper disposal when performing maintenance and service tasks Contact local authorities for p...

Page 33: ...hieved by correct selection and adjustment of the vehicle towing hitch and on variable height running gear adjustment of the drawbar Make sure wheels tires and tow bar connectors are in safe operating condition and tow bar is properly connected before towing Steps for determining correct load limit 1 Locate the statement The weight of cargo should never exceed xxx kg or xxx lbs on your vehicle s p...

Page 34: ...34 22442578 ...

Page 35: ...Book 23252059 08 2010 Rev B 35 General Arrangement ...

Page 36: ...s mm D Access items A Instrument panel access door Fuel fill B Package air inlet Engine oil filter C Access items Fuel filter Separator element fill Engine and compressor air filter Compressor oil filter E Access items Fuel filters Radiator fill Dipstick F Package air outlet Engine oil fill G Track width Coolant bottle fill ...

Page 37: ... air inlet F Package air outlet C Access items G Track width Separator element fill H Variable height drawbar Compressor oil filter 184 29 4681 minimum 189 21 4806 maximum Fuel filters J Variable height drawbar Dipstick 18 98 482 minimum 37 17 944 maximum Engine oil fill Coolant bottle fill D Access items Fuel fill Engine oil filter Fuel filter Engine and compressor air filter ...

Page 38: ...125 HP450WJD 10 3 bar 150 PSI Normal operating discharge pressure 14 115 VHP400WJD 14 bar 200 PSI Maximum allowable pressure 7 170 P600WJD 8 6 bar 125 PSI Maximum allowable pressure 10 125 HP450WJD 12 1 bar 175 PSI Maximum allowable pressure 14 115 VHP400WJD 15 5 bar 225 PSI Safety valve setting 7 170 P600WJD 10 bar 150 PSI Safety valve setting 10 125 HP450WJD 14 bar 200 PSI Safety valve setting 1...

Page 39: ...0 F TO 120 F Maximum discharge temperature 120 C 248 F Cooling system Oil injection Oil capacity 36 litres 9 5 GAL Maximum oil system temperature 120 C 248 F Maximum oil system pressure 7 170 P600WJD 8 6 bar 125 PSI Maximum oil system pressure 10 125 HP450WJD 12 1 bar 175 PSI Maximum oil system pressure 14 115 VHP400WJD 15 5 bar 225 PSI ...

Page 40: ...o TecTM No other oils fluids should be mixed with Pro TecTM because the resulting mixture could cause damage to the airend In the event that Pro TecTM is not available and or the end user needs to use an approved single grade engine oil the complete system including separator receiver cooler and pipework must be flushed clear of the first fill fluid and new Ingersoll Rand oil filters installed Whe...

Page 41: ...on is known Before towing the unit ensure that the tire pressures are correct refer to the GENERAL INFORMATION section of this manual Before towing the unit during the hours of darkness ensure that the lights are functioning correctly where fitted ENGINE P600WJD 7 120 HP450WJD 10 125 VHP400WJD 14 115 Type model Ingersoll Rand Number of cylinders 6 Oil capacity 32 5 litres 8 6 GAL Speed at full loa...

Page 42: ...uld be removed by suitable means especially to avoid strain on any rigid discharge piping Attach the battery cables to the battery s ensuring that they are tightened securely Attach the negative cable before attaching the positive cable WARNING All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine rated pressure and mate...

Page 43: ...Book 23252059 08 2010 Rev B 43 Operating Instructions ...

Page 44: ...ctor When the unit has to be operated out of level it is important to keep the engine oil level near the high level mark with the unit level CAUTION Do not overfill either the engine or the compressor with oil 2 Check the engine lubrication oil in accordance with the operating instructions in the Engine Operator s Manual 3 Check the compressor oil level in the sight glass located on the separator ...

Page 45: ...to ensure that all pressure is relieved from the system Close the service valve s 7 Check the radiator coolant level with the unit level CAUTION Do not operate the machine with the canopy doors in the open position as this may cause overheating and expose operators to high noise levels 8 Check the radiator coolant level with the unit level 9 Check the air restriction indicator s Refer to the MAINT...

Page 46: ...n See Wedge diagnostic panel for more detail 3 Hourmeter Records running time for maintenance 4 Compressor Discharge Pressure Gauge Indicates pressure in receiver tank psi kPa 5 Fuel Level Gauge Indicates amount of fuel in tank CONTROLS STANDARD 6 Power Switch Flip ON to activate systems prior to starting Flip OFF to stop engine 7 Service Air Switch After warm up PUSH Provides full air pressure at...

Page 47: ...ne speed 10 Discharge Air Temp Gauge Indicates in F and C Normal operating range 185 F 85 C to 248 F 120 C 11 Engine Oil Pressure Gauge Indicates engine oil pressure psi kPa 12 Engine Water Temp Gauge Indicates coolant temperature with normal operating range from 180 F 82 C to 210 F 99 C 13 Voltmeter Indicates battery condition 14 Spare ...

Page 48: ... Wedge diagnostic display panel is arranged as shown above A description of each diagnostic indicator is as follows 1 High Compressor Temp Fault indicator lamp Indicates shutdown due to high compressor temperature 2 Spare 3 Low Engine Oil Pressure Fault indicator lamp Indicates shutdown due to low engine oil pressure ...

Page 49: ... due to compressor system fault Refer to Fault Code List 9 Low Battery Voltage Alarm indicator lamp Indicates battery or charging system requires service 10 Engine Malfunction Engine Fault code Refer to service card or engine manual for codes and service requirements 11 Malfunction Code 4 Digit Compressor or engine fault Refer to manual for list of codes and service requirements Alert Shutdown Con...

Page 50: ...or Fault 54 CPRSR Malf Serial Comm Problem 70 CPRSR Malf CAN Bus Problem 71 CPRSR Malf Alert Shutdown Condition Code Light Blinks Code Light Steady Delay sec Dedicated Lights Low Fuel Level Fuel Level 1 Fuel Level 3 Air Filter Restriction Option Soiled Filter Low Battery Voltage Battery Charging Condition Engine Oil Pressure 18 PSI Low Engine Oil Pressure Engine Coolant Temperature 220 deg F High ...

Page 51: ...Problem 102 Turbo Boost Problem 105 Manifold Air Temperature Problem 108 Atmospheric Pressure Reading Problem 110 Engine Coolant Temperature Problem 157 Fuel Pressure Problem 158 ECU Power Down Error 174 Fuel Temperature Problem 611 Injector WJDing Problem 629 ECU Failure 636 Engine CAM Position Sensor Error 637 Crank Sensor Position Error 1136 Engine ECU Temperature High 1172 Turbo Inlet temperat...

Page 52: ...ion 3 engine start position NOTE Position 2 not used on AWJD models Release to position 1 when engine starts The engine will now be running at a reduced speed At temperatures below 0 C or if there is difficulty starting first time Open the service valve fully with no hose connected Complete starting sequence above Close service valve as soon as engine runs freely Do not allow machine to run for lo...

Page 53: ... rated pressure cfm remains nominally constant Starting and stopping are unaffected by the selection and during normal running the selector switch may be safely operated Precaution must be taken to ensure that downstream equipment is rated to suit the available pressure The pressure gauge indicates which setting has been selected Stopping the Machine Close the service valve Allow the machine to ru...

Page 54: ...splay codes table for a listing of shutdown conditions CAUTION To ensure an adequate flow of oil to the compressor at low temperature never allow the discharge pressure to fall below 3 5 bar 50 psi Decommissioning When the machine is to be permanently decommissioned or dismantled it is important to ensure that all hazard risks are either eliminated or notified to the recipient of the machine In pa...

Page 55: ...um Cetane number greater than 50 is preferred especially for temperatures below 20 C 4 F or elevations above 1500 m 5000 ft Cold Filter Plugging Point CFPP below the expected low temperature OR Cloud Point at least 5 C 9 F below the expected low temperature Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as measured by AST...

Page 56: ...njectors and in the combustion chamber Handling and Storing Bio Diesel Fuel WARNING Handle fuel carefully Do not fill the fuel tank when engine is running DO NOT smoke while you fill the fuel tank or service the fuel system Fill the fuel tank at the end of each day s operation to prevent water condensation and freezing during cold weather Keep all storage tanks as full as practicable to minimize c...

Page 57: ...d steel containers specially coated for diesel fuel storage Avoid storing fuel over long periods of time If fuel is stored for more than a month prior to use other is a slow turnover in fuel tank or supply tank add a fuel conditioner to stabilize the fuel prevent water condensation Minimizing the Effect of Cold Weather on Diesel Engines Ingersoll Rand branded diesel engines are designed to operate...

Page 58: ...ce interval by 50 Diesel fuel with sulfur content greater than 1 0 10 000 ppm is not recommended Diesel Engine Coolant The engine cooling system is filled to provide year round protection against corrosion and cylinder liner pitting and winter freeze protection to 37 C 34 F Low silicate ethylene glycol base coolants for heavy duty engines may be used if they meet one of the following specification...

Page 59: ...ant supplier and follow the manufacturer s recommendation for use of supplemental coolant additives The use of non recommended supplemental coolant additives may result in additive drop out and gelation of the coolant Add the manufacturer s recommended concentration of supplemental coolant additive DO NOT add more than the recommended amount Coolant Drain Intervals Drain the factory fill engine co...

Page 60: ...ter may be used as coolant in emergency situations only Foaming hot surface aluminum and iron corrosion scaling and cavitation will occur when water is used as the coolant even when coolant conditioners are added Drain cooling system and refill with recommended glycol base engine coolant as soon as possible Engine Break In Service The engine is ready for normal operation However extra care during ...

Page 61: ...Book 23252059 08 2010 Rev B 61 Lubrication ...

Page 62: ... Clean Crankcase Vent Tube Check Air Intake Hoses Connections System Replace Fuel Filter Elements Bleed Fuel System Check Belt Tensioner and Belt Wear Check Engine Electrical Ground Connection Check Cooling System Pressure Test Cooling System Flush Cooling System Test Thermostats Check and Adjust Engine Valve Clearance Add Coolant Replace Air Cleaner Elements Replace Poly Vee Belt A Replace primar...

Page 63: ...er into a suitable container and dispose of properly a Loosen drain plugs A at bottom of fuel filters or bowls if equipped two or three turns b Loosen air bleed plug B two full turns on fuel filter mounting and drain water from bottom until fuel starts to drain out c When fuel starts to drain out tighten drain plugs securely After draining water from the fuel filters the filters must be primed by ...

Page 64: ...by hand until firmly against dust seal DO NOT apply an extra to 1 1 4 turn after gasket contact as done with standard filters 8 Tighten drain plug to specifications 9 Fill engine crankcase with pro TecTM Engine Fluid To determine the correct oil fill quantity for your engine see ENGINE CRANKCASE OIL FILL QUANTITIES in the Specifications Section of this manual IMPORTANT Immediately after completing...

Page 65: ... leaks Do not use your hand 1 Close fuel shut off valve if equipped 2 Thoroughly clean fuel filter assemblies and surrounding areas 3 Disconnect water sensor WJDing if equipped 4 Loosen drain plugs and drain fuel into a suitable container NOTE Lifting up on retaining ring as it is rotated helps to get it past raised locators 5 Firmly grasp the retaining ring and rotate it counterclockwise turn Rem...

Page 66: ...tensioner is designed to operate within the limit of arm movement provided by the case stops when correct belt length and geometry is used Visually inspect cast stops on belt tensioner assembly If the tensioner stop on swing arm is hitting the fixed stop check mounting brackets alternator belt tensioner idler pulley etc and the belt length Replace belt as needed Checking Tensioner Spring Tension A...

Page 67: ...t is essential in your cooling system to protect against rust liner pitting and corrosion and freeze ups due to incorrect coolant dilution DO NOT mix one brand of SCA with a different brand Recharge the system per instructions printed on label of the Coolant Conditioner IMPORTANT Always maintain coolant at correct level and concentration DO NOT operate engine without coolant even for a few minutes...

Page 68: ...and check belt alignment Bleeding the Fuel System Bleed the Fuel System Engines with Electronic Fuel Systems and Stanadyne DE10 Pump CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury Avoid hazards by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect h...

Page 69: ...nnection Retighten connection to specifications 3 Repeat procedure for remaining injection nozzles if necessary until all air has been removed from fuel system If engine still will not start see your authorized servicing dealer or engine distributor Do Not Modify Fuel System IMPORTANT Modification or alteration of the injection pump the injection pump timing or the fuel injectors in ways not recom...

Page 70: ...siest things first Double check before beginning the disassembly Determine cause and make a thorough repair After making repairs operate the engine under normal conditions to verify that the problem and cause was corrected NOTE The engines covered in this manual have electronic control systems which send diagnostic trouble codes to signal problems Precautions for Welding on Engines Equipped with E...

Page 71: ... Check fuel tank Air in fuel line Bleed fuel line Cold weather Use cold weather starting aids Slow starter speed See Starter Cranks Slowly Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier use proper type fuel for operating conditions Water dirt or air in fuel system Drain flush fill and bleed system Clogged fuel filter Replace filter element Dirty or ...

Page 72: ...ded Reduce load Intake air restriction Service air cleaner Clogged fuel filter Replace filter elements Improper type of fuel Use proper fuel Overheated engine See Engine Overheats Below normal engine temperature Remove and check thermostat Improper valve clearance See your authorized servicing dealer Dirty or faulty injection nozzles Have authorized servicing dealer check injectors Injection pump ...

Page 73: ...authorized servicing dealer Engine emits white smoke Improper type of fuel Use proper fuel Low engine temperature Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Defective injection nozzles See your authorized servicing dealer Engine emits black or gray exhaust smoke Improper type of fuel Use proper fuel Clogged or dirty air cleaner Service air clean...

Page 74: ...sary Incorrect grade of fuel Use correct grade of fuel High fuel Consumption Improper type of fuel Use correct grade of fuel Clogged or dirty air cleaner Service air cleaner Engine overloaded Reduce load Improper valve clearance See your authorized servicing dealer Injection nozzles dirty See your authorized servicing dealer Electronic fuel system problem See your authorized servicing dealer Defec...

Page 75: ...nsioner Adjust belt tension or replace belts Starter will not crank PTO engaged Disengage PTO Loose or corroded connections Clean and tighten loose connections Low battery output voltage See your authorized servicing dealer Faulty start circuit replay See your authorized servicing dealer Blown fuse Replace fuse Starter cranks slowly Low battery output See your authorized servicing dealer Crankcase...

Page 76: ...ity looking for WJDes that have pulled out of connectors poorly positioned terminals damaged connectors and corroded or damaged splices and terminals Look for broken WJDes damaged splices and WJDe to WJDe shorts Use good judgement if component replacement is thought to be required NOTE The engine control unit ECU is the component LEAST likely to fail Suggestions for diagnosing intermittent faults ...

Page 77: ...g Engine for Long Term Storage The following storage preparations are good for long term engine storage up to one year After that the engine should be started warmed up and retreated for an extended storage period IMPORTANT Any time your engine will not be used for over six 6 months the following recommendations for storing it and removing it from storage will help to minimize corrosion and deteri...

Page 78: ...ces that you may not be familiar with 1 Remove all protective coverings from engine Unseal all openings in engine and remove covering from electrical systems 2 Remove the batteries from storage Install batteries fully charged and connect the terminals 3 Install fan alternator poly vee belt if removed 4 Fill fuel tank 5 Perform all appropriate pre starting checks IMPORTANT DO NOT operate starter mo...

Page 79: ... Intake Checking 0 31 0 38 mm 0 012 0 015 in Exhaust Adjusting 0 36 mm 0 014 in Intake Checking 0 31 0 38 mm 0 012 0 015 in Exhaust Checking 0 41 0 48 mm 0 016 0 019 in Intake Adjusting 0 36 mm 0 014 in Exhaust Adjusting 0 46 mm 0 018 in Max Crank Pressure 0 5 kPa 2 H2O Vibration Damper Maximum Radial Runout 1 50 mm 0 060 in Governor Regulation Industrial 7 10 Thermostat Start To Open 82 C Tempera...

Page 80: ...tems to be performed and the service intervals required see chart earlier in this manual Emission System Warranty U S EPA Emissions Control Warranty Statement Emissions control related parts and components are warranted for five years or 3000 hours of operation whichever occurs first Further the engine covered by this warranty was designed built and equipped so as to conform at the time of sale wi...

Page 81: ...rtable1 equipment The presence of an emissions labels signifies that the engine has been certified with the EPA and or CARB The EPA and CARB warranties only apply to new engines having the certification label affixed to the engine and sold as stated above in the geographic areas The presence of an EU number in the third line of the label signifies that the engine has been certified with the Europe...

Page 82: ...82 Book 23252059 08 2010 Rev B ...

Page 83: ...Book 23252059 08 2010 Rev B 83 Maintenance ...

Page 84: ...Indicators C Fuel Tank Fill at end of day C D Fuel Water Separator Drain C Oil Leaks C Fuel Leaks C Drain Water From Fuel Filters D Coolant Leaks C Radiator Filler Cap C Air Cleaner Precleaner Dumps C Fan Alternator Belts C Battery Connections Electrolyte C Tire Pressure and Surface C Wheel Lug Nuts C Hoses Oil Air Intake etc C Automatic Shutdown System C Air Cleaner System C Compressor Oil Cooler...

Page 85: ...ne 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 ...

Page 86: ...Element R Compressor Oil R Engine Oil Change R Engine Oil Filter R Water Pump Grease R Wheels Bearings Seals etc C Engine Coolant C R Fuel Filter Element R Injection Nozzle Check C Shutdown Switch Settings T Scavenger Orifice Related Parts C Oil Separator Element R Feed Pump Strainer Cleaning C Coolant Replacement R Valve Clearance Check C Lights running brake turn CBT Pintle Eye Bolts CBT Brakes ...

Page 87: ...riate 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 ...

Page 88: ...nk 2 exterior CR Lubricator Fill C 2 Yrs 4 Yrs 6 Yrs Safety valve C Hoses R Separator tank 2 interior C 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 indicate...

Page 89: ...ble personal 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 If the automatic blowdown valve is used for this purpose then allow enough time for it to complete the operation The discharge ...

Page 90: ...r removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed all hazards present are known e g pressurized components electrically live components removed panels covers and guards extreme temperatures inflow and outflow of air intermittently moving parts safety valve discharge etc appropriate personal protective equipment is wo...

Page 91: ... intervals test the low engine fuel level switch by removing and operating the float manually CAUTION Never remove or replace switches when the machine is running Scavenge Line The scavenge line runs from the combined orifice drop tube in the separator tank to the orifice fitting located in the airend Examine the orifice check valve and hoses at every service or in the event of oil carryover into ...

Page 92: ...kwise 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 the compressor lubricating and cooling oil has deteriorated and that it should be changed immediately Refer to LUBRICATION later in this section Reassembly Clean the filter gasket contact area and install the new elem...

Page 93: ...over plate Remove the separator element Inspection Examine the filter element Examine all hoses and tubes and replace if necessary Reassembly Thoroughly clean the orifice drop tube and filter gasket contact area before reassembly Install the new element WARNING Do not remove the staple from the anti static gasket on the separator element since it serves to ground any possible static build up Do no...

Page 94: ... remove any accumulation of oil grease and dirt from the exterior core of the cooler so that the entire cooling area can radiate the heat of the lubricating and cooling oil water into the air stream WARNING Hot engine coolant and steam can cause injury When adding coolant or antifreeze solution to the engine radiator stop the engine at least one minute prior to releasing the radiator filler cap Us...

Page 95: ...al at the end of the element and replace if any sign of damage is evident Reassembly Assemble the new element into the filter housing ensuring that the seal seats properly Reset the restriction indicator by depressing the rubber diaphragm Assemble the dust collector box parts ensuring that they are correctly positioned Before restarting the machine check that all clamps are tight Ventilation Alway...

Page 96: ...intake system should be checked periodically to keep the engine at peak efficiency At the recommended intervals see the SERVICE MAINTENANCE CHART inspect all of the intake lines to the air filter and all flexible hoses used for air lines oil lines and fuel lines Periodically inspect all pipe work for cracks leaks etc and replace immediately if damaged Electrical System WARNING Always disconnect th...

Page 97: ...ness and chafing Any suspect parts should be replaced before the machine is put back into service Tyres Tyre Tire Pressure See the GENERAL INFORMATION section of this manual Running Gear Wheels Check the wheel nut torque 20 miles 30 kilometres after refitting the wheels Refer to the TORQUE SETTING TABLE later in this section Lifting jacks should only be used under the axle The bolts securing the r...

Page 98: ...ation Refer to the Engine section of this manual Engine Oil Filter Element The engine oil filter element should be changed at the engine manufacturer s recommended intervals Refer to the Engine section of this manual Compressor Lubricating Oil Refer to the SERVICE MAINTENANCE CHART in this section for service intervals NOTE If the machine has been operating under adverse conditions or has suffered...

Page 99: ...hen most of the sediment will be in suspension and will therefore drain more readily CAUTION Some oil mixtures are incompatible and result in the formation of varnishes shellacs or lacquers which may be insoluble NOTE Always specify INGERSOLL RAND Pro TecTM oil for use at all ambient temperatures above 23 C Compressor Oil Filter Element Refer to the SERVICE MAINTENANCE CHART in this section for se...

Page 100: ...rew Start the machine Refer to STARTING INSTRUCTIONS in the OPERATING INSTRUCTIONS section of this manual Adjust the service valve on the outside of the machine to maintain rated pressure at full speed If full speed is not maintained at rated pressure then turn the adjusting screw clockwise to increase the pressure Optimum adjustment is achieved when full speed is achieved at rated pressure Close ...

Page 101: ...Maintenance Operating Maintenance Manual Book 23252059 08 2010 Rev B 101 ...

Page 102: ...Operating Maintenance Manual Maintenance 102 Book 23252059 08 2010 Rev B ...

Page 103: ...the ambient temperature expected to be encountered before the next oil change NOTE Fluids listed as preferred are required for extended warranty Compressor oil carryover oil consumption may be greater with the use of alternative fluids Preferred Ingersoll Rand Fluids Use of these fluids with original Ingersoll Rand branded filters can extend airend warranty Refer to operator s manual warranty sect...

Page 104: ...ngersoll Rand XHP 605 Alternate Ingersoll Rand XHP 405 ISO Viscosity Grade 68 Group 3 or 5 with rust and oxidation inhibitors designed for air compressor service 65 F to 125 F 18 C to 52 C Preferred XHP605 Ingersoll Rand XHP 1001 Ingersoll Rand Preferred Fluids 1 gal 3 8 Litre 5 gal 19 0 Litre 55 gal 208 2 Litre 220 gal 836 litre Preferred Ingersoll Rand Pro TecTM 36899698 36899706 36899714 368997...

Page 105: ...Book 23252059 08 2010 Rev B 105 Machine Systems ...

Page 106: ...overnor R3 Idle sel J50 G2 Wait to start lamp RS Relay spst J50 K3 Inlet heater RT1 Thermistor separator tank temperature 30 2550 F P51 Coolant temp RT2 Thermistor airend discharge temperature 30 2550F P52 Inject P53 Crank sensor SI Switch inputs P54 Fuel temp SM Starter motor P55 Manifold air temp SW1 Spare P56 Oil pressure SW2 Display scroll POUT1 Engine key switch SW3 Low fuel shutdown POUT2 So...

Page 107: ...ating Maintenance Manual Book 23252059 08 2010 Rev B 107 POUT4 Engine fault lamp SW6 Spare POUT5 Start relay SW7 Spare POUT6 Spare SW8 Switch start POUT7 Hour meter TE Transducer exitation POUT8 Spare WCON Wedge controller ...

Page 108: ...Operating Maintenance Manual Machine Systems 108 Book 23252059 08 2010 Rev B Wedge to Engine Interface Engine Harness System Schematic ...

Page 109: ...Machine Systems Operating Maintenance Manual Book 23252059 08 2010 Rev B 109 J1939 CAN Communications Schematic ...

Page 110: ...Operating Maintenance Manual Machine Systems 110 Book 23252059 08 2010 Rev B ...

Page 111: ...Book 23252059 08 2010 Rev B 111 Service Tools ...

Page 112: ...678 Deutsch Terminal Removal Tool Blue Used to repair Deutsch connectors 54729686 Deutsch Terminal Removal Tool Red Used to repair Deutsch connectors 54729694 Deutsch Terminal Removal Tool Yellow Used to repair Deutsch connectors HDT 48 00 Deutsch Terminal Crimp Tool Used to crimp Deutsch connector terminals DD Deutsch Terminal Crimping Tool Used to crimp Deutsch connector terminals 54729710 Elect...

Page 113: ...istor circuits 54699616 Deutsch Terminal Removal Tool Used to repair Deutsch connectors 54699657 Deutsch Terminal Removal Tool Used to repair Deutsch connectors 54749643 Packard Metri Pack Terminal Removal Tool Used to repair Metri Pack connectors 54749635 Connector Repair Kit Used to make connector repairs Tool Tool Description ...

Page 114: ...Tool Description Tool Illustration Fluke 87 Digital multimeter Available from electrical and electronic parts distributors 54729660 Weather Pack Terminal Removal Tool 54699632 Deutsch Terminal Removal Tool Blue 54699640 Deutsch Terminal Removal Tool Red 54699624 Deutsch Terminal Removal Tool Yellow ...

Page 115: ...8 2010 Rev B 115 DT RT1 Crimp Tool for Deutsh pins Crimp Available from Ladd Industries 800 223 1236 54729710 Electrical Contact Cleaner 54729728 PDA Service Tool 54699616 Deutsch Terminal Removal Tool 22073886 Packard Crimp Tool 22073878 Thermistor Simulator ...

Page 116: ... PER MACHINE 36920825 0 100 psi PRESSURE TRANSDUSER 1 54731427 FUEL LEVEL SENDER 1 54765946 0 500 psi PRESSURE TRANSDUSER 1 22173579 WEDGE CONTROLLER 1 36898922 THERMISTOR PROBE 2 22199061 W1 CHASSIS HARNESS 1 36840841 SOLENOID VALVE 1 22179659 W1 CHASSIS HARNESS DIAGRAM N A 36853521 STARTER AND INLET HEATER RELAY 2 36792083 FUSE 20 AMP BLADE 1 35610856 NEGATIVE BATTERY CABLE 1 22071591 FUSE 10 AM...

Page 117: ...Book 23252059 08 2010 Rev B 117 Fault Finding ...

Page 118: ... good Fuel starvation Check the fuel level and fuel system components Replace the fuel filter if necessary Relay failed Replace the relay Faulty stop solenoid Check the stop solenoid Engine stops while in service or is reluctant to start Low fuel level Fill fuel tank and bleed air from fuel system if necessary Refer to MAINTENANCE SECTION Safety shut down system in operation Check the safety shut ...

Page 119: ...Engine Overheats Low water level Check the level and replenish if necessary Blocked radiator Stop the machine and clean the cooling fins with compressed air or steam Use reduced pressure for cleaning the fins Reduced cooling air from fan Check the fan and the drive belts Check for any obstruction inside the cowl Faulty thermostat Check the thermostat and replace if necessary Engine speed too high ...

Page 120: ...p the oil level and check for leaks Dirty or blocked oil cooler Clean the oil cooler fins Incorrect grade of oil Use recommended oil Defective by pass valve Check the operation of the element and replace if necessary Recirculation of cooling air Move the machine to avoid recirculation Reduced cooling air from fan Check the fan and the drive belts Check for any obstruction inside the fan cowl Exces...

Page 121: ...TEMPT A REPAIR Oil is forced back into the air filter Incorrect stopping procedure used Always employ the correct stopping procedure Close the discharge valve and allow the machine to run on idle before stopping Faulty inlet valve Check for free operation of the inlet valve s Machine goes to full pressure when started Faulty load valve Replace the valve Machine fails to load when the load button i...

Page 122: ...122 ...

Page 123: ...Book 23252059 08 2010 Rev B 123 Options ...

Page 124: ...e that the machine is stopped and the system has been completely relieved of all air pressure Refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual CAUTION If the nylon tubes to the lubricator are disconnected then ensure that each tube is re connected in its original location General Information Oil capacity 1 QT Option 0 95 Litre 1qt 2 QT Option 1 9 Litre 2qts Oil speci...

Page 125: ...for use with at least the higher rated pressure Operating instructions Commissioning Check that switch and solenoid are functioning correctly Switch handle up Lower pressure selected Switch handle right Higher pressure selected Starting and Use Select higher pressure setting with valve handle handle to right and start machine normally If lower pressure is required then turn handle to up position T...

Page 126: ...ing reduced engine life and reduced airend life CAUTION Excessively restricted filter elements may cause an increase in the amount of aerosol water and oil carryover which could result in damage to downstream equipment Normal service intervals should not be exceeded CAUTION Blockage of the condensate will result in flooding of the vessels if flooding occurs excessive condensate may enter the air s...

Page 127: ...Do not operate at temperatures less that 2º C 35º F unless equipped with low ambient IQ option Operating Instructions Starting and use Select desired air type using diverter valve and start machine normally Using diverter valve toggle between standard air and IQ air as required ...

Page 128: ...triction indicators for the filters are mounted on the filter heads If so equipped an automatic restriction indicator located behind the filters will shut down the compressor if restriction exceeds recommended values Filter replacement Remove all WJDes and hoses connected to drains on bottom of each filter housing Inspect fittings and hoses for any blockage Clean if necessary Using a chain wrench ...

Page 129: ...Revision History Rev EC Number Comments A Original release B Edits C SVC31262 Changed Model from WIR to WJD ...

Page 130: ... 2009 Doosan Infracore International Inc Printed in the USA Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 www doosanportablepower com ...

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