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Operating & Maintenance Manual

Operating Instructions

Book: 22846471 (3-09-07) Rev. B

WEDGE DIAGNOSTIC DISPLAY CODES

ALERT

SHUTDOWN

Condition

Code

Light (Blinks)

Code

Light (Steady)

Delay (Sec)

Engine Speed < Min.
RPM

CPRSR Malf

Engine Speed > Max.
RPM

CPRSR Malf

Engine Crank Time
Exceeded

CPRSR Malf

High Engine Oil Temp

CPRSR Malf

High Intake Manifold
Temp

CPRSR Malf

Water in Fuel

CPRSR Malf

Engine Not
Responding to Throttle
Command

CPRSR Malf

Too Many Start
Attemps During
Autostart

CPRSR Malf

Engine Shuts Itself
Down: reason
unknown

CPRSR Malf

Low AE oil pressure

CPRSR Malf

Disch. Temp (RT2)
Sensor Fault

CPRSR Malf

Sep. Tank Temp (PT1)
Sensor Fault

CPRSR Malf

Sep. Tank Press. >20
psi during start attempt
(engine will not crank)

CPRSR Malf

Machine Over
Pressure

CPRSR Malf

Book:46623600 (10-12-2012) Rev. A

Summary of Contents for HP900

Page 1: ...o Shi Road Changning District Shanghai www doosanportablepower com Book 2012 10 Rev A This manual contains important safety information Do not destroy this manual This manual must be available to the...

Page 2: ...2...

Page 3: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm...

Page 4: ...Schedule 21 A Compressed Air Leaks 21 B Safety and Control Systems 21 C Acoustic Materials 21 D Fasteners 22 E Enclosure Panels 22 F Air Intake and Engine Exhaust 22 G Cooling Systems 22 H Isolation...

Page 5: ...ressor Oil Separator Element 57 Removal 57 Inspection 57 Reassembly 57 Compressor Oil Cooler Engine Radiator Air Charge Cooler 58 Air Filter Element 59 Removal 59 Inspection 59 Reassembly 59 Ventilati...

Page 6: ...77 Fault Finding 78 OPTIONS 83 Options 84 IQ System Operating Diagram 84 IQ System General 85 IQ System Operating Instructions 85 Low Ambient Option Operation 86 Maintenance 86 Daily Maintenance 86 We...

Page 7: ...6 TABLE OF CONTENTS Operation Maintenance Manual TITLE PAGE Always Use IR Replacement Parts Always Use DOOSAN Replacement Parts...

Page 8: ...Book 22846471 3 09 07 Rev B 7 Foreword Book 46623600 10 07 2012 Rev A...

Page 9: ...proved by Portable Power clearly rated for a pressure at least equal to the machine maximum allowable working pressure compatible with the compressor lubricant coolant accompanied with instructions fo...

Page 10: ...nce items on a special preventive maintenance schedule for each machine It is very important that the minimum service and maintenance requirements explained in this manual be performed at the required...

Page 11: ...Operating Maintenance Manual Foreword 10 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement Parts Book 46623600 10 12 2012 Rev A Always Use DOOSAN Replacement Parts...

Page 12: ...Book 22846471 3 09 07 Rev B 11 Safety Book 46623600 10 12 2012 Rev A...

Page 13: ...articular safety related parts such as coupling hitch drawbar components road wheels and lifting bail should be checked for total security All components which are loose damaged or unserviceable must...

Page 14: ...n serious injury or death Always carefully vent air supply line at tool or vent valve before performing any service The discharged air contains a very small percentage of compressor lubricating oil an...

Page 15: ...ry electrolyte WARNING Avoid ingestion skin contact and inhalation of fumes Should compressor lubricant come into contact with the eyes then irrigate with water for at least 5 minutes Should compresso...

Page 16: ...to slave start a frozen battery since this may cause it to explode Exercise extreme caution when using booster battery To jump battery connect ends of one booster cable to the positive terminal of eac...

Page 17: ...es safety chains are connected to the towing vehicle The machine must be towed in a level attitude in order to maintain correct handling braking and lighting functions This can be achieved by correct...

Page 18: ...ANGER Red Background Indicates the presence of a hazard which WILL cause serious injury death or property damage if ignored WARNING Orange Background Indicates the presence of a hazard which CAN cause...

Page 19: ...lable free of charge Safety decals are identified by the decal heading DANGER WARNING or CAUTION Decal part numbers are on the bottom of each decal and are also listed in the compressor s parts manual...

Page 20: ...Book 22846471 3 09 07 Rev B 19 Noise Emission...

Page 21: ...ser 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 lim...

Page 22: ...diately 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 bypas...

Page 23: ...pected 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 cooli...

Page 24: ...22846471 3 09 07 Rev B 23 Table 1 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK OR COMMENTS HOURMETER READING MAINT INSPECT DATE LOCATION CITY STATE...

Page 25: ...24 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts Book 46623600 10 12 2012 Rev A Always Use DOOSAN Replacement Parts...

Page 26: ...Book 22846471 3 09 07 Rev B 25 General Information Book 46623600 10 12 2012 Rev A...

Page 27: ...Operating Maintenance Manual General Information 26 Book 22846471 3 09 07 Rev B General Information MSA SRG HRG Book 46623600 10 12 2012 Rev A...

Page 28: ...General Information Operating Maintenance Manual Book 22846471 3 09 07 Rev B 27 Book 46623600 10 12 2012 Rev A...

Page 29: ...5 18 5 70 Maximum oil system temperature F C 248 120 248 120 Maximum oil system pressure psi bar 362 25 250 17 LUBRICATING OIL SPECIFICATION for the specified ambient temperatures SEE NOTE Protec Prot...

Page 30: ...ation may be obtained by request through Ingersoll Rand customer services department RUNNING GEAR TIRE DATA Site Running Gear SRG High Speed Running Gear HSRG Number of wheels 4 4 Tire size 750x16 LT...

Page 31: ...30 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts Book 46623600 10 12 2012 Rev A Always Use DOOSAN Replacement Parts...

Page 32: ...Book 22846471 3 09 07 Rev B 31 Operating Instructions Book 46623600 10 12 2012 Rev A...

Page 33: ...ing materials are discarded Ensure that the correct fork lift truck slots or marked lifting tie down points are used whenever the machine is lifted or transported When selecting the working position o...

Page 34: ...possible The design of the unit permits a 15 degree lengthways and sideways limit on out of level operation When the unit has to be operated out of level it is important to keep the engine oil level n...

Page 35: ...ain fuel filter water separator of water ensuring that any released fuel is safely contained 6 Check the radiator coolant level with the unit level 7 Open the service valve s to ensure that all pressu...

Page 36: ...chine in temperatures below or approaching 0 C 32 F ensure that the operation of the regulation system the unloader valve the safety valve and the engine are not impaired by ice or snow and that all i...

Page 37: ...ipped 8 Low Fuel Level Fault indicator lamp Indicates shutdown due to low fuel level Lamp blinks at low fuel warning 9 Compressor Malfunction Fault indicator lamp Indicates shutdown due to compressor...

Page 38: ...iver tank normally from 0 psi kPa to the rated pressure of the machine 21 Engine Tachometer Indicates engine speed in RPM from 0 when stopped to full speed 22 Fuel Level Gage Indicate fuel level in ta...

Page 39: ...hutdown due to low engine oil pressure 3 High Engine Coolant Temp Fault indicator lamp Indicates shutdown due to high engine water temperature 4 Low Fuel Level Fault indicator lamp Indicates shutdown...

Page 40: ...es shutdown due to high pressure in IQ air filters if equipped 9 Compressor Malfunction Fault indicator lamp Indicates shutdown due to compressor system fault Refer to Fault Code List 10 Engine Malfun...

Page 41: ...CPRSR Malf High Intake Manifold Temp 6 CPRSR Malf Water in Fuel 8 CPRSR Malf Engine Not Responding to Throttle Command 10 CPRSR Malf Too Many Start Attemps During Autostart 11 CPRSR Malf 0 Engine Shu...

Page 42: ...55 CPRSR Malf 3 Minimum Pressure Not Met 56 CPRSR Malf Serial Comm Problem 70 CPRSR Malf CAN Bus Problem 71 CPRSR Malf Auto Start Stop Module Failure No Comm for 17 sec 73 CPRSR Malf Low Fuel Level Fu...

Page 43: ...or short to ground 26 Atmospheric pressure open short batt Atmospheric pressure short to ground 27 Engine coolant temperature open short to batt Engine coolant temperature short to ground 28 Throttle...

Page 44: ...h engine coolant temperature WARNING High engine coolant temperature derate High engine coolant temperature shutdown 62 Low engine coolant level WARNING Low engine coolant level derate Low engine cool...

Page 45: ...valve The wedge controller will execute a lamp test The low engine oil pressure and low battery lamps will flash indicating proper communication between wedge and engine ECM Inlet heater Wait to start...

Page 46: ...AINTENANCE section of this manual and to the ENGINE MANUFACTURER S MANUAL Stopping the Machine Close the service valve Allow the machine to run unloaded for a short period of time to reduce the engine...

Page 47: ...switched off because of a machine malfunction then identify and correct the fault before attempting to re start If the machine has been switched off for reasons of safety then ensure that the machine...

Page 48: ...hine In particular Do not destroy batteries or components containing asbestos without containing the materials safely Do not dispose of any pressure vessel that is not clearly marked with its relevant...

Page 49: ...Operating Maintenance Manual Operating Instructions 48 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts Book 46623600 10 12 2012 Rev A Always Use DOOSAN Replacement Parts...

Page 50: ...Book 22846471 3 09 07 Rev B 49 Maintenance Book 46623600 10 12 2012 Rev A...

Page 51: ...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 Precleane...

Page 52: ...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 Service interval varies with fuel quality R Injection N...

Page 53: ...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 Separa...

Page 54: ...erate then pressure must be gradually relieved by operating the manual blowdown valve Suitable personal protective equipment should be worn Ensure that maintenance personnel are adequately trained com...

Page 55: ...ted 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 pressurised components electrically live components...

Page 56: ...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 combine...

Page 57: ...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 co...

Page 58: ...n 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 ele...

Page 59: ...y 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...

Page 60: ...f the safety element is to be renewed thoroughly clean the interior of the filter housing prior to removing the safety element Inspection Check for cracks holes or any other damage to the element by h...

Page 61: ...tank s it is advisable to top up after the machine is shut down or at the end of each working day At six month intervals drain any sediment or condensate that may have accumulated in the tank s Fuel...

Page 62: ...ion of parts acrid smells and blistered paint Battery WARNING Always disconnect the battery cables before performing any maintenance or service Keep the battery terminals and cable clamps clean and li...

Page 63: ...or a nominal period of operation for more information consult The Engine Manufacturer s Manual CAUTION Always check the oil levels before a new machine is put into service If for any reason the unit h...

Page 64: ...drain the receiver separator system including the piping and oil cooler by removing the drain plug s and collecting the used oil in a suitable container Replace the drain plug s ensuring that each on...

Page 65: ...fully clockwise 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 air cylinder fully contract...

Page 66: ...s i To increase the warm up pressure turn the air cylinder rod in an anti clockwise direction to open the butterfly valve To reduce warm up pressure turn air cylinder rod in clockwise direction to clo...

Page 67: ...Operating Maintenance Manual Maintenance 66 Book 22846471 3 09 07 Rev B Torque Values Book 46623600 10 12 2012 Rev A...

Page 68: ...s Torque Ft Lbs Torque N m Torque ft Lbs 13 Wheel 80 90 15 Wheel 105 115 M12 Bolts 85 95 62 70 16 Wheel 105 115 M14 Bolts 145 155 107 115 16 5 Wheel 105 115 M16 Bolts 175 185 129 137 5 8 Lug Nuts M18...

Page 69: ...anty NOTE Compressor oil carryover oil consumption may be greater with the use of alternative fluids Design Operating Pressure Ambient Temperature Specification 100 psi to 300 psi 10 F to 125 F 23 C t...

Page 70: ...nty section for details or contact your IR representative Ingersoll Rand Preferred Fluids 1 gal 3 8 Litre 5 gal 19 0 Litre 5 gal 208 2 Litre 220 gal 836 litre Preferred IR Pro TecTM 36899698 36899706...

Page 71: ...70 Always use Ingersoll Rand Replacement parts Always Use DOOSAN Replacement Parts...

Page 72: ...Book 22846471 3 09 07 Rev B 71 Machine Systems Book 46623600 10 12 2012 Rev A...

Page 73: ...the control panel The LED annunciators are part of the front panel of the WEDGE They can be seen through the laminate on the front of the control panel The WEDGE is attached to the control panel with...

Page 74: ...Machine Systems Operating Maintenance Manual Book 22846471 3 09 07 Rev B 73 Book 46623600 10 12 2012 Rev A...

Page 75: ...Operating Maintenance Manual Machine Systems 74 Book 22846471 3 09 07 Rev B Book 46623600 10 12 2012 Rev A...

Page 76: ...are provided with 5 VDC excitation to power the device These are three wire devices excitation signal and ground Digital Inputs and Outputs The WEDGE controller scans digital inputs such as switch con...

Page 77: ...inal and the machine metal The engine diagnostics connector is located on the left side of the engine This is used to connect the engine manufacturer s service tools to the CAN network This connector...

Page 78: ...Book 22846471 3 09 07 Rev B 77 Fault Finding Book 46623600 10 12 2012 Rev A...

Page 79: ...ation 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...

Page 80: ...if necessary Engine Overheats Low water level Check the level and replenish if necessary Blocked radiator Stop the machine and clean the cooling fins with compressed air or steam Use reduced pressure...

Page 81: ...and check for leaks Dirty or blocked oil cooler Clean the oil cooler fins Incorrect grade of oil Use Ingersoll Rand recommended oil Defective by pass valve Check the operation of the element and repla...

Page 82: ...k the relieving pressure Replace the safety valve if faulty DO NOT ATTEMPT A REPAIR Oil is forced back into the air filter Incorrect stopping procedure used Always employ the correct stopping procedur...

Page 83: ...82 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts Book 46623600 10 12 2012 Rev A Always Use DOOSAN Replacement Parts...

Page 84: ...Book 22846471 3 09 07 Rev B 83 Options Book 46623600 10 12 2012 Rev A...

Page 85: ...ons 84 Book 22846471 3 09 07 Rev B Options IQ System Operating Diagram Key 1 Three way valve 5 Filters 2 Ball valve1 6 Aftercooler 3 Ball valve2 7 Minimum pressure valve 4 Safety valve 8 Separator tan...

Page 86: ...ses the IQ System and delivers air quality equivalent to a standard oil flooded portable compressor If the IQ System is enabled by proper setting of the selector valve the compressed air first enters...

Page 87: ...ndicators for the filters are mounted inside the control panel and will shut down the compressor if restriction exceeds recommended values Weekly Maintenance Remove Y strainer screens at the bottom of...

Page 88: ...d This will result in operation at excessive horsepower levels causing overheating reduced engine life and reduced airend life CAUTION Excessively restricted filter elements may cause an increase in t...

Page 89: ...88 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts Book 46623600 10 12 2012 Rev A Always Use DOOSAN Replacement Parts...

Page 90: ...Doosan Infracore Portable Power Shanghai Co Ltd 88 Guanghua road Songjiang District Shanghai Hotline 400 920 2829 www doosanportablepower com...

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