Doosan Ingersoll Rand HP375 WIR Operating & Maintenance Manual Download Page 112

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Operating & Maintenance Manual

Service Tools

112

22442578

Service Tools

Electronic Systems

The following special tools are recommended to perform service procedures in this mannual.
The tools can be purchased from Portable Power or equivalent substitutes can be used.

Tool

Tool Description

Fluke 87

Digital Multimeter

Used to measure electrical circuits: volts,
ohms amps

54729660

Weather-Pack Terminal Removal Tool

Used to repair Packard Electric Weather-
Pack Connectors.

54729678

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

Deutsch Terminal Crimping Tool

Used to crimp Deutsch connector terminals

54729710

Electrical Contact Cleaner

Used to clean electrical contacts and
connectors

54729728

PDA Service Tool

Palm Pilot based service tool used to
connect to Intellisys (SGP) Controller to
load software and extract service
information

22073886

Packard Crimp Tool

Used to crimp Packard connector terminals

Summary of Contents for Ingersoll Rand HP375 WIR

Page 1: ...operate and maintain this machine Operating Maintenance Manual Compressor Models Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of...

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 SA...

Page 4: ...Diesel Engine Coolant 59 Supplemental Coolant Additives 60 Coolant Drain Intervals 60 Operating in Warm Temperature Climates 61 LUBRICATION 63 Lubrication 64 Lubrication and Maintenance Service Interv...

Page 5: ...cation Label 83 MAINTENANCE 85 Maintenance 86 Routine Maintenance 91 Productive Shutdown System 93 Scavenge Line 93 Compressor Oil Filter 94 Compressor Oil Separator Element 95 Compressor Oil Cooler a...

Page 6: ...ice Tools 112 Electronic Systems 112 Service Tools 114 Electrical Parts 116 FAULT FINDING 117 Fault Finding 118 OPTIONS 123 Options Lubricator 124 Safety 124 General Information 124 Operating Instruct...

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

Page 8: ...8 Always use Ingersoll Rand Replacement parts...

Page 9: ...22442578 9 Foreword...

Page 10: ...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 reput...

Page 11: ...ginal 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...

Page 12: ...12 22442578...

Page 13: ...22442578 13 Decals...

Page 14: ...se 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 underst...

Page 15: ...Decals Operating Maintenance Manual 22442578 15...

Page 16: ...Operating Maintenance Manual Decals 16 22442578...

Page 17: ...Decals Operating Maintenance Manual 22442578 17...

Page 18: ...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 inj...

Page 19: ...Decals Operating Maintenance Manual 22442578 19...

Page 20: ...rge 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 Submit orders fo...

Page 21: ...he 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...

Page 22: ...22 22442578...

Page 23: ...22442578 23 Noise Emission...

Page 24: ...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 N...

Page 25: ...ely 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...

Page 26: ...ms 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 compone...

Page 27: ...ating Maintenance Manual 22442578 27 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK OR COMMENTS HOURMETER READING MAINT INSPECT DATE LOCATION CITY STAT...

Page 28: ...28 22442578...

Page 29: ...22442578 29 Safety...

Page 30: ...ve 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 a...

Page 31: ...ntrolled by work procedures so that one machine cannot accidently be pressurised over pressurised by another Compressed air must not be used for a direct feed to any form of breathing apparatus or mas...

Page 32: ...cant 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 ma...

Page 33: ...rrect selection and adjustment of the vehicle towing hitch and on variable height running gear adjustment of the drawbar Make sure wheels tyres and tow bar connectors are in safe operating condition a...

Page 34: ...34 22442578...

Page 35: ...22442578 35 General Arrangement...

Page 36: ...ss 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 Acces...

Page 37: ...inlet F Package air outlet C Access items G Track width Separator element fill H Variable height drawbar Compressor oil filter 162 4114 minimum 168 4277 maximum Fuel filters J Variable height drawbar...

Page 38: ...Normal operating discharge pressure 14 85 VHP3000AWIR 14 bar 200 PSI Maximum allowable pressure 7 120 P425AWIR 8 6 bar 125 PSI Maximum allowable pressure 9 110 XP375AWIR 10 3 bar 150 PSI Maximum allo...

Page 39: ...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 7 120 P425AWIR 8 6 bar 125 PSI Maximum oil system pressu...

Page 40: ...TM 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 a...

Page 41: ...ing the unit ensure that the tyre 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 functioni...

Page 42: ...oved 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 at...

Page 43: ...22442578 43 Operating Instructions...

Page 44: ...he 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...

Page 45: ...rvice valve s to ensure that all pressure is relieved from the system Close the service valve s 7 CAUTION Do not operate the machine with the canopy doors in the open position as this may cause overhe...

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 Indic...

Page 47: ...Air Temp Gauge Indicates in F and C Normal operating range 185 F 85 C to 248 F 120 C 10 Engine Oil Pressure Gauge Indicates engine oil pressure psi kPa 11 Engine Water Temp Gauge Indicates coolant tem...

Page 48: ...gnostic 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 temperat...

Page 49: ...pressor 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...

Page 50: ...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 L...

Page 51: ...age Low 18 Engine Oil Pressure Moderately Low 105 3 Manifold Air Temperature Input Voltage High 4 Manifold Air Temperature Input Voltage Low 16 Manifold Air Temperature Moderately High 110 0 Engine Co...

Page 52: ...ve Closure Too Long 1 Pump Control Valve Closure Too Short 5 Pump Solenoid Circuit Open 6 Pump Solenoid Circuit Severely Shorted 7 Pump Control Valve Closure Not Detected 10 Pump Solenoid Circuit Mode...

Page 53: ...ne start position NOTE Position 2 not used on AWIR 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...

Page 54: ...sure 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 d...

Page 55: ...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 Decommissioni...

Page 56: ...umber 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 le...

Page 57: ...nd 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 th...

Page 58: ...ntainers 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...

Page 59: ...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 c...

Page 60: ...r 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 c...

Page 61: ...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 add...

Page 62: ...62 22442578...

Page 63: ...22442578 63 Lubrication...

Page 64: ...nkcase 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 Sys...

Page 65: ...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...

Page 66: ...il 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...

Page 67: ...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 wiring if equipped 4 Loosen drain plugs and drain fu...

Page 68: ...s 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...

Page 69: ...ial 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 p...

Page 70: ...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...

Page 71: ...etighten 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...

Page 72: ...gs 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 w...

Page 73: ...l 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 fu...

Page 74: ...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 temperatur...

Page 75: ...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...

Page 76: ...ect 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 Imprope...

Page 77: ...just 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 ser...

Page 78: ...g for wires that have pulled out of connectors poorly positioned terminals damaged connectors and corroded or damaged splices and terminals Look for broken wires damaged splices and wire to wire short...

Page 79: ...r 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 peri...

Page 80: ...ou 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 batterie...

Page 81: ...king 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 A...

Page 82: ...o 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...

Page 83: ...uipment 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 a...

Page 84: ...84 22442578...

Page 85: ...22442578 85 Maintenance...

Page 86: ...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 Alter...

Page 87: ...00 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 Rep...

Page 88: ...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 Sc...

Page 89: ...his 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...

Page 90: ...ior 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...

Page 91: ...l 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...

Page 92: ...s 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 pressurised components electrically live comp...

Page 93: ...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 c...

Page 94: ...ction 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...

Page 95: ...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...

Page 96: ...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 97: ...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 dep...

Page 98: ...em 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 flexibl...

Page 99: ...hafing 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...

Page 100: ...r 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...

Page 101: ...f 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 insolub...

Page 102: ...he 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 s...

Page 103: ...Maintenance Operating Maintenance Manual 22442578 103...

Page 104: ...Operating Maintenance Manual Maintenance 104 22442578...

Page 105: ...t 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...

Page 106: ...erred Ingersoll 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 Pref...

Page 107: ...22442578 107 Machine Systems...

Page 108: ...Isochronous governor R3 Idle sel J50 G2 Wait to start lamp RS Relay spst J50 K3 Inlet heater RT1 Thermistor separator tank temperature 30 2550F P51 Coolant temp RT2 Thermistor airend discharge temper...

Page 109: ...109 Wedge to Engine Interface IR Engine POUT3 Comp fault lamp SW5 Air filter rest option POUT4 Engine fault lamp SW6 Spare POUT5 Start relay SW7 Spare POUT6 Spare SW8 Switch start POUT7 Hour meter TE...

Page 110: ...Operating Maintenance Manual Machine Systems 110 22442578 Harness System Schematic J1939 CAN Communications Schematic...

Page 111: ...22442578 111 Service Tools...

Page 112: ...h 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...

Page 113: ...its 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...

Page 114: ...iption Tool Illustration Fluke 87 Digital multimeterAvailable from electrical and electronic parts distributors 54729660 Weather Pack Terminal Removal Tool 54699632 Deutsch Terminal Removal Tool Blue...

Page 115: ...78 115 DT RT1 Crimp Tool for deutsh pins CrimpAvailable from Ladd Industries 800 223 1236 54729710 Electrical Contact Cleaner 54729728 PDA Service Tool 54699616 Deutsch Terminal Removal Tool 22073886...

Page 116: ...E 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 3...

Page 117: ...22442578 117 Fault Finding...

Page 118: ...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 servic...

Page 119: ...rheats 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 R...

Page 120: ...d check for leaks Dirty or blocked oil cooler Clean the oil cooler fins Incorrect grade of oil Use Portable Power recommended oil Defective by pass valve Check the operation of the element and replace...

Page 121: ...AIR 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...

Page 122: ...122 22442578...

Page 123: ...22442578 123 Options...

Page 124: ...icator without first making sure that the machine is stopped and the system has been completely relieved of all air pressure Refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this ma...

Page 125: ...cator oil level and fill as necessary Prior to Starting Check the lubricator oil level and replenish as necessary Maintenance Check the lubricator oil level and replenish as necessary Fault Finding FA...

Page 126: ...126 22442578...

Page 127: ...2008 Doosan Infracore International Printed in the USA Doosan Infracore Portable Power 1293 Glenway Drive Statesville NC 28625 www doosanportablepower com...

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