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Doosan NHP10-425WCU-EU-FX-T3, Operation And Maintenance Manual

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Doosan NHP10-425WCU-EU-FX-T3 Operation And Maintenance Manual Download Page 82

**Always use Ingersoll Rand Replacement parts!**

78

 

Legend: Electrical Components

Legend: Mechanical Components

FL - Fuel Level

Gauge - Oil Pressure Indicator

MI - Run Fuel Pump

Temp Ind - Oil Temperature Indicator

Lvl Ind - Oil Level Indicator

F

uel Coo

ler

ENGINE

MI

3 way valve

QD Out

Return Tank

Fill

Breather

Strainer

FL

Bypass

QD In

Supply Tank

Fill

Breather

Strainer

Figure  4: Fuel  System  Schematic

3 way valve

Filter

Filter

Valve

Pressure Indicator

Summary of Contents for NHP10-425WCU-EU-FX-T3

Page 1: ...3 Rev D This manual contains important safety information Do not destroy this manual This manual must be available to the personnel who operate and maintain this compressor OPERATION and MAINTENANCE N...

Page 2: ...2...

Page 3: ...other proprietary identifying marks belonging to Ingersoll Rand Company in this manual is historical or nom inative in nature and is not meant to suggest a current affiliation between Ingersoll Rand...

Page 4: ...2...

Page 5: ...ghts feet meters 19 Running Gear 19 Expendable Service Parts 19 OPERATING INSTRUCTIONS 21 Operating Controls and Instruments 22 Lifting Unit 24 Wheel Chock 24 Before Towing 24 Towing 24 Setting up All...

Page 6: ...tenance Schedule 47 Torque Values 50 LUBRICATION 53 General Information 54 Compressor Hydraulic Oil Change 54 Compressor Lubrication 54 FAULT FINDING 57 Introduction 58 Action Plan 58 Think Before Act...

Page 7: ...3 TABLE OF CONTENTS Operation Maintenance Manual TITLE PAGE SYSTEM DIAGRAMS 73...

Page 8: ...4...

Page 9: ...5 Foreword...

Page 10: ...formity follows CPN 46552201 re 9 Serial number 10 is are in conformity with the relevant provisions of the following EC Directive s 11 2006 42 EC The Machinery Directive 12 2004 108 EC The Electromag...

Page 11: ...cant coolant accompanied with instructions for safe installation operation and maintenance Details of approved equipment are available from the Portable Power Service departments The use of repair par...

Page 12: ...manual is to train the operator with functions operation and basic service and maintenance requirements of the compressor During the preparation of this manual every effort was made to ensure the ade...

Page 13: ...9 Safety...

Page 14: ...nance personnel are adequately trained competent and have read the Maintenance manuals Make sure that all protective covers are in place and that the canopy doors are closed during operation The speci...

Page 15: ...and controlled by work procedures so that one machine cannot accidentally be pressurised over pressurised by another Compressed air must not be used for a direct feed to any form of breathing apparatu...

Page 16: ...off immediately Consult a physician if large amounts of compressor lubricant are ingested Consult a physician if compressor lubricant is inhaled Never give fluids or induce vomiting if the patient is...

Page 17: ...own points are used When loading or transporting machines ensure that the towing vehicle its size weight towing hitch and electrical supply are all suitable to provide safe and stable towing at speeds...

Page 18: ...RNING Hot surface WARNING For operating temperature below 0 C consult the operation and maintenance manual WARNING Before connecting the tow bar or commenting to tow consult the operation and maintena...

Page 19: ...chine Do not remove the Operating and Maintenance manual and manual holder from this machine Do not stack Do not operate the machine without the guar d being fitted Do not stand on any service valve o...

Page 20: ...On power Off power Read the Operation and Maintenance manua l before operation or maintenance of thi s machine is undertaken When parking use prop stand handbrake and wheel chocks Compressor oil fill...

Page 21: ...17 General Information...

Page 22: ...r Delivery cfm litres sec 1500 708 Rated Operating Pressure psi kPa 60 150 41 1050 Manufacturer Cummins Model QSX 15 Rated Horsepower at 1800 rpm 600 Electrical System 24 VDC Full Load Speed rpm 1800...

Page 23: ...unning gear 16x5 Tire Size standard running gear 18x9 Towing Speed Maximum mph km hr 15 24 Inflation Pressure Solid Part Number Description Where Used Quantity 39911615 Filter Oil Hyd Airend 2 3686436...

Page 24: ...20...

Page 25: ...21 Operating Instructions...

Page 26: ...ll as name of measured parameter temperature pressure etc 3 Menu Selection Buttons used to select different menus viewed in message display status main menu etc 4 Scroll Up Button Press this button to...

Page 27: ...use Stop button item 9 to stop machine before switching to OFF 11 Lights Switch Operates Lamp 12 Ether Inject Button Injects a measured shot of ether for aid in cold weather starting of engine CAUTIO...

Page 28: ...w this unit in excess of 15 mph 24km hr Use a tow vehicle whose towing capacity is greater than the gross weight of this unit see general data Machine is not designed to be Highway Towable Setting up...

Page 29: ...4 female connector supply one 3 4 male connector return Open rear door and locate fuel manifold Lever handle in the vertical position permits fueling from onboard tanks Lever handle in the horizontal...

Page 30: ...olation valve at the plant air header Allow machine to self vent after shutdown and assure output pressure is 0 psi Unrestricted air flow from a hose will result in a whipping motion of the hose which...

Page 31: ...estraining cable at each end of each 3 hose to prevent accidental hose whipping 5 For three NHP1500 machines plumb the 3 air hose from each machine into a 3 unit manifold Kit 36012243 Each 3 air hose...

Page 32: ...lled at the customer plant air header and if one of the two automatic line pressure modulation modes is to be used This allows each machine to automatically modulate as required to maintain the desire...

Page 33: ...required Do not overfill To jump start connect the positive booster charger cable to the 24 VDC positive terminal of the battery Then connect the negative booster charger cable to the engine block Not...

Page 34: ...mum service from the engine Refer to the Engine Operator s Section for fuel specifications NOTICE To minimize condensation water in the fuel tank it is recommended to fill the tank at the end of each...

Page 35: ...the engine has not started after the 3rd try the START sequence must be manually reinstated by the Operator If after two complete start sequences the engine has still not started begin troubleshooting...

Page 36: ...tch the required volume flow Full flow at set point pressure at 1200 RPM is approximately 1000 CFM Full flow at set point pressure at 1800 RPM is 1500 CFM Operation Loaded Assume engine has been start...

Page 37: ...ational profile of the plant 2 EMERGENCY OR BACKUP AIR FOR PLANT AIR SYSTEMS In these applications the compressor is operated in a standby mode and is set to load and furnish air if plant air pressure...

Page 38: ...hen line pressure drops below AUTO START PRESSURE the compressor will automatically start and load The compressor will then perform as stated in the Normal Operation Section loading and unloading base...

Page 39: ...When the cool down is complete the engine will stop 4 Switch the POWER switch to OFF 5 Turn battery disconnect switch to the OFF position NOTICE Once the engine stops the automatic blowdown valve will...

Page 40: ...achine to a plant system for communication purposes Any additional requirements consult the factory INTELLISYS Controller Display The Message Display program is based on a top level menu structure wit...

Page 41: ...T8 that can be selected and calibrated using the SELECT and CALIBRATE buttons the unit must be completely cooled down so that all temperatures and pressures are equivalent to ambient conditions 3 Fact...

Page 42: ...the engine coolant temperature entering the radiator 15 Battery Voltage volts Displays the onboard battery voltage 16 Software Version B Engine Status Displays the following engine sensor values 1 En...

Page 43: ...39 Maintenance...

Page 44: ...oduced and used as a checklist by the service personnel In the event unusual environmental operating conditions exist the schedule should be adjusted accordingly Compressor Oil Level The oil level is...

Page 45: ...d cap seals tightly 360 around the air cleaner body The air cleaner system housing and piping should be inspected every month for any leakage paths or inlet obstructions Make sure the air cleaner moun...

Page 46: ...can transmit the heat of the fluid to the air stream If foreign deposits such as sludge and lacquer accumulate in the coolers high temperature is likely to occur causing shut down of the unit Radiator...

Page 47: ...necessary that all clamps be replaced if missing It is also important the operator does not use the hoses as convenient hand hold or steps Such use can cause early cover wear and hose failure NOTICE P...

Page 48: ...ed every 1000 hours of operation To service the oil filters it will first be necessary to shut the unit down Wipe off any external dirt and oil from the exterior of the filter to minimize any contamin...

Page 49: ...ths whichever comes first Engine Cooling Fan Drive The heat exchanger or cooling fan is driven by a single belt arrangement from the engine Inspect the cooling fan belt weekly These belts should be ma...

Page 50: ...Operating Maintenance Manual Maintenance 46 NOTICE Disregard any maintenance pertaining to components not provided on your machine NOTICE Drain the frame after power washing cleaning or heavy rains...

Page 51: ...ller Cap C Air Cleaner Pre cleaner 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...

Page 52: ...e Moisture Separator Strainer C Feed Pump Strainer Cleaning C Valve Clearance Check C Lights running brake turn CBT Pintle Eye Bolts CBT Brakes CBT C Brake linkage C Emergency stop T Fasteners C Runni...

Page 53: ...ator Fill C 2 yrs 4 yrs 6 yrs Safety valve C Hoses R Disregard if not appropriate for this particular machine D Drain 1 or 3000 miles 5000km whichever is the sooner G Grease R replace C check adjust c...

Page 54: ...212 376 5 16 18 3 8 16 7 16 14 1 2 13 9 16 12 5 8 11 3 4 10 Nm Nm FT LBF FT LBF 9 10 6 2 3 7 5 1 4 8 1 7 3 5 2 8 4 6 1 4 2 3 TABL E 1 INCH FASTENERS NOMINAL DESIGN TORQUE CAPSCREW OR NUT THREAD SIZE A...

Page 55: ...13 31 62 109 173 270 526 M8 X 1 25 M10 X 1 5 M12 X 1 75 M14 X 2 M16 X 2 M20 X 2 5 Nm Nm FT LBF FT LBF Nm FT LBF 9 10 6 2 3 7 5 1 4 8 1 7 3 5 2 8 4 6 1 4 2 3 TABL E 2 METRIC FASTENERS CAPSCREW OR NUT...

Page 56: ...52...

Page 57: ...53 Lubrication...

Page 58: ...tion All filters and filter elements for air and compressor lubricant must be obtained through Portable Power to assure the proper size and filtration for the compressor Compressor Hydraulic Oil Chang...

Page 59: ...nce against the accumulation of dirt sludge or oxidized oil products Completely drain the reservoir piping and cooler If the oil is drained immediately after the unit has been run for some time most o...

Page 60: ...56...

Page 61: ...57 Fault Finding...

Page 62: ...to find the potential cause or causes The causes are listed in order 1 2 3 etc to suggest an order to follow in troubleshooting Action Plan A Think Before Acting Study the problem thoroughly and ask y...

Page 63: ...certain trouble and all evidence is destroyed during disassembly Check again to be sure an easy solution to the problem has not been overlooked D Find and Correct Basic Cause After a mechanical failu...

Page 64: ...ice filters See Engine Operator s Manual Out of Fuel Add CLEAN fuel Compressor Oil Temp Too High See Complaint 10 Engine Water Temp Too High Check fluid level If necessary Add Engine Oil Pressure Too...

Page 65: ...ve Malfunctioning Fan Check fan belt tension Tighten or replace belt set Defective Oil Cooler Relief Valve Replace valve Defective Minimum Pressure Valve Repair or replace valve Blocked or Restricted...

Page 66: ...adjust per Section 6 Ice in Regulation Lines Orifice Apply heat to line s and or orifice Load Solenoid Leak Replace load solenoid Plugged Vent Leak Clean and or replace 13 Safety Valves Relieves Oper...

Page 67: ...0 34 PT1 5 034 2 Hi Stg 2 Disch Press PT3 psig bar 200 13 8 4 1002 6 9 3 Lo Compr Oil Inj Press PT6 psig bar 202 1 38 1 Hi Stg 1 Disch Temp RT1 deg F C 450 232 1 460 238 2 Hi Stg 2 Inlet Temp RT2 deg...

Page 68: ...64...

Page 69: ...65 Electrical...

Page 70: ...the engine A square wave frequency signal from 150 Hz to 375 Hz is sent from the INTELLISYS Controller to the engine controller The signal is a linear signal from 150 Hz at engine idle 1200 RPM to 37...

Page 71: ...selected discharge pressure Electronic Engine The NHP1500 machine contains an emissions certified diesel engine In order to meet the emissions requirements the engine has an electronic control system...

Page 72: ...udes information on how to make harness repairs and information on the connectors used The electrical circuits are protected using ATC style fuses A fuse should only be replaced with one of the same r...

Page 73: ...Electrical Operating Maintenance Manual 69 Electronic Control Systems...

Page 74: ...Always use Ingersoll Rand Replacement parts 70...

Page 75: ...Electrical Operating Maintenance Manual 71...

Page 76: ...will not unload when the Unload Button is Pressed Defective Membrane Panel Switch 24 VDC Signal not being removed from Inlet Valve Solenoid Engine Speed will not increase when Load Button is Pressed D...

Page 77: ...73 System Diagrams...

Page 78: ...d MS L5 RT4 PT4 Fuel Pump RT8 PT8 PT2 L4 HM MUF CV PT5 PT6 Hydraulic Tank RT2 PT3 RT3 RT5 RT1 V2 V1 IV PT1 RT7 G2 Engine Engine Air Filter FL Ambient Air HC FC OC IC AC 1 st MS BVD Stage 2 Stage 1 RT6...

Page 79: ...st Stage Moisture Separator PT6 Oil Filter Out Pressure V2 2nd Stage Venturi PT7 Remote Pressure 2nd MS 2nd Stage Moisture Separator PT8 Hyd Level Switch CV Check Valve RT1 1st Stg Out Temp HM Hydraul...

Page 80: ...p Control Valve PT6 Oil Filter Outlet Pressure PRV Pressure Relief Valve RT5 Comp Oil Injection Temp Lvl Ind Oil Level Indicator L1 3 Way Solenoid Valve Optional 2 Valves IV Inlet Valve Figure 2 Lube...

Page 81: ...er Fill L3 Lvl Ind Breather FAN M Cooler SUMP MANIFOLD DETAIL L3 RELIEF Gear Box Hydraulic Sump Hyd Cooler Legend Electrical Components L3 Proportional Valve Input Gauge Temp Ind Lvl Ind Oil Pressure...

Page 82: ...Gauge Oil Pressure Indicator MI Run Fuel Pump Temp Ind Oil Temperature Indicator Lvl Ind Oil Level Indicator Fuel Cooler ENGINE MI 3 way valve QD Out Return Tank Fill Breather Strainer FL Bypass QD I...

Page 83: ...ce Manual 79 Figure 5 Standard Product 24 Volt DC Heating Schematic 2 nd MS HM MUF CV V2 V1 IV Engine Engine Air Filter HC FC OC IC AC 1 st MS BVD Stage 2 Stage 1 AE Air Filter CAC RAD Exhaust Out Top...

Page 84: ...el Switch IR Model Only Battery Pad Battery Pad Oil Pan Heater Coolant Heater Start Pressure Switch Outlet Outlet Heat Trace 2Lines Start Start Pressure Switch Oil Sump Heater Hyd Sump Heater Engine O...

Page 85: ...d MUF Blowdown Muffler RAC1 Fuel Heater V1 1st Stage Venturi RAC2 Fuel Heater 1st MS 1st Stage Moisture Separator K2 DC Heater Relay V2 2nd Stage Venturi 2nd MS 2nd Stage Moisture Separator CV Check V...

Page 86: ...cal Components L4 Condensate Solenoid Valve IC 1st MS 1st Stage Moisture Separator L5 Condensate Solenoid Valve AC 2nd MS 2nd Stage Moisture Separator HM Hydraulic Motor HC Hydraulic Cooler CAC Engine...

Page 87: ...Revision History Rev EC Number Comments A Original release B Updates C CN026601 Doosan reference updates D CN034865 Added Flex Models to Front Cover...

Page 88: ...2012 Doosan Infracore Portable Power Printed in the U S A Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 www doosanportablepower com...

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