Ingersoll-Rand Doosan HP675WCU-T3 Operation & Maintenance Manual Download Page 87

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Machine Systems

Operation & Maintenance Manual

Book 22826226

ELECTRICAL PARTS LIST -

Part #

Qty

Description

Schematic

Ref

22616965

Alternator, Engine

36793545

Battery

35598986

Battery Cable, Jumper

36780609

Battery Cable, Negative

54765383

Battery Cable, Pos. Jumper

35582410

Battery Cable, Positive

22101968

Circuit Breaker Air Intake Heater

35376169

Diode Plug

D1, D2

22056394

Gauge, 4 in 1

36891216

Gauge, Pressure

22692602

Gauge, Fuel Level

22055883

Gauge, Tachometer

22132153

Ground Strap, Engine

22132153

Ground Strap, Frame

22785349

Harness, Air Intake Heater

22784698

Harness, Instrument Panel

22770879

Harness, Main Chassis

22054175

Hourmeter

22633044

Instrument Panel Assy

22050553

Lamp, Wait to Start

DS1

36853521

Relay, Air Intake Heater

36853521

Relay, Starter Solenoid

36892362

Relay, Switched Power

36870608

Sender, Engine Oil Pressure

RP1

22155451

Sender, Fuel Level

35604180

Sender, Temp A/E

RT3

Summary of Contents for Doosan HP675WCU-T3

Page 1: ...E COMPRESSOR MODELS HP675WCU T3 B74 MANUAL HP750WCU T3 B76 XP750WCU T3 B75 XP825WCU T3 B77 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company o...

Page 2: ...2...

Page 3: ...EMISSION 25 Noise Emission 26 Compressor Noise Emission Control Information 26 Noise Emission Control Maintenance Log 27 Noise Emission Warranty 27 Introduction 28 Maintenance Schedule 28 A Compresse...

Page 4: ...chine ensure that 60 Prior to attempting any maintenance work on a running machine ensure that 60 PROTECTIVE SHUTDOWN SYSTEM 60 Low engine fuel level switch 60 SCAVENGE LINE 61 COMPRESSOR OIL FILTER 6...

Page 5: ...MS 87 Electrical Schematics 88 ELECTRICAL 93 Electrical 94 WEDGE Controller 94 Sensors and Transducers 94 Controller Outputs 95 Pressure Control 95 Electronic Engine 95 Electrical System 95 OPTIONS 97...

Page 6: ...6 Always use Ingersoll Rand Replacement parts...

Page 7: ...Book 22826226 7 Foreword...

Page 8: ...e of a type approved 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 i...

Page 9: ...maintenance 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...

Page 10: ...Operation Maintenance Manual Foreword 10 Book22826226 Always use Ingersoll Rand Replacement Parts...

Page 11: ...Book 22826226 11 Safety...

Page 12: ...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 be rectified without delay Air disch...

Page 13: ...efully 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 and care should be taken to ensure tha...

Page 14: ...el battery 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 c...

Page 15: ...attempt 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 termin...

Page 16: ...be towed in a level attitude in order to maintain correct handling braking and lighting functions This can be achieved by correct selection and adjustment of the vehicle towing hitch and on variable h...

Page 17: ...Safety Operation Maintenance Manual Book 22826226 17 Decals Graphic Form and Meaning of ISO Symbols...

Page 18: ...Operation Maintenance Manual Safety 18 Book22826226...

Page 19: ...Safety Operation Maintenance Manual Book 22826226 19...

Page 20: ...Operation Maintenance Manual Safety 20 Book22826226...

Page 21: ...tes 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 I...

Page 22: ...Operation Maintenance Manual Safety 22 Book22826226...

Page 23: ...Safety Operation Maintenance Manual Book 22826226 23...

Page 24: ...24 Book22826226...

Page 25: ...harge Safety Decals are identified by the decal heading DANGER WARNING or CAUTION Decal parts numbers are on the bottom of each decal and are also listed in the compressor s parts manual Submit orders...

Page 26: ...Operation Maintenance Manual Safety 26 Book22826226...

Page 27: ...Book 22826226 25 Noise Emission...

Page 28: ...parts 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 co...

Page 29: ...r 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 Regulati...

Page 30: ...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...

Page 31: ...tems 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 compo...

Page 32: ...enance Manual Noise Emission 30 Book22826226 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK HOURMETER READING MAINT INSPECT DATE LOCATION CITY STATE WO...

Page 33: ...Book 22826226 31 General Data...

Page 34: ...ble Pressure XP825WCU 10 3 bar 150 psi HP750WCU 12 1 bar 175 psi XP750WCU 10 3 bar 150 psi HP675WCU 12 1 bar 175 psi Safety Valve Setting XP825WCU 14 bar 200 psi HP750WCU 14 bar 200 psi XP750WCU 14 ba...

Page 35: ...Available at Full Load XP825EWCU HP750EWCU 209kW 280hp XP750EWCU HP675EWCU 194kW 260hp Electrical System 24 V neg ground Fuel Tank Capacity 462 litres 122 gal Oil Specification Refer to engine manual...

Page 36: ...34 Book22826226 Always use Ingersoll Rand Replacement parts...

Page 37: ...Book 22826226 35 Operating Instructions...

Page 38: ...hine ensure that there is sufficient clearance for ventilation and exhaust requirements Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintena...

Page 39: ...rials compatible with the compressor lubricant refer to the GENERAL DATA SECTION WARNING If more than one compressor is connected to one common downstream plant effective check valves and isolation va...

Page 40: ...in the Engine Operator s Manual or section 3 Check the compressor oil level in the sight tube located on the separator tank The most accurate reading can be made before the machine is started with th...

Page 41: ...TION Do not operate the machine with the canopy doors in the open position as this may cause overheating and operators to be exposed to high noise levels Check the air filter restriction indicator s R...

Page 42: ...PUSH Provides full air pressure at the service outlet Allows unit to warm up at reduced pressure 6 Engine Speed Gauge lndicates engine speed RPM 7 Discharge Air Temp Gauge lndicates airend discharge...

Page 43: ...icates shutdown 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 s...

Page 44: ...rvice requirements 11 Malfunction Code 4 Digit Compressor or engine fault Refer to manual for list of codes and service requirements ALERT SHUTDOWN CODE LIGHT BLINKS CODE LIGHT STEADY DELAY sec Engine...

Page 45: ...ank Temp RT1 Sensor Fault 53 CPRSR Malfunction 10 Reg System Pressure PT2 Sensor Fault 54 CPRSR Malfunction Estop Button Pushed 55 CPRSR Malfunction 55 CPRSR Malfunction 3 Minimum Pressure Not Met 56...

Page 46: ...ions 44 Book22826226 High Engine Coolant Temperature Shutdown High Engine Temp 10 IQ Filter Restriction IQ Filt Rest 3 High Discharge Temp RT2 247 deg F High Comp Temp 3 CAN derived data ALERT SHUTDOW...

Page 47: ...requency Throttle Signal Abnormal Frequency Pulse Width or Period 148 Frequency Throttle Signal Abnormal Frequency Pulse Width or Period 151 Engine Coolant Temperature Low Critical 153 Intake Manifold...

Page 48: ...olenoid Valve Circuit Voltage Above Normal or Shorted High 275 Fuel Pumping Element Front Mechanical System Malfunction 281 High Fuel Pressure Solenoid Valve Mechanical System Malfunction 284 Engine S...

Page 49: ...h 452 Injector Metering Rail Pressure Sensor Circuit Voltage Below Normal or Shorted Low 488 Intake Manifold Air Temperature High Warning 553 Injector Metering Rail Pressure High Warning 554 Fuel Pres...

Page 50: ...al or Shorted High 2112 Engine Coolant Temperature 2 Sensor Circuit Voltage Below Normal or Shorted Low 2113 Engine Coolant Temperature 2 High Warning 2114 Engine Coolant Temperature 2 High Critical 2...

Page 51: ...d Abnormal Rate of Change 2555 Intake Air Heater 1 Circuit Voltage Above Normal or Shorted High 2556 Intake Air Heater 1 Circuit Voltage Below Normal or Shorted Low 2963 Engine Coolant Temperature Hig...

Page 52: ...he Inlet Heater Wait to Start Lamp extinguishes NOTE Position 2 is not used on this model Pre heaters are controlled automatically by the engine Turn the key switch to crank position 3 engine start po...

Page 53: ...full load to the engine CAUTION If the engine does not start repeat the above procedure after waiting for a minimum of one minute If the engine fails to start refer to the MAINTENANCE section of this...

Page 54: ...mergency Stopping In the event that the unit has to be stopped in an emergency TURN THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO THE 0 OFF POSITION or push the EMERGENCY STOP SWITCH when fitted I...

Page 55: ...t all hazard risks are either eliminated or notified to the recipient of the machine In particular Do not destroy batteries or components containing asbestos without containing the materials safely Do...

Page 56: ...Operation Maintenance Manual Operating Instructions 54 Book22826226 Always use Ingersoll Rand Replacement Parts...

Page 57: ...Book 22826226 55 Maintenance...

Page 58: ...eaner 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...

Page 59: ...h Settings T Scavenger Orifice Related Parts C Oil Separator Element R Feed Pump Strainer Cleaning C Valve Clearance Check C Lights running brake turn CBT Pintle Eye Bolts CBT Brakes C C Brake linkage...

Page 60: ...rs 4 Yrs 6 Yrs Safety valve C Hoses R Separator tank 2 interior C Disregard if not appropriate for this particular machine D Drain 1 or 3000 miles 5000km whichever is the sooner G Grease 2 or as defin...

Page 61: ...be gradually relieved by operating the manual blowdown valve Suitable personal protective equipment should be worn Ensure that maintenance personnel are adequately trained competent and have read the...

Page 62: ...me temperatures inflow and outflow of air intermittently moving parts safety valve discharge etc appropriate personal protective equipment is worn loose clothing jewelry long hair etc is made safe war...

Page 63: ...icing intervals Removal WARNING Do not remove the filter s without first making sure that the machine is stopped and the system has been completely relieved of all air pressure Refer to STOPPING THE M...

Page 64: ...re the machine is put back into service COMPRESSOR OIL SEPARATOR ELEMENT Refer to the MAINTENANCE CHART in this section for the recommended servicing intervals If however the element has to be replace...

Page 65: ...ONS section of this manual and check for leakage before the machine is put back into service COMPRESSOR OIL COOLER AND ENGINE RADIATOR When grease oil and dirt accumulate on the exterior surfaces of t...

Page 66: ...eaner dumps should be cleaned as indicated in the MAINTENANCE CHART more frequently in dusty operating conditions Removal CAUTION Never remove and replace element s when the machine is running Clean t...

Page 67: ...uel tank should be filled daily or every eight hours To minimise condensation in the fuel tank s it is advisable to top up after the machine is shut down or at the end of each working day Drain any se...

Page 68: ...PRESSURE SYSTEM Regularly it is necessary to inspect the external surfaces of the system from the airend through to the service valve s including hoses tubes tube fittings and the separator tank for v...

Page 69: ...ng under adverse conditions or has suffered long shutdown periods then more frequent service intervals will be required WARNING DO NOT under any circumstances remove any drain plugs or the oil filler...

Page 70: ...sed should conform to specification MIL G 10924 PRESSURE REGULATOR Normally regulation requires no adjusting but if proper adjustment is lost proceed as follows Before Starting Unit 1 Atop separator c...

Page 71: ...at full speed 5 Close service valve engine will slow to no load or idle speed 6 If necessary repeat steps 3 and 4 7 At pressure regulator PR tighten lock nut G 8 Ensure unloader solenoid US acts to ho...

Page 72: ...Operation Maintenance Manual Maintenance 70 Book22826226 Torque Values...

Page 73: ...Maintenance Operation Maintenance Manual Book 22826226 71...

Page 74: ...Operation Maintenance Manual Maintenance 72 Book22826226 Always use Ingersoll Rand Replacement parts...

Page 75: ...Book 22826226 73 Lubrication...

Page 76: ...ed for extended warranty Compressor oil carryover oil consumption may be greater with the use of alternative fluids DesignOperating Pressure Ambient Temperature Specification 100 psi to 300 psi 10 F t...

Page 77: ...anty Refer to operator s manual warranty section for details or contact your Portable Power representative Ingersoll Rand Preferred Fluids 1 gal 3 8 Litre 5 gal 19 0 Litre 55 gal 208 2 Litre 220 gal 8...

Page 78: ...76 Book22826226 Always use Ingersoll Rand Replacement parts...

Page 79: ...Book 22826226 81 Fault Finding...

Page 80: ...el 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 ser...

Page 81: ...replace 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 p...

Page 82: ...the oil level 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 ele...

Page 83: ...connections Check all pipe hose connections Faulty safety valve Check the relieving pressure Replace the safety valve if faulty DO NOT ATTEMPT A REPAIR Oil is forced back into the air filter Incorrec...

Page 84: ...Always use Ingersoll Rand Replacement parts 86 Book22826226 Always use Ingersoll Rand Replacement parts...

Page 85: ...Book 22826226 87 Machine Systems...

Page 86: ...Operation Maintenance Manual Machine Systems 88 Book22826226 Electrical Schematics Control System Schematic Control System Schematic...

Page 87: ...394 1 Gauge 4 in 1 M3 36891216 1 Gauge Pressure M4 22692602 1 Gauge Fuel Level M2 22055883 1 Gauge Tachometer M5 22132153 1 Ground Strap Engine 22132153 1 Ground Strap Frame 22785349 1 Harness Air Int...

Page 88: ...1 Solenoid Valve Unloader L2 22345755 1 Starter Engine B1 36847838 2 Switch Air Filter Restriction S4 S5 36757581 1 Switch Airend Oil Pressure S6 36896975 1 Switch Battery Disconnect 22127385 1 Switc...

Page 89: ...Book 22826226 93 Electrical...

Page 90: ...control The WEDGE monitors the regulation system air pressure and varies the engine throttle to maintain the setpoint discharge air pressure The setpoint pressure is set using the regulator on the sep...

Page 91: ...is determined by the WEDGE controller The WEDGE measures the pneumatic system regulation pressure and computes an engine throttle setting This throttle setting is sent to the engine via the frequency...

Page 92: ...eration of switch S1 Check wiring from S1 to WEDGE controller Check battery voltage Ensure battery disconnect switch is turned ON WEDGE controller annunciator lamps and 4 digit LED display initialize...

Page 93: ...Book 22826226 97 Options...

Page 94: ...ntenance Manual Options 98 Book22826226 Options IQ System Operating Instructions 1 Key 1 Three way valve 5 Filters 2 Ball valve1 6 Aftercooler 3 Ball valve2 7 Minimum pressure valve 4 Safety valve 8 S...

Page 95: ...path allows Standard Operation which bypasses 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 sele...

Page 96: ...striction Restriction indicators 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 s...

Page 97: ...to maintain regulated pressure at the separator tank DO NOT adjust regulation to provide full regulation pressure at the service valve when the IQ System is enabled This will result in operation at e...

Page 98: ...102 22826226 Always use Ingersoll Rand Replacement parts...

Page 99: ...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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