Ingersoll-Rand HP915WCU Operation & Maintenance Manual Download

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Operating & Maintenance Manual

Operating Instructions

Book: 22846430 (8-21-06) Rev. A

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 Temeprature High - Alert

2964

Intake Manifold Air Temeprature - Alert

2973

Intake Manifold Pressure Sensor Circuit - Data incorrect

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Definition

Summary of Contents for HP915WCU

Page 1: ...to the personnel who operate and maintain this machine Revised 10 12 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks s...

Page 2: ...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 3: ...oise Emission Control Maintenance Log 22 Noise Emission Warranty 22 Introduction 23 Maintenance Schedule 23 A Compressed Air Leaks 23 B Safety and Control Systems 23 C Acoustic Materials 23 D Fastener...

Page 4: ...ight 49 Stopping the Machine 50 Emergency Stopping 51 Re Starting After an Emergency 51 Monitoring During Operation 51 Decommissioning 52 MAINTENANCE 53 Maintenance 54 Maintenance Interval Chart 54 Ro...

Page 5: ...ubricating Oil 68 Engine Lubricating Oil Specification 68 Engine Oil Filter Element 68 Compressor Lubricating Oil 69 Torque Values 73 Portable Compressor Fluid Chart 75 MACHINE SYSTEMS 79 Control Syst...

Page 6: ...6 TABLE OF CONTENTS Operation Maintenance Manual TITLE PAGE...

Page 7: ...Book 22846430 8 21 06 Rev A 7 Foreword...

Page 8: ...of repair parts other than those included within the Ingersoll Rand approved parts list may create hazardous conditions over which Ingersoll Rand has no control Therefore Ingersoll Rand cannot be held...

Page 9: ...ng these intervals may reduce the reliability of the machine The purpose of this manual is to train the operator with functions operation and basic service and maintenance requirements of the compress...

Page 10: ...10 Book 22846430 8 21 06 Rev A Always use Ingersoll Rand Replacement parts...

Page 11: ...Book 22846430 8 21 06 Rev A 13 Safety...

Page 12: ...anical parts In particular 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 un...

Page 13: ...ich can result in 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 lu...

Page 14: ...iesel fuel 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...

Page 15: ...Do not 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...

Page 16: ...break away cables 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 achi...

Page 17: ...decal headings DANGER 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...

Page 18: ...ty Decals are available 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 compres...

Page 19: ...Book 22846430 8 21 06 Rev A 21 Noise Emission...

Page 20: ...r 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 limit...

Page 21: ...ut down 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...

Page 22: ...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 c...

Page 23: ...Manual Book 22846430 8 21 06 Rev A 25 Table 1 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK OR COMMENTS HOURMETER READING MAINT INSPECT DATE LOCATION...

Page 24: ...26 Always use Ingersoll Rand Replacement parts...

Page 25: ...Book 22846430 8 21 06 Rev A 27 General Information...

Page 26: ...Operating Maintenance Manual General Information 28 Book 22846430 8 21 06 Rev A General Information MSA SRG HRG...

Page 27: ...General Information Operating Maintenance Manual Book 22846430 8 21 06 Rev A 29...

Page 28: ...18 5 70 Maximum oil system temperature F C 248 120 248 120 248 120 Maximum oil system pressure psi bar 217 15 217 15 217 15 LUBRICATING OIL SPECIFICATION for the specified ambient temperatures SEE NOT...

Page 29: ...o 79 113 EEC 72dB A estimated Machine only at maximum load in open site conditions C US EPA 76dB A Site Running Gear SRG High Speed Running Gear HSRG Further information may be obtained by request thr...

Page 30: ...32 Always use Ingersoll Rand Replacement parts...

Page 31: ...Book 22846430 8 21 06 Rev A 33 Operating Instructions...

Page 32: ...nsport and packing 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 wor...

Page 33: ...nected to one common downstream plant effective check valves and isolation valves must be fitted and controlled by work procedures so that one machine cannot accidently be pressurised over pressurised...

Page 34: ...il level in the sight glass located on the separator tank Liquid level should be in the green zone 4 Check the diesel fuel level A good rule is to top up at the end of each working day This prevents c...

Page 35: ...mergency stop Rotate knob as indicated to release 10 Close the manual relief valve inside the service door near the emergency stop When starting or operating the machine in temperatures below or appro...

Page 36: ...s if equipped 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 com...

Page 37: ...pressure in receiver 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...

Page 38: ...amp Indicates 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 Indi...

Page 39: ...tor lamp Indicates 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...

Page 40: ...ngine Oil Temp 5 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 M...

Page 41: ...55 CPRSR Malf 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 Lo...

Page 42: ...equency Throttle Signal Abnormal Frequency pulse width or period 151 Engine Coolant Temperature Low Critical 153 Intake Manifold Temperature Sensor Circuit voltage above normal or shorted high 154 Int...

Page 43: ...Solenoid Valve Mechanical system malfunction 284 Engine Speed Position Sensor Crankshaft Circuit Voltage below normal or shorted low 285 SAE J1939 Multiplexing PGN Timeout Error 286 SAE J1939 Multipl...

Page 44: ...old Air Temperature High Warning 553 Injector Metering Rail 1 Pressure High Warning 554 Fuel Pressure Sensor Error Data Incorrect 559 Injector Metering Rail Pressure Low Warning 595 Turbocharger Speed...

Page 45: ...al or shorted low 2113 Engine Coolant Temperature 2 High Warning 2114 Engine Coolant Temperature 2 High Critical 2115 Engine Coolant Pressure 2 Circuit Voltage above normal or shorted high 2116 Engine...

Page 46: ...r Heater 1 Circuit Voltage above normal or shorted high 2556 Intake Air Heater 1 Circuit Voltage below normal or shorted low 2963 Engine Coolant Temeprature High Alert 2964 Intake Manifold Air Temepra...

Page 47: ...lose the inlet 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 heate...

Page 48: ...refer to the MAINTENANCE 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 re...

Page 49: ...achine has been 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 t...

Page 50: ...ticular 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 data plate...

Page 51: ...Operating Instructions Operating Maintenance Manual Book 22846430 8 21 06 Rev A 53 Always use Ingersoll Rand Replacement Parts...

Page 52: ...Operating Maintenance Manual Operating Instructions 54 Book 22846430 8 21 06 Rev A...

Page 53: ...Book 22846430 8 21 06 Rev A 53 Maintenance...

Page 54: ...ps C Air Cleaner 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 C...

Page 55: ...e 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 Gre...

Page 56: ...tor Element R Compressor Oil Filter Element R Compressor Oil R Engine Oil Change R CU Engine Oil Filter R CU Water Pump Grease R Wheels Bearings Seals etc C Engine Coolant C R Fuel Filter Element Serv...

Page 57: ...chever 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...

Page 58: ...ust 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...

Page 59: ...down fails to operate then pressure must be gradually relieved by operating the manual blowdown valve Suitable personal protective equipment should be worn Ensure that maintenance personnel are adequa...

Page 60: ...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 pressurised components electrically...

Page 61: ...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 f...

Page 62: ...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 lu...

Page 63: ...lement 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 Ins...

Page 64: ...should 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 st...

Page 65: ...asing the nut If 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 t...

Page 66: ...tion 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 At six month intervals drain any sediment or condensate that may have accumulated in...

Page 67: ...cables deformation 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 clam...

Page 68: ...il sufficient for 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 re...

Page 69: ...his manual Completely 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...

Page 70: ...and full speed position If the tachometer moves away from the full speed position before normal operating discharge pressure is attained then turn the adjusting screw A clockwise to increase the pres...

Page 71: ...ve pivot shaft K 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 cylinde...

Page 72: ...0 bar 50 70 p 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 d...

Page 73: ...Maintenance Operating Maintenance Manual Book 22846430 8 21 06 Rev A 73 Torque Values...

Page 74: ...tric 1 2 lug nuts 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...

Page 75: ...r extended warranty 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...

Page 76: ...to operator s manual warranty 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 P...

Page 77: ...77 Always use Ingersoll Rand Replacement parts...

Page 78: ...Operating Maintenance Manual Maintenance 78 Book 22846430 8 21 06 Rev A...

Page 79: ...Book 22846430 8 21 06 Rev A 79 Machine Systems...

Page 80: ...o the back of 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 contr...

Page 81: ......

Page 82: ...Operating Maintenance Manual Machine Systems 82 Book 22846430 8 21 06 Rev A...

Page 83: ...Machine Systems Operating Maintenance Manual Book 22846430 8 21 06 Rev A 83...

Page 84: ...Operating Maintenance Manual Machine Systems 84 Book 22846430 8 21 06 Rev A...

Page 85: ...WEDGE controller scans digital inputs such as switch contacts These are either ON 24VDC or OFF 0 VDC These digital inputs are connected to switches within the package such as the key start switch air...

Page 86: ...tion properly The shield from the cable is connected to the machine metal at the WEDGE controller end This connection must be properly made with good metal to metal contact between the wire terminal a...

Page 87: ...Machine Systems Operating Maintenance Manual Book 22846430 8 21 06 Rev A 87 Always use Ingersoll Rand Replacement Parts...

Page 88: ...Operating Maintenance Manual Machine Systems 88 Book 22846430 8 21 06 Rev A...

Page 89: ...Book 22846430 8 21 06 Rev A 85 Fault Finding...

Page 90: ...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...

Page 91: ...er and 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 re...

Page 92: ...Top up 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...

Page 93: ...eck 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 proced...

Page 94: ...90 Book 22846430 8 21 06 Rev A Always use Ingersoll Rand Replacement parts...

Page 95: ...Book 22846430 8 21 06 Rev A 91 Options...

Page 96: ...ance Manual Options 92 Book 22846430 8 21 06 Rev A 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...

Page 97: ...ion 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 selector valve the compressed ai...

Page 98: ...riction 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 scr...

Page 99: ...ystem is enabled 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 a...

Page 100: ...96 Book 22846430 8 21 06 Rev A Always use Ingersoll Rand Replacement parts...

Page 101: ...2004 Ingersoll Rand Company Printed in the USA...

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