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Operating & Maintenance Manual

Operating Instructions

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

Wedge Diagnostic Display Codes

High Compressor Temp:

Fault indicator lamp. Indicates shutdown due to high

compressor temperature.

Low Engine Oil Pressure:

Fault indicator lamp. Indicates shutdown due to low

engine oil pressure.

High Engine Coolant Temp:

Fault indicator lamp. Indicates shutdown due to

high engine water temperature.

Low Fuel Level:

Fault indicator lamp. Indicates shutdown due to low fuel level.

Lamp blinks at low fuel warning.

Low Battery Voltage

: Alarm indicator lamp. Indicates battery or charging

system requires service.

Low Radiator Coolant Level:

Alarm indicator lamp. Indicates engine coolant

needs service.

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

Содержание HP900

Страница 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...

Страница 2: ...2...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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