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Operation & Maintenance Manual

Operating Instructions

Book 22826226

Restricted Air Filter:

Alarm indicator lamp. Indicates engine/compressor air

inlet filters need service.

Restricted IQ Air Filters:

Fault indicator lamp. Indicates shutdown due to high

pressure in “IQ” air filters (if equipped).

Compressor Malfunction:

Fault indicator lamp. Indicates shutdown due to

compressor system fault. Refer to Fault Code List.

10.

Engine Malfunction:

Engine Fault code. Refer to service card or engine

manual for codes and service 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 Speed<Min. RPM

CPRSR Malfunction.

Engine Speed>Max. RPM

CPRSR Malfunction.

Engine Crank Time Exceeded

CPRSR Malfunction.

*High Engine Oil Temperature

CPRSR Malfunction.

*High Intake Manifold
Temperature

CPRSR Malfunction.

*Water In Fuel-CUMMINS

CPRSR Malfunction.

Engine Not Responding To
Throttle command

CPRSR Malfunction.

Too Many Crank Attempts
During Autostart

CPRSR Malfunction.

Engine Shut Itself Down: reason
unknown

CPRSR Malfunction.

Low AE Oil Pressure

CPRSR Malfunction.

Содержание Doosan HP675WCU-T3

Страница 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...

Страница 2: ...2...

Страница 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...

Страница 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...

Страница 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...

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

Страница 7: ...Book 22826226 7 Foreword...

Страница 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...

Страница 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...

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

Страница 11: ...Book 22826226 11 Safety...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

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

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

Страница 24: ...24 Book22826226...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 57: ...Book 22826226 55 Maintenance...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 75: ...Book 22826226 73 Lubrication...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 89: ...Book 22826226 93 Electrical...

Страница 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...

Страница 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...

Страница 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...

Страница 93: ...Book 22826226 97 Options...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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