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Book 54757919 (5/02)

SERVICE TOOLS

Electronic Systems

The following special tools are recommended to perform service procedures in this manual.
The tools can be purchased from Ingersoll Rand or equivalent substitutes can be used.

Tool

Tool Description

Fluke 87

Digital Multimeter

Used to Measure electrical circuits:

volts, ohms amps

54729660

Weather--Pack Terminal Removal Tool

Used to repair Packard Electric Weather--Pack
Connectors

54729678

Deutsch Terminal Removal Tool (Blue)

Used to repair Deutsch connectors

54729686

Deutsch Terminal Removal Tool (Red)

Used to repair Deutsch connectors

54729694

Deutsch Terminal Removal Tool (Yellow)

Used to repair Deutsch connectors

HDT--48--00

Deutsch Terminal Crimp Tool

Used to crimp Deutsch connector terminals

Deutsch Terminal Crimping Tool

Used to crimp Deutsch connector terminals

54729710

Electrical Contact Cleaner

Used to clean electrical contacts and connectors

54729728

PDA Service Tool

Palm Pilot based service tool used to connect to Intellisys (SGP) Controller
to load software and extract service information

22073886

Packard Crimp Tool

Used to crimp Packard connector terminals

22073878

Thermistor Simulator Plug

Used to test thermister circuits

54699616

Deutsch Terminal Removal Tool

Used to repair Deutsch connectors

54699657

Deutsch Terminal Removal Tool

Used to repair Deutsch connectors

54749643

Packard Metri--Pack Terminal Removal Tool

Used to repair Metri--Pack connectors

54749635

Connector Repair Kit

Used to make connector repairs

Содержание HP1300WCU

Страница 1: ...Sanford Ave Mocksville N C 27028 HP1600WCU HP1300WCU Code Revised 10 12 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks...

Страница 2: ...d services that consistently meet the requirements of our customers and each other CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of Califo...

Страница 3: ...countries requires that the machine display the EC Mark and conform to various directives In such cases the design specification of this machine has been certified as complying with EC directives Any...

Страница 4: ...Lunsford Manager of Quality Control Machine models represented in this manual may be used in various locations worldwide Machines sold and shipped into European common market countries requires that...

Страница 5: ...hanges or add such improvements to products sold previously Theintendedusesofthismachine areoutlined belowand examplesofunapprovedusage arealso given However Ingersoll Rand cannot anticipate every app...

Страница 6: ...structions should be carefully read to obtain a thorough knowledge of the duties to be performed Please take pride in the compressor keep it clean and in good mechanical condition To enable proper mai...

Страница 7: ...ATION SECTION 3 GENERAL DATA SECTION 4 OPERATION SECTION 5 MAINTENANCE SECTION 6 LUBRICATION SECTION 7 TROUBLESHOOTING SECTION 8 ELECTRICAL SECTION 9 SYSTEM DIAGRAMS SECTION 10 PARTS ORDERING SECTION...

Страница 8: ...ust be fitted and controlled by work procedures so that one machine cannot accidentally be pressurized or over pressurized by another Compressed air must not be used for a feed to any form of breathin...

Страница 9: ...us burns Do not open radiator while hot Rotating fan blade can cause serious injury Do not operate without guard in place Use care to avoid contacting hot surfaces engine exhaust manifold and piping a...

Страница 10: ...WARNING Flammable liquid Air gas flow or Air discharge Look forthese signs onmachines shippedtointernationalmarkets outside NorthAmerica whichpoint out potential hazards to the safety of you and othe...

Страница 11: ...nual Rough Service Designation Wet Location Operation WARNING Consult the operation and maintenance manual before performing any maintenance WARNING Before connecting the tow bar or when preparing to...

Страница 12: ...and Maintenance manual before operation or maintenance of this machine is undertaken XX km h Pressurized component or system Do not exceed the speed limit Pressurized vessel Do not remove the Operatin...

Страница 13: ...rkets in North America which point out potential hazards to the safety of you and others Read and understand thoroughly Heed warnings and follow instructions If you do not understand inform you superv...

Страница 14: ...h 105 km hr Rotating fan blade Can cause serious Do not operate without guard in place WARNING injury Falling off machine Can cause serious injury Access lifting bail from inside machine or death WARN...

Страница 15: ...are present on the machines Replace decals that are not readable FREE SAFETY DECALS CAUTION This engine is equipped with an electric heater starting aid DO NOT USE ETHER ENGINE DAMAGE WILL OCCUR High...

Страница 16: ...f twenty four 24 months from shipment to or the accumulation of 4 000 hours of service by the initial user For Air Ends the warranty against defects will include replacement of the complete Air End pr...

Страница 17: ...workmanship during the period prescribed above Such part will be repaired or replaced without charge to the initial user during normal working hours at the place of business of an Ingersoll Rand dist...

Страница 18: ...compressors in generators as of 1 1 01 24 24 2000 2000 5 yrs 5000 hrs using OEM fluids and filters with 250 deductible 2 yrs 4000 hrs using IR fluids and filters DEUTZ 24 2000 Available at dealer ING...

Страница 19: ...e change of ownership Machines shipped outside the United States require notification be made to initiate the machine warranty Fill out the Warranty Registration Form in this section keep a copy for...

Страница 20: ...ctric water etc Utility Contractor SERVICING DISTRIBUTOR USER ACKNOWLEDGEMENT 1 The Purchaser has been instructed and or has read the manual and understands proper preventative maintenance general ope...

Страница 21: ...21 Book 54757919 5 02 Ingersoll Rand Company Portable Compressor Division P O Box 868 Mocksville North Carolina 27028 Attention Warranty Department fold...

Страница 22: ...Overall Length 24 2 7 4 19 0 5 79 19 0 5 79 Overall Height 8 33 2 54 8 33 2 54 7 25 2 21 Overall Width 7 5 2 29 7 5 2 29 7 5 2 29 Gross Weight pounds kg 17 200 7810 17 200 7810 16 700 7590 including f...

Страница 23: ...mpressor Malfunction Fault indicator lamp Indicates shutdown due to compressor system fault Refer to Fault Code List 10 Low Battery Voltage Alarm indicator lamp Indicates battery or charging system re...

Страница 24: ...unit in an open well ventilated area Posi tion as level as possible The design of these units permits a maximum 15 degree limit on out of level operation When the unit is to be operated out of level i...

Страница 25: ...G Open service valves Inspect the complete installation including remote fuel lines if any and air hose routing and connections Check battery for proper connections and condition WARNING Combustible g...

Страница 26: ...and compressor and protect the hearing of surrounding personnel Make sure no one is IN or ON the compressor unit STARTING NOTICE This unit is equipped with a battery disconnect switch which removes po...

Страница 27: ...d Assume engine has been started and is running in the unload state at 1200 RPM If there is air demand pressure falls below the load point pressure compressor will load at 1200 RPM by opening the inle...

Страница 28: ...e selector valve the compressed air first enters the aftercooler The aftercooler is cooled by the incoming compressor package air which is controlled by movable louvers mounted on the aftercooler if e...

Страница 29: ...riction indicators do not show excessive restriction Restriction indicators for the filters are mounted inside the control panel and will shut down the compressor if restriction exceeds recommended va...

Страница 30: ...ing from falling to the floor panel S Lower the housing to floor panel and lean it against the airend Remove and replace the filter element being careful not to damage outer wrap Verify the part numbe...

Страница 31: ...vice valve on outside of the unit to obtain the rated operating pressure on the discharge pressure gauge 6 If necessary repeat steps 3 and 4 7 At pressure regulator PR tighten lock nut G 8 To adjust t...

Страница 32: ...ced 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 mos...

Страница 33: ...e inside of air cleaner housing with a clean damp cloth to remove any dirt accumulation especially in the area where the element seals against the housing 4 If a new air filter element is to be used c...

Страница 34: ...g system can result in serious personal injury The engine cooling system is filled at the factory with a 50 50 mixture of water and ethylene glycol This permanent type antifreeze contains rust inhibit...

Страница 35: ...d 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 Piping systems operating at less than...

Страница 36: ...new oil filter element when the old gasket remains on the oil filter head will cause an oil leak and can cause property damage 4 Lubricate the new filter gasket with the same oil being used in the ma...

Страница 37: ...pounds of air pressure This will allow the primer to splatter causing the textured look Note you must be careful not to put too much primer on at one time this will effect the amount of texture that y...

Страница 38: ...C Wheel Lug Nuts C Hoses oil air intake etc C Automatic Shutdown System Test C Air Cleaner System Visual C Compressor Oil Cooler Exterior C CLEAN Engine Radiator Exterior C CLEAN Fasteners Guards C Ai...

Страница 39: ...in the formation of varnishes shellacs or lacquers which may be insoluble Such deposits can cause se rious troubles including clogging of the filters Where possible do NOT mix oils of different types...

Страница 40: ...art COMPRESSOR LUBRICATION 23_C to 52_C 10_F to 125_F 40_F to 125_F 40_C to 52_C Mil PRF 2104G SAE 10W IR Pro Tect IR Performance 500 Mil L 46167 IR XHP 505 10_F to 125_F 23_C to 52_C 65_F to 125_F 18...

Страница 41: ...he compressor will still operate is it safe to continue operating it to make further checks B Do The Simplest Things First Most troubles are simple and easily corrected For example most complaints are...

Страница 42: ...ition Sensor Circuit Lost both signals from Magnetic Pickup Sensor 121 Engine Speed Position Sensor Circuit Lost one or two signals from Magnetic PU Sensor 122 Intake Manifold Pressure Sensor 1 Circui...

Страница 43: ...Actuator 1 Circuit Open Circuit 395 Timing Actuator 1 Circuit Grounded Circuit 396 Fueling Actuator 2 Circuit Open Circuit 397 Fueling Actuator 2 Circuit Grounded Circuit 398 Timing Actuator 2 Circuit...

Страница 44: ...t Shorted High 582 Fuel Supply Pump Inlet Pressure Sensor Circuit Shorted Low 583 Fuel Supply Pump Inlet Pressure Low Warning Level 595 Turbocharger 1 Speed High Warning Level 596 Electrical Charging...

Страница 45: ...emp RT2 Sensor Fault 32 CPRSR Malf 10 High Separator Tank Temp RT1 247 deg F 50 CPRSR Malf 3 Machine ID Not Valid 51 CPRSR Malf 0 IQ Filter Restriction IQ Filt Rest 3 Sep Tank Temp RT1 Sensor Fault 53...

Страница 46: ...ROUBLE SHOOTING CHART Bold Headings depict the COMPLAINT Subheadings suggest the CAUSE Note Subheadings suggest sequence to follow troubleshooting Add CLEAN diesel Fuel See Complaint 10 Check coolant...

Страница 47: ...by flushing or replace See Complaint 11 12 13 15 16 or 18 6 Corrective Action Low Engine Oil Pressure Low Oil Level Out of Level 15 degrees Wrong Lube Oil Clogged Oil Filter Element s Engine Malfunct...

Страница 48: ...eaner Life Dirty Operating Conditions Inadequate Element Cleaning Incorrect Stopping Procedure Wrong Air Filter Element Will Not Unload Malfunctioning Inlet Butterfly Valve Ice in Regulation Lines Ori...

Страница 49: ...39 CAN network The WEDGE controller provides the engine throttle setting software versions 2 0 and greater to the engine controller via the J1939 CAN Network and retrieves diagnostic information from...

Страница 50: ...y throttle in terface with the engine is used for software versions earlier than 2 0 Figure 8 2 shows the connections between the WEDGE controller and the engine controller J1939 Data Link The CAN net...

Страница 51: ...Controller CONTROL PANEL SWITCHES GAUGES 24VDC HEATERS ENGINE ECM DIAGNOSTIC INTERFACE ESTOP SWITCHES SOLENOID VALVES SPEED SENSOR FUEL LEVEL SWITCH PRESSURE TRANSDUCERS TEMPERATURE SENSORS BATTERY S...

Страница 52: ...WEDGE TO ENGINE INTERFACE CUMMINS ENGINE J1 34 J1 35 J1 1 J1 37 J1 24 CUMMINS CM570 ENGINE CONTROLLER J2 46 J2 37 J2 36 J3 22 J3 16 CAN HI CAN LO CANSHLD J1 38 J1 31 FREQ THT RANGE 150 Hz 1200 RPM to...

Страница 53: ...7919 5 02 HP XHP VIKING J1939 CAN COMMUNICATIONS SCHEMATIC ENGINE CONTROLLER WEDGE CONTROLLER P15 TERMINATOR TERMINATOR ENGINE DIAGNOSTICS JACK J8 R5 R4 P7 AUTO START OPTION CAN NODE WITH POWER P11 P6...

Страница 54: ...reading of fuel level It also has a switch for low fuel level and low fuel shutdown These switches connect to WEDGE RT1 RT1 is a 10K ohm Thermistor temperature sensor that measures separator tank tem...

Страница 55: ...S14 Safety Valve Press Switch 36757581 B2 Startup Compressor 36850691 K1 Auxiliary Start Relay 35577873 R3 Control Orifice Heater 36841526 R1 Regulator Heater 36864677 R2 Machine ID Plug 54765953 U1 F...

Страница 56: ...orking Check for 24VDC key switch at engine CAN network wiring problem Ensure 24VDC power to engine ECM Check connector pins Engine cranks but will not start Ensure key switch 24VDC at engine Frozen f...

Страница 57: ...57 Book 54757919 5 02 Replace this sheet with 11 x 17 System Schematic Sheet 1 of 5...

Страница 58: ...58 Book 54757919 5 02 Replace this sheet with 11 x 17 System Schematic Sheet 2 of 5...

Страница 59: ...59 Book 54757919 5 02 Replace this sheet with 11 x 17 System Schematic Sheet 3 of 5...

Страница 60: ...60 Book 54757919 5 02 Replace this sheet with 11 x 17 System Schematic Sheet 4 of 5...

Страница 61: ...61 Book 54757919 5 02 Replace this sheet with 11 x 17 System Schematic Sheet 5 of 5...

Страница 62: ...emp RT2 Sensor Fault 32 CPRSR Malf 10 High Separator Tank Temp RT1 247 deg F 50 CPRSR Malf 3 Machine ID Not Valid 51 CPRSR Malf 0 IQ Filter Restriction IQ Filt Rest 3 Sep Tank Temp RT1 Sensor Fault 53...

Страница 63: ...crank 34 CPRSR Malf 0 Machine Over Pressure 35 CPRSR Malf 1 Safety Valve Open 36 CPRSR Malf 0 Sep Tank Temp 247 degrees F 50 CPRSR Malf 3 Machine ID Not Valid 51 CPRSR Malf 0 Sep Tank Temp Rt1 Sensor...

Страница 64: ...ngine Coolant Temperature Sensor Circuit Shorted High 145 Engine Coolant Temperature Sensor Circuit Shorted Low 147 Frequency throttle signal low see note 1 151 Engine Coolant Temperature High Critica...

Страница 65: ...linder 1 Circuit Grounded Circuit 312 Injector Solenoid Valve Cylinder 5 Circuit Grounded Circuit 313 Injector Solenoid Valve Cylinder 3 Circuit Grounded Circuit 314 Injector Solenoid Valve Cylinder 6...

Страница 66: ...Metering Rail 1 Pressure Sensor Circuit Shorted High 452 Injector Metering rail 1 Pressure Sensor Circuit Shorted low 466 Turbocharger 1 Wastegate Control Circuit Data Incorrect 482 Fuel Pressure Low...

Страница 67: ...g System Voltage Low Critical Level 611 Engine Hot Shutdown 753 Engine Speed Position 2 Cam Sync Error 755 Injector Metering Rail 1 Pressure Malfunction 758 Injector Metering Rail 2 Pressure Malfuncti...

Страница 68: ...nd in location relative to the other parts in the assembly The part number the description of the part and the quantity of parts required are shown on each illustration or on adjacent page The quantit...

Страница 69: ...also permanently stamped in the metal of the frame side rail c Always specify the number of the parts list pub lication d Always specify the quantity of parts required e Always specify the part numbe...

Страница 70: ...no event be liable to the Purchaser any successors in in terest or any beneficiary of this order for any conse quential incidental indirect special or punitive dam ages arising out of this order or an...

Страница 71: ...nder 36757581 1 Comp Oil Pressure Switch 36850691 1 Startup Compressor 35577873 1 Auxilary Start Relay 54720701 1 Eng Temp Sender Adaptor 36841526 1 Control Heater 36864677 1 Regulator Heater 54765367...

Страница 72: ...ir Deutsch connectors HDT 48 00 Deutsch Terminal Crimp Tool Used to crimp Deutsch connector terminals DD Deutsch Terminal Crimping Tool Used to crimp Deutsch connector terminals 54729710 Electrical Co...

Страница 73: ...le from electrical and electronic parts distributors 54729660 Weather Pack Terminal Removal Tool 54699632 Deutsch Terminal Removal Tool Blue 54699640 Deutsch Terminal Removal Tool Red 54699624 Deutsch...

Страница 74: ...ok 54757919 5 02 54729710 Electrical Contact Cleaner 54729728 PDA Service Tool 54699616 Deutsch Terminal Removal Tool 22073886 Packard Crimp Tool 22073878 Thermistor Simulator 54749635 Connector Repai...

Страница 75: ...75 Book 54757919 5 02 54699657 Deutsch Terminal Removal Tool 54749643 Packard Metri Pack Removal Tool...

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