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Operating & Maintenance Manual

Operating Instructions

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

CATERPILLAR C-9 Engine Diagnostic and Event Flash Codes

Displayed Code

Definition

5 volt sensor DC power supply short to + batt

5 volt sensor DC power supply short to ground

8 volt DC supply short to + batt

8 volt DC supply short to ground

Engine oil pressure open/short to + batt

Engine oil pressure short to ground

Engine oil pressure abnormal rate of change

Boost pressure sensor abnormal rate of change

Boost pressure sensor open/short to + batt

Boost pressure sensor short to ground

Atmospheric pressure open/short + batt

Atmospheric pressure short to ground

Engine coolant temperature open/short to + batt

Engine coolant temperature short to ground

Throttle position calibration required

Throttle position signal abnormal

Engine speed signal abnormal

Secondary engine speed signal abnormal

Engine overspeed WARNING

Engine overspeed shutdown

Fuel pressure open/short + batt

Fuel pressure short to ground

Intake manifold air temperature open/short + batt

Intake manifold air temperature short to ground

Injector actuation pressure signal erratic

Injector actuation pressure voltage high

Injector actuation pressure voltage low

Injector actuation pressure system fault

Содержание VHP750WCAT

Страница 1: ...ODE E OPERATION MAINTENANCE MANUAL COMPRESSOR MODELS XHP750WCAT VHP750WCAT Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of tradema...

Страница 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...

Страница 3: ...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 4: ...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 5: ...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 6: ...6 TABLE OF CONTENTS Operation Maintenance Manual TITLE PAGE Always Use IR Replacement Parts...

Страница 7: ...Book 22846471 3 09 07 Rev B 7 Foreword...

Страница 8: ...ssible be 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 accompanie...

Страница 9: ...ce and 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...

Страница 10: ...Operating Maintenance Manual Foreword 10 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement Parts...

Страница 11: ...Book 22846471 3 09 07 Rev B 11 Safety...

Страница 12: ...nical 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 uns...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 18: ...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 compresso...

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

Страница 20: ...bsequent 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 Regulations This warr...

Страница 21: ...s shut 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 eit...

Страница 22: ...systems 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 co...

Страница 23: ...nce Manual Book 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 LOCAT...

Страница 24: ...24 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts...

Страница 25: ...Book 22846471 3 09 07 Rev B 25 General Information...

Страница 26: ...Operating Maintenance Manual General Information 26 Book 22846471 3 09 07 Rev B General Information MSA SRG HRG...

Страница 27: ...General Information Operating Maintenance Manual Book 22846471 3 09 07 Rev B 27...

Страница 28: ...s Litres 19 8 75 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 N...

Страница 29: ...meters Further information 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...

Страница 30: ...30 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts...

Страница 31: ...Book 22846471 3 09 07 Rev B 31 Operating Instructions...

Страница 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...

Страница 33: ...is as level as 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 eng...

Страница 34: ...equipment 5 Drain 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...

Страница 35: ...perating the machine 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...

Страница 36: ...filters 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 42: ...st pressure sensor 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 gro...

Страница 43: ...ications 61 High 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...

Страница 44: ...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...

Страница 45: ...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...

Страница 46: ...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...

Страница 47: ...ient of the machine 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 wi...

Страница 48: ...Operating Maintenance Manual Operating Instructions 48 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts...

Страница 49: ...Book 22846471 3 09 07 Rev B 49 Maintenance...

Страница 50: ...s 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 Cl...

Страница 51: ...ilter Element R 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 qualit...

Страница 52: ...n 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 more in...

Страница 53: ...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...

Страница 54: ...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...

Страница 55: ...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...

Страница 56: ...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...

Страница 57: ...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...

Страница 58: ...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...

Страница 59: ...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...

Страница 60: ...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...

Страница 61: ...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...

Страница 62: ...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...

Страница 63: ...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...

Страница 64: ...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...

Страница 65: ...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...

Страница 66: ...Operating Maintenance Manual Maintenance 66 Book 22846471 3 09 07 Rev B Torque Values...

Страница 67: ...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...

Страница 68: ...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...

Страница 69: ...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...

Страница 70: ...70 Always use Ingersoll Rand Replacement parts...

Страница 71: ...Book 22846471 3 09 07 Rev B 71 Machine Systems...

Страница 72: ...d to 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 co...

Страница 73: ...Machine Systems Operating Maintenance Manual Book 22846471 3 09 07 Rev B 73...

Страница 74: ...Operating Maintenance Manual Machine Systems 74 Book 22846471 3 09 07 Rev B...

Страница 75: ...se transducers 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 suc...

Страница 76: ...en the wire terminal 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...

Страница 77: ...Book 22846471 3 09 07 Rev B 77 Fault Finding...

Страница 78: ...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...

Страница 79: ...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...

Страница 80: ...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...

Страница 81: ...afety valve Check 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 s...

Страница 82: ...82 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts...

Страница 83: ...Book 22846471 3 09 07 Rev B 83 Options...

Страница 84: ...ance Manual Options 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...

Страница 85: ...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...

Страница 86: ...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...

Страница 87: ...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...

Страница 88: ...88 Book 22846471 3 09 07 Rev B Always use Ingersoll Rand Replacement parts...

Страница 89: ...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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