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OPERATION & MAINTENANCE MANUAL
COMPRESSOR MODELS
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
Doosan Infracore Portable Power
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
www.doosanportablepower.com
Book: 23209307 (01/08) Rev C
Revised (09-12)
P425 WIR
XP375 WIR
HP375 WIR
Code: C
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
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Table of Contents
Related Manuals for Doosan Ingersoll Rand P425 WIP
Summary of Contents for Doosan Ingersoll Rand P425 WIP
- Page 1 Ingersoll-Rand Company in this manual is historical or nominative www.doosanportablepower.com in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Doosan Company or the products of either. Book: 23209307 (01/08) Rev C Revised (09-12)
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Page 3: Table Of Contents
TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE FOREWORD ............9 Foreword. - Page 4 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE OPERATING INSTRUCTIONS ..........43 Operating Instructions .
- Page 5 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE Precautions for Welding on Engines Equipped with Electronic Engine Control Unit (ECU) ..70 Displaying of Diagnostic Trouble Codes (DTCs) ........76 Intermittent Fault Diagnostics (With Electronic Controls) .
- Page 6 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE SERVICE TOOLS ............111 Service Tools .
- Page 7 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE...
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Page 9: Foreword
Foreword Book: 23209307 (1-7-08) Rev C... -
Page 10: Foreword
Operating & Maintenance Manual Foreword Foreword The contents of this manual are considered to be proprietary and confidential to Doosan Infracore Portable Power (herein referred to as “Portable Power”), and should not be reproduced without the prior written permission of Portable Power. - Page 11 Foreword Operating & Maintenance Manual This machine has been designed and supplied for use only in the following specified conditions and applications: • Compression of normal ambient air containing no known or detectable additional gases, vapors or particles. • Operation within the ambient temperature range specified in the GENERAL INFORMATION section of this manual.
- Page 12 Book: 23209307 (1-7-08) Rev C...
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Page 13: Decals
Decals Book: 23209307 (1-7-08) Rev C... -
Page 14: Decals
Operating & Maintenance Manual Decals DECALS Look for these signs on machines manufactured in Europe, 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 your supervisor. GRAPHIC FORM AND MEANING OF ISO SYMBOLS Book: 23209307 (1-7-08) Rev C... - Page 15 Decals Operating & Maintenance Manual Book: 23209307 (1-7-08) Rev C...
- Page 16 Operating & Maintenance Manual Decals Book: 23209307 (1-7-08) Rev C...
- Page 17 Decals Operating & Maintenance Manual Book: 23209307 (1-7-08) Rev C...
- Page 18 Operating & Maintenance Manual Decals Look for these signs on machines manufactured 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 your supervisor Indicates the presence of a hazard which WILL cause DANGER...
- Page 19 Decals Operating & Maintenance Manual Book: 23209307 (1-7-08) Rev C...
- Page 20 Operating & Maintenance Manual Decals Book: 23209307 (1-7-08) Rev C...
- Page 21 Decals Operating & Maintenance Manual This section pertains only to machines distributed within the United States. WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
- Page 22 Operating & Maintenance Manual Decals Book: 23209307 (1-7-08) Rev C...
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Page 23: Noise Emission
Noise Emission Book: 23209307 (1-7-08) Rev C... -
Page 24: Noise Emission Control Maintenance Log
Operating & Maintenance Manual Noise Emission NOISE EMISSION CONTROL MAINTENANCE LOG COMPRESSOR MODEL_________________________ SERIAL NO. __________________________________ USER UNIT NO. _______________________________ UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: ENGINE MAKE & MODEL: SERIAL NO:_________________ __________________________________ PURCHASER OR OWNER:__________ __________________________________ ADDRESS: ____________________ DATE PURCHASED:_______________ The Noise Control Act of 1972 (86 Stat. -
Page 25: Introduction
Noise Emission Operating & Maintenance Manual Introduction The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air Compressors. The purpose of this book is to provide (1) the Maintenance Performance Schedule below for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when. -
Page 26: Fasteners
Operating & Maintenance Manual Noise Emission D. Fasteners All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be inspected for looseness after each 100 hours of operation. They should be retightened, repaired, or if missing, replaced immediately to prevent subsequent damage and noise emission increase. - Page 27 Noise Emission Operating & Maintenance Manual MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK OR COMMENTS HOURMETER MAINT/ INSPECT LOCATION CITY/ WORK DONE READING DATE STATE BY (NAME) Book: 23209307 (1-7-08) Rev C...
- Page 28 Book: 23209307 (1-7-08) Rev C...
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Page 29: Safety
Safety Book: 23209307 (1-7-08) Rev C... -
Page 30: Safety
Operating & Maintenance Manual Safety Safety Indicates the presence of a hazard which WILL cause DANGER serious injury, death or property damage, if ignored. (Red Background) Indicates the presence of a hazard which CAN cause WARNING serious injury, death or property damage, if ignored. (Orange Background) Indicates the presence of a hazard which WILL or can CAUTION... -
Page 31: Compressed Air
Safety Operating & Maintenance Manual disconnecting battery cable(s) to prevent Compressed air must not be used for a direct accidental starting. feed to any form of breathing apparatus or mask. Do not use petroleum products (solvents or fuels) under high pressure as this can High pressure Air can cause serious injury or penetrate the skin and result in serious death. -
Page 32: Materials
Operating & Maintenance Manual Safety Never allow the unit to sit stopped with engine lubricants should be obtained from pressure in the receiver-separator system. the lubricant supplier. Never operate the engine of this machine inside a building without adequate Materials ventilation. -
Page 33: Transport
Safety Operating & Maintenance Manual Transport Steps for determining correct load limit: When loading or transporting machines Locate the statement “The weight of ensure that the specified lifting and tie down cargo should never exceed xxx kg or points are used. xxx lbs”... - Page 34 Book: 23209307 (1-7-08) Rev C...
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Page 35: General Arrangement
General Arrangement Book: 23209307 (1-7-08) Rev C... -
Page 36: General Arrangement
Operating & Maintenance Manual General Arrangement General Arrangement All dimensions in inches(mm) D Access items: A Instrument panel access door Fuel fill B Package air inlet Engine oil filter C Access items: Fuel filter Separator element & fill Engine and compressor air filter Compressor oil filter E Access items: Fuel filters... - Page 37 General Arrangement Operating & Maintenance Manual All dimensions in inches(mm) E Access items: A Instrument panel access door Radiator fill B Package air inlet F Package air outlet C Access items: G Track width Separator element & fill H Variable height drawbar Compressor oil filter 162 (4114) minimum/168 (4277) maximum Fuel filters...
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Page 38: Compressor
Operating & Maintenance Manual General Arrangement Compressor COMPRESSOR Actual free air delivery. (7/120) (P425WIR) 12, 0 m (425 CFM) Actual free air delivery. (9/110) (XP375WIR) 10, 5 m (375 CFM) Actual free air delivery. (10/110) (HP375WIR) 10, 5m (375 CFM) Normal operating discharge pressure. - Page 39 General Arrangement Operating & Maintenance Manual Operating ambient temperature. Whisperized -12°C TO +49°C(10°F TO 120°F) Maximum discharge temperature 120°C (248°F) Cooling system. Oil injection Oil capacity. 36 litres (9.5 GAL) Maximum oil system temperature. 120°C (248°F) Maximum oil system pressure. (7/120) (P425WIR) 8,6 bar (125 PSI) Maximum oil system pressure.
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Page 40: Lubricating Oil Specification
Operating & Maintenance Manual General Arrangement Lubricating Oil Specification LUBRICATING OIL SPECIFICATION (for the specified ambient temperatures). ABOVE -23°C(-9°F) Recommended: Pro-Tec Approved: SAE 10W, API CF-4/CG-4 BELOW -23°C(-9°F) Mandatory: Ingersoll Rand Performance 500 Ingersoll Rand Pro-Tec compressor fluid is factory-fitted, for use at all ambient temperatures above -23°C(-9°F). -
Page 41: Engine
General Arrangement Operating & Maintenance Manual Engine ENGINE P425WIR(7/120) XP375WIR (9/110), HP375WIR (10/110) Type/model. Ingersoll Rand Number of cylinders. Oil capacity. 13.2 litres (3.5 GAL) 2200 revs Speed at full load. min (RPM) Speed at idle. (RPM) 1500 revs min Electrical system. - Page 42 Operating & Maintenance Manual General Arrangement Ensure that all transport 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 working position of the machine, ensure that there is sufficient clearance for ventilation and exhaust requirements, observing any specified minimum dimensions (to walls, floors etc.).
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Page 43: Operating Instructions
Operating Instructions Book: 23209307 (1-7-08) Rev C... -
Page 44: Operating Instructions
Operating & Maintenance Manual Operating Instructions Operating Instructions Prior to Starting 1. Place the unit in a position that is as level as possible. The design of the unit permits a 15 degree lengthways and sideways limit on out of level operation. It is the engine, not the compressor, that is the limiting factor. - Page 45 Operating Instructions Operating & Maintenance Manual CAUTION Use only a No. 2-D diesel fuel oil with a minimum octane number of 45 and a sulphur content not greater than 0.5%. CAUTION When refueling:- • switch off the engine. • do not smoke. •...
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Page 46: Control Panel
Operating & Maintenance Manual Operating Instructions Control Panel Diagnostic/Auto Shutdown (Standard) 1. Compressor Fault - Needs attention. See Wedge diagnostic panel for more detail. 2. Engine Fault - Needs attention. See Wedge diagnostic panel for more detail. 3. Hourmeter - Records running time for maintenance. 4. - Page 47 Operating Instructions Operating & Maintenance Manual Optional Controls 9. Engine Speed Gauge - Indicates engine speed. 10. Discharge Air Temp. Gauge - Indicates in °F and °C. Normal operating range: 185°F/85°C to 248°F/120°C. 11. Engine Oil Pressure Gauge - Indicates engine oil pressure (psi (kPa). 12.
- Page 48 Operating & Maintenance Manual Operating Instructions WEDGE DIAGNOSTIC DISPLAY PANEL. The Wedge diagnostic display panel is arranged as shown above. A description of each diagnostic indicator is as follows: 1. High Compressor Temp: Fault indicator lamp. Indicates shutdown due to high compressor temperature.
- Page 49 Operating Instructions Operating & Maintenance Manual 4. Restricted Air Filter: Alarm indicator lamp. Indicates engine/compressor air inlet filters need service. 5. High Engine Coolant Temp: Fault indicator lamp. Indicates shutdown due to high engine water temperature. 6. Spare 7. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to low fuel level. Lamp blinks at low fuel warning.
- Page 50 Operating & Maintenance Manual Operating Instructions Alert Shutdown Delay Condition Code Light (Blinks) Code Light (Steady) (sec). Engine Shut Itself Down: reason CPRSR Malf. unknown Disch. Temp (RT2) CPRSR Malf. Sensor Fault Sep. Tank Pressure (PT1) CPRSR Malf. Sensor Fault Separator Tank Temp.
- Page 51 Operating Instructions Operating & Maintenance Manual Listing of Diagnostic Trouble Codes (DTCs) Displayed Definition Code Analog Throttle (B) Input Voltage Error Analog Throttle (A) Input Voltage Error Multi-state Throttle Input Voltage Error Fuel Pressure Problem Engine Oil Pressure Problem Turbo Boost Problem Manifold Air Temperature Problem Atmospheric Pressure Reading Problem Engine Coolant Temperature Problem...
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Page 52: Starting The Machine
Operating & Maintenance Manual Operating Instructions Starting the Machine WARNING Under no circumstances should volatile liquids such as Ether be used for starting this machine. All normal starting functions are incorporated in the key operated switch. • Turn the key switch to position 1. The engine fault and compressor fault lamps will flash. -
Page 53: Push After Warm Up
Operating Instructions Operating & Maintenance Manual Push After Warm Up NOTE: In order to allow the machine to start at a reduced load, a valve, which is operated by a button located on the instrument panel, is incorporated in the regulation system. -
Page 54: Re-Starting After An Emergency
Operating & Maintenance Manual Operating Instructions Re-Starting After an Emergency If the machine 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 that the machine can be operated safely before re-starting. -
Page 55: Engine
Operating Instructions Operating & Maintenance Manual Engine Engine Serial Number Plate Each engine has a 13-digit engine serial number. The engine's serial number plate is located on the right-hand side of cylinder block behind the fuel filter. Fuels, Lubricants and Coolant Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area. -
Page 56: Bio-Diesel Fuel
Operating & Maintenance Manual Operating Instructions Bio-Diesel Fuel Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM PS121, DIN 51606 or equivalent specification. It has been found that bio-diesel fuels may improve lubricity in concentrations up to a 5% blend in petroleum diesel fuel. -
Page 57: Diesel Fuel Storage
Operating Instructions Operating & Maintenance Manual Diesel Fuel Storage WARNING Handle fuel carefully. Do not fill the fuel tank when engine is running. DO NOT smoke while you fill the fuel tank or service the fuel system. Fill the fuel tank at the end of each day's operation to prevent water condensation and freezing during cold weather. -
Page 58: Diesel Engine Oil
Operating & Maintenance Manual Operating Instructions Diesel Engine Oil Use SAE 15W-40 oil viscosity based on the expected air temperature range of 10°F to 122°F (-12°C-40°C) during the period between oil changes. The following oil is preferred: • Pro-Tec Engine Fluid Other oils may be used if they meet one or more of the following: •... -
Page 59: Supplemental Coolant Additives
Operating Instructions Operating & Maintenance Manual Chlorides <40mg/L Sulfates <100 mg/L Total Dissolved Solids <340 mg/L Total Hardness <170 mg/L 5.5 to 9.0 IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives. Supplemental Coolant Additives The concentration of coolant additives is gradually depleted during engine operation. -
Page 60: Operating In Warm Temperature Climates
Operating & Maintenance Manual Operating Instructions Operating in Warm Temperature Climates Ingersoll Rand branded engines are designed to operate using glycol base engine coolants. Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required. IMPORTANT: Water may be used as coolant in emergency situations only. -
Page 61: Lubrication
Lubrication Book: 23209307 (1-7-08) Rev C... -
Page 62: Lubrication
Operating & Maintenance Manual Lubrication Lubrication Lubrication and Maintenance Service Interval Chart NOTE: The Service intervals below are for standard industrial engines. See details in Sections which follow these charts. Item Lubrication and Maintenance Service Intervals 2000 500 Hours/ Check Engine Oil and Coolant Level Daily Hours/ 12months... -
Page 63: Lubrication & Maintenance/Daily
Lubrication Operating & Maintenance Manual Lubrication & Maintenance/Daily Daily Pre-starting Checks Do the following BEFORE STARTING THE ENGINE for the first time each day: Check engine oil level on dipstick. IMPORTANT: DO NOT add makeup oil until the oil level is below the crosshatch marks on the dipstick. -
Page 64: To Change Engine Oil And Oil Filter
Operating & Maintenance Manual Lubrication To change engine oil and oil filter: 1. Run engine approximately 5 minutes to warm up oil. Shut engine off. 2. Remove oil pan drain plug. 3. Drain crankcase oil from engine while warm. 4. Turn filter element using a suitable filter wrench to remove. Discard oil filter element. -
Page 65: Cleaning Crankcase Vent Tube
Lubrication Operating & Maintenance Manual Cleaning Crankcase Vent Tube If you operate the engine in dusty conditions, clean the tube at shorter intervals. 1. Remove and clean crankcase vent tube. 2. Install the vent tube. Be sure the O-ring fits correctly in the rocker arm cover for elbow adapter. -
Page 66: Checking Belt Tensioner Spring Tension And Belt Wear (Automatic Tensioner)
Operating & Maintenance Manual Lubrication 9. Install retaining ring onto mounting base making certain dust seal is in place on filter base. Hand tighten ring (about 1/3 turn) until it "snaps" into the detent. DO NOT overtighten retaining ring. NOTE: The proper installation is indicated when a "click" is heard and a release of the retaining ring is felt. -
Page 67: Checking Engine Electrical Ground Connections
Lubrication Operating & Maintenance Manual Specification Spring Tension-Torque 18-22 N.m (13-16 Ib-ft) NOTE: Threads on belt tensioner roller cap screw are LEFT-HAND threads. Checking Engine Electrical Ground Connections Keep all engine ground connections clean and tight to prevent electrical arcing which can damage electronic components. -
Page 68: Replacing Fan And Alternator Belts
Operating & Maintenance Manual Lubrication Replacing Fan and Alternator Belts Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Lubrication and Maintenance/500 Hour/12 Month Section for additional information on the belt tensioner. 1. Inspect belts for cracks, fraying, or stretched out areas. Replace if necessary. 2. -
Page 69: At Fuel Injection Pump
Lubrication Operating & Maintenance Manual At Fuel Injection Pump 1. Loosen fuel return line at fuel injection pump. 2. Operate fuel supply pump primer lever or primer button on fuel filter base (if equipped). 3. As soon as fuel flow is free from air bubbles, tighten fuel return line to specification. -
Page 70: Troubleshooting
Operating & Maintenance Manual Lubrication Troubleshooting General Troubleshooting Information Troubleshooting engine problems can be difficult. In this section is a list of possible engine problems that may be encountered accompanied by possible causes and corrections. The illustrated diagrams and troubleshooting information are of a general nature. - Page 71 Lubrication Operating & Maintenance Manual Symptom Problem Solution Engine cranks but will Incorrect starting procedure Verify correct starting procedure. not start No fuel. Check fuel in tank. Check and correct exhaust Exhaust restricted. restriction. Fuel filter plugged or full of Replace fuel filter or drain water from water filter.
- Page 72 Operating & Maintenance Manual Lubrication Symptom Problem Solution Engine runs Low coolant temperature. Remove and check thermostat. irregularly or stalls Clogged fuel filter. Replace fuel filter element. frequently Drain, flush, fill, and bleed system. Dirty or Water, dirt, or air in fuel faulty injection nozzles.
- Page 73 Lubrication Operating & Maintenance Manual Symptom Problem Solution Low oil pressure Low oil level. Add oil Drain, fill crankcase with oil of proper Improper type of oil. Viscosity and quality. High oil consumption Crankcase oil too light. Use proper viscosity oil. Check for leaks in lines, gaskets, and Oil leaks.
- Page 74 Operating & Maintenance Manual Lubrication Symptom Problem Solution Engine overheats Engine overloaded. Reduce load. Fill radiator to proper level, check radiator Low coolant level. and hoses for loose connection s or leaks. Faulty radiator cap. Have technician check. Stretched poly-vee belt or Check automatic belt tensioner and check defective belt tensioner.
- Page 75 Lubrication Operating & Maintenance Manual Symptom Problem Solution Battery uses too much Check for moisture and replace Cracked battery case. Water as necessary. Defective battery. Test battery. Battery charging rate too high. Test charging system. Batteries will not charge Loose or corroded connections. Clean and tighten connections.
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Page 76: Displaying Of Diagnostic Trouble Codes (Dtcs)
Operating & Maintenance Manual Lubrication Displaying of Diagnostic Trouble Codes (DTCs) Stored and active diagnostic trouble codes are output on the instrument panel according to the J1939 standard as a two-part code as shown on the tables in the Operating Instruction Section. -
Page 77: Possible Causes Of Intermittent Faults
Lubrication Operating & Maintenance Manual Possible causes of intermittent faults: • Faulty connection between sensor and actuator harness. • Faulty contact between terminals in connector. • Faulty terminal/wire connection. • Electromagnetic interference (EMI) from an improperly installed 2-way radio, etc., can cause faulty signals to be sent to the ECU. -
Page 78: Removing Engine From Long Term Storage
Operating & Maintenance Manual Lubrication 8. Clean the exterior of the engine with salt-free water and touch up any scratched or chipped painted surfaces with a good quality paint. 9. Coat all exposed (machined) metal surfaces with grease or corrosion inhibitor if not feasible to paint. -
Page 79: Specifications
Lubrication Operating & Maintenance Manual Specifications General Engine Specifications. ITEM 4IRD5AE Number of Cylinders Bore 106 mm (4.19 in.) Stroke 127 mm (5.0 in.) Displacement 4.5 L (276 cu in.) Compression Ratio 17.0:1 Aspiration Turbocharged Engine Firing Order 1-3-4-2 Valves Per Cylinder 1 Intake 1 Exhaust Valve Clearance (Cold) -
Page 80: Engine Crankcase Oil Fill Quantities
Operating & Maintenance Manual Lubrication ITEM 4IRD5AE Length 860 mm (33.9 in.) Width 612 mm (24.1 in.) Height 994 mm (39.l in.) Weight 451 kg (993 Ib) Engine Crankcase Oil Fill Quantities Crankcase Oil Capacity L (qt) 13.5 (14.3) Lubrication and Maintenance Records Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Section for detailed service procedures. -
Page 81: Emissions Control System Certification Label
Lubrication Operating & Maintenance Manual Emissions Control System Certification Label CAUTION Statutes providing severe penalties for tampering with emissions controls may apply to the user or dealer. The emissions warranty applies only to those engines marketed by John Deere that have been certified by the United States Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB);... - Page 82 Book: 23209307 (1-7-08) Rev C...
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Page 83: Maintenance
Maintenance Book: 23209307 (1-7-08) Rev C... -
Page 84: Maintenance
Operating & Maintenance Manual Maintenance Maintenance Initial Monthly Daily Weekly Monthly Monthly Monthly miles/ 1000 250 hrs. 500 hrs. 850 km hrs. Compressor Oil Level Engine Oil Level *Radiator Coolant Level Gauges/Lamps *Air Cleaner Service Indicators Fuel Tank (Fill at end of day) *Fuel/Water Separator Drain Oil Leaks Fuel Leaks... - Page 85 Maintenance Operating & Maintenance Manual *Disregard if not appropriate for this particular machine (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 = Grease...
- Page 86 Operating & Maintenance Manual Maintenance Initial Monthly Monthly miles/ Daily Weekly Monthly Monthly Monthly 1000 1000 250 hrs. 500 hrs *Fuel/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease. Wheels (Bearings, Seals, etc.) *Engine Coolant Fuel Filter Element...
- Page 87 Maintenance Operating & Maintenance Manual Running gear linkage Safety valve Running gear bolts (1) *Disregard if not appropriate for this particular machine (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.
- Page 88 Operating & Maintenance Manual Maintenance Initial Daily Weekly Monthly Monthly Monthly Monthly miles/ 250 hrs. 500 hrs 1000 hrs 850 km Scavenge line Pressure system Engine breather element Pressure gauge Pressure regulator Separator tank (2) exterior Lubricator (Fill) 2 Yrs 4 Yrs 6 Yrs Safety valve...
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Page 89: Routine Maintenance
Maintenance Operating & Maintenance Manual Routine Maintenance This section refers to the various components which require periodic maintenance and replacement. The SERVICE/MAINTENANCE CHART indicates the various components' descriptions and the intervals when maintenance has to take place. Oil capacities, etc., can be found in the GENERAL INFORMATION section of this manual. - Page 90 Operating & Maintenance Manual Maintenance Prior to opening or removing panels or covers to work inside a machine, ensure that:- • anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts. •...
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Page 91: Productive Shutdown System
Maintenance Operating & Maintenance Manual Productive Shutdown System Refer to the Wedge diagnostic display codes table for a listing of shutdown conditions. Low engine fuel level switch. At three month intervals, test the low engine fuel level switch circuit as follows: •... -
Page 92: Compressor Oil Filter
Operating & Maintenance Manual Maintenance Compressor Oil Filter Refer to the MAINTENANCE CHART in this section for the recommended servicing 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 UNIT in the OPERATING INSTRUCTIONS section of this manual). -
Page 93: Compressor Oil Separator Element
Maintenance Operating & Maintenance Manual Compressor Oil Separator Element Normally the separator element will not require periodic maintenance provided that the air and oil filter elements are correctly maintained. If, however, the element has to be replaced, then proceed as follows: Removal WARNING Do not remove the filter(s) without first making sure that the machine is... -
Page 94: Compressor Oil Cooler And Engine Radiator
Operating & Maintenance Manual Maintenance CAUTION Start the machine (refer to PRIOR TO STARTING and STARTING THE UNIT in the OPERATING INSTRUCTIONS 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 the oil cooler and radiator, the efficiency is impaired. -
Page 95: Air Filter Elements
Maintenance Operating & Maintenance Manual Air Filter Elements The air filter should be inspected regularly (refer to the SERVICE/MAINTENANCE CHART) and the element replaced when the restriction indicator shows red or every 6 Months (500 hours), whichever comes first. The dust collector box(es) should be cleaned daily (more frequently in dusty operating conditions) and not allowed to become more than half full. -
Page 96: Fuel System
Operating & Maintenance Manual Maintenance Fuel System The fuel tank should be filled daily or every eight hours. To minimize 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. -
Page 97: Battery
Maintenance Operating & Maintenance Manual Battery Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion. They retaining clamp should be kept tight enough to prevent the battery from moving. Pressure System At 500 hour intervals it is necessary to inspect the external surfaces of the system (from the airend through to the discharge valve(s)) including hoses, tubes, tube fittings and the separator tank, for visible signs of impact damage, excessive corrosion, abrasion, tightness and chafing. -
Page 98: Lubrication
Operating & Maintenance Manual Maintenance Lubrication The engine is initially supplied with engine oil sufficient for a nominal period of operation (for more information, consult the Engine section of this manual). CAUTION Always check the oil levels before a new machine is put into service. If, for any reason, the unit has been drained, it must be re-filled with new oil before it is put into operation. -
Page 99: Compressor Oil Filter Element
Maintenance Operating & Maintenance 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) ensuring that each one is secure. NOTE: If the oil is drained immediately after the machine has been running, then most of the sediment will be in suspension and will therefore drain more readily. -
Page 100: Speed And Pressure Regulation Adjustment
Operating & Maintenance Manual Maintenance Speed and Pressure Regulation Adjustment Normally, regulation requires no adjusting, but if correct adjustment is lost, proceed as follows: Refer to the diagram above. A. Adjusting screw Start the machine (Refer to STARTING INSTRUCTIONS in the OPERATING INSTRUCTIONS section of this manual). - Page 101 Maintenance Operating & Maintenance Manual Book: 23209307 (1-7-08) Rev C...
- Page 102 Operating & Maintenance Manual Maintenance Book: 23209307 (1-7-08) Rev C...
- Page 103 Maintenance Operating & Maintenance Manual Compressor Lubrication Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change. NOTE: Fluids listed as "preferred"...
- Page 104 Operating & Maintenance Manual Maintenance Design Operating Ambient Temperature Specification Pressure ° ° ° ° 100 psi to300 psi Preferred: Ingersoll Rand Pro-Tec F to 125 F (-23 C to 52 Alternate: ISO Viscosity Grade 46 with rust and oxidation inhibitors, designed for air compressor service.
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Page 105: Machine Systems
Machine Systems Book: 23209307 (1-7-08) Rev C... -
Page 106: Machine Systems
Operating & Maintenance Manual Machine Systems Machine Systems Battery Pressure transducer, separator tank 0-500 PSIG RS232C comms Pressure transducer, regulation system 0-100 PSIG ECON Engine controller Plug, machine ID Isochronous governor Idle sel J50-G2 Wait to start lamp Relay-spst J50-K3 Inlet heater Thermistor, separator tank temperature -30- 255 Coolant temp... - Page 107 Machine Systems Operating & Maintenance Manual POUT4 Engine fault lamp Spare POUT5 Start relay Spare POUT6 Spare Switch, start POUT7 Hour meter Transducer exitation POUT8 WCON Spare Wedge controller Book: 23209307 (1-7-08) Rev C...
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Page 108: Wedge To Engine Interface - Ir Engine
Operating & Maintenance Manual Machine Systems Wedge to Engine Interface - IR Engine Harness System Schematic Book: 23209307 (1-7-08) Rev C... -
Page 109: J1939 Can Communications Schematic
Machine Systems Operating & Maintenance Manual J1939 CAN Communications Schematic Book: 23209307 (1-7-08) Rev C... - Page 110 Operating & Maintenance Manual Machine Systems Book: 23209307 (1-7-08) Rev C...
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Page 111: Service Tools
Service Tools Book: 23209307 (1-7-08) Rev C... -
Page 112: Service Tools
Operating & Maintenance Manual Service Tools Service Tools Electronic Systems The following special tools are recommended to perform service procedures in this manual. The tools can be purchased from Portable Power or equivalent substitutes can be used. Tool Tool Description Fluke 87 Digital Multimeter Used to measure electrical circuits: volts,... - Page 113 Service Tools Operating & Maintenance Manual Tool Tool Description 22073878 Thermistor Simulator Plug Used to test thermistor 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...
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Page 114: Service Tools
Operating & Maintenance Manual Service Tools Service Tools Tool No Tool Description Tool Illustration Digital multimeterAvailable Fluke 87 from electrical and electronic parts distributors Weather-Pack Terminal 54729660 Removal Tool Deutsch Terminal Removal 54699632 Tool (Blue) Deutsch Terminal Removal 54699640 Tool (Red) Deutsch Terminal Removal 54699624 Tool (Yellow) - Page 115 Service Tools Operating & Maintenance Manual Crimp Tool for Deutsh pins DT-RT1 Crimp Available from: Ladd Industries (800-223-1236) 54729710 Electrical Contact Cleaner 54729728 PDA Service Tool Deutsch Terminal Removal 54699616 Tool 22073886 Packard Crimp Tool 22073878 Thermistor Simulator Book: 23209307 (1-7-08) Rev C...
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Page 116: Electrical Parts
Operating & Maintenance Manual Service Tools 54749635 Connector Repair Kit Deutsch Terminal Removal 54699657 Tool 54749643 Packard Metri-Pack Removal Tool Electrical Parts PARTS QTY PER PARTS QTY PER DESCRIPTION DESCRIPTION NUMBERS MACHINE NUMBERS MACHINE 0-100 psi PRESSURE 36920825 54731427 FUEL LEVEL SENDER TRANSDUSER 0-500 psi PRESSURE 54765946... -
Page 117: Fault Finding
Fault Finding Book: 23209307 (1-7-08) Rev C... -
Page 118: Fault Finding
Operating & Maintenance Manual Fault Finding Fault Finding FAULT CAUSE REMEDY No reaction from Emergency stop Reset emergency stop button. instrument panel actuated. when key turned to Batteries not connected. Connect batteries. (I) position. Fuse at starter motor Replace fuse. ‘blown’. - Page 119 Fault Finding Operating & Maintenance Manual FAULT CAUSE REMEDY Engine starts but Electrical fault. Test the electrical circuits. will not run or Low engine oil pressure. Check the oil level and oil filter(s). engine shuts down prematurely. Safety shut-down Check the safety shut-down switches. system in operation.
- Page 120 Operating & Maintenance Manual Fault Finding FAULT CAUSE REMEDY Excessive vibration. Engine speed too low. See ”Engine speed too low” Leaking oil seal. Improperly fitted oil seal. Replace the oil seal. Refer also to the Engine Manufacturer’s Manual. Air discharge Engine speed too low.
- Page 121 Fault Finding Operating & Maintenance Manual FAULT CAUSE REMEDY Refer to SPEED AND PRESSURE Inlet valve set REGULATION ADJUSTMENT in the incorrectly. MAINTENANCE section of this manual. Loose pipe/hose Check all pipe/hose connections. connections. Check the relieving pressure. Replace the Faulty safety valve.
- Page 122 Book: 23209307 (1-7-08) Rev C...
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Page 123: Options
Options Book: 23209307 (1-7-08) Rev C... -
Page 124: Options - Lubricator
Operating & Maintenance Manual Options Options - Lubricator (For units manufactured in North America) Safety WARNING Ensure that the lubricator filler cap is re-tightened correctly after replenishing with oil. WARNING Do not replenish the lubricator oil, or service the lubricator without first making sure that the machine is stopped and the system has been completely relieved of all air pressure (Refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual). -
Page 125: Operating Instructions
Options Operating & Maintenance Manual Operating Instructions Commissioning Check the lubricator oil level and fill as necessary. Prior to Starting Check the lubricator oil level and replenish as necessary. Maintenance Check the lubricator oil level and replenish as necessary. Fault Finding FAULT CAUSE REMEDY... - Page 126 Book: 23209307 (1-7-08) Rev C...
- Page 127 Doosan Infracore Portable Power P.O. Box 868 - 501 Sanford Ave Mocksville, N.C. 27028 www.doosanportablepower.com Book: 23209307 (01/08) Rev C ©2008 Doosan Infracore International, Printed in the USA...