Ingersoll-Rand Doosan HP750WCU-T2 Operation & Maintenance Manual
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Ingersoll-Rand Doosan HP750WCU-T2 Operation & Maintenance Manual

Ingersoll-Rand Doosan HP750WCU-T2 Operation & Maintenance Manual

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OPERATION, MAINTENANCE
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
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 22482517 (7-09) Rev A
Revised (09-12)
MANUAL
HP750WCU-T2 (C09)
XP750WCU-T2 (C08)
XP825WCU-T2 (C10)
COMPRESSOR MODELS
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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  • Page 1 OPERATION, MAINTENANCE MANUAL HP750WCU-T2 (C09) XP750WCU-T2 (C08) XP825WCU-T2 (C10) 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 purchased Bobcat Company from Ingersoll-Rand Company in 2007.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE FOREWORD ............. . 7 Foreword.
  • Page 4 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE Compressor Mounting ............38 Prior to Starting .
  • Page 5 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE LUBRICATION ............61 Lubrication .
  • Page 6 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 7: Foreword

    Foreword Book 22482517 (7-09) Rev A...

  • Page 8: Foreword

    Operation & 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. Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Portable Power products described herein.
  • Page 9 Foreword Operation & Maintenance Manual This machine should not be used: A. For direct or indirect human consumption of the compressed air. B. Outside the ambient temperature range specified in the general data section of this manual. C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists.
  • Page 10 Operation & Maintenance Manual Foreword **Always use Ingersoll-Rand Replacement Parts** Book 22482517 (7-09) Rev A...

  • Page 11: Safety

    Safety Book 22482517 (7-09) Rev A...

  • Page 12: Safety

    Operation & Maintenance Manual Safety Safety Safety Precautions General Information Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

  • Page 13: Compressed Air

    Safety Operation & Maintenance Manual blow gun tips, etc. well away from moving parts. Compressed Air Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.

  • Page 14: Materials

    Operation & Maintenance Manual Safety Materials The following substances may be produced during the operation of this machine: • brake lining dust • engine exhaust fumes WARNING Avoid inhalation Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times.

  • Page 15: Battery

    Safety Operation & Maintenance Manual This machine may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authorities for proper disposal of these materials. Battery A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive.

  • Page 16: Transport

    Operation & Maintenance Manual Safety Transport When loading or transporting machines ensure that the specified lifting and tie down points are used. When loading or transporting machines ensure that the towing vehicle, its size, weight, towing hitch and electrical supply are all suitable to provide safe and stable towing at speeds either, up to the legal maximum for the country in which it is being towed or, as specified for the machine model if lower than the legal maximum.

  • Page 17: Decals

    Safety Operation & Maintenance Manual Decals Graphic Form and Meaning of ISO Symbols Book 22482517 (7-09) Rev A...
  • Page 18 Operation & Maintenance Manual Safety Book 22482517 (7-09) Rev A...
  • Page 19 Safety Operation & Maintenance Manual Book 22482517 (7-09) Rev A...
  • Page 20 Operation & Maintenance Manual Safety Book 22482517 (7-09) Rev A...
  • Page 21 Safety Operation & Maintenance Manual Look for these signs, 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 serious injury, death or property damage, if ignored.
  • Page 22 Operation & Maintenance Manual Safety Book 22482517 (7-09) Rev A...
  • Page 23 Safety Operation & Maintenance Manual Book 22482517 (7-09) Rev A...
  • Page 24 Book 22482517 (7-09) Rev A...
  • Page 25 Safety Operation & Maintenance Manual FREE SAFETY DECALS To promote communication of Safety Warnings on products manufactured by the Portable Power Division in Statesville, N.C., Safety Decals are available FREE of charge. 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.
  • Page 26 Operation & Maintenance Manual Safety Book 22482517 (7-09) Rev A...

  • Page 27: Noise Emission

    Noise Emission Book 22482517 (7-09) Rev A...

  • Page 28: Noise Emission

    Operation & Maintenance Manual Noise Emission Noise Emission 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 29: Noise Emission Control

    Noise Emission Operation & Maintenance Manual 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 30: Introduction

    Operation & Maintenance Manual Noise Emission 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 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 31: Fasteners

    Noise Emission Operation & Maintenance Manual 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 32 Operation & Maintenance Manual Noise Emission MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY DESCRIPTION OF WORK HOURMETER MAINT/ INSPECT LOCATION WORK DONE ITEM NO. READING DATE CITY/ STATE BY (NAME) Book 22482517 (7-09) Rev A...

  • Page 33: General Data

    Section C - General Data Book 22482517 (7-09) Rev A...

  • Page 34: General Data

    Operation & Maintenance Manual General Data General Data Actual free air delivery (9/235) (XP825DWCU) 23,4 m /min (825 CFM) (HP750DWCU) 21,2 (750 CFM) (XP750DWCU) 21,2 (750 CFM) (HP675 WCU) 19,1 (675 CFM) Normal operating discharge pressure (9/235) (XP825DWCU) 8,6 bar (125 psi) (HP750DWCU) 10,3 bar (150 psi) (XP750DWCU)
  • Page 35 General Data Operation & Maintenance Manual Engine (XP825DWCU), (HP750DWCU), (XP750DWCU), (HP675WCU) Type/Model Cummins/6C8.3TAA Number of Cylinders Oil Capacity 31.7 litres (8.4 gal) Speed at Full Load min -1 (RPM) 2000 revs Speed at Idle min -1 (RPM) 1500 revs Power Available at Full Load (XP825DWCU), (HP750DWCU), 205kW (275hp) (XP750DWCU), (HP675WCU)
  • Page 36 **Always use Ingersoll-Rand Replacement parts!** Book 22482517 (7-09) Rev A...

  • Page 37: Operating Instructions

    Section D - Operating Instructions Book 22482517 (7-09) Rev A...

  • Page 38: Operating Instructions

    Operation & Maintenance Manual Operating Instructions Operating Instructions Commissioning Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the instructions given below in PRIOR TO STARTING. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.
  • Page 39 Operating Instructions Operation & Maintenance Manual WARNING All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine safety valve setting, and materials compatible with the compressor lubricant (refer to the GENERAL DATA SECTION).

  • Page 40: Prior To Starting

    Operation & Maintenance Manual 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. When the unit has to be operated out of level, it is important to keep the engine oil level near the high level mark (with the unit level).
  • Page 41 Operating Instructions Operation & Maintenance Manual 6. Open the service valve(s) to ensure that all pressure is relieved from the system. Close the service valve(s). CAUTION 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.

  • Page 42: Control Panel

    Operation & Maintenance Manual Operating Instructions Control Panel 1. Hourmeter - Records running time for maintenance. 2. Compressor Discharge Pressure Gauge - lndicates pressure in receiver tank. 3. Fuel Level Gauge - lndicates amount of fuel in tank. 4. Power Switch - Activates systems for STARTING and STOPPING. 5.

  • Page 43: Diagnostic Display Panel

    Operating Instructions Operation & Maintenance Manual Diagnostic Display Panel The diagnostic display panel is arranged as shown above. A description of each diagnostic indicator is as follows. 1. High Compressor Temp: Fault indicator lamp. lndicates shutdown due to high compressor temperature. 2.

  • Page 44: Starting The Machine

    Operation & Maintenance Manual Operating Instructions Starting The Machine All normal starting functions are incorporated in the key operated switch. • Turn the key switch to position 1. The diagnostic lamps will flash. • Turn the key switch to crank position (3) (engine start position) NOTE: Position (2) not used on this model.

  • Page 45: Push After Warm Up

    Operating Instructions Operation & 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. (The valve automatically returns to the start position when the machine is switched off and air pressure relieved from the system).

  • Page 46: Re-Starting After An Emergency

    Operation & 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 47: Maintenance

    Section E - Maintenance Book 22482517 (7-09) Rev A...

  • Page 48: Maintenance

    Operation & Maintenance Manual Maintenance Maintenance Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months 500 hrs. 1000 hrs. /850 km 2000 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 49 Maintenance Operation & Maintenance Manual Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months Months 500 hrs. 1000 hrs /850 km 2000 hrs 3000 hrs *Fue/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease.

  • Page 50: Routine Maintenance

    Operation & Maintenance Manual Maintenance Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months 500 hrs. 1000 hrs /850 km 2000 hrs Scavenge line * Engine breather element Separator tank (2) exterior *Lubricator (Fill) 2 Yrs 6 Yrs Safety valve Separator Tank (2) interior *Disregard if not appropriate for this particular machine.

  • Page 51: Prior To Attempting Any Maintenance Work, Ensure That

    Maintenance Operation & Maintenance Manual Prior to attempting any maintenance work, ensure that:- • all air pressure is fully discharged and isolated from the system. If the automatic blowdown valve is used for this purpose, then allow enough time for it to complete the operation.

  • Page 52: Upon Completion Of Maintenance Tasks And Prior To Returning The Machine Into Service, Ensure That

    Operation & Maintenance Manual Maintenance Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:- • the machine is suitably tested. • all guards and safety protection devices are refitted. • all panels are replaced, canopy and doors closed. •...

  • Page 53: Compressor Oil Filter

    Maintenance Operation & Maintenance Manual 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 MACHINE in the OPERATING INSTRUCTIONS section of this manual) Clean the exterior of the filter housing and remove the spin-on element.

  • Page 54: Compressor Oil Separator Element

    Operation & Maintenance Manual Maintenance COMPRESSOR OIL SEPARATOR ELEMENT Refer to the MAINTENANCE CHART in this section for the recommended servicing intervals. 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 stopped and the system has been completely relieved of all air pressure.

  • Page 55: Compressor Oil Cooler And Engine Radiator

    Maintenance Operation & Maintenance Manual CAUTION Start the machine (refer to PRIOR TO STARTING and STARTING THE MACHINE 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 56: Air Filter Elements

    Operation & Maintenance Manual Maintenance AIR FILTER ELEMENTS The air filter element should be replaced regularly (refer to the MAINTENANCE CHART) or when the restriction indicator shows red, whichever comes first. The aircleaner precleaner dumps should be cleaned as indicated in the MAINTENANCE CHART (more frequently in dusty operating conditions).

  • Page 57: Fuel Filter Water Separator

    Maintenance Operation & Maintenance Manual FUEL FILTER WATER SEPARATOR The fuel filter water separator contains a filter element which should be replaced at regular intervals (see the SERVICE/MAINTENANCE CHART). CHARGE AIR COOLER PIPEWORK Inspect all hoses and clamps on the charge cooler pipe work. Engine damage will occur if the charge cooling system leaks.

  • Page 58: Tire Pressure

    Operation & Maintenance Manual Maintenance TIRE PRESSURE See the GENERAL DATA SECTION of this manual. RUNNING GEAR/WHEELS Check the wheel nut torque 20 miles (30 kilometres) after refitting the wheels. Refer to the TORQUE SETTING TABLE later in this section. Lifting jacks should only be used under the axle The bolts securing the running gear to the chassis should be checked periodically for tightness (refer to the MAINTENANCE CHART for frequency) and re-tighten where necessary.

  • Page 59: Compressor Lubricating Oil

    Maintenance Operation & Maintenance Manual COMPRESSOR LUBRICATING OIL Refer to the MAINTENANCE CHART in this section for service intervals. NOTE: If the machine has been operating under adverse conditions, or has suffered long shutdown periods, then more frequent service intervals will be required.
  • Page 60 **Always use Ingersoll-Rand Replacement parts!** Book 22482517 (7-09) Rev A...

  • Page 61: Lubrication

    Section F - Lubrication Book 22482517 (7-09) Rev A...

  • Page 62: Lubrication

    ISO Viscosity Grade 46 with rust and oxidation inhibitors, designed for air compressor service. -10°F to 125°F Preferred: Preferred Ingersoll Rand Fluids - Use of these (-23°C to 52°C) IR XHP 605 fluids with original IR branded filters can extend Alternate: IR XHP405 airend warranty.

  • Page 63: Speed And Pressure Regulation Adjustment

    Lubrication Operation & Maintenance Manual 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. Throttle Arm B. Adjusting Screw C. Engine Governor D. Separator Tank E.

  • Page 64: Torque Setting Table

    Operation & Maintenance Manual Lubrication Torque Setting Table Book 22482517 (7-09) Rev A...

  • Page 65: Torque Setting Table

    Lubrication Operation & Maintenance Manual Torque Setting Table Book 22482517 (7-09) Rev A...

  • Page 66: Fault Finding

    Operation & Maintenance Manual Lubrication Fault Finding FAULT CAUSE REMEDY Batteries not connect batteries. No reaction from connected. instrument panel when key turned Fuse at starter motor Replace fuse. to (I) position. ‘blown’. Low battery charge. Check the fan belt tension, battery and cable connections.
  • Page 67 Lubrication Operation & Maintenance Manual FAULT CAUSE REMEDY Electrical fault. Test the electrical circuits. Low engine oil Check the oil level and oil filter(s). pressure. Safety shut-down Check the safety shut-down switches. system in operation. Engine starts but Fuel starvation. Check the fuel level and fuel system components.
  • Page 68 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2009 Doosan Infracore International, Inc. Printed in the USA...

This manual is also suitable for:

Doosan xp750wcu-t2Doosan xp825wcu-t2Hp675wcuHp750wcuXp750wcuXp825wcu

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