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Ingersoll-Rand HP1300WCU Operating, Maintenance & Parts Manual
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Ingersoll-Rand HP1300WCU Operating, Maintenance & Parts Manual

Ingersoll-Rand HP1300WCU Operating, Maintenance & Parts Manual

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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. 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.
Portable Power
P.O. Box 868 - - 501 Sanford Ave
Mocksville, N.C. 27028
Book 54757919 (5/02)
OPERATING, MAINTENANCE,
COMPRESSOR MODELS
HP1300WCU
Code: C
Revised (10-12)
PARTS MANUAL
HP1600WCU
Code:
( )
1

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Summary of Contents for Ingersoll-Rand HP1300WCU

  • Page 1 This manual must be available to the personnel who operate and maintain this machine. 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...
  • Page 2 QUALITY POLICY We will supply products and 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 California to cause cancer, birth defects, and other reproductive harm.
  • Page 3 Foreword Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European common market 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.
  • Page 4 Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European common market 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.
  • Page 5 Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll--Rand products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such products, which are available upon request.
  • Page 6 Your Ingersoll--Rand dealer will assist with setup and initial startup of the compressor. He will also provide brief operating and service instructions and will insure that a copy of this manual is included with the machine. Before starting the compressor, this manual and instructions should be carefully read to obtain a thorough knowledge of the duties to be performed.
  • Page 7 TABLE OF CONTENTS SECTION 1 ....SAFETY SECTION 2 ....WARRANTY/REGISTRATION SECTION 3 .
  • Page 8 SECTION 1- - SAFETY SAFETY PRECAUTIONS Compressed air must not be used for a feed to any form of breathing apparatus or mask. General Information The discharged air contains a very small percentage Ensure that the operator reads and understands the of compressor lubricating oil and care should be taken decals and consults the manuals before maintenance to ensure that downstream equipment is compatible.
  • Page 9 This machine may include such materials as oil, diesel Use care to avoid contacting hot surfaces (engine fuel, antifreeze, brake fluid, oil/air filters and batteries exhaust manifold and piping, air receiver and air which may require proper disposal when performing discharge piping, etc.).
  • Page 10 SAFETY LABELS Look for these signs on machines shipped to international markets outside 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 supervisor. Hot Surface Corrosion risk Lifting point...
  • Page 11 Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken. WARNING - - Maintain correct tire pressure. (Refer to the GENERAL INFORMATION section of this manual). WARNING: Consult the operation and maintenance manual before performing any maintenance. Rough Service Designation Wet Location Operation Do not stack...
  • Page 12 Oil Drain km/h WARNING undertake Do not exceed the speed limit. maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved. Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken Do not remove the Operating and Maintenance manual and manual holder from this machine.
  • Page 13 Look for these signs on machines shipped to markets 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 supervisor. Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored.
  • Page 14 km/h WARNING WARNING Improper operation of this equipment. Collapsing jackstand. Can cause serious injury or death. Can cause serious injury. Read Operator’s Manual supplied with this machine before operation or Insert locking pin completely. servicing. Excessive towing speed. Modification or alteration of this machine. Can cause serious injury or death.
  • Page 15 CAUTION WARNING DO NOT USE ETHER. High pressure air. Can cause serious ENGINE DAMAGE WILL OCCUR. injury or death. This engine is equipped with an Relieve pressure before electric heater starting aid. removing filler plugs/caps, fittings or covers. NOTICE USE DIESEL COOLANT FILL INSTRUCTIONS Adding: Do NOT remove radiator cap.
  • Page 16 SECTION 2 - - Warranty Ingersoll--Rand, through its distributor, warrants that each item of equipment manufactured by it and delivered hereunder to the initial user will be free of defects in material and workmanship for a period of three (3) months from initial operation or six (6) months from the date of shipment to the initial user, whichever occurs first.
  • Page 17 Ingersoll- -Rand Platinum Drive Train Warranty (Optional) – Platinum drive train pertains to the Ingersoll-- Rand Engine and Airend combination. The earlier of sixty (60) months from shipment to, or the accumulation of 10,000 hours of service. The starter, alternator, fuel injection system and all electrical components are ex- cluded from the extended warranty.
  • Page 18 GENERAL WARRANTY INFORMATION GENERAL WARRANTY Extended Coverage Portable Compressor Package 1 year/2000 hrs Airend 2 yrs/4000 hrs 5 yrs/10,000 hrs Limited warranty, major components (refer to operator’s manual). Portable Genset 8kW, 11KW, Package 1 yr/2000 hrs None 20KVA thru 575KVA Generator 2 yrs/4000 hrs None...
  • Page 19 WARRANTY REGISTRATION Complete Machine Registration Machines shipped to locations within the United States do not require a warranty registration unless the machine status changes (i.e. change of ownership). Machines shipped outside the United States require notification be made to initiate the machine warranty.
  • Page 20 WARRANTY REGISTRATION Selling Distributor Servicing Distributor Name Name Owner/User Name Address Address Address City City City County County County State State State Zip Code Zip Code Zip Code Telephone Telephone Telephone Complete the Applicable Blocks Owner/User Type of Business (check one only) Construction--Heavy Asphalt Contractor Coal Mining...
  • Page 21 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Book 54757919 (5/02)
  • Page 22 HP1600WCU ......HP1300WCU Air Delivery -- cfm (litres/sec) ....
  • Page 23 SECTION 4 - - OPERATING INSTRUCTIONS High Engine Coolant Temp: Fault indicator lamp. Indicates shutdown due to high engine water temperature. E STOP Restricted IQ Air Filters: Fault indicator Control Panel lamp. Indicates shutdown due to high Pon IQ air filters (if equipped). Low Fuel Level: Fault indicator lamp.
  • Page 24 SETTING UP (ALL UNITS) WARNING Place the unit in an open, well--ventilated area. Posi- Do not climb on top of unit. tion as level as possible. The design of these units LIFTING UNIT permits a maximum 15 degree limit on out--of--level Central Lifting Bail operation.
  • Page 25 WARNING WARNING Combustible gas can cause severe burns, blindness or death. Keep sparks and open flame Do not connect the air discharge on this unit away from battery. onto a common header with any other unit of any description, or any other source of compressed air, without first making sure a check- -valve is Check the compressor lubricating oil level.
  • Page 26 NOTICE: If the appropriate mixture of antifreeze is not used during freezing temperatures, failure to STARTING - - drain the engine may cause costly engine damage. NOTICE Never use water only as corrosion inhibitors are required in engine coolant fluid. This unit is equipped with a battery disconnect switch which removes power from the machine controller for long term storage.
  • Page 27 CAUTION Operation -- Unloaded Ether is an extremely volatile, high flammable If there is no air demand at 1200 RPM (Pressure rises gas. Use Sparingly! If too much is injected, the above the unload point prssure), the compressor will uncontrolled explosion may result in costly unload by closing the inlet valve.
  • Page 28 IQ System IQ SYSTEM OPERATION TO AFTERCOOLER The IQ System is a complete, self--contained system AFTER-- COOLER which provides cooler, cleaner air than from a standard portable compressor. The system utilizes an integral aftercooler, high--efficiency filtration, and a patented condensate disposal system to provide the cool, clean air.
  • Page 29 CAUTION Excessively restricted filter elements may cause CAUTION an increase in the amount of aerosol water and oil carryover, which could result in damage to down- stream equipment. Normal service intervals The compressor regulation system is adjusted to should not be exceeded. maintain regulated pressure at the separator tank.
  • Page 30 Filter Replacement S With engine stopped, ensure pressure is relieved S Put a small amount of petroleum jelly or other from air system. non--synthetic grease on the element o--ring to aid installation into the filter head. S Remove all wires and hoses connected to drains on bottom of each filter housing.
  • Page 31 Pressure Regulation Insure that pressure is maintained at rated pressure, then turn regulator adjustment screw (H) counterclockwise until engine speed just begins to be reduced. Note: Turning regulator adjustment screw (H) clockwise will raise pressure at full speed. Close service valve (engine will slow to no load or idle speed).
  • Page 32 SECTION 5 - - MAINTENANCE GENERAL COMPRESSOR OIL LEVEL In addition to periodic inspections, many of the The oil level is most consistent when the unit is components in these units require periodic servicing running unloaded and should be checked at this to provide maximum output and performance.
  • Page 33 Bare Airend -- Pertains to major airend parts (rotors, Wipe inside of air cleaner housing with a housings, and bearings). clean, damp cloth to remove any dirt accumulation, especially in the area where the element seals against the housing. Airend Components Pertains to auxiliary attachments to the bare airend (drive coupling, seals, pumps, valves, tubes, hoses, fittings and filter...
  • Page 34 Every six months the drain plugs should be removed The engine cooling system is filled at the factory with from the tanks so that any sediment or accumulated a 50/50 mixture of water and ethylene glycol. This condensate may be drained. When replacing the permanent type antifreeze contains rust inhibitors drain plugs, make sure they are tightened securely.
  • Page 35 ENGINE CRANKCASE VAPOR CONDENSATE NOTICE The engine is equipped with a system to collect engine crankcase vapor condensate (oil and water) Piping systems operating at less than 150 psi for disposal. Check the collection bottle near the (1050 kPa) may use a special nylon tubing. The engine oil pan before starting the unit.
  • Page 36 This bypass does not provide any filtration but does 5. Install new filter by turning element clockwise allow a maximum flow of compressor lubricating oil until gasket makes initial contact. Tighten an to preclude any possible damage from loss of oil. additional 1/2 to 3/4 turn.
  • Page 37 If the paint has faded or chalked, the use Apply any of Duponts Topcoat Finishes of a commercial grade, non- -abrasive car such as Imront or Centarit according wax may partially restore the color and to the label instructions. gloss. Note: To re- -topcoat the textured surfaces when sheet metal repairs are not necessary, follow steps 1, 2, 4, 5, 6, 8 and...
  • Page 38 MAINTENANCE SCHEDULE These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty or wet). Daily Weekly Monthly 3 MOS . 6 MOS. 12 MOS. SMALL UNITS (P100- -P600) 250 hours 500 hours 1000 hours LARGE UNITS (HP600- -P1600) 500 hours 1000 hours 2000 hours...
  • Page 39 SECTION 6 - - LUBRICATION GENERAL INFORMATION Lubrication is an essential part of preventive mainte- nance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some compo- If the unit has been operated for the time/ hours men- nents in the unit require more frequent lubrication than tioned above, it should be completely drained of oil.
  • Page 40 RATED OPERATING PRESSURE COMPRESSOR 350 PSI 100 - - 300 PSI 500 PSI 125_F LUBRICATION 50_C 40_C 104_F Portable Compressor Fluid Chart XHP505 XHP 1001 XHP1001 86_F 30_C Refer to these charts for correct compressor 65_F 20_C fluid required. Note that the selection of fluid is PER FORMANCE PRO- -TECt dependent on the design operating pressure...
  • Page 41 SECTION 7 - - Trouble Shooting INTRODUCTION B. Do The Simplest Things First Trouble shooting for a portable air compressor Most troubles are simple and easily corrected. is an organized study of a particular problem or example, most complaints are “low capacity” which may series of problems and a planned method of be caused by too low an engine speed or “compressor procedure for investigation and correction.
  • Page 42 A list of compressor and engine faults is attached with General Information the placards inside the machine control panel and pro- vided in this section. The table of Alert/Sutdown condi- tions in this section also lists the compressor fault The WEDGE controller records and displays diagnos- codes and a list of the engine fault codes is provided.
  • Page 43 FAULT CODE DESCRIPTION SAE J1939 Multiplexing PGN Timeout Error SAE J1939 Multiplexing Configuration Error SAE J1939 Multiplexing Remote Throttle Error Ambient Air Pressure Sensor Circuit -- Data Incorrect Engine Shutdown Commanded By J1939 Injector Solenoid Valve Cylinder #1 Circuit Grounded Circuit Injector Solenoid Valve Cylinder #5 Circuit Grounded Circuit Injector Solenoid Valve Cylinder #3 Circuit Grounded Circuit Injector Solenoid Valve Cylinder #6 Circuit Grounded Circuit...
  • Page 44 FAULT CODE DESCRIPTION Injector Metering Rail #2 Pressure Low -- Warning Engine Speed/Position Sensor #2 (Camshaft) Supply Voltage Fuel Delivery Pressure Sensor Circuit -- Shorted High Fuel Delivery Pressure Sensor Circuit -- Shorted Low Injector Metering Rail #1 Pressure High -- Warning Fuel Supply Pump Inlet Pressure Sensor Circuit -- Shorted High Fuel Supply Pump Inlet Pressure Sensor Circuit -- Shorted Low Fuel Supply Pump Inlet Pressure Low -- Warning Level...
  • Page 45 ALERT/SHUTDOWN CONDITIONS Software V1.10 ALERT SHUTDOWN LIGHT CODE LIGHT DELAY CODE (sec) (BLINKS) (STEADY) Low Engine Speed (RPM<800) CPRSR Malf. High Engine Speed (RPM >1900) CPRSR Malf. Engine Crank Time Exceeded CPRSR Malf. Low Fuel Level Fuel Level Fuel Level Engine Oil Temperature >...
  • Page 46 TROUBLE SHOOTING CHART Bold Headings depict the COMPLAINT - - Subheadings suggest the CAUSE Note: Subheadings suggest sequence to follow troubleshooting. Corrective Action Unit Shutdown: Out of Fuel Add CLEAN diesel Fuel Compressor Oil Temp. Too High See Complaint 10 Engine Water Temp.
  • Page 47 Corrective Action Low Engine Oil Pressure Low Oil Level Add oil. Out of Level >15 degrees Relocate or reposition. Wrong Lube Oil See Engine Oil Spec. Change oil. Clogged Oil Filter Element(s) Replace element(s). Engine Malfunctioning See Trouble Shooting in Engine Manual. Loose Wire Connection.
  • Page 48 Corrective Action Excessive Vibration: Rubber Mounts, Loose or Damaged Tighten or replace. Defective Fan Replace fan. Drive Coupling Defective Replace coupling. Engine Malfunctioning See Trouble Shooting in Engine Manual. Airend Malfunctioning See Complaint 15 and 17. Engine idle speed too low. See Engine Manual.
  • Page 49 SECTION 8 - - ELECTRICAL GENERAL INFORMATION AND OPERATIONAL THEORY Software versions under 2.0 use the frequency throttle to communicate with the engine. A square wave fre- General quency signal from 150 Hz to 375 Hz is sent from the The HP1600/1300 machine has an electronic monitor WEDGE controller to the engine controller.
  • Page 50 Controller Outputs: Figure 8--2 shows the connections between the The WEDGE controller has three different types of out- WEDGE controller and the engine controller. puts: frequency, pulse width modulated (PWM) and 24 VDC digital (ON / OFF). The frequency output is used J1939 Data Link -- The CAN network is a single pair as a throttle signal for the engine (software versions shielded cable within the W1 main harness.
  • Page 51 Book 54757919 (5/02)
  • Page 52 Book 54757919 (5/02)
  • Page 53 Book 54757919 (5/02)
  • Page 54 KEY ELECTRICAL COMPONENTS FUNCTION PT1: PT1 is a 0--225 psi gauge pressure transducer that measures discharge air pressure. PT2: PT2 is a 0--100 psi gauge pressure transducer that measures regulation system pressure. U1 is resistive level detector that measures the fuel level in the fuel tank. It provides a continuous reading of fuel level.
  • Page 55 ELECTRICAL PARTS LIST Ref Designator Description Part Number IQ Wiring Harness 54757224 Coolant Level Switch 54474572 Battery Disconnect Switch 36896975 0--225 psi pressure transducer 54496973 0--100 psi Pressure Transducer 36920825 Relay, 24VDC SPDT 36892362 Mag Speed Sensor 36785319 Thermistor Temperature Sensor 36898922 Start / Run Solenoid Valve 36842300...
  • Page 56 TROUBLE SHOOTING FLOW CHART Check F1 fuse Control panel key is turned to “ON” position, Check operation of switch S1 WEDGE controller annunciator lamps and 4 Check wiring from S1 to WEDGE controller digit LED display do not come on Check battery voltage, ensure battery dis- connect switch is turned ON J1939 CAN communications not working –...
  • Page 57 Replace this sheet with 11 x 17 System Schematic Sheet 1 of 5 Book 54757919 (5/02)
  • Page 58 Replace this sheet with 11 x 17 System Schematic Sheet 2 of 5 Book 54757919 (5/02)
  • Page 59 Replace this sheet with 11 x 17 System Schematic Sheet 3 of 5 Book 54757919 (5/02)
  • Page 60 Replace this sheet with 11 x 17 System Schematic Sheet 4 of 5 Book 54757919 (5/02)
  • Page 61 Replace this sheet with 11 x 17 System Schematic Sheet 5 of 5 Book 54757919 (5/02)
  • Page 62 ALERT/SHUTDOWN CONDITIONS Software V1.01 ALERT SHUTDOWN LIGHT CODE LIGHT DELAY CODE (sec) (BLINKS) (STEADY) Low Engine Speed (RPM<800) CPRSR Malf. High Engine Speed (RPM >1900) CPRSR Malf. Engine Crank Time Exceeded CPRSR Malf. Low Fuel Level Fuel Level Fuel Level Engine Oil Temperature >...
  • Page 63 ALERT/SHUTDOWN CONDITIONS Software V1.22 ALERT SHUTDOWN LIGHT CODE LIGHT DELAY CODE (sec) (BLINKS) (STEADY) Low Engine Speed < 1000 RPM CPRSR Malf. High Engine Speed >1900 RPM CPRSR Malf. Engine Crank Time Exceeded CPRSR Malf. Engine Oil Temperature > 252 deg. F CPRSR Malf.
  • Page 64 FAULT CODES FOR QSX15 CUMMINS ENGINE Fault Code Description Engine Control Module -- Critical Internal Failure Engine Speed/Position Sensor Circuit -- Lost both signals from Magnetic Pickup Sensor Engine Speed/Position Sensor Circuit -- Lost One of Two Signals From the Magnetic Pickup Sensor Intake Manifold Pressure Sensor #1 Circuit -- Shorted High Intake Manifold Pressure Sensor #1 Circuit -- Shorted Low Engine Oil Pressure Sensor Circuit -- Shorted High...
  • Page 65 Engine Speed High -- Critical Engine Coolant Level Low -- Critical Vehicle Speed Sensor Circuit -- Data Incorrect Fan Clutch Circuit -- Shorted Low Fuel Shutoff Valve Circuit -- Shorted Low Fuel Shutoff Valve Circuit -- Shorted High Fuel Shutoff Valve -- Stuck Open Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit -- Shorted Low SAE J1939 Multiplexing PGN Timeout Error SAE J1939 Multiplexing Configuration Error...
  • Page 66 Timing Actuator #2 Circuit -- Open Circuit Timing Actuator #2 Circuit -- Grounded Circuit Engine Oil Pressure Low -- Critical Water In Fuel Indicator High -- Maintenance Engine Coolant Level Sensor Circuit -- Data Incorrect SAE J1939 Datalink -- Cannot Transmit Water In Fuel Sensor Circuit -- Shorted High Water In Fuel Sensor Circuit -- Shorted Low Intake Manifold Pressure Sensor Circuit -- Data Incorrect...
  • Page 67 Turbocharger #1 Speed High -- Warning Level Electrical Charging System Voltage High -- Warning Level Electrical Charging System Voltage Low -- Warning Level Electrical Charging System Voltage Low -- Critical Level Engine Hot Shutdown Engine Speed/Position #2 Cam Sync Error Injector Metering Rail #1 Pressure Malfunction Injector Metering Rail #2 Pressure Malfunction Cylinder Power Imbalance Between Cylinders...
  • Page 68 SECTION 10 - - PARTS ORDERING A series of illustrations show each part distinctly and in GENERAL location relative to the other parts in the assembly. The part number, the description of the part and the This publication, which contains an illustrated parts quantity of parts required are shown on each breakdown, has been prepared as an aid in locating...
  • Page 69 MARKINGS AND DECALS Always specify the number of the parts list pub- lication. NOTICE Always specify the quantity of parts required. Do not paint over safety warnings or instructional decals. If safety warning decals become illegible, Always specify the part number, as well as the immediately order replacements from the factory.
  • Page 70 Warranty: The Company warrants that parts ages arising out of this order or any breach thereof, or manufactured by it will be as specified and will be free any defect in, or failure of, or malfunction of the parts from defects in materials and workmanship. The hereunder, whether based upon loss of use, lost prof- Company’s liability under this warranty shall be limited its or revenue, interest, lost goodwill, work stoppage,...
  • Page 71 VIKING ELECTRICAL COMPONENTS I- -R Part Number Quantity per Mach Description 54757224 IQ Wiring Harness 54474572 Coolant Level Switch 36896975 Battery Disconnect Switch 54765946 0--500 psi Pressure Transducer 36920825 0--100 psi Pressure Transducer 36892362 24V Sealed Relay 36785319 Mag Speed Sensor 36898922 Thermistor Temperature Probe 36842300...
  • Page 72 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...
  • Page 73 SERVICE TOOLS Tool No. Tool Description Tool Illustration Fluke 87 Digital Multimeter Available 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 Terminal Removal Tool (Yellow) DT--RT1 Crimp Tool for Deutsch Pins Crimp Available from:...
  • Page 74 54729710 Electrical Contact Cleaner 54729728 PDA Service Tool 54699616 Deutsch Terminal Removal Tool 22073886 Packard Crimp Tool 22073878 Thermistor Simulator 54749635 Connector Repair Kit Book 54757919 (5/02)
  • Page 75 54699657 Deutsch Terminal Removal Tool 54749643 Packard Metri- -Pack Removal Tool Book 54757919 (5/02)

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