Ingersoll-Rand Doosan P600WJD T3 Operation & Maintenance Manual
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Ingersoll-Rand Doosan P600WJD T3 Operation & Maintenance Manual

Ingersoll-Rand Doosan P600WJD T3 Operation & Maintenance Manual

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OPERATION, MAINTENANCE,
P600WJD T3
HP450WJD T3
VHP400WJD T3 (14/115) C56 (D20)
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: 23252059 (08-2010) Rev B
All manuals and user guides at all-guides.com
MANUAL
(7/170)
(10/125) C55 (D19)
COMPRESSOR MODELS
C54 (D18)

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  • Page 1 All manuals and user guides at all-guides.com OPERATION, MAINTENANCE, MANUAL P600WJD T3 (7/170) C54 (D18) HP450WJD T3 (10/125) C55 (D19) VHP400WJD T3 (14/115) C56 (D20) 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 1293 Glenway Drive Statesville, N.C.
  • Page 2 All manuals and user guides at all-guides.com...

  • Page 3: Table Of Contents

    All manuals and user guides at all-guides.com TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE FOREWORD ............9 Foreword.
  • Page 4 All manuals and user guides at all-guides.com TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE OPERATING INSTRUCTIONS ..........43 Operating Instructions .
  • Page 5 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE SERVICE TOOLS ............111 Service Tools .
  • Page 7 All manuals and user guides at all-guides.com TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE...
  • Page 8 All manuals and user guides at all-guides.com...

  • Page 9: Foreword

    All manuals and user guides at all-guides.com Foreword Book: 23252059 (08-2010) Rev B...

  • Page 10: Foreword

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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.
  • Page 12 All manuals and user guides at all-guides.com Book: 23252059 (08-2010) Rev B...

  • Page 13: Decals

    All manuals and user guides at all-guides.com Decals Book: 23252059 (08-2010) Rev B...

  • Page 14: Decals

    All manuals and user guides at all-guides.com 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: 23252059 (08-2010) Rev B...
  • Page 15 All manuals and user guides at all-guides.com Decals Operating & Maintenance Manual Book: 23252059 (08-2010) Rev B...
  • Page 16 All manuals and user guides at all-guides.com Operating & Maintenance Manual Decals Book: 23252059 (08-2010) Rev B...
  • Page 17 All manuals and user guides at all-guides.com Decals Operating & Maintenance Manual Book: 23252059 (08-2010) Rev B...
  • Page 18 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com Decals Operating & Maintenance Manual Book: 23252059 (08-2010) Rev B...
  • Page 20 All manuals and user guides at all-guides.com Operating & Maintenance Manual Decals Book: 23252059 (08-2010) Rev B...
  • Page 21 All manuals and user guides at all-guides.com 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...
  • Page 22 All manuals and user guides at all-guides.com 22442578...

  • Page 23: Noise Emission

    All manuals and user guides at all-guides.com Noise Emission Book: 23252059 (08-2010) Rev B...

  • Page 24: Noise Emission Control Maintenance Log

    All manuals and user guides at all-guides.com 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:__________ __________________________________...

  • Page 25: Introduction

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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: 23252059 (08-2010) Rev B...
  • Page 28 All manuals and user guides at all-guides.com 22442578...

  • Page 29: Safety

    All manuals and user guides at all-guides.com Safety Book: 23252059 (08-2010) Rev B...

  • Page 30: Safety

    All manuals and user guides at all-guides.com 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.

  • Page 31: Compressed Air

    All manuals and user guides at all-guides.com 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...

  • Page 32: Materials

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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.
  • Page 34 All manuals and user guides at all-guides.com 22442578...

  • Page 35: General Arrangement

    All manuals and user guides at all-guides.com General Arrangement Book: 23252059 (08-2010) Rev B...

  • Page 36: General Arrangement

    All manuals and user guides at all-guides.com 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 &...
  • Page 37 All manuals and user guides at all-guides.com 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 &...

  • Page 38: Compressor

    All manuals and user guides at all-guides.com Operating & Maintenance Manual General Arrangement Compressor COMPRESSOR Actual free air delivery. (7/170) (P600WJD) 17, 0 m (600 CFM) Actual free air delivery. (10/125) (HP450WJD) 12, 5 m (450 CFM) Actual free air delivery. (14/115) (VHP400WJD) 11, 0m (400 CFM) Normal operating discharge pressure.
  • Page 39 All manuals and user guides at all-guides.com 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.

  • Page 40: Lubricating Oil Specification

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com General Arrangement Operating & Maintenance Manual Engine ENGINE P600WJD(7/120) HP450WJD (10/125), VHP400WJD (14/115) Type/model. Ingersoll Rand Number of cylinders. Oil capacity. 32.5 litres (8.6 GAL) 2200 revs min Speed at full load. min (RPM) Speed at idle.
  • Page 42 All manuals and user guides at all-guides.com 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.).

  • Page 43: Operating Instructions

    All manuals and user guides at all-guides.com Operating Instructions Book: 23252059 (08-2010) Rev B...

  • Page 44: Operating Instructions

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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:- •...

  • Page 46: Control Panel

    All manuals and user guides at all-guides.com 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.
  • Page 47 All manuals and user guides at all-guides.com 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.
  • Page 48 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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.
  • Page 50 All manuals and user guides at all-guides.com 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.
  • Page 51 All manuals and user guides at all-guides.com 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...

  • Page 52: Starting The Machine

    All manuals and user guides at all-guides.com 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. •...

  • Page 53: Push After Warm Up

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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.

  • Page 56: Bio-Diesel Fuel

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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: •...

  • Page 59: Supplemental Coolant Additives

    All manuals and user guides at all-guides.com 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.

  • Page 60: Operating In Warm Temperature Climates

    All manuals and user guides at all-guides.com 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.

  • Page 61: Lubrication

    All manuals and user guides at all-guides.com Lubrication Book: 23252059 (08-2010) Rev B...

  • Page 62: Lubrication

    All manuals and user guides at all-guides.com 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...

  • Page 63: Lubrication & Maintenance/Daily

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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.

  • Page 65: Cleaning Crankcase Vent Tube

    All manuals and user guides at all-guides.com 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)

    All manuals and user guides at all-guides.com 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.

  • Page 67: Checking Engine Electrical Ground Connections

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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.

  • Page 69: At Fuel Injection Pump

    All manuals and user guides at all-guides.com 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).

  • Page 70: Troubleshooting

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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.
  • Page 72 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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.
  • Page 74 All manuals and user guides at all-guides.com 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.
  • Page 75 All manuals and user guides at all-guides.com 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.

  • Page 76: Displaying Of Diagnostic Trouble Codes (Dtcs)

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com Lubrication Operating & Maintenance Manual Possible causes of intermittent faults: • Faulty connection between sensor and actuator harness. • Faulty contact between terminals in connector. • Faulty terminal/WJDe 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

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com Lubrication Operating & Maintenance Manual Specifications General Engine Specifications. ITEM 6IRF8TE Number of Cylinders Bore 106 mm (4.19 in.) Stroke 127 mm (5.0 in.) Displacement 6.8 L (414 cu in.) Compression Ratio 17.0:1 Aspiration Turbocharged Engine Firing Order...

  • Page 80: Engine Crankcase Oil Fill Quantities

    All manuals and user guides at all-guides.com Operating & Maintenance Manual Lubrication ITEM 6IRF8TE Length 1116 mm (43.9 in.) Width 623 mm (24.5 in.) Height 1012 mm (39.9 in.) Weight 587 kg (1290 Ib) Engine Crankcase Oil Fill Quantities Crankcase Oil Capacity L (qt) 19.5 (20.6) 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

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com Book: 23252059 (08-2010) Rev B...

  • Page 83: Maintenance

    All manuals and user guides at all-guides.com Maintenance Book: 23252059 (08-2010) Rev B...

  • Page 84: Maintenance

    All manuals and user guides at all-guides.com 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...
  • Page 85 All manuals and user guides at all-guides.com 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.
  • Page 86 All manuals and user guides at all-guides.com 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.
  • Page 87 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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...

  • Page 89: Routine Maintenance

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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.

  • Page 91: Productive Shutdown System

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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.

  • Page 93: Compressor Oil Separator Element

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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.

  • Page 96: Fuel System

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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...

  • Page 98: Lubrication

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com Maintenance Operating & Maintenance Manual Book: 23252059 (08-2010) Rev B...
  • Page 102 All manuals and user guides at all-guides.com Operating & Maintenance Manual Maintenance Book: 23252059 (08-2010) Rev B...
  • Page 103 All manuals and user guides at all-guides.com 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.
  • Page 104 All manuals and user guides at all-guides.com 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.

  • Page 105: Machine Systems

    All manuals and user guides at all-guides.com Machine Systems Book: 23252059 (08-2010) Rev B...

  • Page 106: Machine Systems

    All manuals and user guides at all-guides.com 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...
  • Page 107 All manuals and user guides at all-guides.com Machine Systems Operating & Maintenance Manual POUT4 Engine fault lamp Spare POUT5 Start relay Spare POUT6 Spare Switch, start POUT7 Hour meter Transducer exitation POUT8 Spare WCON Wedge controller Book: 23252059 (08-2010) Rev B...

  • Page 108: Wedge To Engine Interface - Ir Engine

    All manuals and user guides at all-guides.com Operating & Maintenance Manual Machine Systems Wedge to Engine Interface - Engine Harness System Schematic Book: 23252059 (08-2010) Rev B...

  • Page 109: J1939 Can Communications Schematic

    All manuals and user guides at all-guides.com Machine Systems Operating & Maintenance Manual J1939 CAN Communications Schematic Book: 23252059 (08-2010) Rev B...
  • Page 110 All manuals and user guides at all-guides.com Operating & Maintenance Manual Machine Systems Book: 23252059 (08-2010) Rev B...

  • Page 111: Service Tools

    All manuals and user guides at all-guides.com Service Tools Book: 23252059 (08-2010) Rev B...

  • Page 112: Service Tools

    All manuals and user guides at all-guides.com 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...
  • Page 113 All manuals and user guides at all-guides.com 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...

  • Page 114: Service Tools

    All manuals and user guides at all-guides.com Operating & Maintenance Manual Service Tools Service Tools Tool No Tool Description Tool Illustration Digital multimeter Available Fluke 87 from electrical and electronic parts distributors Weather-Pack Terminal 54729660 Removal Tool Deutsch Terminal Removal 54699632 Tool (Blue) Deutsch Terminal Removal...
  • Page 115 All manuals and user guides at all-guides.com 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: 23252059 (08-2010) Rev B...

  • Page 116: Electrical Parts

    All manuals and user guides at all-guides.com 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...

  • Page 117: Fault Finding

    All manuals and user guides at all-guides.com Fault Finding Book: 23252059 (08-2010) Rev B...

  • Page 118: Fault Finding

    All manuals and user guides at all-guides.com 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.
  • Page 119 All manuals and user guides at all-guides.com 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.
  • Page 120 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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.
  • Page 122 All manuals and user guides at all-guides.com...

  • Page 123: Options

    All manuals and user guides at all-guides.com Options Book: 23252059 (08-2010) Rev B...

  • Page 124: Options

    All manuals and user guides at all-guides.com Operating & Maintenance Manual Options 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: Prior To Starting

    All manuals and user guides at all-guides.com Options Operating & Maintenance Manual 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 No oil flow. Incorrect connection Reverse the nylon tube connections to the...

  • Page 126: Options - Iq System

    All manuals and user guides at all-guides.com Operating & Maintenance Manual Options Options - IQ System Safety CAUTION The compressor regulation system is adjusted to maintain regulated pressure at the separator tank. DO NOT adjust regulation to provide full regulation pressure at the service valve when the IQ system is enabled. This will result in operation at excessive horsepower levels, causing overheating, reduced engine life, and reduced airend life.

  • Page 127: Operating Instructions

    All manuals and user guides at all-guides.com Options Operating & Maintenance Manual NOTICE Do not operate at temperatures less that 2º C (35º F) unless equipped with low ambient IQ option. Operating Instructions Starting and use: Select desired air type using diverter valve and start machine normally. Using diverter valve, toggle between standard air and IQ air as required.

  • Page 128: Maintenance

    All manuals and user guides at all-guides.com Operating & Maintenance Manual Options Maintenance Daily maintenance: Verify, during full-load (maximum compressed air delivery) that the IQ system filter restriction indicators do not show excessive restriction. Restriction indicators for primary and secondary filters are located on the filter heads. If so equipped, an automatic restriction indicator is located behind the filter mounting bracket and will shut down the compressor if restriction exceeds recommended values.
  • Page 129 All manuals and user guides at all-guides.com Revision History   Rev. EC Number Comments Original release Edits Changed Model from WIR to WJD SVC31262...
  • Page 130 All manuals and user guides at all-guides.com 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 hp450wjd t3Doosan vhp400wjd t3

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