OPERATION, MAINTENANCE MANUAL...OPERATION, MAINTENANCE COMPRESSOR MODELS HP675WCU-T3 (B74) MANUAL...

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Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com Book: 22826226 (4-09) Rev A 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. OPERATION, MAINTENANCE COMPRESSOR MODELS HP675WCU-T3 (B74) MANUAL HP750WCU-T3 (B76) XP750WCU-T3 (B75) XP825WCU-T3 (B77)

Transcript of OPERATION, MAINTENANCE MANUAL...OPERATION, MAINTENANCE COMPRESSOR MODELS HP675WCU-T3 (B74) MANUAL...

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Doosan Infracore Portable Power 1293 Glenway DriveStatesville, N.C. 28625www.doosanportablepower.com

Book: 22826226 (4-09) Rev A

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.

OPERATION, MAINTENANCE

COMPRESSOR MODELS

HP675WCU-T3 (B74)

MANUAL

HP750WCU-T3 (B76) XP750WCU-T3 (B75)XP825WCU-T3 (B77)

Doosan
Disclaimer
Doosan
DATE OCTOBER
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TABLE OF CONTENTSOperation & Maintenance Manual

TITLE PAGEFOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Safety chains/connections and their adjustment where fitted: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Graphic Form and Meaning of ISO Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Compressor Noise Emission Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Noise Emission Control Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

A. Compressed Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28B. Safety and Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28C. Acoustic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28D. Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29E. Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29F. Air Intake and Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29G. Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29H. Isolation Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29I. Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29J. Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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TITLE PAGECompressor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Prior to Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Wedge Diagnostic Display Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Engine Codes: Cummins Engine Model QSC8.3, QSL9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Starting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Push After Warm Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Dual Pressure Regulation When Fitted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Emergency Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Re-Starting After an Emergency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Monitoring During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56ROUTINE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Prior to attempting any maintenance work, ensure that:- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Prior to opening or removing panels or covers to work inside a machine, ensure that:- . . . . . . . . . 60Prior to attempting any maintenance work on a running machine, ensure that:- . . . . . . . . . . . . . . . 60

PROTECTIVE SHUTDOWN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Low engine fuel level switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

SCAVENGE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61COMPRESSOR OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

COMPRESSOR OIL SEPARATOR ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

COMPRESSOR OIL COOLER AND ENGINE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63AIR FILTER ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

VENTILATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65COOLING FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65FUEL FILTER WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65CHARGE AIR COOLER PIPEWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66PRESSURE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66RUNNING GEAR/WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67ENGINE LUBRICATING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67COMPRESSOR LUBRICATING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67RUNNING GEAR WHEEL BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68PRESSURE REGULATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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TITLE PAGELUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

FAULT FINDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

MACHINE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Electrical Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94WEDGE Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Sensors and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Controller Outputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Electronic Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98IQ System Operating Instructions - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

IQ System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99IQ System Operating Instructions - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Low Ambient Option Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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6

**Always use Ingersoll-Rand Replacement parts!**

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Foreword

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Operation & Maintenance Manual Foreword

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ForewordThe 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. 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.

This manual contains instructions and technical data to cover all routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be referred to an authorized Portable Power Service department.

All components, accessories, pipes and connectors added to the compressed air system should be:

• of good quality, procured from a reputable manufacturer and, wherever possible, beof a type approved by Portable Power.

• clearly rated for a pressure at least equal to the machine maximum allowable workingpressure.

• compatible with the compressor lubricant/coolant.

• accompanied with instructions for safe installation, operation and maintenance.

Details of approved equipment are available from the Portable Power Service departments. The use of repair parts other than those included within the approved parts list may create hazardous conditions over which Ingersoll-Rand has no control. Therefore, Portable Power cannot be held responsible for equipment in which non-approved repair parts are installed.

Portable Power reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.

The intended uses of this machine are outlined below and examples of unapproved usage are also given. However, Portable Power cannot anticipate every application or work situation that may arise. If in doubt, consult supervision.

This machine has been designed and supplied for above ground operation to be used for compression of normal ambient air containing no additional gases, vapors or particles within the ambient temperature range specified in the general data section of this manual.

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Foreword Operation & Maintenance Manual

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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 ofthis manual.

C. When an actual or foreseeable risk of hazardous levels of flammable gases orvapors exists.

D. With other than Portable Power approved components.

E. With guards, or controls or switches missing or disabled.

F. For storage or transportation of materials inside or on the enclosure.

This company accepts no responsibility for errors in translation of this manual from the original English version.

You as the customer are expected to provide certain service and maintenance items. Your Portable Power dealer will provide all other more detailed service and maintenance items on a special preventive maintenance schedule for each machine. It is very important that the minimum service and maintenance requirements explained in this manual be performed at the required intervals. Exceeding these intervals may reduce the reliability of the machine.

The purpose of this manual is to train the operator with functions, operation, and basic service and maintenance requirements of the compressor. During the preparation of this manual, every effort was made to ensure the adequacy and accuracy of the contents.

Your Portable Power 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. Please take pride in the compressor, keep it clean, and in good mechanical condition.

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**Always use Ingersoll-Rand Replacement Parts**

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Safety

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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.

Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

Make sure that all protective covers are in place and that the canopy/doors are closed during operation.

The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas. If such an application is required then all local regulations, codes of practice and site rules must be observed. To ensure that the machine can operate in a safe and reliable manner, additional equipment such as gas detection, exhaust spark arrestors, and intake (shut-off) valves may be required, dependent on local regulations or the degree of risk involved.

A weekly visual check must be made on all fasteners/fixing screws securing mechanical parts. In particular, safety-related parts such as coupling hitch, drawbar components, road-wheels, and lifting bail should be checked for total security.

All components which are loose, damaged or unserviceable, must be rectified without delay.

Air discharged from this machine may contain carbon monoxide or other contaminants which will cause serious injury or death. Do not breathe this air.

This machine produces loud noise with the doors open or service valve vented. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open or service valve is vented.

Never inspect or service unit without first disconnecting battery cable(s) to prevent accidental starting.

Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent debris from injuring eye(s).

Rotating fan blade can cause serious injury. Do not operate without guard in place.

Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.).

Ether is an extremely volatile, highly inflammable gas. When it is specified as a starting aid, use sparingly. DO NOT USE ETHER IF THE MACHINE HAS GLOW PLUGS OR INLET HEATER STARTING AIDS OR ENGINE DAMAGE WILL RESULT.

Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools,

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Safety Operation & Maintenance Manual

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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.

Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel.

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.

If more than one compressor is connected to one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidentally be pressurized or over pressurized by another.

Compressed air must not be used for a direct feed to any form of breathing apparatus or mask.

High Pressure Air can cause serious injury or death. Relieve pressure before removing filler plugs/caps, fittings or covers.

Air pressure can remain trapped in air supply line which can result in serious injury or death. Always carefully vent air supply line at tool or vent valve before performing any service.

The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible.

If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided.

When using compressed air, always use appropriate personal protective equipment.

All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions.

Avoid bodily contact with compressed air.

The safety valve located in the separator tank must be checked periodically for correct operation.

Whenever the machine is stopped, air will flow back into the compressor system from devices or systems downstream of the machine unless the service valve is closed. Install a check valve at the machine service valve to prevent reverse flow in the event of an unexpected shutdown when the service valve is open.

Disconnected air hoses whip and can cause serious injury or death. Always attach a safety flow restrictor to each hose at the source of supply or branch line in accordance with OSHA Regulation 29CFR Section 1926.302(b).

Never allow the unit to sit stopped with pressure in the receiver-separator system.

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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.

The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly:

• anti-freeze

• compressor lubricant

• engine lubricant

• preservative grease

• rust preventative

• diesel fuel

• battery electrolyte

WARNING!

Avoid ingestion, skin contact and inhalation of fumes

Should compressor lubricant come into contact with the eyes, then irrigate with water for at least 5 minutes.

Should compressor lubricant come into contact with the skin, then wash off immediately.

Consult a physician if large amounts of compressor lubricant are ingested.

Consult a physician if compressor lubricant is inhaled.

Never give fluids or induce vomiting if the patient is unconscious or having convulsions.

Safety data sheets for compressor and engine lubricants should be obtained from the lubricant supplier.

Do NOT start or operate this machine in a confined area. Avoid breathing exhaust fumes when working on or near the machine.

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Safety Operation & Maintenance Manual

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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. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water.

WARNING!

Do not attempt to slave start a frozen battery since this may cause it toexplode.

Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After starting unit, always disconnect cables in reverse order.

Radiator

Hot engine coolant and steam can cause injury. Ensure that the radiator filler cap is removed with due care and attention.

Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing pressure cap.

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Operation & Maintenance Manual Safety

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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.

Do not exceed gross vehicle weight rating.

Before towing the machine, ensure that:-

• the tires and towing hitch are in a serviceable condition.

• the canopy is secure.

• all ancillary equipment is stored in a safe and secure manner.

• the brakes and lights are functioning correctly and meet necessary road trafficrequirements.

• break-away cables/safety chains are connected to the towing vehicle.

The machine must be towed in a level attitude in order to maintain correct handling, braking and lighting functions. This can be achieved by correct selection and adjustment of the vehicle towing hitch and, on variable height running gear, adjustment of the drawbar.

1. Make sure wheels, tires and tow bar connectors are in safe operating conditionand tow bar is properly connected before towing.

2. When parking always use the handbrake and, if necessary, suitable wheelchocks.

Safety chains/connections and their adjustment where fitted:

Ensure that the breakaway cable is securely coupled to the trailer and also to a substantial point on the towing vehicle.

Ensure that the cable length is as short as possible, while still allowing enough slackness for the trailer to articulate without the handbrake being applied.

Loop the chains onto the towing vehicle using the towing vehicle hitch as an anchorage point, or any other point of similar strength.

Ensure that the effective chain length is as short as possible while still allowing normal articulation of the trailer and effective operation of the breakaway cable.

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Safety Operation & Maintenance Manual

Book 22826226 17

Decals

Graphic Form and Meaning of ISO Symbols

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Safety Operation & Maintenance Manual

Book 22826226 21

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

DANGER!

WARNING!

CAUTION!

NOTICE

Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored.

Indicates the presence of a hazard which CAN cause serious injury, death or property damage, if ignored.

Indicates the presence of a hazard which WILL or can cause injury or property damage, if ignored.

Indicates important set-up, operating or maintenance information.

(Red Background)

(Orange Background)

(Yellow Background)

(Blue Background)

understand, inform your supervisor.

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Safety Operation & Maintenance Manual

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24 Book 22826226

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Safety Operation & Maintenance Manual

Book 22826226 25

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. Submit orders for Safety Decals to the Statesville Parts Service Department. The no charge order should contain only Safety Decals.

Help promote product safety! Assure that decals are present on the machines. Replace decals that are not readable.

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Book 22826226 25

Noise Emission

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Operation & Maintenance Manual Noise Emission

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Noise EmissionThis 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; or (2) the use of the compressor after such device or element of design has been removed or rendered inoperative by any person.

Among those acts included in the prohibition against tampering are these:

1. Removal or rendering inoperative any of the following:

a. the engine exhaust system or parts thereofb. the air intake system or parts thereofc. enclosure or parts thereof

2. Removal of any of the following:

a. fan shroudb. vibration mountsc. sound absorption material

3. Operation of the compressor with any of the enclosure doors open.

Compressor Noise Emission Control Information

A. The removal or rendering inoperative, other than for the purpose ofmaintenance, repair, or replacement of any noise control device or element ofdesign incorporated into this compressor in compliance with the noise controlact;

B. The use of this compressor after such device or element of design has beenremoved or rendered inoperative.

NOTE: the above information applies only to units that are built incompliance with the U.S. Environmental Protection Agency.

Portable Power reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.

The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor.

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Book 22826226 27

Noise Emission Control Maintenance Log

The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations, specifically 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 new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the compressor after such device or element of design has been removed or rendered inoperative by any person.

Noise Emission WarrantyThe manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built and equipped to conform at the time of sale to the first retail purchaser, with all applicable U.S. EPA Noise Control Regulations.

This warranty is not limited to any particular part, component, or system of the air compressor. Defects in the design, assembly or in any part, component, or system of the compressor which, at the time of sale to the first retail purchaser, caused noise emissions to exceed Federal Standards are covered by this warranty for the life of air compressor.(40FR204.58-1)

COMPRESSOR MODEL_________________________

SERIAL NO. __________________________________

USER UNIT NO. _______________________________

UNIT IDENTIFICATION

Engine Make & Model:_________________

DEALER OR DISTRIBUTOR FROMWHOM PURCHASED:

Serial No.:__________________________ __________________________________

Purchaser or Owner:__________________ __________________________________

Address: ___________________________ Date Purchased:_____________________

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IntroductionThe 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. The Maintenance Schedule and detailed instructions on the maintenance items are given on following page.

Maintenance Schedule

A. Compressed Air Leaks

Correct all compressed air leaks during the first shutdown period after discovery. If severe enough to cause serious noise problems and efficiency loss, shut down immediately and correct the leak(s).

B. Safety and Control Systems

Repair or replace all safety and control systems or circuits as malfunction occurs. No compressor should be operated with either system bypassed, disabled, or nonfunctional.

C. Acoustic Materials

In daily inspections, observe these materials. Maintain all acoustic material as nearly as possible in its original condition. Repair or replace all sections that have: 1) sustained damage, 2) have partially separated from panels to which they were attached, 3) are missing, or have otherwise deteriorated due to severe operating or storage conditions.

ITEM AREA PERIOD

A. Compressed Air Leaks As Detected

B. Safety and Control Systems As Detected

C. Acoustic Materials Daily

D. Fasteners 100 hours

E. Enclosure Panels 100 hours

F. Air Intake & Engine Exhaust 100 hours

G. Cooling Systems 250 hours

H. Isolation Mounts 250 hours

I. Engine Operation See Operator’s Manual

J. Fuels & Lubricants See Operator’s Manual

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Noise Emission Operation & Maintenance Manual

Book 22826226 29

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.

E. Enclosure Panels

Enclosure panels should also be inspected at 100 hour operational intervals. All panels that are warped, punctured, torn, or otherwise deformed, such that their noise containment function is reduced, should be repaired or replaced before the next operation interval. Doors, access panels, and hatch closures especially, should be checked and adjusted at this time to insure continuous seating between gasket or acoustic material and the mating frame.

F. Air Intake and Engine Exhaust

Engine and compressor air intake and engine exhaust systems should be inspected after each 100 hours of operation for loose, damaged, or deteriorated components. Repairs or replacements should be made before the next period of use.

G. Cooling Systems

All components of the cooling system for engine water and compressor oil should be inspected every 250 hours of use. Any discrepancies found should be corrected before placing the unit back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at all times during operation.

H. Isolation Mounts

Engine/airend isolation mounts should be inspected after each 250 hours of operation. Those mounts with cracks or splits in the molded rubber, or with bent or broken bolts due to operation or storage in severe environments, all should be replaced with equivalent parts.

I. Engine Operation

Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer.

J. Fuels and Lubricants

Use only the types and grades of fuels and lubricants recommended in the Portable Power and Engine Manufacturer’s Operator and Maintenance Manuals.

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MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY

ITEM NO. DESCRIPTION OF WORK HOURMETERREADING

MAINT/ INSPECT DATE

LOCATION CITY/ STATE

WORK DONE BY (NAME)

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General Data

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General Data

Actual free air deliveryXP825WCU 23,4 m3/min (825 CFM)HP750WCU 21,2 (750 CFM)XP750WCU 21,2 (750 CFM)HP675WCU 19,1 (675 CFM)

Normal operating discharge pressureXP825WCU 8,6 bar (125 psi)HP750WCU 10,3 bar (150 psi)XP750WCU 8,6 bar (125 psi)HP675WCU 10,3 bar (150 psi)

Maximum Allowable PressureXP825WCU 10,3 bar (150 psi)HP750WCU 12,1 bar (175 psi)XP750WCU 10,3 bar (150 psi)HP675WCU 12,1 bar (175 psi)

Safety Valve SettingXP825WCU 14 bar (200 psi)HP750WCU 14 bar (200 psi)XP750WCU 14 bar (200 psi)HP675WCU 14 bar (200 psi)

Maximum Pressure Ratio (absolute)XP825WCU 9,6 : 1HP750WCU 11,3 : 1XP750WCU 9,6 : 1HP675WCU 11,3 : 1

Operating ambient temperatureW (Whisperized) -12°C to +49°C (10°F to 120°F)HA (High Ambient) -12°C to +52°C (10°F to 125°F)Cooling system Oil injectionOil capacity 64 litres (17 gal)Maximum oil system temperature 120°C (248°F)

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General Data Operation & Maintenance Manual

Book 22826226 33

Engine (XP825EWCU), (HP750EWCU), (XP750EWCU), (HP675EWCU)Type/Model Cummins QSC 8.3Number of Cylinders 6Oil Capacity 19 litres (5 gal)Speed at Full Load min -1 (RPM) 2000 revsSpeed at Idle min -1 (RPM) 1200Power Available at Full Load(XP825EWCU), (HP750EWCU), 209kW (280hp)(XP750EWCU), (HP675EWCU) 194kW (260hp)Electrical System 24 V neg. groundFuel Tank Capacity 462 litres (122 gal)Oil Specification Refer to engine manualCoolant Capacity 28 litres (7.5 gal)

Sound Level DataA) "W” Model, EPA Noise 76 dB (A)B) "HA” Model NA

Wheels and Tires (XP825EWCU), (HP750EWCU), (XP750EWCU), (HP675EWCU)Number of Wheels 4Tire Size ST225/75R15 (D)Tire Pressure 4.5 bar (65 psi)Net Weight (Less Fuel) 3800KG (8400 Ib)

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34 Book 22826226

**Always use Ingersoll-Rand Replacement parts!**

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Book 22826226 35

Operating Instructions

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Operation & Maintenance Manual Operating Instructions

36 Book 22826226

Operating Instructions

CommissioningUpon 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.

Ensure that the position of the emergency stop device is known and recognized by its markings. Ensure that it is functioning correctly and that the method of operation is known.

Before towing the unit, ensure that the tyre pressures are correct (refer to the GENERAL DATA SECTION of this manual). Before towing the unit, ensure that the lights are functioning correctly (where fitted).

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.

Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks.

Ensure that the machine is positioned securely and on a stable foundation. Any risk of movement should be removed by suitable means, especially to avoid strain on any rigid discharge piping.

Attach the battery cables to the battery(s) ensuring that they are tightened securely. Attach the positive cable before attaching the negative cable.

Compressor Mounting

Portable compressors, which are modified to remove the running gear and mount the machine direct to trailers, truck beds or frame, etc. may experience failure of the enclosure, frame, and/or other components. It is necessary to isolate the compressor package from the carrier base with a flexible mounting system. Such a system must also prevent detachment of the package from the carrier base in the event the isolators fail. Contact Portable Power representative for flexible mounting kits.

Warranty does not cover failures attributable to mounting of the compressor package to the carrier base unless it is a Portable Power system.

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Operating Instructions Operation & Maintenance Manual

Book 22826226 37

WARNING!

All air pressure equipment installed in or connected to the machine musthave safe working pressure ratings of at least the machine safety valvesetting, and materials compatible with the compressor lubricant (refer tothe GENERAL DATA SECTION).

WARNING!

If more than one compressor is connected to one common downstreamplant, effective check valves and isolation valves must be fitted andcontrolled by work procedures, so that one machine cannot accidently bepressurised / over pressurised by another.

WARNING!

When flexible discharge hoses are used, it is recommended that safetyretaining wires are fitted.

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Operation & Maintenance Manual Operating Instructions

38 Book 22826226

Prior to Starting

1. Place the unit in a position that is as level as possible. The design of the unitpermits 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 engineoil level near the high level mark (with the unit level).

2. Check the engine lubrication oil in accordance with the operating instructionsin the Engine Operator's Manual or section.

3. Check the compressor oil level in the sight tube located on the separator tank.The most accurate reading can be made before the machine is started with theunit level, engine off, and zero pressure in the separator tank.

4. Check the diesel fuel level. A good rule is to top up at the end of each workingday. This prevents condensation from occurring in the tank. Refer to the engineoperator's manual/section for diesel fuel specification.

CAUTION!

When refueling:-

• switch off the engine.

• do not smoke.

• extinguish all naked lights.

• do not allow the fuel to come into contact with hot surfaces.

• wear personal protective equipment.

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Operating Instructions Operation & Maintenance Manual

Book 22826226 39

5. Drain the fuel filter water separator of water, ensuring that any released fuel issafely contained.

6. Open the service valve(s) to ensure that all pressure is relieved from thesystem. Close the service valve(s).

7. Check the radiator coolant level (with the unit level).

CAUTION!

Do not operate the machine with the canopy/doors in the open positionas this may cause overheating and operators to be exposed to high noiselevels.

Check the air filter restriction indicator(s). Refer to the MAINTENANCE section of this manual.

When starting or operating the machine in temperatures below or approaching 0°C (32°F), ensure that the operation of the regulation system, the unloader valve, the safety valve, and the engine are not impaired by ice or snow, and that all inlet and outlet pipes and ducts are clear of ice and snow.

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Operation & Maintenance Manual Operating Instructions

40 Book 22826226

Control Panel

1. Hourmeter - Records running time for maintenance.

2. Compressor Discharge Pressure Gauge - lndicates pressure in receivertank.

3. Fuel Level Gauge - lndicates amount of fuel in tank.

4. Power Switch - Activates systems for STARTING and STOPPING.

5. Service Air Switch - After warm-up, PUSH. Provides full air pressure at theservice outlet. Allows unit to warm-up at reduced pressure.

6. Engine Speed Gauge - lndicates engine speed (RPM).

7. Discharge Air Temp. Gauge - lndicates airend discharge temperature

8. Engine Oil Pressure Gauge - lndicates engine oil pressure.

9. Engine Water Temp Gauge - lndicates coolant temperature.

10. Voltmeter - lndicates charging system voltage.

11. Spare - Used for optional accessories.

12. Inlet Heater/Wait to Start Lamp - Indicates engine manifold pre-heater isenergized. Wait until lamp extinguishes before engaging starter.

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Operating Instructions Operation & Maintenance Manual

Book 22826226 41

Wedge Diagnostic Display Codes

1. High Compressor Temp: Fault indicator lamp. Indicates shutdown due to highcompressor temperature.

2. Low Engine Oil Pressure: Fault indicator lamp. Indicates shutdown due to lowengine oil pressure.

3. High Engine Coolant Temp: Fault indicator lamp. Indicates shutdown due tohigh engine water temperature.

4. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to low fuel level.Lamp blinks at low fuel warning.

5. Low Battery Voltage: Alarm indicator lamp. Indicates battery or chargingsystem requires service.

6. Low Radiator Coolant Level: Alarm indicator lamp. Indicates engine coolantneeds service.

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Operation & Maintenance Manual Operating Instructions

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7. Restricted Air Filter: Alarm indicator lamp. Indicates engine/compressor airinlet filters need service.

8. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to highpressure in “IQ” air filters (if equipped).

9. Compressor Malfunction: Fault indicator lamp. Indicates shutdown due tocompressor system fault. Refer to Fault Code List.

10. Engine Malfunction: Engine Fault code. Refer to service card or enginemanual for codes and service requirements.

11. Malfunction Code (4 Digit): Compressor or engine fault. Refer to manual forlist of codes and service requirements.

ALERT SHUTDOWN

CODE LIGHT BLINKS CODE LIGHT STEADY DELAY(sec)

Engine Speed<Min. RPM 1 CPRSR Malfunction. 30

Engine Speed>Max. RPM 2 CPRSR Malfunction. 30

Engine Crank Time Exceeded 3 CPRSR Malfunction. 0

*High Engine Oil Temperature 5 CPRSR Malfunction.

*High Intake Manifold Temperature 6 CPRSR Malfunction.

*Water In Fuel-CUMMINS 8 CPRSR Malfunction.

Engine Not Responding To Throttle command 10 CPRSR Malfunction.

Too Many Crank Attempts During Autostart 11 CPRSR Malfunction. 0

Engine Shut Itself Down: reason unknown 29 CPRSR Malfunction. 0

Low AE Oil Pressure 31 CPRSR Malfunction. 20

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Operating Instructions Operation & Maintenance Manual

Book 22826226 43

Disch. Temp (RT2) Sensor Fault 32 CPRSR Malfunction. 10

Sep. Tank Pressure (PT1) Sensor Fault 33 CPRSR Malfunction. CPRSR Malfunction.

Separator Tank Pressure >20 PSI During Start Attempt (Engine Will Not Crank)

34 CPRSR Malfunction. 0

Machine Over Pressure 35 CPRSR Malfunction. 1

Safety Valve Open 36 CPRSR Malfunction. 2

*CAN derived data

Separator Tank Temp>(247 deg.F) 50 CPRSR Malfunction. 3

Machine ID Not Valid 51 CPRSR Malfunction. 0

Sep. Tank Temp (RT1) Sensor Fault 53 CPRSR Malfunction. 10

Reg. System Pressure (PT2) Sensor Fault 54 CPRSR Malfunction.

Estop Button Pushed 55 CPRSR Malfunction. 55 CPRSR Malfunction. 3

Minimum Pressure Not Met 56 CPRSR Malfunction.

Serial Comm. Problem 70 CPRSR Malfunction.

CAN Bus Problem 71 CPRSR Malfunction.

Communication With Autostart Module Lost 73 CPRSR Malfunction.

Dedicated Lights:

Low Fuel Level Fuel Level 3

Air Filter Restriction Soiled Filter

Low Battery Voltage Battery Charging Condition

*Low Engine Oil Pressure Low Engine Oil Pressure

*Low Coolant Level– CUMMINS

Engine Coolant Level

*High Engine Coolant Temperature Alert High Engine Temp.

ALERT SHUTDOWN

CODE LIGHT BLINKS CODE LIGHT STEADY DELAY(sec)

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Operation & Maintenance Manual Operating Instructions

44 Book 22826226

*High Engine Coolant Temperature Shutdown High Engine Temp. 10

IQ Filter Restriction IQ Filt. Rest 3

High Discharge Temp.(RT2>247 deg. F) High Comp Temp. 3

*CAN derived data

ALERT SHUTDOWN

CODE LIGHT BLINKS CODE LIGHT STEADY DELAY(sec)

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Operating Instructions Operation & Maintenance Manual

Book 22826226 45

Engine Codes: Cummins Engine Model QSC8.3, QSL9

Displayed Code Definition

111 Engine Control Module - Critical internal failure

115 Engine Speed/Position Sensor Circuit - Lost both of two signals

122 Intake Manifold Pressure Sensor Circuit - Voltage Above Normal, or Shorted High

123 Intake Manifold Pressure Sensor Circuit - Voltage Below Normal, or Shorted Low

135 Engine Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted High

141 Engine Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted Low

143 Engine Oil Pressure Low - Warning

144 Engine Coolant Temperature Sensor Circuit - Voltage Above Normal, or Shorted High

145 Engine Coolant Temperature Sensor Circuit - Voltage Below Normal, or Shorted Low

146 Engine Coolant Temperature High - Warning

147 Frequency Throttle Signal - Abnormal Frequency, Pulse Width, or Period

148 Frequency Throttle Signal - Abnormal Frequency, Pulse Width, or Period

151 Engine Coolant Temperature Low - Critical

153 Intake Manifold Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted High

154 Intake Manifold Air Temperature Sensor Circuit - Voltage Below Normal, or Shorted Low

155 Intake Manifold Air Temperature High - Critical

187 Sensor Supply Voltage #2 Circuit - Voltage Below Normal, or Shorted Low

195 Engine Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted High

196 Engine Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted Low

197 Engine Coolant Level Low - Warning

212 Engine Oil Temperature Sensor 1 Circuit - Voltage Above Normal, or Shorted High

213 Engine Oil Temperature Sensor 1 Circuit - Voltage Below Normal, or Shorted Low

214 Engine Oil Temperature High - Critical

221 Barometric Pressure Sensor Circuit - Voltage Above Normal, or Shorted High

222 Barometric Pressure Sensor Circuit - Voltage Below Normal, or Shorted Low

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Operation & Maintenance Manual Operating Instructions

46 Book 22826226

227 Sensor Supply Voltage #2 Circuit - Voltage Above Normal, or Shorted High

231 Engine Coolant Pressure Sensor Circuit - Voltage Above Normal, or Shorted High

232 Engine Coolant Pressure Sensor Circuit - Voltage Below Normal, or Shorted Low

233 Engine Coolant Pressure Low - Warning

234 Engine Speed High - Critical

235 Engine Coolant Level Low - Critical

238 Sensor Supply Voltage #3 Circuit - Voltage Below Normal, or Shorted Low

249 Ambient Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted High

256 Ambient Air Temperature Sensor Circuit - Voltage Below Normal, or Shorted Low

261 Engine Fuel Temperature High - Warning

263 Engine Fuel Temperature Sensor 1 Circuit - Voltage Above Normal, or Shorted High

265 Engine Fuel Temperature Sensor 1 Circuit - Voltage Below Normal, or Shorted Low

268 Fuel Pressure Sensor Circuit - Data Incorrect

271 High Fuel Pressure Solenoid Valve Circuit – Voltage Below Normal, or Shorted Low

272 High Fuel Pressure Solenoid Valve Circuit - Voltage Above Normal, or Shorted High

275 Fuel Pumping Element (Front) - Mechanical System Malfunction

281 High Fuel Pressure Solenoid Valve - Mechanical System Malfunction

284 Engine Speed/Position Sensor (Crankshaft) Circuit - Voltage Below Normal, or Shorted Low

285 SAE J1939 Multiplexing PGN Timeout Error

286 SAE J1939 Multiplexing Configuration Error

287 SAE J1939 Multiplexing Throttle Error

295 Barometric Pressure Sensor Circuit - Data Incorrect

319 Real Time Clock Power Interrupt - Data Incorrect

322 Injector Solenoid Cylinder #1 Circuit - Current Below Normal, or Open Circuit

323 Injector Solenoid Cylinder #5 Circuit - Current Below Normal, or Open Circuit

324 Injector Solenoid Cylinder #3 Circuit - Current Below Normal, or Open Circuit

325 Injector Solenoid Cylinder #6 Circuit - Current Below Normal, or Open Circuit

331 Injector Solenoid Cylinder #2 Circuit - Current Below Normal, or Open Circuit

332 Injector Solenoid Cylinder #4 Circuit - Current Below Normal, or Open Circuit

334 Engine Coolant Temperature Sensor Circuit - Data Incorrect

342 Electronic Calibration Code Incompatibility - Out of Calibration

351 Injector Power Supply - Bad Intelligent Device or Component

Displayed Code Definition

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Operating Instructions Operation & Maintenance Manual

Book 22826226 47

352 Sensor Supply Voltage #1 Circuit - Voltage Below Normal, or Shorted Low

386 Sensor Supply Voltage #1 Circuit - Voltage Above Normal, or Shorted High

415 Engine Oil Pressure Low - Critical

418 Water in Fuel Indicator High - Maintenance

422 Engine Coolant Level - Data Incorrect

425 Engine Oil Temperature - Data Incorrect

428 Water in Fuel Sensor Circuit - Voltage Above Normal, or Shorted High

429 Water in Fuel Sensor Circuit - Voltage Below Normal, or Shorted Low

433 Intake Manifold Pressure Sensor Circuit - Data Incorrect

435 Engine Oil Pressure Sensor Circuit - Data Incorrect

441 Battery Voltage Low - Warning

442 Battery Voltage High - Warning

449 Fuel Pressure High - Warning

451 Injector Metering Rail Pressure Sensor Circuit - Voltage Above Normal, or Shorted High

452 Injector Metering Rail Pressure Sensor Circuit - Voltage Below Normal, or Shorted Low

488 Intake Manifold Air Temperature High - Warning

553 Injector Metering Rail Pressure High - Warning

554 Fuel Pressure Sensor Error - Data Incorrect

559 Injector Metering Rail Pressure Low - Warning

595 Turbocharger Speed High - Warning

596 Electrical Charging System Voltage High - Warning

597 Electrical Charging System Voltage Low - Warning

598 Electrical Charging System Voltage Low - Critical

687 Turbocharger Speed Low - Warning

689 Primary Engine Speed Sensor Error - Data Incorrect

691 Turbocharger Compressor Inlet Temp Sensor Circuit - Voltage Above Normal, or Shorted High

692 Turbocharger Compressor Inlet Temp Sensor Circuit - Voltage Below Normal, or Shorted Low

697 ECM Internal Temperature Sensor Circuit - Voltage Above Normal, or Shorted High

698 ECM Internal Temperature Sensor Circuit - Voltage Below Normal, or Shorted Low

719 Extended Crankcase Blow-by Pressure Circuit - Voltage Above Normal, or Shorted High

Displayed Code Definition

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Operation & Maintenance Manual Operating Instructions

48 Book 22826226

729 Extended Crankcase Blow-by Pressure Circuit - Voltage Below Normal, or Shorted Low

731 Engine Speed/Position #2 Mechanical Misalignment - Mechanical System Malfunction

753 Engine Speed/Position #2 Camshaft Sync Error - Data Incorrect

778 Engine Speed Sensor (Camshaft) Error - Data Incorrect

951 Cylinder Power Imbalance Between Cylinders - Data Incorrect

1139 Injector Cylinder #1 - Mechanical System Malfunction

1141 Injector Cylinder #2 - Mechanical System Malfunction

1142 Injector Cylinder #3 - Mechanical System Malfunction

1143 Injector Cylinder #4 - Mechanical System Malfunction

1144 Injector Cylinder #5 - Mechanical System Malfunction

1145 Injector Cylinder #6 - Mechanical System Malfunction

1911 Injector Metering Rail Pressure High - Critical

2111 Engine Coolant Temperature 2 Sensor Circuit - Voltage Above Normal, or Shorted High

2112 Engine Coolant Temperature 2 Sensor Circuit - Voltage Below Normal, or Shorted Low

2113 Engine Coolant Temperature 2 High - Warning

2114 Engine Coolant Temperature 2 High - Critical

2115 Engine Coolant Pressure 2 Circuit - Voltage Above Normal, or Shorted High

2116 Engine Coolant Pressure 2 Circuit -Voltage Below Normal, or Shorted Low

2117 Engine Coolant Pressure 2 Low - Warning

2185 Sensor Supply Voltage #4 Circuit – Voltage Above Normal, or Shorted High

2186 Sensor Supply Voltage #4 Circuit – Voltage Below Normal, or Shorted Low

2215 Fuel Pump Delivery Pressure Low - Warning

2216 Fuel Pump Delivery Pressure High - Warning

2249 Injector Metering Rail Pressure Low - Critical

2265 Fuel Priming Pump Control Signal Circuit - Voltage Above Normal, or Shorted High

2266 Fuel Priming Pump Control Signal Circuit - Voltage Below Normal, or Shorted Low

2292 Fuel Inlet Meter Device - High - Warning

2293 Fuel Inlet Meter Device - Low - Warning

2311 Fueling Actuator #1 Circuit Error - Condition Exists

2321 Engine Speed/Position Sensor #1 - Data Incorrect

Displayed Code Definition

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Operating Instructions Operation & Maintenance Manual

Book 22826226 49

2322 Engine Speed/Position Sensor #2 - Data Incorrect

2345 Turbocharger Speed - Abnormal Rate of Change

2555 Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted High

2556 Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted Low

2963 Engine Coolant Temperature High - Alert

2964 Intake Manifold Air Temperature High - Alert

2973 Intake Manifold Pressure Sensor Circuit - Data Incorrect

Displayed Code Definition

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Operation & Maintenance Manual Operating Instructions

50 Book 22826226

Starting the MachineEnsure emergency stop button is reset.

WARNING!

Under no circumstances should volatile fluids such as ether be used forstarting this machine.

All normal starting functions are incorporated in the key operated switch.

Turn the keyswitch to (position 1); The diagnostic lamps will flash.

— The low engine oil pressure and low battery voltage lamps will flash indicating propercommunication between wedge and engine ECM.

— Leave the key switch ON (position 1) until the Inlet Heater/Wait to Start Lampextinguishes.

NOTE: Position 2 is not used on this model. Pre-heaters are controlledautomatically by the engine.

• Turn the key switch to crank position 3 (engine start position).

• Release to on (position 1) when the engine starts. The engine will now be running ata reduced speed.

• During warm up, the engine will idle at a higher speed. After warm up the engine willidle at a lower speed.

At temperatures below 32°F (0°C), or if there is difficulty starting first time:

• Open the manual blowdown valve fully.

• Complete starting sequence above.

• Close manual blowdown valve as soon as engine runs freely.

• Do not allow machine to run for long periods with manual blowdown valve open.

• Allow the engine to reach operating temperature.

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Operating Instructions Operation & Maintenance Manual

Book 22826226 51

• At this point in the operation of the machine it is safe to apply full load to the engine.

NOTE: Wear hearing protection at all times when the engine is startedwith the manual blowdown valve open and air is flowing from the valve.

Push After Warm Up

NOTE: In order to allow the machine to start at a reduced load, a valve,which is operated by a service air switch located on the instrument panel,is incorporated in the regulation system. (The valve automatically returnsto the start position when the machine is switched off and air pressurerelieved from the system).

• Allow the engine to reach its operating temperature - then press the Service AirSwitch.

• At this point in the operation of the machine it is safe to apply full load to the engine.

CAUTION!

If the engine does not start, repeat the above procedure after waiting fora minimum of one minute.

If the engine fails to start, refer to the MAINTENANCE section of this manual, and to the ENGINE MANUFACTURER’S MANUAL.

Dual Pressure Regulation When Fitted

Machines which operate in excess of 7 bar (100 psi) can optionally be fitting with a dual pressure control inside the unit. This switch selects between 7 bar (100 psi) and the machine rated pressure, cfm remains nominally constant.

Starting and stopping are unaffected by the selection, and during normal running, the selector switch may be safely operated. Precaution must be taken to ensure that downstream equipment is rated to suit the available pressure.

The pressure gauge indicates which setting has been selected.

Stopping the Machine

• Close the service valve.

• Allow the machine to run unloaded for a short period of time to reduce the enginetemperature.

• Turn the ON/OFF start switch to the 0 (off) position.

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Operation & Maintenance Manual Operating Instructions

52 Book 22826226

NOTE: As soon as the engine stops, the automatic blowdown valve willrelieve all pressure from the system, except for the discharge pipe/manifold area. This area should be depressurised by opening thedischarge valve, keeping clear of any airflow from it.

If the automatic blowdown valve fails to operate, then pressure must be relieved from the system by means of the service valve(s).

WARNING!

WARNING: When relieving system pressure by means of the servicevalve(s), a small amount of pressure will remain in the system. Nomaintenance work should be carried out if this situation exists. Relievethis pressure by opening the manual blowdown valve.

CAUTION!

Never allow the machine to stand idle with pressure in the system.

Emergency Stopping

In the event that the unit has to be stopped in an emergency, TURN THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO THE “0” (OFF) POSITION, or push the EMERGENCY STOP SWITCH (when fitted).

If the unit is not fitted with an emergency stop switch, rotate the start switch to the (0) off position.

Re-Starting After an Emergency

Disengage emergency stop control from engaged (depressed) position. (IF FITTED)

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.

Refer to the PRIOR TO STARTING and STARTING THE UNIT instructions earlier in this section before re-starting the machine.

Monitoring During Operation

Should any of the safety shut-down conditions occur, the unit will stop.

Refer to the wedge diagnostic display codes table for a listing of shutdown conditions.

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CAUTION!

To ensure an adequate flow of oil to the compressor at low temperature,never allow the discharge pressure to fall below 3,5 bar (50 psi).

Decommissioning

When the machine is to be permanently decommissioned or dismantled, it is important to ensure that all hazard risks are either eliminated or notified to the recipient of the machine. In particular:-

• Do not destroy batteries or components containing asbestos without containing thematerials safely.

• Do not dispose of any pressure vessel that is not clearly marked with its relevant dataplate information or rendered unusable by drilling, cutting etc.

• Do not allow lubricants or coolants to be released into land surfaces or drains.

• Do not dispose of a complete machine without documentation relating to instructionsfor its use.

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** Always use Ingersoll-Rand Replacement Parts!**

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Maintenance

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Maintenance

Initial 500 miles /850 km

Daily Weekly Monthly 3 Months 500 hrs.

6 Months 1000 hrs.

12 Months

2000 hrs.

Compressor Oil Level C

Engine Oil Level C

*Radiator Coolant Level C

Gauges/Lamps C

*Air Cleaner Service Indicators C

Fuel Tank (Fill at end of day) C D

*Fuel/Water Separator Drain C

Oil Leaks C

Fuel Leaks C

Drain Water From Fuel Filters D

Coolant Leaks C

Radiator Filler Cap C

Air Cleaner Precleaner Dumps C

Fan/Alternator Belts C

Battery Connections/Electrolyte C

Tire Pressure and Surface C

*Wheel Lug Nuts C

Hoses (Oil, Air, Intake, etc.) C

Automatic Shutdown System C

Air Cleaner System C

Compressor Oil Cooler Exterior C

*Engine Rad/Oil Cooler Exterior C

Fasteners, Guards C

Air Cleaner Elements R/WI

*Disregard if not appropriate for this particular machine. D = Drain

(1) or 3000 miles/5000km whichever is the sooner G = Grease

C = Check (adjust, clean or replace as necessary) R = Replace

CBT = Check before towing. T = Test

CR = Check and report W I = or when indicated if earlier.

Refer to specific sections of the operator's manual for more information.

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Initial 500 miles /850 km

Daily Weekly Monthly 3 Months 500 hrs.

6 Months 1000 hrs

12 Months2000 hrs

18 Months3000 hrs

Engine Coolant Conditioner Element

R

*Fuel/Water Separator Element R

Compressor Oil Filter Element R

Compressor Oil R

Engine Oil Change R

Engine Oil Filter R

*Water Pump Grease. R

*Wheels (Bearings, Seals, etc.) C G

*Engine Coolant C R

Fuel Filter Element R

*Injection Nozzle Check C

Shutdown Switch Settings T

Scavenger Orifice & Related Parts C

Oil Separator Element R

*Feed Pump Strainer Cleaning. C

*Valve Clearance Check C

Lights (running, brake, & turn) CBT

Pintle Eye Bolts CBT

* Brakes C C

* Brake linkage C

* Emergency stop T

Running gear linkage G

Safety valve C

Running gear bolts(1) C

*Disregard if not appropriate for this particular machine. D = Drain

(1) or 3000 miles/5000km whichever is the sooner G = Grease

(2) or as defined by local or national legislation R = Replace

C = Check (adjust, clean or replace as necessary) T = Test

CBT = Check before towing. W I = or when indicated if earlier.

CR = Check and report Refer to specific sections of the operator's manual for more information.

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Initial 500 miles /850 km

Daily Weekly Monthly 3 Months 500 hrs.

6 Months 1000 hrs

12 Months2000 hrs

Scavenge line C

* Engine breather element C

Separator tank (2) exterior CR

*Lubricator (Fill) C

2 Yrs 4 Yrs 6 Yrs

Safety valve C

Hoses R

Separator tank (2) interior C

*Disregard if not appropriate for this particular machine. D = Drain

(1) or 3000 miles/5000km whichever is the sooner G = Grease

(2) or as defined by local or national legislation R = Replace

C = Check (adjust, clean or replace as necessary) T = Test

CBT = Check before towing. W I = or when indicated if earlier.

CR = Check and report Refer to specific sections of the operator's manual for more information.

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ROUTINE MAINTENANCEThis section refers to the various components which require periodic maintenance and replacement.

The 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 DATA SECTION of this manual.

For any specification or specific requirement on service or preventative maintenance for the engine, refer to the Engine Section.

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.

If the automatic blowdown fails to operate, then pressure must be gradually relieved by operating the manual blowdown valve. Suitable personal protective equipment should be worn.

Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

Prior to attempting any maintenance work, ensure that:-

• all air pressure is fully discharged and isolated from the system. If the automaticblowdown valve is used for this purpose, then allow enough time for it to completethe operation.

• the discharge pipe / manifold area is depressurised by opening the service valve,while keeping clear of any airflow from it.

WARNING!

Pressure will remain in the system between the minimum pressure valveand the service valve after shutdown and operation of the auto blowdownvalve.

This pressure must be relieved by :

(a) Disconnecting any downstream equipment.

(b) Opening the service valve to atmosphere.

• the machine cannot be started. Post warning signs and/or fit anti-start devices.

• Disconnect battery cables.

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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 theadditional hazards, including hot surfaces and intermittently moving parts.

• The machine cannot be started.

Prior to attempting any maintenance work on a running machine, ensure that:-

• the work carried out is limited to only those tasks which require the machine to run.

• the work carried out with safety protection devices disabled or removed is limited toonly those tasks which require the machine to be running with safety protectiondevices disabled or removed.

• all hazards present are known (e.g. pressurised components, electrically livecomponents, removed panels, covers and guards, extreme temperatures, inflow andoutflow of air, intermittently moving parts, safety valve discharge etc.).

• appropriate personal protective equipment is worn.

• loose clothing, jewelry, long hair etc. is made safe.

• warning signs indicating that Maintenance Work is in Progress are posted in aposition that can be clearly seen.

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.

• hazardous materials are effectively contained and disposed of.

PROTECTIVE SHUTDOWN SYSTEMRefer to the diagnostic display codes table for a listing of shutdown conditions.

Low engine fuel level switch.Test the low engine fuel level switch circuit as follows:

• Start the machine.NOTE: Do not press the load button.

• Disconnect the switch, the machine should shutdown.

• Re-connect the switch.

Test the low engine fuel level switch by removing and operating the float manually.

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WARNING!

Never remove or replace switches when the machine is running.

SCAVENGE LINEThe scavenge line runs from the combined orifice/check valve at drop tube in the separator tank, to the orifice fitting located in the airend.

Check that the scavenge line and tube are clear of any obstruction each time the compressor lubricant is changed as any blockage will result in oil carryover into the discharge air.

COMPRESSOR OIL FILTERRefer 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 isstopped and the system has been completely relieved of all air pressure.(Refer to STOPPING THE MACHINE in the OPERATING INSTRUCTIONSsection of this manual)

Clean the exterior of the filter housing and remove the spin-on element.

lnspectionInspect the oil filter head to be sure the gasket was removed with the oil filter element. Clean the gasket seal area on the oil filter head.

CAUTION!

If there is any indication of the formation of varnishes, shellacs orlacquers on the filter element, it is a warning that the compressorlubricating and cooling oil has deteriorated and that it should be changedimmediately. Refer to LUBRICATION later in this section.

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NOTICEInstalling a new oil filter element when the old gasket remains on the filterhead, will cause an oil leak and can cause property damage.

Reassembly

Clean the filter gasket contact area and install the new element.Tighten until the gasket makes contact with the filter housing. Tighten an additional 1/2 to 3/4 of a revolution.

CAUTION!

Start the machine (refer to PRIOR TO STARTING and STARTING THEMACHINE in the OPERATING INSTRUCTIONS section of this manual) andcheck for leakage before the machine is put back into service.

COMPRESSOR OIL SEPARATOR ELEMENTRefer 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 isstopped and the system has been completely relieved of all air pressure.(Refer to STOPPING THE MACHINE in the OPERATING INSTRUCTIONSsection of this manual).

Disconnect all hoses and tubes from the separator tank cover plate. Remove the drop-tube from the separator tank cover plate and then remove the cover plate. Remove the separator element.

lnspection

Examine the filter element. Examine all hoses and tubes, and replace if necessary.

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Reassembly

Thoroughly clean the orifice/drop tube and filter gasket contact area before reassembly. Install the new element.

WARNING!

DO not remove the staple from the anti-static gasket on the separatorelement since it serves to ground any possible static build-up. Do not usegasket sealant since this will affect electrical conductance.

Reposition the cover plate, taking care not to damage the gasket, and replace the cover plate screws tightening in a criss-cross pattern to the recommended torque (refer to the TORQUE SETTING TABLE later in this section).

Reconnect all hoses and tubes to the separator tank cover plate.

Replace the compressor oil (refer to LUBRICATION later in this section).

CAUTION!

Start the machine (refer to PRIOR TO STARTING and STARTING THEMACHINE in the OPERATING INSTRUCTIONS section of this manual) andcheck for leakage before the machine is put back into service.

COMPRESSOR OIL COOLER AND ENGINE RADIATORWhen grease, oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator, the efficiency is impaired. It is recommended that each month the oil cooler and radiator be cleaned by directing a jet of compressed air, (carrying if possible a non-flammable cleaning solvent) over the exterior core of the cooler/radiator. This should remove any accumulation of oil, grease and dirt from the exterior core of the cooler so that the entire cooling area can radiate the heat of the lubricating and cooling oil/water into the air stream.

WARNING!

Hot engine coolant and steam can cause injury. When adding coolant orantifreeze solution to the engine radiator, stop the engine at least oneminute prior to releasing the radiator filler cap. Using a cloth to protectthe hand, slowly release the filler cap, absorbing any released fluid withthe cloth. Do not remove the filler cap until all excess fluid is released and

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the engine cooling system fully depressurized.

WARNING!

Follow the instructions provided by the antifreeze supplier when addingor draining the antifreeze solution. It is advisable to wear personalprotective equipment to prevent skin and eye contact with the antifreezesolution.

AIR FILTER ELEMENTSThe 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).

Removal

CAUTION!

Never remove and replace element(s) when the machine is running.

Clean the exterior of the filter housing and remove the filter element by releasing the nut.

If the safety element is to be renewed, thoroughly clean the interior of the filter housing prior to removing the safety element.

Inspection

Check for cracks, holes or any other damage to the element by holding it up to a light source, or by passing a lamp inside.

CAUTION!

If inspection reveals damage to the main element, the safety elementmust be replaced.

Check the seal at the end of the element and replace if any sign of damage is evident.

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Reassembly

Assemble the new element into the filter housing ensuring that the seal seats properly. Secure element by tightening nut.

Before restarting the machine, check that all clamps are tight.

VENTILATIONAlways check that the air inlets and outlets are clear of debris etc.

COOLING FAN DRIVEPeriodically check that the fan mounting bolts in the fan hub have not loosened. If, for any reason, it becomes necessary to remove the fan or re-tighten the fan mounting bolts, apply a good grade of commercially available thread locking compound to the bolt threads and tighten to the torque value shown in the TORQUE SETTING TABLE later in this section.

The fan belt(s) should be checked regularly for wear and correct tensioning.

FUEL SYSTEMThe fuel tank should be filled daily or every eight hours. To minimise 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. Drain any sediment or condensate that may have accumulated in the tank(s). Refer to MAINTENANCE CHART.

FUEL FILTER WATER SEPARATORThe fuel filter water separator contains a filter element which should be replaced at regular intervals (see the SERVICE/MAINTENANCE CHART).

CHARGE AIR COOLER PIPEWORKInspect all hoses and clamps on the charge cooler pipe work.

Engine damage will occur if the charge cooling system leaks.

HOSESAll components of the engine cooling air intake system should be checked periodically to keep the engine at peak efficiency.

At the recommended intervals, (see the MAINTENANCE CHART), inspect all of the intake lines to the air filter, and all flexible hoses used for air lines, oil lines and fuel lines.

Periodically inspect all pipework for cracks, leaks, etc. and replace immediately if damaged.

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ELECTRICAL SYSTEM

WARNING!

Disconnect the battery cables before performing any maintenance orservice.

Check the security of electrical terminals on the switches and relays i.e. nuts or screws loose, which may cause local hot spot oxidation.

Inspect the components and wiring for signs of overheating i.e. discolouration, charring of cables, deformation of parts, acrid smells and blistered paint.

BATTERYKeep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion.

The battery restraint should be kept tight enough to prevent the battery from moving.

PRESSURE SYSTEMRegularly, it is necessary to inspect the external surfaces of the system (from the airend through to the service valve(s)) including hoses, tubes, tube fittings and the separator tank, for visible signs of impact damage, excessive corrosion, abrasion, tightness and chafing. Any suspect parts should be replaced before the machine is put back into service.

TIRE PRESSURESee the GENERAL DATA SECTION of this manual.

RUNNING GEAR/WHEELSCheck 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. Refer to the TORQUE SETTING TABLE later in this section.

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LUBRICATION

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.

ENGINE LUBRICATING OILThe engine oil and oil filter element should be changed at the engine manufacturer's recommended intervals. Refer to the Engine operator manual/section.

Refer to the Engine operators' manual/section for engine oil specifications.

COMPRESSOR LUBRICATING OILRefer to the MAINTENANCE CHART in this section for service intervals.

NOTE: If the machine has been operating under adverse conditions, orhas suffered long shutdown periods, then more frequent service intervalswill be required.

WARNING!

DO NOT, under any circumstances, remove any drain plugs or the oilfiller-plug from the compressor lubricating and cooling system withoutfirst making sure that the machine is stopped and the system has beencompletely relieved of all air pressure (refer to STOPPING THE MACHINEin the OPERATING INSTRUCTIONS section of this 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 mostof the sediment will be in suspension and will therefore drain more readily.

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CAUTION!

Some oil mixtures are incompatible and result in the formation ofvarnishes, shellacs or lacquers which may be insoluble. Refer to PortableCompressor Fluid Chart.

RUNNING GEAR WHEEL BEARINGSWheel bearings should be packed with grease every 12 months. The type of grease used should conform to specification MIL-G-10924.

PRESSURE REGULATOR

Normally, regulation requires no adjusting, but if proper adjustment is lost, proceed as follows:

Before Starting Unit

1. Atop separator cover at pressure regulator (PR) loosen locknut (G)counterclockwise. Turn adjustment screw (H) counter clockwise on full turn.

After Starting Unit

2. Allow unit to warm up, then push “Service Air Switch” on control panel.

3. Open and adjust service valve on outside of the unit to obtain the ratedoperating pressure on the discharge pressure gauge.

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NOTE: If the rated operating pressure cannot be maintained with engineat full load speed, turn regulator adjustment screw (H) clockwise andadjust service valve until engine maintains rated full load speed.

4. Insure that pressure is maintained at rated pressure, then turn regulatoradjustment screw (H) counter clockwise until engine speed just begins to bereduced.

NOTE: Turning regulator adjustment screw (H) clockwise will raise pressure at full speed.

5. Close service valve (engine will slow to no load or idle speed).

6. If necessary, repeat steps 3 and 4.

7. At pressure regulator (PR) tighten lock nut (G).

8. Ensure unloader solenoid (US) acts to hold pressure in inlet unloader (IU) aftershutdown. After start-up, the compressor controller will open unloader solenoid(US).

Wheel Torque Chart - Inch Wheel Torque Chart - Metric

1/2” lug nuts Torque (Ft-Lbs) Torque (N-m) Torque (ft-Lbs)13” Wheel 80-90

15” Wheel 105-115 M12 Bolts 85-95 62-70

16” Wheel 105-115 M14 Bolts 145-155 107-115

16.5” Wheel 105-115 M16 Bolts 175-185 129-137

5/8” Lug Nuts M18 Bolts 205-215 151-159

16” Wheel 190-210

17” Wheel 190-210

9/16” Clamp nuts/Demountable Wheels14.5” Wheel 105-115

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Torque Values

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** Always use Ingersoll-Rand Replacement parts!**

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Lubrication

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Lubrication

Portable Compressor Fluid ChartRefer 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” are required for extended warranty.

Compressor oil carryover (oil consumption) may be greater with the use of alternative fluids.

Design Operating Pressure

Ambient Temperature Specification

100 psi to 300 psi

-10°F to 125°F(-23°C to 52°C)

Preferred:IR Pro-Tec™Alternate:ISO Viscosity Grade 46 with rust and oxidation inhibitors, designed for air compressor service.

350 psi

-10°F to 125°F (-23°C to 52°C)

65°F to 125°F (18°C to 52°C)

Preferred:IR XHP 605Alternate:IR XHP405ISO Viscosity Grade 68 Group 3 or 5 with rust and oxidation inhibitors designed for air compressor service.Preferred:XHP605IR XHP1001

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Preferred Ingersoll Rand Fluids - Use of these fluids with original IR branded filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your Portable Power representative.

Ingersoll Rand Preferred Fluids 1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Litre)

Preferred:

IR Pro-Tec™ 36899698 36899706 36899714 36899722

IR XHP605 - 22252076 22252050 22252068

IR XHP1001 - 35612738 35300516 -

XHP405 - 22252126 22252100 22252118

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**Always use Ingersoll-Rand Replacement parts!**

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Fault Finding

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Fault Finding

FAULT CAUSE REMEDY

No reaction from instrument panel when key turned to (I) position.

Emergency stop actuated.

Reset emergency stop button.

Batteries not connected. Connect batteries.

Fuse at starter motor ‘blown’.

Replace fuse.

Engine fails to start. Low battery charge. Check the fan belt tension, battery and cable connections.

Bad earth connection. Check the earth cables, clean as required.

Loose connection. Locate and make the connection good.

Fuel starvation. Check the fuel level and fuel system components. Replace the fuel filter if necessary.

Relay failed. Replace the relay.

Faulty stop solenoid Check the stop solenoid

Engine stops while in service or is reluctant to start.

Low fuel level. Fill fuel tank and bleed air from fuel system if necessary. (Refer to MAINTENANCE SECTION).

Safety shut-down system in operation.

Check the safety shut-down switches.

Engine starts but stalls when the switch returns to position

Electrical fault Test the electrical circuits.

Low engine oil pressure. Check the oil level and the oil filter(s).

Low water level Check if the low water lamp is extinguished.

Faulty relay Check the relays.

Faulty key-switch Check the key-switch.

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Engine starts but will not run or engine shuts down prematurely.

Electrical fault. Test the electrical circuits.

Low engine oil pressure. Check the oil level and oil filter(s).

Safety shut-down system in operation.

Check the safety shut-down switches.

Fuel starvation. Check the fuel level and fuel system components. Replace the fuel filter if necessary.

Switch failure. Test the switches.

High compressor oil temperature.

Check the compressor oil level and oil cooler. Check the fan drive.

Water present in fuel system.

Check the water separator and clean if required.

Faulty relay. Check the relay in the holder and replace if necessary.

Engine Overheats. Low water level Check the level and replenish if necessary.

Blocked radiator. Stop the machine and clean the cooling fins with compressed air or steam. Use reduced pressure for cleaning the fins.

Reduced cooling air from fan.

Check the fan and the drive belts. Check for any obstruction inside the cowl.

Faulty thermostat Check the thermostat and replace if necessary.

Engine speed too low.

Blocked fuel filter. Check and replace if necessary.

Blocked air filter. Check and replace the element if necessary.

Faulty regulator valve. Check the regulation system.

Premature unloading. Check the regulation and the operation of the air cylinder.

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.

FAULT CAUSE REMEDY

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Operation & Maintenance Manual Fault Finding

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Air discharge capacity too low.

Engine speed too low. Check the air cylinder and air filter(s).

Blocked air cleaner. Check the restriction indicators and replace the element(s) if necessary.

High pressure air escaping.

Check for leaks.

Incorrectly set regulation system.

Reset the regulation system. Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in the MAINTENANCE section of this manual.

Compressor overheats.

Low oil level. Top up the oil level and check for leaks.

Dirty or blocked oil cooler.

Clean the oil cooler fins.

Incorrect grade of oil. Use Ingersoll-Rand recommended oil.

Defective by-pass valve. Check the operation of the element and replace if necessary.

Recirculation of cooling air.

Move the machine to avoid recirculation.

Reduced cooling air from fan.

Check the fan and the drive belts. Check for any obstruction inside the fan cowl.

Excessive oil present in the discharge air.

Blocked scavenge line. Check the scavenge line, drop tube and orifice. Clean and replace.

Perforated separator element.

Replace the separator element.

Pressure in the system is too low.

Check the minimum pressure valve.

FAULT CAUSE REMEDY

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Safety valve operates.

Operating pressure too high.

Check the setting and operation of the regulator valve piping.

Incorrect setting of the regulator.

Adjust the regulator.

Faulty regulator. Replace the regulator.

Inlet valve set incorrectly.

Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in the MAINTENANCE section of this manual.

Loose pipe/hose connections.

Check all pipe/hose connections.

Faulty safety valve. Check the relieving pressure. Replace the safety valve if faulty. DO NOT ATTEMPT A REPAIR.

Oil is forced back into the air filter.

Incorrect stopping procedure used

Always employ the correct stopping procedure. Close the discharge valve and allow the machine to run on idle before stopping.

Faulty inlet valve. Check for free operation of the inlet valve(s).

Machine goes to full pressure when started. Faulty load valve. Replace the valve.

Machine fails to load when the load button is pressed.

Faulty load valve. Replace the valve.

FAULT CAUSE REMEDY

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**Always use Ingersoll-Rand Replacement parts!**

86 Book 22826226

**Always use Ingersoll-Rand Replacement parts!**

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Machine Systems

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Operation & Maintenance Manual Machine Systems

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Electrical Schematics Control System SchematicControl System Schematic

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ELECTRICAL PARTS LIST -

Part # Qty Description Schematic Ref

22616965 1 Alternator, Engine G1

36793545 2 Battery

35598986 1 Battery Cable, Jumper

36780609 1 Battery Cable, Negative

54765383 1 Battery Cable, Pos. Jumper

35582410 1 Battery Cable, Positive

22101968 1 Circuit Breaker Air Intake Heater

35376169 2 Diode Plug D1, D2

22056394 1 Gauge, 4 in 1 M3

36891216 1 Gauge, Pressure M4

22692602 1 Gauge, Fuel Level M2

22055883 1 Gauge, Tachometer M5

22132153 1 Ground Strap, Engine

22132153 1 Ground Strap, Frame

22785349 1 Harness, Air Intake Heater

22784698 1 Harness, Instrument Panel

22770879 1 Harness, Main Chassis

22054175 1 Hourmeter M1

22633044 1 Instrument Panel Assy

22050553 1 Lamp, Wait to Start DS1

36853521 1 Relay, Air Intake Heater K3

36853521 1 Relay, Starter Solenoid K1

36892362 1 Relay, Switched Power K2

36870608 1 Sender, Engine Oil Pressure RP1

22155451 1 Sender, Fuel Level U1

35604180 1 Sender, Temp A/E RT3

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Operation & Maintenance Manual Machine Systems

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35604180 1 Sender, Temp. Engine RT4

22769186 1 Sensor, Coolant Level U2

36785319 1 Sensor, Mag Speed G2

22806004 1 Sensor, Temp. A/E Disch. RT2

22806004 1 Sensor, Temp. Sep. Tank RT1

36840841 1 Solenoid Valve, Start-Run L1

36881944 1 Solenoid Valve, Unloader L2

22345755 1 Starter, Engine B1

36847838 2 Switch, Air Filter Restriction S4, S5

36757581 1 Switch, Airend Oil Pressure S6

36896975 1 Switch, Battery Disconnect

22127385 1 Switch, Key Start S1

22054076 1 Switch, Start-Run S2

36920825 1 Transducer, Regulation Pressure PT2

54496773 1 Transducer, Sep. Tank Pressure PT1

22173579 1 WEDGE Controller

89303135 2 Option - Emergency Stop Contact

89303127 1 Option - Emergency Stop Operator

Part # Qty Description Schematic Ref

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Electrical

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ElectricalGeneral Information and Operational Theory

This machine has an electronic monitor and control system to provide discharge air pressure control and engine and package monitor functions. The system uses the WEDGE controller to perform these functions. The electrical system connects all the necessary switches, sensors and transducers to the WEDGE controller in order for it to perform the monitor and control functions.

WEDGE ControllerThe WEDGE controller is the heart of the machine monitor and control system. It provides data collection, alarming and control functions for compressor operations. It is a micro controller based unit with analog and digital inputs and outputs.

The WEDGE controller is attached to the back of the control panel. The LED annunciators are part of the front panel of the WEDGE. They can be seen through the laminate on the front of the control panel. The WEDGE is attached to the control panel.

The first function of the WEDGE is to scan all analog and digital inputs at a fixed time interval. The analog values are then compared against minimum and maximum values and an ALERT or SHUTDOWN is issued, if a value is out of range.

The second function of the WEDGE controller is machine discharge pressure control. The WEDGE monitors the regulation system air pressure and varies the engine throttle to maintain the setpoint discharge air pressure. The setpoint pressure is set using the regulator on the separator tank.

The third function of the WEDGE controller is to communicate with the diesel engine via the J1939 CAN network. The WEDGE provides the engine throttle setting to the engine controller and retrieves diagnostic information from the engine.

A frequency throttle is used to communicate with the engine. A square wave frequency signal from 150 Hz to 375 Hz is sent from the WEDGE controller to the engine controller. The signal is linear from 150 Hz at engine idle to 375 Hz at maximum run speed.

Sensors and Transducers

The electronics system contains sensors and transducers that are used to collect process data from the compressor. The temperature is measured by a thermistor. This device exhibits a change in resistance as the temperature changes. The resistance causes an input voltage change to the WEDGE controller input and is interpreted as a temperature change.

The electronics system also contains pressure transducers to measure process pressure changes. These devices have an output signal of .45 VDC to 4.5 VDC, corresponding to 0 psi and the maximum measured psi for a particular device. The maximum pressure transducer ranges are 100 or 225 psi. The 100 and 225 psi devices are gauge pressure devices. These are three wire devices: excitation, signal and ground (return) connections.

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Electrical Operation & Maintenance Manual

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Digital Inputs and OutputsThe WEDGE controller scans digital inputs such as switch contacts. These are either “ON” (24V DC) or “OFF (0V DC). These digital inputs are connectd to switches within the package such as the key start switch, air filter switches and IQ filter switches.

The WEDGE controller provides 24V DC digital outputs to control solenoids, start compressor and DC heaters. These are 24V DC “ON” and Zero Volt DC “OFF”. They are current limited and short circuit protected.

Controller Outputs:

The WEDGE controller has three different types of outputs: frequency, pulse width modulated (PWM) and 24 VDC digital (ON / OFF). The frequency output is used as a throttle signal for the engine.

The WEDGE controller varies the frequency from 150 Hz to 375 Hz. The frequency signal is a 50% duty cycle, 24V DC, square wave. This throttle signal is used with the Cummins engine.

The PWM signal is used as a throttle signal for the Caterpillar engine. It has a base frequency of 500 Hz and the duty cycle varies from 10% to 90%.

Pressure Control

The discharge pressure is controlled by manipulating the engine speed and compressor inlet valve position. The inlet valve position is controlled pneumatically and the engine speed setpoint is determined by the WEDGE controller. The WEDGE measures the pneumatic system regulation pressure and computes an engine throttle setting. This throttle setting is sent to the engine via the frequency throttle, PWM or J1939 throttle, depending on which technique is used. The engine controller will control engine speed to this throttle setting.

Electronic Engine

This machine contains an emissions certified diesel engine. In order to meet the emissions requirements, the engine has an electronic control system.

The control system handles all the monitor, alarm and control functions for the engine. The WEDGE controller communicates with the engine controller over the J1939 CAN network.

The WEDGE controller receives diagnostic and run time data from the engine over the J1939 CAN network.

J1939 Data Link - The CAN network is a single pair shielded cable within the W1 main harness. The termination resistors (Terminator) are important to prevent reflections on the transmission line and must be in place for the network to function properly. The shield from the cable is connected to the machine metal at the WEDGE controller end.

The connection must be properly made with good metal to metal contact between the wire terminal and the machine metal.

The engine diagnostics connector is located on the left side of the engine. This is used to connect the engine manufacturers service tools to the CAN network. This connector also provides 24 VDC power to these service tools.

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Operation & Maintenance Manual Electrical

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Electrical System

The electrical system consists of the wiring harnesses and associated electrical devices such as relays, switches, lights, solenoids and alarm horn.

The schematic diagrams show the connections for these harnesses.

The electrical circuits are protected using ATC style fuses. A fuse should only be replaced with one of the same rating. Replacing a fuse with one of a larger rating could lead to harness damage. If a fault occurs and the circuit does not have the appropriate size fuse, wires could be burned in the harness and damage other circuits.

Trouble Shooting Flow Chart

Control panel key is turned to “ON” position, WEDGE controller annunciator lamps and 4 digit LED display do not come on.

Check F1 fuse

Check operation of switch S1

Check wiring from S1 to WEDGE controller

Check battery voltage, Ensure battery disconnect switch is turned ON

WEDGE controller annunciator lamps and 4 digit LED display initialize OK but alternator lamp and engine oil pressure lamps do not blink.

J1939 CAN communications not working

Check for 24 VDC key switch at engine, CAN network wiring problem

Ensure 24VDC power to engine ECM

Check connector pins

Engine cranks but will not start

Ensure key switch (24VDC) at engine

Frozen fuel cooler or associated piping

Estop Button pressed (ESA units) or

Estop jumpers not making connection

Clear active engine fault code

Engine does not crank when key turned to crank position

Check switch S1

Check relay K1

Check starter solenoid

Check starter motor

Check WEDGE output to K1 relay

Check battery voltage

Compressor fails to load when “Service Air” switch pressed

Check Run/Start valve operation

Verify frequency throttle signal at engine

Check “Service Air” switch operation

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Options

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Operation & Maintenance Manual Options

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Options

IQ System Operating Instructions - 1

Key

1 Three way valve 5 Filters

2 Ball valve1¼” 6 Aftercooler

3 Ball valve2” 7 Minimum pressure valve

4 Safety valve 8 Separator tank

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IQ System

The IQ System is a complete, self-contained system 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. The condensate disposal system injects all liquid condensed from the moisture separator and filters into the engine exhaust system where it is vaporized by heat. This eliminates the need for collecting the condensate, and the added cost of disposing of the condensate, which is often regulated by local, state, and/or federal regulations.

When equipped with the low ambient feature, the IQ System automatically adjusts movable louvers to control airflow through the aftercooler, ensuring that the compressed air temperature always remains above freezing temperatures (typically 45°F (7°C)) at any ambient temperature down to -10°F (-23°C). This prevents the need for 120V AC heat tracing systems, or any manual adjustment to prevent freezing of the compressed air system. All drain points for the condensate handling system are heated with 24VDC heaters, which are integral to the compressor heater system.

Standard Non-Louvered configuration not to be operated below freezing.

IQ System Operating Instructions - 2The compressed air exits the separator tank through the top cover piping, and can then travel along one of two paths, selectable via manual valving.

One path allows Standard Operation, which bypasses the IQ System, and delivers air quality equivalent to a standard oil-flooded portable compressor. If the IQ System is enabled by proper setting of the selector valve, the compressed air first enters the aftercooler.

The aftercooler is cooled by the incoming compressor package air, which is controlled by movable louvers mounted on the aftercooler (if equipped with low ambient option). At most conditions, the louvers are fully open, and maximum aftercooling is available. The compressed air and condensate (water with a small amount of compressor lubricant) exits the aftercooler and enters the moisture separator, where most of the condensate is removed. The compressed air then flows through two stages of filtration, where the aerosol water and oil is removed down to approximately 0.01 ppm, and all particulates are removed down to 0.01 micron.

At the bottom of the moisture separator and both filters are strainers and constant-bleed orifices, which are sized to allow the maximum flow of condensate while minimizing compressed air loss.

The condensate lines are then piped together, and the condensate is injected at a single point into the engine exhaust piping. The compressed air then travels through the minimum pressure valve, and out through the service air valve. The air pressure gauge on the instrument panel indicates the pressure inside the separator tank.

If the IQ System is bypassed (Standard Operation selected), the delivered air pressure will be approximately equal to the separator tank pressure. If the IQ System operation is selected, the delivered air pressure will be slightly less, depending on the restriction of the filters.

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Operation & Maintenance Manual Options

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Low Ambient Option Operation

When the ambient temperature falls to the point that the aftercooler outlet temperature is approaching 45°F (7°C), the Temperature Control Unit (TCU), mounted on the rear of the control panel, will automatically adjust the louvers to control the cooling airflow through the aftercooler.

In the event that the unit is operating under abnormal conditions (i.e., an enclosure door open) which would cause excessive cooling of the aftercooler, a temperature sensor in the aftercooler outlet header will signal the TCU to further close the louvers if the compressed air temperature falls to approximately 36°F (2°C) or lower.

There are no user selectable or serviceable components in the TCU. Contact Ingersoll-Rand Service if any abnormal operation of the freeze protection control system occurs.

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 the filters are mounted inside the control panel, and will shut down the compressor if restriction exceeds recommended values.

Weekly Maintenance:

• Remove Y-strainer screens at the bottom of the moisture separator and both filtersand clean out any residue.

• Verify that the orifices below the Y-strainers are not clogged.

• Verify that the piping from the orifice purge points to the exhaust system is notclogged.

Yearly Maintenance:

The normal maintenance interval on the primary and secondary IQ System filters is one year, or earlier if pressure drop becomes excessive. Restriction indicators for the filters are mounted inside the control panel, and will shut down the compressor if restriction exceeds recommended values.

Filter Replacement

• With engine stopped, ensure pressure is relieved from air system.

• Remove all wires and hoses connected to drains on bottom of each filter housing.Inspect fittings and hoses for any blockage. Clean if necessary.

• Using a chain wrench or similar tool, loosen the housing. The housing should beremoved by hand after loosening, taking care to prevent the housing from falling tothe floor panel.

• Lower the housing to floor panel and lean it against the airend.

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• Remove and replace the filter element, being careful not to damage outer wrap.

Verify the part number of new element vs. old element, as the two IQ filters are of different media.

• Put a small amount of petroleum jelly or other non-synthetic grease on the elementO-Ring to aid installation into the filter head.

• Replace housing, making sure to not overtighten.

• Repeat the above procedure on the remaining filter element.

• Reconnect all wires and hoses to drains on bottom of each filter housing.

SAFETY

CAUTION!

The compressor regulation system is adjusted to maintain regulatedpressure at the separator tank. DO NOT adjust regulation to provide fullregulation pressure at the service valve when the IQ System is enabled.This will result in operation at excessive horsepower levels, causingoverheating, reduced engine life, and reduced airend life.

CAUTION!

Excessively restricted filter elements may cause an increase in theamount of aerosol water and oil carryover, which could result in damageto downstream equipment. Normal service intervals should not beexceeded.

CAUTION!

Blockage of the condensate will result in flooding of the vessels. Ifflooding occurs, excessive condensate may enter the air stream andcould result in damage to downstream equipment.

NOTICEDo not operate at temperatures less that 2°C (36°F) unless equipped withlow ambient IQ option.

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102 22826226

**Always use Ingersoll-Rand Replacement parts!**

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©2009 Doosan Infracore International, Inc. Printed in the USA

Doosan Infracore Portable Power 1293 Glenway DriveStatesville, N.C. 28625www.doosanportablepower.com