Ingersoll Rand P 425AWIR, P 600WIR, XP 375AWIR, HP 375AWIR, HP 450WIR, VHP 300AWIR, VHP 400WIR portable compressor Operation and maintenance manual

7/120, 9/110, 10/105, 14/85
7/170, 10/125, 14/115
OPERATION AND MAINTENANCE MANUAL
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
7/120 9/110
10/105 14/85
7/170 10/125 14/115
SERIAL No :
C.C.N.
DATE
320001 –>
: 22191225 GB
: SEPTEMBER 2003
Machine models represented in this manual may be used in various locations world–wide. Machines sold
and shipped into European Union Territories require that the machine display the EC Mark and conform
to various directives. In such cases, the design specification of this machine has been certified as
complying with EC directives. Any modification to any part is absolutely prohibited and would result in
the CE Certification and marking being rendered invalid. A declaration of that conformity follows:
DECLARATION OF CONFORMITY WITH EC DIRECTIVES
98/37/EC, 93/68/EEC, 89/336/EEC
We
Ingersoll–Rand Company
Represented in EC by:
P.O. Box 868
501 Sanford Avenue
Mocksville, North Carolina 27028
Ingersoll–Rand Company Limited
Swan Lane
Hindley Green
Wigan WN2 4EZ
United Kingdom
Declare that, under our sole responsibility for manufacture and supply, the product(s)
7/120 (P425AWIR) 9/110 (XP375AWIR) 10/105 (HP375AWIR)
14/85 (VHP300AWIR)
to which this declaration relates, is (are) in conformity with the provisions of the above
directives using the following principal standards
EN29001 : EN292, EN60204–1, EN1012–1, PN8NTC2, EN50081, EN50082
Issued at Mocksville on
1–1–2003
Issued at Hindley Green on
1–1–2003
________________________________
________________________________
Harry Seddon
Quality assurance manager
Ric Lunsford
Manager of quality control
CONFORMITY WITH NOISE DIRECTIVE 2000/14/EC
Ingersoll–Rand Company Limited declare that the following Portable Compressors have been
manufactured in conformity with the directive as shown
Directive
2000/14/EC
Annex VI
Part I
kW
Mean
measured
value
Guaranteed
Level
Notified body
93
100.2 LWA
101 LWA
A V Technology
Stockport UK
Nr 1067
Machine
Type
14/85WIR
10/105WIR
9/110WIR
7/120WIR
________________________________
Issued at . . . . . . . . . Mocksville, NC
1st Declaration . . . . January 11, 2003
Ric Lunsford
Manager of quality control
EC Pressure Equipment Directive and Related Regulations
We declare that this product has been assessed according to the Pressure Equipment Directive (97/23/EC)
and, in accordance with the terms of this Directive, has been excluded from the scope of this Directive.
It may carry ”CE” marking in compliance with other applicable EC Directives.
Machine models represented in this manual may be used in various locations world–wide. Machines sold
and shipped into European Union Territories require that the machine display the EC Mark and conform
to various directives. In such cases, the design specification of this machine has been certified as
complying with EC directives. Any modification to any part is absolutely prohibited and would result in
the CE Certification and marking being rendered invalid. A declaration of that conformity follows:
DECLARATION OF CONFORMITY WITH EC DIRECTIVES
98/37/EC, 93/68/EEC, 89/336/EEC
We
Ingersoll–Rand Company
Represented in EC by:
P.O. Box 868
501 Sanford Avenue
Mocksville, North Carolina 27028
Ingersoll–Rand Company Limited
Swan Lane
Hindley Green
Wigan WN2 4EZ
United Kingdom
Declare that, under our sole responsibility for manufacture and supply, the product(s)
7/170 (P600WIR) 10/125 (HP450WIR) 14/115 (VHP400WIR)
to which this declaration relates, is (are) in conformity with the provisions of the above
directives using the following principal standards
EN29001 : EN292, EN60204–1, EN1012–1, PN8NTC2, EN50081, EN50082
Issued at Mocksville on
1–1–2003
Issued at Hindley Green on
1–1–2003
________________________________
________________________________
Harry Seddon
Quality assurance manager
Ric Lunsford
Manager of quality control
CONFORMITY WITH NOISE DIRECTIVE 2000/14/EC
Ingersoll–Rand Company Limited declare that the following Portable Compressors have been
manufactured in conformity with the directive as shown
Directive
2000/14/EC
Annex VI
Part I
kW
Mean
measured
value
Guaranteed
Level
Notified body
126.5
100.2 LWA
101 LWA
A V Technology
Stockport UK
Nr 1067
Machine
Type
14/115
10/125
7/170
________________________________
Issued at . . . . . . . . . Mocksville, NC
1st Declaration . . . . January 11, 2003
Ric Lunsford
Manager of quality control
EC Pressure Equipment Directive and Related Regulations
We declare that this product has been assessed according to the Pressure Equipment Directive (97/23/EC)
and, in accordance with the terms of this Directive, has been excluded from the scope of this Directive.
It may carry ”CE” marking in compliance with other applicable EC Directives.
1
CONTENTS
61
SERVICE TOOLS
2
FOREWORD
65
FAULT FINDING
3
WARRANTY
67
OPTIONS
9
DECALS
70
PARTS ORDERING
13
SAFETY
16
GENERAL INFORMATION
Dimensions
Data
21
ABBREVIATIONS & SYMBOLS
####
Contact
number
ENGINE INSTRUCTION MANUAL
46
MAINTENANCE
Routine maintenance
Lubrication
Speed & pressure regulation
Torque settings table
Compressor lubrication
58
MACHINE SYSTEMS
Electrical system
Piping & instrumentation system
for
serial
–>#### Up to Serial No.
####–> From Serial No.
OPERATING INSTRUCTIONS
Commissioning
Prior to starting
Starting
Stopping
Emergency stopping
Re–starting
Monitoring during operation
Decommissioning
29
Ingersoll–Rand
*
†
AR
D
DK
E
F
GB
HA
I
N
NL
P
S
SF
F.H.R.G.
V.H.R.G.
1
Not illustrated
Option
As required
Germany
Denmark
Spain
France
Great Britain
High ambient machine
Italy
Norway
Netherlands
Portugal
Sweden
Finland
Fixed height running gear
Variable height running gear
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
This machine has been designed and supplied for use only in
the following specified conditions and applications:
. Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in
the GENERAL INFORMATION section of this manual.
FOREWORD
The contents of this manual are considered to be proprietary
and confidential to Ingersoll–Rand and should not be
reproduced without the prior written permission of
Ingersoll–Rand.
UNITS MANUFACTURED IN NORTH AMERICA: Generation
of electricity at 120V (1ph) at 60 Hertz.
Nothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied,
regarding the Ingersoll–Rand products described herein. Any
such warranties or other terms and conditions of sale of
products shall be in accordance with the standard terms and
conditions of sale for such products, which are available upon
request.
UNITS MANUFACTURED IN EUROPE: Generation of
electricity not applicable.
The use of the machine in any of the situation types
listed in table 1:–
a) Is not approved by Ingersoll–Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll–Rand.
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 authorised
Ingersoll–Rand service department.
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and
purity checks.
The design specification of this machine has been certified
as complying with EC directives. As a result:
(a) Any machine modifications are strictly prohibited, and will
invalidate EC certification.
Use of the machine outside the ambient temperature range
specified in the GENERAL INFORMATION SECTION of this
manual.
(b) A unique specification for USA/Canada is adopted and
tailored to the territory.
This machine is not intended and must not be used in
potentially explosive atmospheres, including situations where
flammable gases or vapours may be present.
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, be of a type approved by Ingersoll–Rand.
. clearly rated for a pressure at least equal to the machine
maximum allowable working pressure.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation,
operation and maintenance.
Details of approved equipment
Ingersoll–Rand Service departments.
are
available
Use of the machine fitted with non Ingersoll–Rand approved
components / lubricants / fluids.
Use of the machine with safety or control components
missing or disabled.
Use of the machine for storage or transportation of materials
inside or on the enclosure except when contained within the
toolbox.
from
The use of repair parts / lubricants / fluids other than those
included within the Ingersoll–Rand approved parts list may
create hazardous conditions over which Ingersoll–Rand has no
control. Therefore Ingersoll–Rand cannot be held responsible
for equipment in which non–approved repair parts are installed.
GENERATOR
Use of the generator to supply load(s) greater than those
specified.
Use of unsafe or unserviceable electrical equipment
connected to the generator.
Ingersoll–Rand 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.
Use of electrical equipment:
(a) Having incorrect voltage and/or frequency ratings.
(b) Containing computer equipment and/or similar electronics.
The intended uses of this machine are outlined below and
examples of unapproved usage are also given, however
Ingersoll–Rand cannot anticipate every application or work
situation that may arise.
The company accepts no responsibility for errors in
translation of this manual from the original English version.
 COPYRIGHT 2003
INGERSOLL–RAND COMPANY
IF IN DOUBT CONSULT SUPERVISION.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
2
G.
WARRANTY
Ingersoll–Rand, through its distributor, warrants that each item
of equipment manufactured by it and delivered hereunder to the
initial user will be free of defects in material and workmanship.
With respect to the following types of equipment, the warranty
period enumerated below will apply.
A.
B.
Aftercoolers – The earlier of nine (9) months from date
of shipment to or six (6) months from start up by initial user.
Ingersoll–Rand Platinum Drive Train Warranty
(Optional) – Platinum drive train pertains to the
Ingersoll–Rand Engine and Airend combination. The
earlier of sixty (60) months from shipment to, or the
accumulation of 10,000 hours of service. The starter,
alternator, fuel injection system and all electrical
components are excluded from the extended warranty.
The airend seal and drive coupling are included in the
warranty (air–end drive belts are not included). The
optional warranty is automatically available when meeting
the following conditions:
The original airend is returned assembled and unopened.
Portable Compressors, Portable Generator Sets
(GENSET), Portable Light Towers and Air Dyers – The
earlier of twelve (12) months from shipment to or the
accumulation of 2,000 hours of service by the initial user.
Continued use of genuine Ingersoll–Rand parts, fluids, oil
and filters.
Maintenance is performed at prescribed intervals.
C.
Portable Compressor Air Ends – The earlier of
twenty–four (24) months from shipment to or the
accumulation of 4,000 hours of service by the initial user.
For Air Ends, the warranty against defects will include
replacement of the complete Air End, provided the original
Air End, is returned assembled and unopened.
It is the obligation of the user to provide verification that
these conditions have been satisfied when submitting
warranty claims.
H.
C.1
Portable Compressor Airend Limited Optional
Warranty – The earlier of sixty (60) months from shipment
to or the accumulation of 10,000 hours of service. The
optional warranty is limited to defects in rotors, housings,
bearings and gears and provided all the following
conditions are met:
Ingersoll–Rand will provide a new part or repaired part, at its
election, in place of any part which is found upon its inspection
to be defective in material and workmanship during the period
prescribed above. Such part will be repaired or replaced without
charge to the initial user during normal working hours at the
place of business of an Ingersoll–Rand distributor authorized to
sell the type of equipment involved or other establishment
authorized by Ingersoll – Rand. User must present proof of
purchase at the time of exercising warranty.
The original airend is returned assembled and unopened.
Continued use of genuine Ingersoll–Rand parts, fluids,
oils and filters.
The above warranty does not apply to failures occurring as a result of abuse; misuse, negligent repairs, corrosion, erosion and
normal wear and tear, alterations or modifications made to the
product without express written consent of Ingersoll–Rand; or
failure to follow the recommended operating practices and
maintenance procedures as provided in the product’s operating
and maintenance publications.
Maintenance is performed at prescribed intervals.
D.
Genset Generators – The earlier of twenty–four (24)
months from shipment to or the accumulation of 4,000
hours of service by the initial user.
E.
Portable Light Tower Generators – The earlier of twelve
(12) months from shipment to or the accumulation of 2,000
hours of service by the initial user. Light Source model
only, the earlier of twenty–four (24) months from shipment
to or the accumulation of 4,000 hours of service.
F.
Ingersoll–Rand Engines – The earlier of twenty—four
(24) months from shipment to or the accumulation of 4,000
hours of service.
Spare Parts – Six (6) months from date of installation
Accessories or equipment furnished by Ingersoll–Rand, but
manufactured by others, including, but not limited to, engines,
tires, batteries, engine electrical equipment, hydraulic
transmissions, carriers, shall carry whatever warranty the
manufacturers have conveyed to Ingersoll–Rand and which
can be passed on to the initial user.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT
OF TITLE), AND THERE ARE NO WARRANTIES OF
MERCHANTABILITY OR OF FITNESS FORA PARTICULAR
PURPOSE.
3
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
GENERAL WARRANTY INFORMATION
GENERAL WARRANTY
Portable Compressor
Portable Genset 8kW, 11KW,
20KVA thru 575KVA
Portable Genset 3.5KW thru
7.0KW and 10KW
Light Tower
Extended Coverage
Package
1 year/2000 hrs
Airend
2 yrs/4000 hrs
5 yrs/10,000 hrs
Limited warranty, major components (refer to operator’s manual).
Package
1 yr/2000 hrs
None
Generator
2 yrs/4000 hrs
None
Package
1 yr/2000 hrs (parts only)
None
Generator
1 yrs/2000 hrs (parts only)
None
Package
1 yr/2000 hrs
Generator
1 yr/2000 hrs
2 years/4000 hours, for Lightsource
introduced 8/16/99.
ENGINES
CATERPILLAR
Months
Hours
Extended Coverage
12
unlimited
Available at dealer
CUMMINS
24
2000
Major components 3 yrs/10,000 hrs
Available at dealer
JOHN DEERE (in compressors)
24
2000
5 yrs/5000 hrs using OEM fluids and filters
with $250 deductible
(in generators as of 1/1/01)
24
2000
2 yrs/4000 hrs using IR fluids and filters
DEUTZ
24
2000
Available at dealer
INGERSOLL–RAND
24
4000
5 yrs/10,000 hrs when using genuine Ingersoll–Rand fluids and parts. Refer to operator’s
manual.
KUBOTA (North America only)
24
2000
Major components 36 mo/3000 hrs (parts only)
(Western Europe & Oceania)
24
2000
None
(Central & South America, Asia, Middle East &
Africa)
12
1000
None
MITSUBISHI
24
2000
2 yrs/4000 hrs using IR fluids and filters
VOLVO
24
2000
2 yrs/4000 hrs using IR fluids and filters
HONDA
12
unlimited
None
VANGUARD
24
unlimited
None
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
4
PARTS
Ingersoll–Rand
Months
Hours
Coverage
6
No Limit
Parts Only
Months
Hours
Extended Coverage
12
2000
2 yrs/4000 hrs – available from
IR.
AIREND EXCHANGE
Airend
Note: Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with
each new product.
5
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Extended Limited Airend Warranty
Ingersoll–Rand Portable Compressor Division is pleased to announce the availability of extended limited airend warranty.
Announcement of the extended warranty coincides with the introduction of Pro–Tec Compressor Fluid. Pro–Tec Compressor Fluid
is an amber coloured fluid specially formulated for Portable Compressors and is being provided as the factory filled fluid for all machines
except 1 XHP650/900/1070
All machines have the standard airend warranty, – The earlier of 24 months from shipment to, or the accumulation of 4000 hours of
service by the initial user.
The warranty against defects will include replacement of the complete Airend, provided the original Airend is returned assembled and
unopened.
The optional limited warranty is the earlier of 60 months from shipment to, or the accumulation of 10,000 hours of service. The optional
warranty is limited to defects in major components (rotors, housings, gears and bearings), and is automatically available when the
following conditions are met:
1. The original airend is returned assembled and unopened.
2. Submissions of proof that Ingersoll–Rand fluid, filters and separators have been used. Refer to the Operation and Parts manual for
the correct fluids, filters and separator elements required.
3. Submissions of proof that maintenance intervals have been followed.
WARRANTY
TIME
*BARE AIREND
**AIREND COMPONENTS
STANDARD
2YRS / 4,000HRS
100% PARTS & LABOUR
100% PARTS & LABOUR
OPTIONAL
5YRS / 10,000HRS
100% PARTS & LABOUR
0%
*BARE AIREND – pertains to major airend parts (rotors, housings, gears and bearings).
**AIREND COMPONENTS – pertains to auxiliary attachments to the bare airend (seals, pumps, valves, tubes, hoses, fittings and filter
housing).
Pro–Tec and XHP505 Compressor Fluids are available from your local Ingersoll–Rand branch or distributor.
For units operating within the USA & Canada, call the Mocksville Product Support Department on 1–800–633–5206
1
XHP650/900/1070 will continue to use XHP505 and will have the extended warranty when above conditions are met.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
6
WARRANTY REGISTRATION
FOR UNITS SOURCED FROM HINDLEY GREEN, UK
Complete Machine Registration
To initiate the machine warranty, fill out the ”Warranty Registration” form 83242 11/99 supplied as part of the machine documentation,
keep a copy for your records and mail the original to:
Ingersoll Rand European Sales Ltd
Portable Power Business
Swan Lane
Hindley Green
Wigan
Lancashire
WN2 4EZ
U.K.
Attn: Customer Service Department
Note: Completion of this form validates the warranty.
Engine Registration:
I–R powered machines do not require separate engine registration.
Deutz require a separate engine registration form to be completed and mailed direct to their Cologne office. The form is supplied as part
of the machine documentation for Deutz powered machines.
Caterpillar, Cummins and Perkins do not require a separate registration form but they stipulate that any new engine should be registered
with their local dealer to initiate warranty.
You MUST provide proof of the “in–service” date when requesting engine warranty repairs.
7
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Selling Distributor
Servicing Distributor
WARRANTY REGISTRATION
Name
Name
Owner/User Name
Address
Address
Address
City
City
City
County
County
County
State
State
State
Zip code
Zip code
Zip code
Telephone
Telephone
Telephone
Complete the Applicable Blocks
Owner/User Type of Business (check one only)
Construction–Heavy
(highway, excavation, etc.)
Asphalt Contractor
Coal Mining
Other Mining
Construction–Light
(carpentry, plumbing, pools,
mason, etc.)
Government
(municipal, state,
county, etc.)
Quarry
Shallow Oil &
Gas
Rental (rental center, rental
fleet, etc.)
Building Contractor
Water well
Utility
Company
(gas, electric,
water, etc.)
Industrial
(plant use)
Other
specify
Exploration
Utility
Contractor
Model S/N
Unit S/N
Engine S/N
Date delivered
Unit–Hours
Airend S/N
Truck S/N
Truck Engine S/N
SERVICING DISTRIBUTOR / USER ACKNOWLEDGEMENT
1. The Purchaser has been instructed and/or has read the manual and understands proper preventative
maintenance, general operation and safety precautions.
2. The warranty and limitation of liability has been reviewed and understood by the owner/user.
3. In the event that this unit is to be used within a nuclear facility, the owner/user shall notify
Ingersoll–Rand of such use so that Ingersoll–Rand may arrange for appropriate nuclear liability
protection from the owner–licensee of the facility.
4. Ingersoll–Rand reserves the right to make design changes or modifications of Ingersoll–Rand products
at anytime without incurring any obligation to make similar changes or modifications on previously sold
units.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
8
DECALS
Look for these signs on machines manufactured in Europe, which point out potential hazards to
the safety of you and others. Read and understand thoroughly. Heed warnings and follow
instructions. If you do not understand, inform you supervisor.
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory
Information / Instructions
WARNING: Electrical shock risk.
WARNING – Pressurised component or
system.
WARNING – Pressure control.
WARNING – Corrosion risk.
Warning
WARNING – Hot surface.
WARNING – Air/gas flow or Air
discharge.
X,X
BAR
WARNING – Pressurised vessel.
WARNING – Hot and harmful exhaust
gas.
9
WARNING – Maintain correct tyre
pressure. (Refer to the GENERAL
INFORMATION section of this manual).
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
0C
WARNING – Flammable liquid.
WARNING – Before connecting the tow
bar or commencing to tow consult the
operation and maintenance manual.
WARNING – For operating temperature
below 0C, consult the operation and
maintenance manual.
WARNING – Do not undertake any
maintenance on this machine until the
electrical supply is disconnected and
the air pressure is totally relieved.
WARNING – Consult the operation and
maintenance manual before
commencing any maintenance.
Do not breathe the compressed air from
this machine.
Do not remove the Operating and
Maintenance manual and manual holder
from this machine.
Do not stack.
Do not operate the machine without the
guard being fitted.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
10
Do not stand on any service valve or other
parts of the pressure system.
Do not operate with the doors or enclosure
open.
Do not use fork lift truck from this side.
XX
km/h
Do not exceed the trailer speed limit.
No naked lights.
Do not open the service valve before the
airhose is attached.
Use fork lift truck from this side only.
Emergency stop.
Tie down point
Lifting point.
On (power).
Off (power).
Read the Operation and Maintenance
manual before operation or maintenance
of this machine is undertaken.
When parking use prop stand, handrake
and wheel chocks.
Compressor oil filling
Diesel fuel
No open flame.
Parking brake.
Rough Service Designation.
Wet Location Operation.
11
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Replace any cracked protective shield.
Oil drain.
Engine Oil
Fuel level/point
Pressure control
Malfunction
Battery charging condition
Low pressure
High pressure
Engine malfunction
High compressor temperature
Compressor malfunction
Low engine oil pressure
Engine high temperature
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
12
Rotating fan blade can cause serious injury. Do not operate
without guard in place.
SAFETY
Use care to avoid contacting hot surfaces (engine exhaust
manifold and piping, air receiver and air discharge piping, etc.).
WARNINGS
Warnings call attention to instructions which must be
followed precisely to avoid injury or death.
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.
CAUTIONS
Cautions call attention to instructions which must be
followed precisely to avoid damaging the product, process or its
surroundings.
NOTES
Notes are used for supplementary information.
Never operate unit with guards, covers or screens removed.
Keep hands, hair, clothing, tools, blow gun tips, etc. well away
from moving parts.
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.
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 operator reads and understands the decals
and consults the manuals before maintenance or operation.
Ensure that the machine is operating at the rated pressure
and that the rated pressure is known to all relevant personnel.
Ensure that the Operation and Maintenance manual, and the
manual holder, are not removed permanently from the machine.
All air pressure equipment installed in or connected to the
machine must have safe working pressure ratings of at least the
machine rated pressure.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
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 accidently be pressurised / over pressurised by
another.
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, dependant on local
regulations or the degree of risk involved.
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.
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.
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.
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.
If the discharged air is to be ultimately released into a
confined space, adequate ventilation must be provided.
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.
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.
Never inspect or service unit without first disconnecting
battery cable(s) to prevent accidental starting.
Avoid bodily contact with compressed air.
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).
The safety valve located in the separator tank must be
checked periodically for correct operation.
13
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
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.
Battery
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).
DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY
SINCE THIS MAY CAUSE IT TO EXPLODE.
A battery contains sulphuric 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.
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.
Never allow the unit to sit stopped with pressure in the
receiver–separator system.
Materials
Radiator
The following substances may be produced during the
operation of this machine:
. brake lining dust
. engine exhaust fumes
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.
AVOID INHALATION
Ensure that adequate ventilation of the cooling system and
exhaust gases is maintained at all times.
Transport
The following substances are used in the manufacture of this
machine and may be hazardous to health if used incorrectly:
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.
anti–freeze
compressor lubricant
engine lubricant
preservative grease
rust preventative
diesel fuel
battery electrolyte
AVOID INGESTION, SKIN CONTACT AND INHALATION OF
FUMES
Ensure that the maximum trailer weight does not exceed the
maximum gross weight of the machine (by limiting the
equipment load), limited by the capacity of the running gear.
Should compressor lubricant come into contact with the
eyes, then irrigate with water for at least 5 minutes.
Note:
Gross mass (on data plate) is for the basic machine and fuel
only, excluding any fitted options, tools, equipment and foreign
materials.
Should compressor lubricant come into contact with the
skin, then wash off immediately.
Before towing the machine, ensure that:–
Consult a physician if large amounts of compressor lubricant
are ingested.
. the tyres 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 traffic requirements.
. break-away cables/safety chains are connected to the
towing
vehicle.
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.
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.
Never operate the engine of this machine inside a building
without adequate ventilation. Avoid breathing exhaust fumes
when working on or near the machine.
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.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
To ensure full braking efficiency, the front (towing eye)
section must always be set level.
When adjusting variable height running gear:–
14
Ensure front (towing eye) section is set level
Where brakes only are fitted:
When raising towing eye, set rear joint first, then front joint.
a) Ensure that the breakaway cable is securely coupled to the
handbrake lever and also to a substantial point on the towing
vehicle.
When lowering towing eye, set front joint first, then rear joint.
b) Ensure that the effective cable length is as short as possible,
whilst still allowing enough slackness for the trailer to articulate
without the handbrake being applied.
Where brakes and safety chains are fitted:
After setting, fully tighten each joint by hand and then tighten further to the next pin. Refit the pin.
a) Loop the chains onto the towing vehicle using the towing
vehicle hitch as an anchorage point, or any other point of similar
strength.
When parking always use the handbrake and, if necessary,
suitable wheel chocks.
b) Ensure that the effective chain length is as short as possible
whilst still allowing normal articulation of the trailer and effective
operation of the breakaway cable.
Make sure wheels, tyres and tow bar connectors are in safe
operating condition and tow bar is properly connected before
towing.
Where safety chains only are fitted:
a) Loop the chains onto the towing vehicle using the towing
vehicle hitch as an anchorage point, or any other point of similar
strength.
Safety chains / connections and their adjustment
b) When adjusting the safety chains there should be sufficient
free length in the chains to allow normal articulation, whilst also
being short enough to prevent the towbar from touching the
ground in the event of an accidental separation of the towing
vehicle from the trailer.
The legal requirements for the joint operation of the
breakaway cable and safety chains are as yet unidentified by
71/320/EEC or UK regulations. Consequently we offer the
following advice / instructions.
15
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
7/120 9/110 10/105 14/85
P425AWIR XP375AWIR HP375AWIR
VHP300AWIR
TOP VIEW
REAR VIEW
SIDE VIEW
FRONT VIEW
MANUFACTURED IN EUROPE
All dimensions in inches(mm)
E Access items:
Radiator fill
A Instrument panel access door
F Package air outlet
B Package air inlet
G Track width
C Access items:
Separator element & fill
Compressor oil filter
Fuel filters
Dipstick
Engine oil fill
Coolant bottle fill
H Variable height drawbar
162 (4114) minimum / 168 (4277) maximum
J Variable height drawbar
17 (420) minimum / 35 (880) maximum
D Access items:
Fuel fill
Engine oil filter
Fuel filter
Engine and compressor air filter
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
16
7/170 10/125 14/115
P600WIR HP450WIR VHP400WIR
TOP VIEW
REAR VIEW
FRONT VIEW
SIDE VIEW
MANUFACTURED IN EUROPE
All dimensions in inches(mm)
E Access items:
Radiator fill
A Instrument panel access door
F Package air outlet
B Package air inlet
G Track width
C Access items:
Separator element & fill
Compressor oil filter
Fuel filters
Dipstick
Engine oil fill
Coolant bottle fill
H Variable height drawbar
184.29 (4681) minimum / 189.21 (4806) maximum
J Variable height drawbar
18.98 (482) minimum / 37.17 (944) maximum
D Access items:
Fuel fill
Engine oil filter
Fuel filter
Engine and compressor air filter
17
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
COMPRESSOR
Actual free air delivery.
(7/120) (P425AWIR)
12,0 m3 min–1 (425 CFM)
Safety valve setting.
(7/120) (P425AWIR)
10 bar (150 PSI)
Safety valve setting.
(9/110) (XP375AWIR)
10 bar (200 PSI)
Actual free air delivery.
(9/110) (XP375AWIR)
10,5 m3 min–1 (375 CFM)
Safety valve setting.
(10/105) (HP375AWIR)
14 bar (200 PSI)
Actual free air delivery.
(10/105) (HP375AWIR)
10,5 m3 min–1 (375 CFM)
Safety valve setting.
(14/85) (VHP300AWIR)
17 bar ( 250 PSI)
Actual free air delivery.
(14/85) (VHP300AWIR)
8,5 m3 min–1 (300 CFM)
Safety valve setting.
(7/170) (P600WIR)
10 bar (150 PSI)
Safety valve setting.
(10/125) (HP450WIR)
14 bar (200 PSI)
Safety valve setting.
(14/115) (VHP400WIR)
17 bar ( 250 PSI)
Maximum pressure ratio (absolute).
(7/120) (P425AWIR)
7 ,9 : 1
Actual free air delivery.
(7/170) (P600WIR)
17,0 m3 min–1 (600 CFM)
Actual free air delivery.
(10/125) (HP450WIR)
12,8 m3 min–1 (450 CFM)
Actual free air delivery.
(14/115) (VHP400WIR)
11,3 m3 min–1 (400 CFM)
7 bar (100 PSI)
Maximum pressure ratio (absolute).
(9/110) (XP375AWIR)
9, 6 : 1
Normal operating discharge pressure.
(7/120) (P425AWIR)
8,6 bar (125 PSI)
Maximum pressure ratio (absolute).
(10/105) (HP375AWIR)
11, 3 : 1
Normal operating discharge pressure.
(9/110) (XP375AWIR)
10,3 bar (150 PSI)
Maximum pressure ratio (absolute).
(14/85) (VHP300AWIR)
14, 8 : 1
Normal operating discharge pressure.
(10/105) (HP375AWIR)
14 bar (200 PSI)
Maximum pressure ratio (absolute).
(7/170) (P600WIR)
7 ,9 : 1
Normal operating discharge pressure.
(14/85) (VHP300AWIR)
7 bar (100 PSI)
Maximum pressure ratio (absolute).
(10/125) (HP450WIR)
11, 3 : 1
Normal operating discharge pressure.
(7/170) (P600WIR)
10,3 bar (150 PSI)
Maximum pressure ratio (absolute).
(14/115) (VHP400WIR)
14, 8 : 1
Normal operating discharge pressure.
(10/125) (HP450WIR)
Normal operating discharge pressure.
(14/115) (VHP400WIR)
14 bar (200 PSI)
Operating ambient temperature.
Whisperized
–12C TO +49C (1OF TO 120F)
Maximum allowable pressure.
(7/120) (P425AWIR)
8,6 bar (125 PSI)
Maximum discharge temperature.
120C (248F)
Cooling system.
Oil injection
Maximum allowable pressure.
(9/110) (XP375AWIR)
10.3 bar (150 PSI)
Oil capacity.
36 litres ( 9.5 GAL)
Maximum allowable pressure.
(10/105) (HP375AWIR)
12.1 bar (175 PSI)
Maximum oil system temperature.
120C (248F)
Maximum allowable pressure.
(14/85) (VHP300AWIR)
15.5 bar (225 PSI)
Maximum oil system pressure.
(7/120) (P425AWIR)
8,6 bar (125 PSI)
Maximum allowable pressure.
(7/170) (P600WIR)
8,6 bar (125 PSI)
Maximum oil system pressure.
(9/110) (XP375AWIR)
10.3 bar (150 PSI)
Maximum allowable pressure.
(10/125) (HP450WIR)
12.1 bar (175 PSI)
Maximum oil system pressure.
(10/105) (HP375AWIR)
12.1 bar (175 PSI)
Maximum allowable pressure.
(14/115) (VHP400WIR)
15.5 bar (225 PSI)
Maximum oil system pressure.
(14/85) (VHP300AWIR)
15.5 bar (225 PSI)
Maximum oil system pressure.
(7/170) (P600WIR)
8,6 bar (125 PSI)
Maximum oil system pressure.
(10/125) (HP450WIR)
12.1 bar (175 PSI)
Maximum oil system pressure.
(14/115) (VHP400WIR)
15.5 bar (225 PSI)
LUBRICATING OIL SPECIFICATION
(for the specified ambient temperatures).
ABOVE –23C(–9_F)
Recommended: Pro–Tec
Approved: SAE 10W, API CF–4/CG–4
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
18
BELOW –23C(–9_F)
Mandatory:
IR Performance 500
ENGINE
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Ingersoll–Rand Pro–TecTM
compressor
fluid
is
factory–fitted, for use at all ambient temperatures above
–23C(–9F).
NOTE: Warranty may be extended only by continuous use of
Pro–Tec and Ingersoll–Rand oil filters and separators.
No other oil/fluids are compatible with Pro–TecTM
Type/model.
Number of cylinders.
Ingersoll–Rand
6
Oil capacity.
22.1 litres (5.75 GAL)
Speed at full load.
2400 revs min–1
(RPM)
Speed at idle.
1400 revs min–1
(RPM)
Electrical system.
Power available at 2400 revs
No other oils/fluids should be mixed with Pro–TecTM
because the resulting mixture could cause damage to the
airend.
In the event that Pro–TecTM is not available and / or the end
user needs to use an approved single grade engine oil, the
complete system including separator / receiver, cooler and
pipework must be flushed clear of the first fill fluid and new
Ingersoll–Rand oil filters installed.
When this has been completed, the following oils are approved:
24V negative earth
min–1
126.8 kW (170 HP)
Fuel tank capacity
276 litres
(73 GAL)
Oil specification
Refer engine section
Coolant capacity
28.4 litres(7.5 GAL)
SOUND LEVEL DATA (‘W’ model)
A) To Pneurop code PN8NTC2.
Equivalent continuous sound pressure level.*
a) for ambient temperatures above –23C(–9F),
SAE 10W, API CF–4/CG–4
.
Rated load
85 dB(A)
(Operator position :–1m from machine)
b) for ambient temperatures below –23C(–9F),
I–R Performance 500 only.
Sound power level (84/533/EEC)
101 dB(A)
B) In compliance with 86/188/EEC.
Safety data sheets can be obtained on request from the
lubricant supplier.
Average sound pressure level at 10m
to 79/113/EEC.*
73 dB(A)
(*Machine only :– at maximum load in open site conditions)
For temperatures outside the specified ambient range,
consult Ingersoll–Rand.
C) EPA Noise
FIXED HEIGHT RUNNING GEAR (European Only)
Braked version
(7/120) ( 9/110), (10/105), (14/85)
ENGINE
7/120 (P425WIR),
9/110 (XP375AWIR),
10/105 (HP375AWIR),
14/85 (VHP300AWIR)
Type/model.
Number of cylinders.
Oil capacity.
Speed at full load.
min–1(RPM)
Speed at idle.
(RPM)
Shipping weight.
Ingersoll–Rand
4
13.2 litres ( 3.5 GAL)
2400
76 dB(A)
revs
1935kg (4266Lbs)
Maximum weight.
2200kg (4850Lbs)
Maximum horizontal towing force.
2009kg (4429Lbs)
Maximum vertical coupling load
(nose weight).
100 kgf (220 Lbs)
1400 revs min–1
Electrical system.
24V negative earth
FIXED HEIGHT RUNNING GEAR (European Only)
Braked version
(7/170), (10/125), (14/115)
Power available at 2400 revs min–1
93 kW (125 HP)
Shipping weight.
2364kg (5200Lbs)
Maximum weight.
2598kg (5715Lbs)
Maximum horizontal towing force.
2700kg (5940Lbs)
Maximum vertical coupling load
(nose weight).
150 kgf (330 Lbs)
Fuel tank capacity
GAL)
219.5 litres ( 58
Oil specification
Refer engine section
Coolant capacity
17 litres(4.5 GAL)
19
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
VARIABLE HEIGHT RUNNING GEAR (European Only)
Braked version
(7/120) ( 9/110), (10/105), (14/85)
Shipping weight.
CAUTION:
This is a safety critical procedure. Double check the torque
settings after assembly
1965kg (4331Lbs)
Maximum weight.
2200kg (4850Lbs)
Maximum horizontal towing force.
2009kg (4429Lbs)
Maximum vertical coupling load
(nose weight).
100 kgf (220 Lbs)
Fit the propstand and coupling. Remove the supports and
set the machine level.
VARIABLE HEIGHT RUNNING GEAR (European Only)
Braked version
(7/170), (10/125), (14/115)
Shipping weight.
2400kg (5280Lbs)
Maximum weight.
2636kg (5800Lbs)
Maximum horizontal towing force.
2900kg (5940Lbs)
Maximum vertical coupling load
(nose weight).
Before towing the unit, ensure that the tyre pressures are
correct (refer to the GENERAL INFORMATION section of this
manual) and that the handbrake is functioning correctly (refer to
the MAINTENANCE section of this manual). Before towing the
unit during the hours of darkness, ensure that the lights are
functioning correctly (where fitted).
Ensure that all transport and packing materials are
discarded.
150 kgf (330 Lbs)
Ensure that the correct fork lift truck slots or marked lifting /
tie down points are used whenever the machine is lifted or
transported.
WHEELS AND TYRES (European) – 7/120, 9/110, 10/105,
14/85
Number of wheels.
2 x 5.5
Tyre size.
205/75 R16
Tyre pressure.
4.5 bar (65 psi)
When selecting the working position of the machine ensure
that there is sufficient clearance for ventilation and exhaust
requirements, observing any specified minimum dimensions (to
walls, floors etc.).
WHEELS AND TYRES (European) – 7/170, 10/125, 14/115
Number of wheels.
2 x 6.0
Tyre size.
205/75 P17.5
Tyre pressure.
6.5 bar (94 psi)
Adequate clearance needs to be allowed around and above
the machine to permit safe access for specified maintenance
tasks.
Further information may be obtained by request through
Ingersoll–Rand customer services department.
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.
COMMISSIONING
Attach the battery cables to the battery(s) ensuring that they
are tightened securely. Attach the negative cable before
attaching the positive cable.
Upon receipt of the unit, and prior to putting it into service, it
is important to adhere strictly to the instructions given below in
PRIOR TO STARTING.
WARNING: All air pressure equipment installed in or
connected to the machine must have safe working
pressure ratings of at least the machine rated pressure,
and materials compatible with the compressor lubricant
(refer to the GENERAL INFORMATION section).
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 recognised by its markings. Ensure that it is
functioning correctly and that the method of operation is known.
Running gear drawbar (European Area) – Machines are
shipped to some areas with the drawbar removed. Fitting
involves four nuts / bolts to secure the drawbar to the axle and
two bolts to fit the drawbar to the front of the machine with the
saddle and spacer block.
Support the front of the machine, fit the wheel chocks to stop
the machine moving and attach the drawbar. Refer to the torque
value table in the MAINTENANCE section of this manual for the
correct torque values.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
WARNING: 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 accidently be
pressurised / over pressurised by another.
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
WARNING: If flexible discharge hoses are to carry more
than 7 bar pressure then it is recommended that safety
retaining wires are used on the hoses.
20
OPERATING INSTRUCTIONS
PRIOR TO STARTING
5. Drain the fuel filter water separator of water, ensuring that
any released fuel is safely contained.
1. Place the unit in a position that is as level as possible. The
design of the unit permits a 15 degree lengthways and sideways
limit on out of level operation. It is the engine, not the
compressor, that is the limiting factor.
6. Open the service valve(s) to ensure that all pressure is
relieved from the system. Close the service valve(s).
When the unit has to be operated out of level, it is important
to keep the engine oil level near the high level mark (with the unit
level).
7. CAUTION: Do not operate the machine with the
canopy/doors in the open position as this may cause
overheating and operators to be exposed to high noise levels.
CAUTION: Do not overfill either the engine or the compressor
with oil.
8. Check the radiator coolant level (with the unit level).
2. Check the engine lubrication oil in accordance with the
operating instructions in the Engine Operator’s Manual.
Check the air restriction indicator(s). Refer to the
MAINTENANCE section of this manual.
3. Check the compressor oil level in the sight glass located on
the separator tank.
When starting or operating the machine in temperatures
below or approaching 0C, 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.
4. Check the diesel fuel level. A good rule is to top up at the end
of each working day. This prevents condensation from
occurring in the tank.
CAUTION: Use only a No. 2–D diesel fuel oil with a minimum
octane number of 45 and a sulphur content not greater than
0,5%.
CAUTION: When refuelling:–
. 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.
21
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Control Panel
9
10
4
8
11
1
12
2
3
5
6
13
7
14
DIAGNOSTIC/AUTO SHUTDOWN (STANDARD)
OPTIONAL CONTROLS
1. Compressor fault – Needs attention. See Wedge
diagnostic panel for more detail.
8. Engine Speed Gauge – Indicates engine speed.
9. Discharge Air Temp. Gauge – Indicates in F and C.
Normal operating range: 185F/85C to 248F /120C.
2. Engine Fault – Needs attention. See Wedge diagnostic
panel for more detail.
10.Engine Oil Pressure Gauge – Indicates engine oil pressure
(psi (kPa).
3. Hourmeter – Records running time for maintenance.
4. Compressor Discharge Pressure Gauge – Indicates
pressure in receiver tank, psi (kPa).
11.Engine Water Temp Gauge – Indicates coolant
temperature, with normal operating range from 180F/82C to
210F /99C.
5. Fuel Level Gauge – Indicates amount of fuel in tank.
12.Voltmeter – Indicates battery condition.
CONTROLS (STANDARD)
13.Spare
6. Power Switch – Flip “ON” to activate systems prior to
Starting. Flip “OFF” to stop engine.
14.Wait To Start Lamp.
7. Service Air Switch – After warm–up, PUSH. Provides full
air pressure at the service outlet.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
22
WEDGE DIAGNOSTIC DISPLAY PANEL.
6. Spare
The Wedge diagnostic display panel is arranged
as shown above. A description of each diagnostic
indicator is as follows.
7. Low Fuel Level:
Fault indicator lamp.
Indicates shutdown due to low fuel level. Lamp
blinks at low fuel warning.
8. Compressor Malfunction: Fault indicator
lamp. Indicates shutdown due to compressor
system fault. Refer to Fault Code List.
1. High Compressor Temp: Fault indicator
lamp. Indicates shutdown due to high
compressor temperature.
9. Low Battery Voltage: Alarm indicator lamp.
Indicates battery or charging system requires
service.
2. Spare
3. Low Engine Oil Pressure: Fault indicator
lamp. Indicates shutdown due to low engine oil
pressure.
10.Engine Malfunction: Engine Fault code.
Refer to service card or engine manual for
codes and service requirements.
4. Restricted Air Filter: Alarm indicator lamp.
Indicates engine/compressor air inlet filters
need service.
11. Malfunction Code (4 Digit): Compressor or
engine fault. Refer to manual for list of codes
and service requirements.
5. High Engine Coolant Temp: Fault indicator
lamp. Indicates shutdown due to high engine
water temperature.
23
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Wedge Diagnostic Display Codes
If the
If the
fault indicator lamp is illuminated, refer to the
Alert/Shutdown list below.
fault indicator lamp is illuminated, refer to the
Engine diagnostic list below.
ALERT/SHUTDOWN CONDITIONS Version: 1.40
Alert
Condition
Code
Shutdown
Light (Blinks)
Code
Light (Steady)
Delay
(sec.)
Engine Speed <900 RPM
1
CPRSR Malf.
30
Engine Speed >2500 RPM
2
CPRSR Malf.
30
3
CPRSR Malf.
0
32
CPRSR Malf.
10
Separator Tank Temp.> 247 deg.F)
50
CPRSR Malf.
3
Machine ID Not Valid
51
CPRSR Malf.
0
Sep. Tank Temp. (RT1) Sensor Fault
53
CPRSR Malf.
10
Engine Crank Time Exceeded
Intake Manifold Temperature > 180
deg. F
6
CPRSR Malf.
Engine Not Responding To Throttle
Command
10
CPRSR Malf.
Engine Shut Itself Down: reason
unknown
29
CPRSR Malf.
Disch. Temp (RT2)
Sensor Fault
Sep. Tank Pressure (PT1)
Sensor Fault
33
CPRSR Malf.
Reg. System Pressure (PT2) Sensor
Fault
54
CPRSR Malf.
Serial Comm. Problem
70
CPRSR Malf.
CAN Bus Problem
71
CPRSR Malf.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
24
Alert
Condition
Code
Shutdown
Light (Blinks)
Code
Light (Steady)
Delay
(sec.)
Fuel Level
3
Engine Coolant Temperature
>= 220 deg. F
High Comp. Temp.
10
High Discharge Temp.
(RT2 > 247 deg. F)
High Comp. Temp.
3
Dedicated Lights:
Low Fuel Level
Fuel Level
Air Filter Restriction (Option)
Soiled Filter
Low Battery Voltage
Battery Charging
Condition
Engine Oil Pressure < 18 PSI
Low Engine Oil Pressure
Engine Coolant Temperature
>= 215 deg. F
High Engine Temp.
ENGINE DIAGNOSTIC CODES
Listing of Diagnostic Trouble Codes (DTCs)
Displayed Code
FMI*
28
3
Analog Throttle (B) Input Voltage High
4
Analog Throttle (B) Input Voltage Low
3
Analog Throttle (A) Input Voltage High
4
Analog Throttle (A) Input Voltage Low
3
Multi–state Throttle Input Voltage High
4
Multi–state Throttle Input Voltage Low
1
Engine Oil Pressure Extremely Low
3
Engine Oil Pressure Input Voltage High
4
Engine Oil Pressure Input Voltage Low
18
Engine Oil Pressure Moderately Low
3
Manifold Air Temperature Input Voltage High
29
91
100
105
Definition
4
Manifold Air Temperature Input Voltage Low
16
Manifold Air Temperature Moderately High
0
Engine Coolant Temperature High Most Severe
3
Engine Coolant Temperature Input Voltage High
4
Engine Coolant Temperature Input Voltage Low
15
Engine Coolant Temperature High Least Severe
16
Engine Coolant Temperature High Moderately Severe
158
17
ECU Power Down Error
174
3
Fuel Temperature Input Voltage High
4
Fuel Temperature Input Voltage Low
110
25
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Listing of Diagnostic Trouble Codes (DTCs)
Displayed Code
190
620
637
FMI*
Definition
16
Fuel Temperature Moderately High
0
Engine Overspeed Extreme
16
Engine Overspeed Moderate
3
Sensor Supply Voltage High
4
Sensor Supply Voltage Low
2
Crankshaft Position Input Noise
10
Crankshaft Position Input Pattern Error
970
31
Auxiliary Engine Shutdown Switch Active
971
31
External Engine Derate Switch Active
1076
0
Pump Control Valve Closure Too Long
1
Pump Control Valve Closure Too Short
5
Pump Solenoid Circuit Open
6
Pump Soleniod Circuit Severely Shorted
7
Pump Control Valve Closure Not Detected
10
Pump Solenoid Circuit Moderately Shorted
1109
31
Engine Shutdown Warning
1110
31
Engine Shutdown
1569
31
Fuel Derate
2000
6
Internal ECU Failure
* FMI (Failure Mode Indicator) – Requires engine diagnostic tool to display.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
26
STARTING THE MACHINE
PUSH AFTER WARM UP
NOTE: In order to allow the machine to start at a reduced load,
a valve, which is operated by a button located on the instrument
panel, is incorporated in the regulation system. (The valve
automatically returns to the start position when the machine is
switched off and air pressure relieved from the system).
WARNING: Under no circumstances should volatile liquids
such as Ether be used for starting this machine.
. Allow the engine to reach its operating temperature – then
press the button (7).
. At this point in the operation of the machine it is safe to apply
full load to the engine.
1
DUAL PRESSURE WHEN FITTED
2
Machines which operate in excess of 7 bar (100 psi) can
optionally be fitted with a dual pressure switch 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.
3
The pressure gauge indicates which setting has been selected.
All normal starting functions are incorporated in the key
operated switch.
STOPPING THE MACHINE
.
. Turn the key switch to position 1. The engine fault and
compressor fault lamps will flash..
Close the service valve.
Wait To Start Lamp.
. Allow the machine to run unloaded for a short period of time
to reduce the engine temperature.
. Turn the key switch to position 1 until the Wait To Start Lamp.
(14) extinguishes.
.
Turn the start switch to the 0 (off) position.
. Turn the key switch to crank position (3) (engine start
position)
.
NOTE: Position (2) not used on AWIR models.
NOTE: As soon as the engine stops, the automatic blowdown
valve will relieve all pressure from the system.
. Release to position (1) when engine starts. The engine will
now be running at a reduced speed.
At temperatures below 0C or if there is difficulty starting first
time:
.
Open the service valve fully, with no hose connected.
.
Complete starting sequence above.
.
Close service valve as soon as engine runs freely.
If the automatic blowdown valve fails to operate, then
pressure must be relieved from the system by means of the
service valve(s).
CAUTION: Never allow the machine to stand idle with pressure
in the system.
. Do not allow machine to run for long periods with service
valve open.
.
EMERGENCY STOPPING
Allow the engine to reach operating temperature.
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.
. At this point in the operation of the machine it is safe to apply
full load to the engine.
RE–STARTING AFTER AN EMERGENCY
If the machine has been switched off because of a machine
malfunction, then identify and correct the fault before attempting
to re–start.
NOTE: Wear hearing protection at all times when the engine is
started with the service valve open and air is flowing from the
valve.
27
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
If the machine has been switched off for reasons of safety,
then ensure that the machine can be operated safely before
re–starting.
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:–
Refer to the PRIOR TO STARTING and STARTING THE
UNIT instructions earlier in this section before re–starting the
machine.
. Do not destroy batteries or components containing asbestos
without containing the materials safely.
MONITORING DURING OPERATION
Should any of the safety shut-down conditions occur, the unit
will stop.
. Do not dispose of any pressure vessel that is not clearly
marked with its relevant data plate information or rendered
unusable by drilling, cutting etc.
Refer to the Wedge diagnostic display codes table for a
listing of shutdown conditions.
. Do not allow lubricants or coolants to be released into land
surfaces or drains.
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)
. Do not dispose of a complete machine without
documentation relating to instructions for its use.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
28
ENGINE
It has been found that bio–diesel fuels may
improve lubricity in concentrations up to a 5%
blend in petroleum diesel fuel.
Engine Serial Number Plate
Each engine has a 13–digit engine serial
number.
When using a blend of bio–diesel fuel, the
engine oil level must be check daily when the air
temperature is –10C (14F) or lower. If the oil
becomes diluted with fuel, shorten oil change
intervals accordingly.
The engine’s serial number plate is located on
the right–hand side of cylinder block behind the
fuel filter.
IMPORTANT: Raw pressed vegetable oils
are NOT acceptable for use for fuel in any
concentration.
Fuels, Lubricants, and Coolant
Diesel Fuel
Consult your local fuel distributor for properties
of the diesel fuel available in your area.
These oils do not burn completely, and will
cause engine failure by leaving deposits on
injectors and in the combustion chamber.
In general, diesel fuels are blended to satisfy
the low temperature requirements of the
geographical area in which they are marketed.
Handing and Storing Bio–Diesel Fuel
WARNING: Handle fuel carefully. Do not fill
the fuel tank when engine is running.
Diesel fuels specified to EN 590 or ASTM D975
are recommended.
DO NOT smoke while you fill the fuel tank or
service the fuel system.
Required fuel properties
In all cases, the fuel must meet the following
properties:
Fill the fuel tank at the end of each day’s
operation to prevent water condensation and
freezing during cold weather.
Cetane number of 45 minimum. Cetane
number greater than 50 is preferred, especially
for temperatures below –20C (–4F) or
elevations above 1500 m (5000 ft).
Keep all storage tanks as full as practicable to
minimize condensation.
Ensure that all fuel tank caps and covers are
installed properly to prevent moisture from
entering.
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at
least 5C (9F) below the expected low
temperature.
Monitor water content of the fuel regularly.
Fuel filter may require more frequent
replacement due to premature plugging.
Fuel lubricity should pass a minimum load
level of 3100 grams as measured by ASTM
D6078 or, maximum scar diameter of 0.45 mm
as measured by ASTM D6079.
Check engine oil level daily prior to starting
engine. A rising oil level may indicate fuel
dilution of the engine oil.
Sulfur content:
• Diesel fuel quality and fuel sulfur content must
comply with all existing regulations for the area
in which the engine operates.
When fuel is stored for an extended period or if
there is a slow turnover of fuel, add a fuel
conditioner to stabilize the fuel and prevent
water condensation. Contact your fuel supplier
for recommendations.
• Sulfur content less than 0.05% (500 ppm) is
preferred.
Diesel Fuel Storage
• If diesel fuel with sulfur content greater than
0.05% (500 ppm) is used, crankcase oil service
intervals may be affected. (See
recommendation for Diesel Engine Oil.)
WARNING: Handle fuel carefully. Do not fill
the fuel tank when engine is running.
DO NOT smoke while you fill the fuel tank or
service the fuel system.
• DO NOT use diesel fuel with sulfur content
greater than 1.0%.
Fill the fuel tank at the end of each day’s
operation to prevent water condensation and
freezing during cold weather.
IMPORTANT: DO NOT mix used engine oil or
any other type of lubricating oil with diesel
fuel.
Bio–Diesel Fuel
Bio–diesel fuels may be used ONLY if the
bio–diesel fuel properties meet the latest edition
of ASTM PS121, DIN 51606 or equivalent
specification.
29
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
IMPORTANT: DO NOT store diesel fuel in
galvanized containers. Diesel fuel stored in
galvanized containers reacts with zinc
coating on container to form zinc flakes. If
fuel contains water, a zinc gel will also form.
The gel and flakes will quickly plug fuel
filters, damage injection nozzles and
injection pump.
Multi–viscosity diesel engine oils are
preferred.
Diesel fuel quality and sulfur content must
comply with all existing emissions regulations
for the area in which the engine operates.
If diesel fuel with sulfur content greater than
0.05% (500 ppm) is used, reduce the oil and
filter change interval by 100 hours.
DO NOT use brass–coated containers for
fuel storage. Brass is an alloy of copper and
zinc.
If diesel fuel with sulfur content greater than
0.5% (5000 ppm) is used, reduce the service
interval by 50%.
Store diesel fuel in plastic, aluminum, and steel
containers specially coated for diesel fuel
storage.
Diesel fuel with sulfur content greater than 1.0%
(10,000 ppm) is not recommended.
Avoid storing fuel over long periods of time. If
fuel is stored for more than a month prior to
use, or there is a slow turnover in fuel tank or
supply tank, add a fuel conditioner to stabilize
the fuel, prevent water condensation.
Minimizing the Effect of Cold Weather on
Diesel Engines
Ingersoll–Rand diesel engines are designed to
operate effectively in cold weather.
See your authorized engine distributor or
servicing dealer for additional information and
availability of cold weather aids.
Use Grade No. 1–D Fuel
When temperatures fall below 5C (40F),
Grade No. 1–D fuel is best suited for cold
weather operation.
Diesel Fuel Additive
IMPORTANT: Treat fuel when outside
temperature drops below 0_C (32_F). For
best results, use with untreated fuel. Follow
all recommended instructions on label.
Use a fuel conditioner (Winter) to treat fuel
during the cold weather season. Winter
formulation is a combination diesel fuel
conditioner and anti–gel additive.
Diesel Engine Oil
Use SAE15W–40 oil viscosity based on the
expected air temperature range of 10F to
122F (–12C–40C) during the period between
oil changes.
The following oil is preferred:
• Pro–Tec Engine Fluid
Other oils may be used if they meet one or
more of the following:
• API Service Classification CI–4
• API Service Classification CH–4
• ACEA Specification E3
• ACEA Specification E4
• ACEA Specification E5
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
30
Diesel Engine Coolant
IMPORTANT: Only use coolant additive to
replenish the coolant. Do not use additive
when the entire system is drained and
refilled.
The engine cooling system is filled to provide
year–round protection against corrosion and
cylinder liner pitting, and winter freeze
protection to –37C (–34F).
Consult the coolant supplier and follow the
manufacturer’s recommendation for use of
supplemental coolant additives.
Low silicate ethylene glycol base coolants for
heavy–duty engines may be used if they meet
one of the following specifications:
The use of non–recommended supplemental
coolant additives may result in additive drop–out
and gelation of the coolant.
• ASTM D5345 (pre–diluted coolant)
• ASTM D4985 (coolant concentrate) in a 40 to
60% mixture of concentrate with quality water.
Add the manufacturer’s recommended
concentration of supplemental coolant additive.
DO NOT add more than the recommended
amount.
Coolants meeting these specifications require
use of supplemental coolant additives,
formulated for heavy–duty diesel engines, for
protection against corrosion and cylinder liner
erosion and pitting.
Coolant Drain Intervals
Drain the factory fill engine coolant, flush the
cooling system, and refill with new coolant after
the first 3 years or 3000 hours of operation.
Subsequent drain intervals are determined by
the coolant used for service. At each interval,
drain the coolant, flush the cooling system, and
refill with new coolant.
A 50% mixture of ethylene glycol engine coolant
in water provides freeze protection to –37C
(–34F). If protection at lower temperatures is
required, consult your dealer for
recommendations.
Water quality is important to the performance of
the cooling system. Distilled, or de–mineralized
water is recommended for mixing with ethylene
glycol base engine coolant concentrate.
Chlorides
<40mg/L
Sulfates
<100 mg/L
Total Dissolved Solids
<340 mg/L
Total Hardness
<170 mg/L
pH
5.5 to 9.0
Operating in Warm Temperature Climates
Ingersoll–Rand engines are designed to operate
using glycol base engine coolants.
Always use a recommended glycol base engine
coolant, even when operating in geographical
areas where freeze protection is not required.
IMPORTANT: Water may be used as coolant
in emergency situations only.
Foaming, hot surface aluminum and iron
corrosion, scaling, and cavitation will occur
when water is used as the coolant, even
when coolant conditioners are added.
Drain cooling system and refill with
recommended glycol base engine coolant
as soon as possible.
IMPORTANT: Do not use cooling system
sealing additives or antifreeze that contains
sealing additives.
Engine Break–In Service
Supplemental Coolant Additives
The engine is ready for normal operation.
However, extra care during the first 100 hours
of operation will result in more satisfactory
long–term engine performance and life. DO
NOT exceed 100 hours of operation with
break–in oil.
The concentration of coolant additives is
gradually depleted during engine operation. For
all recommended coolants, replenish additives
between drain intervals by adding a
supplemental coolant additive every 12 months.
31
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Lubrication and Maintenance Service Interval Chart
NOTE: The Service intervals below are for standard industrial engines. See details in Sections which
follow these charts.
Item
Lubrication and Maintenance Service Intervals
Check Engine Oil and Coolant Level
Daily
Check Fuel Filter/Water Bowl
Check Air Cleaner Dust Unloader Valve & Restriction Indicator
Gauge a
Visual Walk Around Inspection
500 Hours/12
Months
2000
Hours/24
Months
As Required
Service Battery
Check Manual Belt Tensioner and belt wear
Change Engine Oil And Replace Oil Filter
Clean Crankcase Vent Tube
Check Air Intake Hoses, Connections, & System
Replace Fuel Filter Elements—Bleed Fuel System
Check Belt Tensioner and Belt Wear
Check Engine Electrical Ground Connection
Check Cooling System
Pressure Test Cooling System
Flush Cooling System
Test Thermostats
Check and Adjust Engine Valve Clearance
Add Coolant
Replace Air Cleaner Elements
Replace Poly–Vee Belt
A
Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O.
B
During engine break–in, change the oil and filter for the first time before 100 hours of operation.
C
If the recommended engine oils, or Pro–Tec is not used, the oil and filter change interval is reduced to every 250 hours. If
diesel fuel with a sulfur content greater than 0.05% is used, the oil and filter change interval is also reduced.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
32
Lubrication & Maintenance/Daily
5. Apply clean engine oil to the new filter at the
inner and outer seals and to filter threads.
Daily Pre–starting Checks
6. Wipe both sealing surfaces of the header
with a clean rag. Ensure dust seal is in place,
replace if damaged.
Do the following BEFORE STARTING THE
ENGINE for the first time each day:
Check engine oil level on dipstick.
IMPORTANT: When installing filter element,
HAND TIGHTEN only. A filter wrench may be
used for REMOVAL ONLY.
IMPORTANT: DO NOT add makeup oil until
the oil level is BELOW the crosshatch marks
on the dipstick.
7. Install and tighten oil filter by hand until firmly
against dust seal. DO NOT apply an extra
3/4 to 1–1/4 turn after gasket contact as done
with standard filters.
IMPORTANT: DO NOT fill above the top mark
on the dipstick. Oil levels anywhere within
crosshatch are considered in the acceptable
range.
8. Tighten drain plug to specifications.
To change engine oil and oil filter:
Check the fuel filters for water or debris. If filter
is fitted with a see–through bowl, drain as
needed based on a daily visual inspection.
Specification
IMPORTANT: Drain water into a suitable
container and dispose of properly.
Oil Pan Drain Plug With Copper Washer—
Torque 70 N•m (52 lb ft)
a) Loosen drain plugs (A) at bottom of fuel filters
or bowls, if equipped, two or three turns.
Oil Pan Drain Plug With O–Ring—
Torque 50 N•m (37 lb ft)
b) Loosen air bleed plug (B) two full turns on
fuel filter mounting and drain water from
bottom until fuel starts to drain out.
9. Fill engine crankcase with Pro–Tec Engine
Fluid.
c) When fuel starts to drain out, tighten drain
plugs securely.
To determine the correct oil fill quantity for your
engine, see ENGINE CRANKCASE OIL FILL
QUANTITIES in the Specifications Section of
this manual.
After draining water from the fuel filters, the
filters must be primed by bleeding all air from
the fuel system.
IMPORTANT: Immediately after completing
any oil change, crank engine for 30 seconds
without permitting engine to start. This will
help insure adequate lubrication to engine
components before engine starts.
Changing Engine Oil and Replacing Filter
Your engine is equipped with a special oil filter.
NOTE: During break–in, change engine oil and
filter for the first time before 100 hours
maximum of operation.
NOTE: Crankcase oil capacity may vary slightly.
ALWAYS fill crankcase within crosshatch marks
on dipstick. DO NOT overfill.
After break–in, the oil and filter change interval
is 500 hours or every 12 months, whichever
comes first.
10. Start engine and run to check for possible
leaks.
NOTE: If diesel fuel with a sulfur content
greater than 0.05% (500 ppm) is used, the oil
and filter change interval is reduced.
To change engine oil and oil filter:
11. Stop engine and check oil level after 10
minutes. Oil level reading should be within
crosshatch of dipstick.
1. Run engine approximately 5 minutes to warm
up oil. Shut engine off.
Cleaning Crankcase Vent Tube
If you operate the engine in dusty conditions,
clean the tube at shorter intervals.
2. Remove oil pan drain plug.
3. Drain crankcase oil from engine while warm.
1. Remove and clean crankcase vent tube.
4. Turn filter element using a suitable filter
wrench to remove. Discard oil filter element.
2. Install the vent tube. Be sure the O–ring fits
correctly in the rocker arm cover for elbow
adapter.
Important: Filtration of oils is critical to
proper lubrication. Always change filter
regularly.
Replacing Fuel Filter Elements
33
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Checking Belt Tensioner Spring Tension
and Belt Wear (Automatic Tensioner)
Engine is equipped with a primary fuel filter (or
pre–filter) with water bowl and a final filter. Both
filters are replaced at the same 500–hour
interval.
Belt drive systems equipped with automatic
(spring) belt tensioners cannot be adjusted or
repaired. The automatic belt tensioner is
designed to maintain proper belt tension over
the life of the belt. If tensioner spring tension is
not within specification, replace tensioner
assembly.
CAUTION: Escaping fluid under pressure
can penetrate the skin causing serious
injury. Relieve pressure before
disconnecting fuel or other lines. Tighten all
connections before applying pressure. Keep
hands and body away from pinholes and
nozzles which eject fluids under high
pressure. Use a piece of cardboard or paper
to search for leaks. Do not use your hand.
Checking Belt Wear
The belt tensioner is designed to operate within
the limit of arm movement provided by the cast
stops when correct belt length and geometry is
used.
1. Close fuel shut–off valve, if equipped.
2. Thoroughly clean fuel filter assemblies and
surrounding areas.
Visually inspect cast stops on belt tensioner
assembly.
3. Disconnect water sensor wiring (if equipped).
If the tensioner stop on swing arm is hitting the
fixed stop, check mounting brackets (alternator,
belt tensioner, idler pulley, etc.) and the belt
length. Replace belt as needed
4. Loosen drain plugs and drain fuel into a
suitable container.
NOTE: Lifting up on retaining ring as it is
rotated helps to get it past raised locators.
Checking Tensioner Spring Tension
5. Firmly grasp the retaining ring and rotate it
counterclockwise 1/4 turn. Remove ring with
filter element.
6. Inspect filter mounting base for cleanliness.
Clean as required.
A belt tension gauge will not give an accurate
measure of the belt tension when automatic
spring tensioner is used. Measure tensioner
spring tension using a torque wrench and
procedure outlined below:
NOTE: Raised locators on fuel filter canisters
must be indexed properly with slots in mounting
base forcorrect installation.
1. Release tension on belt using a breaker bar
and socket on tension arm. Remove belt from
pulleys.
7. Install new filter elements onto mounting
bases. Be sure elements are properly
indexed and firmly seated on bases. It may
be necessary to rotate filters for correct
alignment.
2. Release tension on tension arm and remove
breaker bar.
3. Put a mark on swing arm of tensioner as
shown.
4. Measure 21 mm (0.83 in.) and put a mark on
tensioner mounting base.
If equipped with water separator bowl (E),
remove filter element from separator bowl.
Drain and clean separator bowl. Dry with
compressed air. Install bowl onto new element.
Tighten securely.
5. Install torque wrench so that it is aligned with
centers of pulley and tensioner. Rotate the
swing arm using a torque wrench until marks
are aligned.
8. Align keys on filter element with slots in filter
base.
6. Record torque wrench measurement and
compare with specification below. Replace
tensioner assembly as required.
9. Install retaining ring onto mounting base
making certain dust seal is in place on filter
base. Hand tighten ring (about 1/3 turn) until
it “snaps” into the detent. DO NOT
overtighten retaining ring.
Specification
Spring Tension—Torque 18–22 N•m (13–16 lb–ft)
NOTE: The proper installation is indicated when
a ”click” is heard and a release of the retaining
ring is felt. A plug is provided with the new
element for plugging the used element.
NOTE: Threads on belt tensioner roller cap
screw are LEFT–HAND threads.
Checking Engine Electrical Ground
Connections
10. Reconnect water sensor wiring (if
equipped).
Keep all engine ground connections clean and
tight to prevent electrical arcing which can
damage electronic components.
11. Open fuel shut–off valve and bleed the fuel
system.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
34
Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant Changes
3. Remove poly–vee belt from pulleys and
discard belt.
NOTE: If system is to be filled with coolant that
does not contain SCAs, the coolant must be
precharged.
4. Install new belt, making sure belt is correctly
seated in all pulley grooves. Refer to belt
routing at right for your application.
Through time and use, the concentration of
coolant additives is gradually depleted during
engine operation. Periodic replenishment of
inhibitors is required. The cooling system must
be recharged with additional supplemental
coolant additives available in the form of liquid
coolant conditioner.
5. Apply tension to belt with tensioner. Remove
socket.
6. Start engine and check belt alignment.
Bleeding the Fuel System
Bleed the Fuel System (Engines with Electronic
Fuel Systems and Stanadyne DE10 Pump)
Maintaining the correct coolant conditioner
concentration (SCAs) and freeze point is
essential in your cooling system to protect
against rust, liner pitting and corrosion, and
freeze–ups due to incorrect coolant dilution.
CAUTION: Escaping fluid under pressure
can penetrate the skin causing serious
injury. Avoid hazards by relieving pressure
before disconnec ing hydraulic or other
lines. Tighten all connections before
applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body
from high pressure fluids.
DO NOT mix one brand of SCA with a
different brand.
Recharge the system per instructions printed on
label of the Coolant Conditioner.
Any time the fuel system has been opened up
for service (lines disconnected or filters
removed), it will be necessary to bleed air from
the system.
IMPORTANT: Always maintain coolant at
correct level and concentration. DO NOT
operate engine without coolant even for a
few minutes.
The fuel system may be bled at one of several
locations. Choose the best location for your
engine/machine application.
If frequent coolant makeup is required, the
glycol concentration should be checked to
ensure that the desired freeze point is
maintained. Follow manufacturer’s
instructions provided with Coolant/Battery
Tester.
1. Loosen the air bleed vent screw two full turns
by hand on fuel filter base.
2. Operate fuel supply pump primer lever (B) or
primer button on fuel filter base (if equipped).
Add the manufacturer’s recommended
concentration of supplemental coolant additive.
DO NOT add more than the recommended
amount.
3. Tighten bleed plug securely, continue
operating primer until pumping action is not
felt.
4. Start engine and check for leaks.
The use of non–recommended supplemental
coolant additives may result in additive drop–out
and gelation of the coolant.
If engine will not start, it may be necessary to
bleed air from fuel system at fuel injection pump
or injection nozzles as explained next.
If other coolants are used, consult the coolant
supplier and follow the manufacturer’s
recommendation for use of supplemental
coolant additives.
At Fuel Injection Pump
1. Loosen fuel return line at fuel injection pump.
Replacing Fan and Alternator Belts
2. Operate fuel supply pump primer lever or
primer button on fuel filter base (if equipped).
Refer to CHECKING BELT TENSIONER
SPRING TENSION AND BELT WEAR in
Lubrication and Maintenance/500 Hour/12
Month Section for additional information on the
belt tensioner.
3. As soon as fuel flow is free from air bubbles,
tighten fuel return line to specifications.
Primer lever is spring–loaded and will return
to normal position.
1. Inspect belts for cracks, fraying, or stretched
out areas. Replace if necessary.
Specification
Fuel Injection Pump Return
Line—Torque 27 N•m (20 lb–ft)
2. To replace belt with automatic tensioner,
release tension on belt using a breaker bar
and socket on tension arm.
To replace belt with manual tensioner, release
tension at belt tensioner.
35
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
At Fuel Injection Nozzles
A reliable program for troubleshooting engine
problems should include the following basic
diagnostic thought process:
IMPORTANT: Always use a backup wrench
when loosening or tightening fuel lines at
nozzles and/or injection pump to avoid
damage.
Know the engine and all related systems.
Study the problem thoroughly.
1. Using two open–end wrenches, loosen two
fuel line connections at injection nozzles.
Relate the symptoms to your knowledge of
engine and systems.
2. Crank engine over with starter motor for 15
seconds (but do not start engine) until fuel
free from bubbles flows out of loosened
connection. Retighten connection to
specifications.
Diagnose the problem starting with the
easiest things first.
Double–check before beginning the
disassembly.
Determine cause and make a thorough
repair.
Specification
Fuel Injection Nozzle Delivery
Lines—Torque 27 N•m (20 lb–ft)
After making repairs, operate the engine
under normal conditions to verify that the
problem and cause was corrected.
3. Repeat procedure for remaining injection
nozzles (if necessary) until all air has been
removed from fuel system.
NOTE: The engines covered in this manual
have electronic control systems which send
diagnostic trouble codes to signal problems.
If engine still will not start, see your authorized
servicing dealer or engine distributor.
Precautions For Welding On Engines
Equipped With Electronic Engine Control
Unit (ECU)
Do Not Modify Fuel System
IMPORTANT: Modification or alteration of
the injection pump, the injection pump
timing, or the fuel injectors in ways not
recommended by the manufacturer will
terminate the warranty obligation to the
purchaser.
IMPORTANT: ALWAYS disconnect Electronic
Control Unit (ECU) connectors and engine
control system–to–machine ground before
welding on engine or machine. High
currents or electro–static discharge in
electronic components from welding may
cause permanent damage.
In addition, tampering with fuel system
which alters emission–related equipment on
engines may result in fines or other
penalties, per EPA regulations or other local
emission laws.
1. Remove the ground connection for the
engine control system–to–machine frame.
2. Disconnect the connectors from the ECU.
3. Connect the welder ground close to the
welding point and be sure ECU or other
electronic components are not in the ground
path.
Do not attempt to service injection pump or
fuel injectors yourself. Special training and
special tools are required. (See your
authorized servicing dealer).
Troubleshooting
General Troubleshooting Information
Troubleshooting engine problems can be
difficult.
In this section is a list of possible engine
problems that may be encountered
accompanied by possible causes and
corrections. The illustrated diagrams and
troubleshooting information are of a general
nature. See your engine distributor or servicing
dealer if you are in doubt.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
36
Symptom
Problem
Solution
Engine cranks but will
not start
Incorrect starting procedure.
Verify correct starting procedure.
No fuel.
Check fuel in tank.
Exhaust restricted.
Check and correct exhaust
restriction.
Fuel filter plugged or full of water.
Replace fuel filter or drain water
from filter.
Injection pump not getting fuel or air
in fue system.
Check fuel flow at supply pump or
bleed system.
Engine starting under load.
Disengage PTO
Improper starting procedure.
Review starting procedure.
No fuel.
Check fuel tank.
Air in fuel line.
Bleed fuel line.
Cold weather.
Use cold weather starting aids.
Slow starter speed.
See “Starter Cranks Slowly”.
Crankcase oil too heavy.
Use oil of proper viscosity.
Improper type of fuel.
Consult fuel supplier; use proper
type fuel for operating conditions.
Water, dirt, or air in fuel system.
Drain, flush, fill, and bleed system.
Clogged fuel filter.
Replace filter element.
Dirty or faulty injection nozzles.
Have authorized servicing dealer or
engine distributor check injectors.
Electronic fuel system problem if
equipped)
See your distributor or servicing
dealer.
Low engine oil level.
Add oil to engine crankcase.
Low coolant temperature.
Remove and check thermostat.
Engine overheating.
See “Engine Overheats”.
Engine cold
Wrong or defective thermostat.
Remove and check thermostat.
Engine hard to start or
will not start
Engine knocks
37
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Symptom
Problem
Solution
Engine runs irregularly
or stalls frequently
Low coolant temperature.
Remove and check thermostat.
Clogged fuel filter.
Replace fuel filter element.
Water, dirt, or air in fuel system.
Drain, flush, fill, and bleed system.
Dirty or faulty injection nozzles.
Have authorized servicing dealer
check injectors.
Electronic fuel system problem
See your distributor or servicing
dealer.
Defective thermostat.
Remove and check thermostat.
Defective temperature gauge or
sender.
Check gauge, sender, and
connections.
Engine overloaded.
Reduce load.
Intake air restriction.
Service air cleaner.
Clogged fuel filter.
Replace filter elements.
Improper type of fuel.
Use proper fuel.
Overheated engine.
See “Engine Overheats”.
Below normal engine temperature.
Remove and check thermostat.
Improper valve clearance.
See your authorized servicing
dealer.
Dirty or faulty injection nozzles.
Have authorized servicing dealer
check injectors.
Injection pump out of time.
See your authorized servicing
dealer.
Electronic fuel system problem
See your authorized servicing
dealer.
Turbocharger not functioning.
(Turbocharger engines only)
See your authorized servicing
dealer.
Leaking exhaust manifold gasket.
See your authorized servicing
dealer.
Defective aneroid control line.
See your authorized servicing
dealer.
Restricted fuel hose.
Clean or replace fuel hose.
Low fast idle speed.
See your authorized servicing
dealer.
Below normal Engine
temperature
Lack of power
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
38
Symptom
Problem
Solution
Low oil pressure
Low oil level.
Add oil.
Improper type of oil.
Drain, fill crankcase with oil of
proper Viscosity and quality.
Crankcase oil too light.
Use proper viscosity oil.
Oil leaks.
Check for leaks in lines, gaskets,
and drain plug.
Restricted crankcase vent tube.
Clean vent tube.
Defective turbocharger.
See your authorized servicing
dealer.
Improper type of fuel.
Use proper fuel.
Low engine temperature.
Warm up engine to normal operating
temperature.
Defective thermostat.
Remove and check thermostat.
Defective injection nozzles.
See your authorized servicing
dealer.
Improper type of fuel.
Use proper fuel.
Clogged or dirty air cleaner.
Service air cleaner.
Engine overloaded.
Reduce load.
Injection nozzles dirty.
See your authorized servicing
dealer.
Electronic fuel system problem
See your authorized servicing
dealer.
Turbocharger not functioning.
See your authorized servicing
dealer.
High oil consumption
Engine emits white
smoke
Engine emits black or
gray exhaust smoke
39
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Symptom
Problem
Solution
Engine overheats
Engine overloaded.
Reduce load.
Low coolant level.
Fill radiator to proper level, check
radiator and hoses for loose
connections or leaks.
Faulty radiator cap.
Have technician check.
Stretched poly–vee belt or defective
belt tensioner.
Check automatic belt tensioner and
check belts for stretching. Replace
as required.
Low engine oil level.
Check oil level. Add oil as required.
Cooling system needs flushing.
Flush cooling system.
Defective thermostat.
Remove and check thermostat.
Defective temperature gauge or
sender.
Check coolant temperature with
thermometer and replace, if
necessary.
Incorrect grade of fuel.
Use correct grade of fuel.
Improper type of fuel.
Use proper type of fuel.
Clogged or dirty air cleaner.
Service air cleaner.
Engine overloaded.
Reduce load.
Improper valve clearance.
See your authorized servicing
dealer.
Injection nozzles dirty.
See your authorized servicing
dealer.
Electronic fuel system problem.
See your authorized servicing
dealer.
Defective turbocharger.
See your authorized servicing dealer
Low engine temperature.
Check thermostat.
Excessive electrical load from
added accessories.
Remove accessories or install
higher output alternator.
Excessive engine idling.
Increase engine rpm when heavy
electrical load is used.
Poor electrical connections on
battery, ground strap, starter, or
alternator.
Inspect and clean as necessary.
Defective battery.
Test battery.
Defective alternator.
Test charging system.
High fuel consumption
Undercharged electrical
system
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
40
Symptom
Problem
Solution
Battery uses too much
Water
Cracked battery case.
Check for moisture and replace as
necessary.
Defective battery.
Test battery.
Battery charging rate too high.
Test charging system.
Loose or corroded connections.
Clean and tighten connections.
Sulfated or worn–out batteries.
See your authorized servicing
dealer.
Stretched poly–vee belt or defective
belt tensioner.
Adjust belt tension or replace belts.
PTO engaged.
Disengage PTO.
Loose or corroded connections.
Clean and tighten loose
connections.
Low battery output voltage.
See your authorized servicing
dealer.
Faulty start circuit relay.
See your authorized servicing
dealer.
Blown fuse
Replace fuse.
Low battery output.
See your authorized servicing
dealer.
Crankcase oil too heavy.
Use proper viscosity oil.
Loose or corroded connections.
Clean and tighten loose
connections.
Faulty battery connection.
Clean and tighten connections.
Sulfated or worn–out batteries.
See your authorized servicing
dealer.
Batteries will not charge
Starter will not crank
Starter cranks slowly
Entire electrical system
does not function
function
Displaying Of Diagnostic Trouble Codes (DTCs)
Stored and active diagnostic trouble codes are output on the instrument panel according to the J1939
standard as a two–part code as shown on the tables in the Operating Instruction Section.
NOTE: The electronic instrument panel can
have communication problems that result in
Error Codes being shown on its LCD display
window.
EE—Error
ACP—Err
XXXXX—BO
The following Error Codes all indicate that there
is a communication error with the ECU.
No Addr
No Data
ACP—Err
XXXXX—BR
BUS—EP
No Data
XXXXX—EP
No Data
Contact your servicing dealer for help in
correcting these codes:
41
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
3. Engines can be stored inside, warehoused,
for up to six (6) months with no long term
preparation.
Intermittent Fault Diagnostics (With
Electronic Controls)
Intermittent faults are problems that periodically
“go away”. A problem such as a terminal that
intermittently doesn’t make contact can cause
an intermittent fault. Other intermittent may be
set only under certain operating conditions such
as heavy load, extended idle, etc. When
diagnosing intermittent faults, take special note
of the condition of wiring and connectors, since
a high percentage of intermittent problems
originate here. Check for loose, dirty or
disconnected connectors. Inspect the wiring
routing, looking for possible shorts caused by
contact with external parts (for example, rubbing
against sharp sheet metal edges). Inspect the
connector vicinity, looking for wires that have
pulled out of connectors, poorly positioned
terminals, damaged connectors and corroded or
damaged splices and terminals. Look for broken
wires, damaged splices, and wire–to–wire
shorts. Use good judgement if component
replacement is thought to be required.
Engines expected to be stored more than six (6)
months, long term storage preparation MUST
BE taken.
Preparing Engine for Long Term Storage
The following storage preparations are good for
long term engine storage up to one year. After
that, the engine should be started, warmed up,
and retreated for an extended storage period.
IMPORTANT: Any time your engine will not
be used for over six (6) months, the
following recommendations for storing it
and removing it from storage will help to
minimize corrosion and deterioration.
1. Change engine oil and replace filter. Used oil
will not give adequate protection.
2. Service air cleaner.
3. Draining and flushing of cooling system is not
necessary if engine is to be stored only for
several months. However, for extended
storage periods of a year or longer, it is
recommended that the cooling system be
drained, flushed, and refilled. Refill with
appropriate coolant.
NOTE: The engine control unit (ECU) is the
component LEAST likely to fail.
Suggestions for diagnosing intermittent
faults:
If the problem is intermittent, try to reproduce
the operating conditions that were present
when the diagnostic trouble code (DTC) set.
4. Crank the engine several revolutions with
starter (do not allow the engine to start).
Observing these values can help determine
the operating conditions when the fault
occurred.
5. Remove fan/alternator poly–vee belt, if
desired.
6. Remove and clean batteries. Store them in a
cool, dry place and keep them fully charged.
If a faulty connection or wire is suspected to
be the cause of the intermittent problem:
clear DTCs, then check the connection or
wire by wiggling it while watching the
diagnostic gauge to see if the fault resets.
7. Disengage the clutch for any driveline.
8. Clean the exterior of the engine with salt–free
water and touchup any scratched or chipped
painted surfaces with a good quality paint.
Possible causes of intermittent faults:
9. Coat all exposed (machined) metal surfaces
with grease or corrosion inhibitor if not
feasible to paint.
Faulty connection between sensor and
actuator harness.
Faulty contact between terminals in
connector.
10. Seal all openings on engine with plastic
bags and tape.
Faulty terminal/wire connection.
11. Store the engine in a dry protected place. If
engine must be stored outside, cover it with a
waterproof canvas or other suitable
protective material and use a strong
waterproof tape.
Electromagnetic interference (EMI) from an
improperly installed 2–way radio, etc., can
cause faulty signals to be sent to the ECU.
Storage
Engine Storage Guidelines
1. Engines can be stored outside for up to three
(3) months with no long term preparation IF
COVERED BY WATERPROOF COVERING.
2. Engines can be stored in a standard
overseas shipping container for up to three
(3) months with no long term preparation.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
42
Removing Engine from Long Term Storage
Specifications
Refer to the appropriate section for detailed
services listed below or have your authorized
servicing dealer or engine distributor perform
services that you may not be familiar with.
General Engine Specifications
ITEM
6IRF8TE
Number of Cylinders
6
Bore
106 mm (4.19 in.)
Stroke
127 mm (5.0 in.)
2. Remove the batteries from storage. Install
batteries (fully charged) and connect the
terminals.
Displacement
6.8 L (414 cu in.)
Compression Ratio
17.0:1
3. Install fan/alternator poly–vee belt if removed.
Aspiration
Turbocharged
4. Fill fuel tank.
Engine Firing Order
1–5–3–6–2–4
5. Perform all appropriate pre–starting checks.
Valves Per Cylinder
1 Intake
1 Exhaust
1. Remove all protective coverings from engine.
Unseal all openings in engine and remove
covering from electrical systems.
IMPORTANT: DO NOT operate starter more
than 30 seconds at a time. Wait at least 2
minutes for starter to cool before trying
again.
Valve Clearance (Cold)
6. Crank engine for 20 seconds with starter (do
not allow the engine to start). Wait 2 minutes
and crank engine an additional 20 seconds to
assure bearing surfaces are adequately
lubricated.
7. Start engine and run at low idle and no load
for several minutes. Warm up carefully and
check all gauges before placing engine under
load.
8. On the first day of operation after storage,
check overall engine for leaks and check all
gauges for correct operation.
Intake (Checking)
0.31–0.38 mm
(0.012–0.015 in)
Exhaust (Checking)
0.41–0.48 mm
(0.016–0.019 in)
Intake (Adjusting)
0.36 mm
(0.014 in.)
Exhaust (Adjusting)
0.46 mm
(0.018 in.)
Max. Crank Pressure
0.5 kPa
(2 H2O)
Vibration Damper Maximum
Radial Runout
1.50 mm
(0.060 in.)
Governor Regulation
(Industrial)
7—10 %
Thermostat Start To Open
Temperature
82C
(180F)
Thermostat Fully Open
Temperature
94
(202F)
Oil Pressure At Rated
Speed, Full Load (± 15 psi)
345 kPa
(50 psi)
Oil Pressure At Low Idle
(Minimum)
105 kPa
(15 psi)
Length
1116 mm
(43.9 in.)
Width
623 mm
(24.5 in.)
Height
1012 mm
(39.9 in.)
Weight
587 kg
(1290 lb)
Engine Crankcase Oil Fill Quantities
6IRF8TE
Crankcase Oil Capacity L (qt) 19.5 (20.6)
General Engine Specifications
ITEM
43
4IRD5AE
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Number of Cylinders
4
Lubrication and Maintenance Records
Bore
106 mm (4.19 in.)
Using Lubrication and Maintenance Records
Stroke
127 mm (5.0 in.)
Displacement
4.5 L (276 cu in.)
Refer to specific Lubrication and Maintenance
Section for detailed service procedures.
Compression Ratio
17.0:1
Aspiration
Turbocharged
Engine Firing Order
1–3–4–2
Valves Per Cylinder
1 Intake
1 Exhaust
1. Keep a record of the number of hours you
operate your engine by regular observation of
hour meter.
2. Check your record regularly to learn when
your engine needs service.
3. DO ALL the services within an interval
section. Write the number of hours (from your
service Records) and the date in the spaces
provided. For a complete listing of all items to
be performed and the service intervals
required, see chart earlier in this manual.
Valve Clearance (Cold)
Intake (Checking)
0.31–0.38 mm
(0.012–0.015 in)
Exhaust (Checking)
0.41–0.48 mm
(0.016–0.019 in)
Emission System Warranty
Intake (Adjusting)
0.36 mm
(0.014 in.)
U.S. EPA Emissions Control Warranty
Statement
Exhaust (Adjusting)
0.46 mm
(0.018 in.)
Max. Crank Pressure
0.5 kPa
(2 H2O)
Vibration Damper Maximum
Radial Runout
1.50 mm
(0.060 in.)
Governor Regulation
(Industrial)
7—10 %
Thermostat Start To Open
Temperature
82C
(180F)
Emissions control–related parts and
components are warranted for five years or
3000 hours of operation, whichever occurs first.
Further, the engine covered by this warranty
was designed, built, and equipped so as to
conform at the time of sale with all U.S.
emissions standards at the time of manufacture,
and that it is free of defects in materials and
workmanship which would cause it not to meet
these standards within the period of five years
or 3000 hours of operation, whichever occurs
first.
Thermostat Fully Open
Temperature
94
(202F)
Oil Pressure At Rated
Speed, Full Load (± 15 psi)
345 kPa
(50 psi)
Oil Pressure At Low Idle
(Minimum)
105 kPa
(15 psi)
Length
860 mm
(33.9 in.)
Width
612 mm
(24.1 in.)
Height
994 mm
(39.1 in.)
Weight
451 kg
(993 lb)
Warranties stated in this manual refer only to
emissions–related parts and components of
your engine.
Emissions Control System Certification
Label
CAUTION: Statutes providing severe
penalties for tampering with emissions
controls may apply to the user or dealer.
The emissions warranty applies only to those
engines marketed by John Deere that have
been certified by the United States
Environmental Protection Agency (EPA) and/or
California Air Resources Board (CARB); and
used in the United States and Canada in
non–road mobile (self–propelled or
portable/transportable1) equipment. The
presence of an emissions labels signifies that
the engine has been certified with the EPA
and/or CARB.
Engine Crankcase Oil Fill Quantities
4IRD5AE
Crankcase Oil Capacity L (qt) 13.5 (14.3)
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
44
The EPA and CARB warranties only apply to
new engines having the certification label
affixed to the engine and sold as stated above
in the geographic areas. The presence of an EU
number in the third line of the label signifies that
the engine has been certified with the European
Union countries per Directive 97/68/EC. The
emissions warranty does not apply to the EU
countries.
NOTE: The hp/kW rating on the engine
emissions certification label specifies the gross
engine hp/kW, which is flywheel power without
fan. In most applications this will not be the
same rating as the advertised vehicle hp/kW
rating.
45
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
MAINTENANCE
Initial 500
miles
/850 km
Daily
Weekly
Monthly
3 Monthly. 6 Monthly.
250 hrs.
500 hrs
12
Monthly.
1000 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
*Fuel/Water Separator Drain
C
Oil Leaks
C
Fuel Leaks
C
Drain Water From Fuel Filters
D
Coolant Leaks
C
Radiator Filler Cap
C
D
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
(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.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
46
Initial
500
miles
/850 km
Daily
Weekly
Monthly
3
6
12
18
Monthly.
Monthly.
Monthly.
Monthly.
250 hrs.
500 hrs
1000
1500
hrs
hrs
*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
*Engine Coolant
C
Fuel Filter Element
R
R
C
*Injection Nozzle Check
Shutdown Switch Settings
T
Scavenger Orifice & Related Parts
C
Oil Separator Element
R
*Feed Pump Strainer Cleaning.
C
Coolant Replacement
R
*Valve Clearance Check
C
Lights (running, brake, & turn)
CBT
Pintle Eye Bolts
CBT
*Brakes
C
*Brake linkage
C
C
Emergency stop
T
Fasteners
C
G
Running gear linkage
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.
47
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Initial 500
miles
/850 km
Daily
Weekly
Monthly
3 Monthly. 6 Monthly.
250 hrs.
500 hrs
12
Monthly.
1000 hrs
Scavenge line
C
Pressure system
C
Engine breather element
C
Pressure gauge
C
Pressure regulator
C
CR
Separator tank (2) exterior
C
Lubricator (Fill)
2 Yrs
Safety valve
4 Yrs
6 Yrs
C
Hoses
R
C
Separator tank (2) interior
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.
*Disregard if not appropriate for this particular machine.
(1) or 3000 miles/5000km whichever is the sooner
(2) or as defined by local or national legislation
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
C = Check (adjust, clean or replace as necessary)
CBT =check before towing.
Prior to attempting any maintenance work, ensure
that:–
CR = Check and report
. all air pressure is fully discharged and isolated from the
system. If the automatic blowdown valve is used for this
purpose, then allow enough time for it to complete the operation.
D = Drain
G = Grease
. the discharge pipe / manifold area is depressurised by
opening the discharge valve, whilst keeping clear of any airflow
from it.
R=Replace
T = Test
W I =or when indicated if earlier.
Refer to specific sections of the operator’s manual for more
MINIMUM PRESSURE VALVE – WHEN FITTED
information.
NOTE: Pressure will always remain in the part of the system
between the minimum pressure valve and the discharge valve
after operation of the auto blowdown valve.
ROUTINE MAINTENANCE
This pressure must be relieved by carefully:
This section refers to the various components which require
periodic maintenance and replacement.
(a) Disconnecting any downstream equipment.
(b) Opening the discharge valve to atmosphere.
The SERVICE/MAINTENANCE CHART indicates the
various components’ descriptions and the intervals when
maintenance has to take place. Oil capacities, etc., can be
found in the GENERAL INFORMATION section of this manual.
(Use hearing protection if necessary).
. the machine cannot be started accidently or otherwise, by
posting warning signs and/or fitting appropriate anti–start
devices.
For any specification or specific requirement on service or
preventative maintenance for the engine, refer to the Engine
Manufacturer’s Manual.
. all residual electrical power sources (mains and battery) are
isolated.
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.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Prior to opening or removing panels or covers to work
inside a machine, ensure that:–
48
. anyone entering the machine is aware of the reduced level
of protection and the additional hazards, including hot surfaces
and intermittently moving parts.
SCAVENGE LINE
The scavenge line runs from the combined orifice/drop tube
in the separator tank, to the orifice fitting located in the airend.
. the machine cannot be started accidently or otherwise, by
posting warning signs and/or fitting appropriate anti–start
devices.
Examine the orifice, check valve and hoses at every service
or in the event of oil carryover into the discharge air.
It is good preventative maintenance to 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.
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.
COMPRESSOR OIL FILTER
Refer to the MAINTENANCE CHART in this section for the
recommended servicing intervals.
. the work carried out with safety protection devices disabled
or removed is limited to only those tasks which require the
machine to be running with safety protection devices disabled
or removed.
Removal
. all hazards present are known (e.g. pressurised
components, electrically live components, removed panels,
covers and guards, extreme temperatures, inflow and outflow of
air, intermittently moving parts, safety valve discharge etc.).
.
appropriate personal protective equipment is worn.
.
loose clothing, jewellery, long hair etc. is made safe.
WARNING: Do not remove the filter(s) without first making
sure that the machine is stopped and the system has been
completely relieved of all air pressure. (Refer to STOPPING
THE UNIT in the OPERATING INSTRUCTIONS section of this
manual).
Clean the exterior of the filter housing and remove the
spin–on element by turning it in a counter–clockwise direction.
. warning signs indicating that Maintenance Work is in
Progress are posted in a position that can be clearly seen.
Inspection
Examine the filter element.
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.
CAUTION: If there is any indication of the formation of
varnishes, shellacs or lacquers on the filter element, it is a
warning that the compressor lubricating and cooling oil has
deteriorated and that it should be changed immediately. Refer
to LUBRICATION later in this section.
. hazardous materials are effectively contained and disposed
of.
Reassembly
Clean the filter gasket contact area and install the new
element by screwing in a clockwise direction until the gasket
makes contact with the filter housing. Tighten a further 1/2 to 3/4
of a revolution.
PROTECTIVE SHUTDOWN SYSTEM
Refer to the Wedge diagnostic display codes table for a
listing of shutdown conditions.
CAUTION: Start the machine (refer to PRIOR TO STARTING
and STARTING THE UNIT in the OPERATING
INSTRUCTIONS section of this manual) and check for leakage
before the machine is put back into service.
Low engine fuel level switch.
At three month intervals, test the low engine fuel level switch
circuit as follows:
.
Start the machine.
COMPRESSOR OIL SEPARATOR ELEMENT
Note: Do not press the load button.
Normally the separator element will not require periodic
maintenance provided that the air and oil filter elements are
correctly maintained.
.
Disconnect the switch, the machine should shutdown.
If, however, the element has to be replaced, then proceed as
follows:
.
Re–connect the switch.
Removal
At twelve month intervals, test the low engine fuel level
switch by removing and operating the float manually.
WARNING: Do not remove the filter(s) without first making
sure that the machine is stopped and the system has been
completely relieved of all air pressure. (Refer to STOPPING
THE UNIT in the OPERATING INSTRUCTIONS section of this
manual).
CAUTION: Never remove or replace switches when the
machine is running.
49
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
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.
AIR FILTER ELEMENTS
The air filter should be inspected regularly (refer to the
SERVICE/MAINTENANCE CHART) and the element replaced
when the restriction indicator shows red or every 6 Months (500
hours), whichever comes first. The dust collector box(es)
should be cleaned daily (more frequently in dusty operating
conditions) and not allowed to become more than half full.
Inspection
Examine the filter element. Examine all hoses and tubes,
and replace if necessary.
Removal
Reassembly
CAUTION: Never remove and replace element(s) when the
machine is running.
Thoroughly clean the orifice/drop tube and filter gasket
contact area before reassembly. Install the new element.
Clean the exterior of the filter housing and remove the filter
element by releasing the nut.
WARNING
Do not remove the staple from the anti–static gasket on
the separator element since it serves to ground any
possible static build–up. Do not use gasket sealant since
this will affect electrical conductance.
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.
Check the seal at the end of the element and replace if any
sign of damage is evident.
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).
Reassembly
Assemble the new element into the filter housing ensuring
that the seal seats properly.
Engage the adaptor in the cover plate with the drop–tube
integral with the filter, reconnect all hoses and tubes to the
separator tank cover plate.
Reset the restriction indicator by depressing the rubber
diaphragm.
Replace the compressor oil (refer to LUBRICATION later in
this section).
Assemble the dust collector box parts, ensuring that they are
correctly positioned.
CAUTION: Start the machine (refer to PRIOR TO STARTING
and STARTING THE UNIT in the OPERATING
INSTRUCTIONS section of this manual) and check for leakage
before the machine is put back into service.
Before restarting the machine, check that all clamps are
tight.
VENTILATION
Always check that the air inlets and outlets are clear of debris
etc.
COMPRESSOR OIL COOLER AND ENGINE RADIATOR
When grease, oil and dirt accumulate on the exterior surfaces
of the oil cooler and radiator, the efficiency is impaired. 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.
CAUTION: NEVER clean by blowing air inwards.
COOLING FAN DRIVE
Periodically 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.
WARNING: Hot engine coolant and steam can cause injury.
When adding coolant or antifreeze solution to the engine
radiator, stop the engine at least one minute prior to
releasing the radiator filler cap. Using a cloth to protect the
hand, slowly release the filler cap, absorbing any released
fluid with the cloth. Do not remove the filler cap until all
excess fluid is released and the engine cooling system fully
depressurised.
The fan belt(s) should be checked regularly for wear and
correct tensioning.
FUEL SYSTEM
The 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. At six month intervals drain any sediment or condensate
that may have accumulated in the tank(s).
WARNING: Follow the instructions provided by the
antifreeze supplier when adding or draining the antifreeze
solution. It is advisable to wear personal protective
equipment to prevent skin and eye contact with the
antifreeze solution.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
50
FUEL FILTER WATER SEPARATOR
RUNNING GEAR/WHEELS
The fuel filter water separator contains a filter element which
should be replaced at regular intervals (see the
SERVICE/MAINTENANCE CHART).
Check the wheel nut torque 20 miles (30 kilometres) after
refitting the wheels. Refer to the TORQUE SETTING TABLE
later in this section.
CHARGE AIR COOLER PIPEWORK
Lifting jacks should only be used under the axle.
Inspect all hoses and clips on the charge cooler pipe work.
HOSES
The bolts securing the running gear to the chassis should be
checked periodically for tightness (refer to the
SERVICE/MAINTENANCE CHART for frequency) and
re–tightened where necessary. Refer to the TORQUE
SETTING TABLE later in this section.
All components of the engine cooling air intake system
should be checked periodically to keep the engine at peak
efficiency.
BRAKES
Engine damage will occur if the charge cooling system leaks.
Check and adjust the brake linkage at 500 miles (850Km)
then every 3000 miles (5000Km) or 3 months (whichever is the
sooner) to compensate for any stretch of the adjustable cables.
Check and adjust the wheel brakes to compensate for wear.
At
the
recommended
intervals,
(see
the
SERVICE/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.
CAUTION: Check the wheel nut torque 20 miles (30 kilometres)
after refitting the wheels (Refer to the TORQUE SETTING
TABLE later in this section).
ELECTRICAL SYSTEM
Adjusting the overrun
(KNOTT Running Gear)
WARNING: Always disconnect the battery cables before
performing any maintenance or service.
braking
system
1: Preparation
Jack up the machine
Disengage the handbrake lever [1].
Fully extend the draw bar [2] on the overrun braking system.
Inspect the safety shutdown system switches and the
instrument panel relay contacts for evidence of arcing and
pitting. Clean where necessary.
Check the mechanical action of the components.
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.
BATTERY
Keep the battery terminals and cable clamps clean and
lightly coated with petroleum jelly to prevent corrosion.
1 Handbrake lever
2 Draw bar and bellows
The retaining clamp should be kept tight enough to prevent
the battery from moving.
3 Handbrake lever pivot
4 Transmission lever
PRESSURE SYSTEM
5 Brake cable
At 500 hour intervals it is necessary to inspect the external
surfaces of the system (from the airend through to the discharge
valve(s)) including hoses, tubes, tube fittings and the separator
tank, for visible signs of impact damage, excessive corrosion,
abrasion, tightness and chafing. Any suspect parts should be
replaced before the machine is put back into service.
6 Breakaway Cable
Requirements:
During the adjustment procedure always start with the wheel
brakes.
TYRES/TYRE/TIRE PRESSURE
Always rotate the wheel in the direction of forward movement.
See the GENERAL INFORMATION section of this manual.
Ensure that an M10 safety screw is fitted to the handbrake pivot.
51
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
The brake actuators must not be pre–tensioned – if necessary
loosen the brake linkage [7] on the brake equalisation assembly
[8].
3: Compensator assembly adjustment
Check that brake actuators and cables [11] operate smoothly.
Fit an M10 safety screw to the handbrake pivot.
Variable Height models
Disconnect the handbrake cable [5] at one end.
Pre–adjust brake linkage [7] lengthways (a little play is
permissible) and re–insert the cable [5], adjusting it to give a
small amount of play.
Remove the M10 safety screw from the handbrake pivot.
All Models
Engage the handbrake lever [1] and check that the position of
the equaliser plate [10] is at right angles to the pulling direction.
If necessary correct the position of the equaliser plate [10] on the
cables [11].
The compression spring [9] must only be slightly pre–tensioned
and when engaged must not touch the axle tube.
7 Brake linkage
4: Brake linkage adjustment
8 Equalisation assembly
Adjust the brake linkage [7] lengthways without pre–tension and
without play in the transmission lever [4].
9 Compression spring
10 Equaliser plate
Readjustment
11 Cable
Engage the handbrake lever [1] forcefully a number of times to
set the brake.
CAUTION
The compression spring [9] must only be lightly pre–tensioned
and when operating must never touch the axle tube.
Never adjust the brakes at the brake linkage [7].
Check the alignment of the equalisation assembly [8], this
should be at right angles to the pulling direction
Check the play in the brake linkage [7]
If necessary adjust the brake linkage [7] again without play and
without pre–tensioning
2. Brake Shoe Adjustment
There must still be a little play in cable [5] (Variable Height Only)
Check the position of the hand brake lever [1]. The start of
resistance should be approximately 10–15mm above the
horizontal position.
Check that the wheels move freely when the handbrake is
disengaged.
Final test
Check the fastenings on the transmission system (cables,
brake equalisation system and linkage).
Check the handbrake cable [5] for a small amount of play and
adjust if necessary (Variable height only)
Check the compression spring [9] for pre–tensioning.
12 Adjusting screw
13 Cable entry
Test run
Width across flats of adjusting screw [12]
Brake size
160x35 / 200x50
250x40
300x60
If necessary carry out 2–3 test brake actions.
Key width
SW 17
SW 19
SW 22
Test brake action
Check the play in brake linkage [7] and if necessary adjust the
length of brake linkage [7] until there is no play.
Tighten adjusting screw [12] clockwise until the wheel locks.
Apply the handbrake while rolling the machine forward, travel of
the handbrake lever up to 2/3 of maximum is allowed.
Loosen adjusting screw [12] anti–clockwise (approx. ½ turn)
until the wheel can be moved freely.
Slight dragging noises that do not impede the free movement of
the wheel are permissible.
Re–adjusting the overrun braking system
(KNOTT Running Gear)
This adjustment procedure must be carried out as described on
both wheel brakes.
Re–adjustment of the wheel brakes will compensate for brake
lining wear. Follow the procedure described in 2: Brake Shoe
Adjustment.
When the brake has been adjusted accurately the actuating
distance is approximately 5–8mm on the cable [11]
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
52
Check the play in the brake linkage [7] and re–adjust if
necessary.
ENGINE OIL FILTER ELEMENT
The engine oil filter element should be changed at the engine
manufacturer’s recommended intervals. Refer to the Engine
section of this manual.
Important
Check the brake actuators and cables [11]. The brake actuators
must not be pre–tensioned.
Excessive operation of the handbrake lever, which may have
been caused by worn brake linings, must not be corrected by
re–adjusting (shortening) the brake linkage [7]
COMPRESSOR LUBRICATING OIL
Refer to the SERVICE/MAINTENANCE CHART in this
section for service intervals.
Re–adjustment
The handbrake lever [1] should be engaged forcefully several
times to set the braking system.
Check the setting of the brake equalisation assembly [8], which
should be at right angles to the pulling direction.
Check the play in the brake linkage [7] again, ensuring that there
is no play in the brake linkage and that it is adjusted without
pre–tension
Check the position of the hand brake lever [1], cable [5] (with
little play) and the compression spring [9] (only slight
pre–tension). The start of resistance of the handbrake lever
should be approximately 10–15mm above the horizontal
position.
NOTE: If the machine has been operating under adverse
conditions, or has suffered long shutdown periods, then more
frequent service intervals will be required.
WARNING: DO NOT, under any circumstances, remove any
drain plugs or the oil filler plug from the compressor
lubricating and cooling system without first making sure
that the machine is stopped and the system has been
completely relieved of all air pressure (refer to STOPPING
THE UNIT in the OPERATING INSTRUCTIONS section of this
manual).
Final test
Check the fastenings on the transmission system (cables,
brake equalisation system and linkage)
Apply the handbrake while rolling the machine forward, travel of
the handbrake lever up to 2/3 of maximum is allowed.
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.
Check the handbrake cable [5] for a small amount of play and
adjust if necessary (Variable height only)
Replace the drain plug(s) ensuring that each one is secure.
Check the compression spring [9] for slight pre–tensioning.
LUBRICATION
NOTE: If the oil is drained immediately after the machine has
been running, then most of the sediment will be in suspension
and will therefore drain more readily.
The engine is initially supplied with engine oil sufficient for a
nominal period of operation (for more information, consult the
Engine section of this manual).
CAUTION: Some oil mixtures are incompatible and result in the
formation of varnishes, shellacs or lacquers which may be
insoluble.
CAUTION: Always check the oil levels before a new machine
is put into service.
NOTE: Always specify INGERSOLL–RAND Pro–TecTM oil for
use at all ambient temperatures above –23C.
If, for any reason, the unit has been drained, it must be
re–filled with new oil before it is put into operation.
COMPRESSOR OIL FILTER ELEMENT
ENGINE LUBRICATING OIL
Refer to the SERVICE / MAINTENANCE CHART in this
section for service intervals.
The engine oil should be changed at the engine
manufacturer’s recommended intervals. Refer to the Engine
section of this manual.
RUNNING GEAR WHEEL BEARINGS
Wheel bearings should be packed with grease every 6
months. The type of grease used should conform to
specification MIL–G–10924.
ENGINE LUBRICATING OIL SPECIFICATION
Refer to the Engine section of this manual.
53
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
SPEED AND PRESSURE REGULATION ADJUSTMENT
Start the machine (Refer to STARTING INSTRUCTIONS in
the OPERATING INSTRUCTIONS section of this manual).
Normally, regulation requires no adjusting, but if correct
adjustment is lost, proceed as follows:
Adjust the service valve on the outside of the machine to
maintain rated pressure at full speed. If full speed is not
maintained at rated pressure, then turn the adjusting screw
clockwise to increase the pressure. Optimum adjustment is
achieved when full speed is achieved at rated pressure.
Refer to the diagram above.
A: Adjusting screw
Close the service valve. The engine will slow to idle speed.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
54
TABLE 1
INCH FASTENERS
NOMINAL DESIGN TORQUE
8AE J249
GRADE 5
(HEAD MARKING)
8AE J249
GRADE 8
(HEAD MARKING)
TYPICAL RECTANGULAR TORQUE
PATTERN
CAPSCREW
OR NUT
THREAD
SIZE AND
PITCH
TYPICAL SQUARE TORQUE
PATTERN
(Nm.)
(FT–LBF)
(Nm.)
(FT–LBF)
1/4 – 20
11
8
16
12
5/16 – 18
24
17
33
25
3/8 – 16
42
31
59
44
7/16 – 14
67
49
95
70
1/2 – 13
102
75
144
106
9/16 – 12
148
109
208
154
5/8 – 11
203
150
287
212
3/4 – 10
361
266
509
376
TYPICAL CIRCULAR TORQUE
PATTERN
55
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
TABLE 2
METRIC FASTENERS
NOMINAL DESIGN TORQUE
PROPERTY
GRADE 8.8
(HEAD MARKING)
PROPERTY
GRADE 10.9
(HEAD MARKING)
PROPERTY
GRADE 12.9
(HEAD MARKING)
TYPICAL RECTANGULAR TORQUE
PATTERN
CAPSCREW
OR NUT
THREAD
SIZE AND
PITCH
TYPICAL SQUARE TORQUE
PATTERN
(Nm.)
(FT–LBF)
(Nm.)
(FT–LBF)
(Nm.)
(FT–LBF)
M6 X 1.0
11
8
15
11
18
13
M8 X 1.25
26
19
36
27
43
31
M10 X 1.5
52
38
72
53
84
62
M12 X 1.75
91
67
126
93
147
109
M14 X 2
145
107
200
148
234
173
M16 X 2
226
166
313
231
365
270
M20 X 2.5
441
325
610
450
713
526
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
56
TYPICAL CIRCULAR TORQUE
PATTERN
COMPRESSOR LUBRICATION
RATED OPERATING PRESSURE
Portable Compressor Fluid Chart
Refer to these charts for correct compressor fluid required.
100 – 300 PSI
50C
125F
40C
104F
30C
86F
20C
65F
10C
50F
0C
32F
–10C
14F
350 PSI
500 PSI
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
IR
XHP505
IR
IR
XHP 1001 XHP1001
change.
Design Operating Ambient
Pressure
Temperature
100 psi to 300 psi
–10F to 125F
(–23C to 52C)
100 psi to 300 psi
–40F to 125F
(–40C to 52C)
IR
PRO–TEC
Specification
IR
PERFORMANCE
IR Pro–Tec
Mil –PRF 2104G
SAE 10W
500
IR
Performance
500
–20C
350 psi
500 psi
–10F to 125F
IR XHP 505
(–23C to 52C)
65F to 125F IR XHP1001
(18C to 52C)
IR
Performance
–40F to 65F
500
(–40C to 18C)
Mil–L–46167
IR
XHP505
10F
–30C
–10F
–22F
–40C
–40F
Mil–L–46167
IR
PERFORMANCE
500
consult
factory
50F to 125F IR XHP1001
(10C to 52C)
10F
to 65F IR XHP 505
(–12C to 18C)
below
10F Consult Factory
(–12C)
Recommended Ingersoll–Rand Fluids – Use of these fluids
with original IR filters can extend airend warranty. Refer to
operator’s manual warranty section for details or contact your
IR representative.
Compressor
Recommended
Fluid
1 Gal.
5 Gal.
55 Gal.
275 Gal. Tote
Europe
Pro–Tec
36899698
36899706
36899714
36899722
89292973
89292981
XHP 505
NA
54418835
54418843
54418827
___
–––
Performance
500
35382928
35382936
35382944
NA
___
–––
XHP1001
NA
35612738
35300516
NA
___
___
Engine Oil
54480918
36875938
36866903
NA
89311716
89311724
57
20 Litre
208 Litre
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
MACHINE SYSTEMS
KEY
BAT
Battery
PT1
Pressure transducer, separator tank 0–500 PSIG
CO
RS232C comms
PT2
Pressure transducer, regulation system 0–100 PSIG
ECON
Engine controller
PM
Plug, machine ID
IG
Isochronous governor
R3
Idle sel
J50–G2 Wait to start lamp
RS
Relay–spst
J50–K3 Inlet heater
RT1
Thermistor, seperator tank temperature –30 – 255F
P51
Coolant temp
RT2
Thermistor, airend discharge temperature –30 –
P52
Inject
P53
Crank sensor
P54
Fuel temp
P55
Manifold air temp
P56
Oil pressure
POUT1
Engine key switch
POUT2
Solenoid, start/run
POUT3
Comp fault lamp
POUT4
Engine fault lamp
POUT5
Start relay
POUT6
Spare
POUT7
Hour meter
POUT8
Spare
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
255F
58
SI
Switch inputs
SM
Starter motor
SW1
Spare
SW2
Display scroll
SW3
Low fuel shutdown
SW4
Switch, service air
SW5
Air filter rest (option)
SW6
Spare
SW7
Spare
SW8
Switch, start
TE
Transducer exitation
WCON
Wedge controller
WEDGE TO ENGINE INTERFACE – IR ENGINE
CAN LO
CAN HI
CAN SHLD
WEDGE
CONTROLLER
ENGINE
CONTROLLER
KEY SWITCH
ANALOG THROTTLE RANGE=
1.10VDC (1400RPM) TO 3.7VDC (2400RPM)
ANALOG THROTTLE
FIGURE 2–1
HARNESS SYSTEM SCHEMATIC
CONTROL PANEL
SWITCHES
24VDC HEATERS
SOLENOID VALVES
WEDGE
CONTROLLER
CONTROLL PANEL HARNESS
SPEED SENSOR
ENGINE ECM
DIAGNOSTIC
INTERFACE
HOURMETER
FUEL LEVEL SWITCH
PRESSURE
TRANSDUCER
ESTOP SWITCHES
GUAGES
TEMPERATURE
SENSOR
BATTERY STARTING
AND CHARGING
SYSTEM
FIGURE 2–2
59
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
J1939 CAN COMMUNICATIONS SCHEMATIC
ENGINE CM
WEDGE
CONTROLLER
TERMINATOR
TERMINATOR
ENGINE DIAGNOSTICS
JACK
FIGURE 2–3
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
60
SERVICE TOOLS
Electronic Systems
The following special tools are recommended to perform service procedures in this manual.
The tools can be purchased from Ingersoll–Rand or equivalent substitutes can be used.
Tool
Tool Description
Fluke 87
Digital Multimeter
Used to Measure electrical circuits:
volts, ohms amps
54729660
Weather–Pack Terminal Removal Tool
Used to repair Packard Electric Weather–Pack Connectors
54729678
Deutsch Terminal Removal Tool (Blue)
Used to repair Deutsch connectors
54729686
Deutsch Terminal Removal Tool (Red)
Used to repair Deutsch connectors
54729694
Deutsch Terminal Removal Tool (Yellow)
Used to repair Deutsch connectors
HDT–48–00
Deutsch Terminal Crimp Tool
Used to crimp Deutsch connector terminals
DD
Deutsch Terminal Crimping Tool
Used to crimp Deutsch connector terminals
54729710
Electrical Contact Cleaner
Used to clean electrical contacts and connectors
54729728
PDA Service Tool
Palm Pilot based service tool used to connect to Intellisys (SGP) Controller
to load software and extract service information
22073886
Packard Crimp Tool
Used to crimp Packard connector terminals
22073878
Thermistor Simulator Plug
Used to test thermister circuits
54699616
Deutsch Terminal Removal Tool
Used to repair Deutsch connectors
54699657
Deutsch Terminal Removal Tool
Used to repair Deutsch connectors
54749643
Packard Metri–Pack Terminal Removal Tool
Used to repair Metri–Pack connectors
54749635
Connector Repair Kit
Used to make connector repairs
61
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
SERVICE TOOLS
Tool No.
Tool Description
Fluke 87
Digital Multimeter
Available from electrical and electronic
parts distributors.
54729660
Weather–Pack Terminal Removal Tool
54699632
Deutsch Terminal Removal Tool (Blue)
54699640
Deutsch Terminal Removal Tool (Red)
54699624
Deutsch Terminal Removal Tool (Yellow)
DT–RT1
Crimp Tool for Deutsch Pins Crimp
Available from:
Ladd Industries (800–223–1236)
54729710
Electrical Contact Cleaner
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Tool Illustration
62
54729728
PDA Service Tool
54699616
Deutsch Terminal Removal Tool
22073886
Packard Crimp Tool
22073878
Thermistor Simulator
54749635
Connector Repair Kit
54699657
Deutsch Terminal Removal Tool
54749643
Packard Metri–Pack Removal Tool
63
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
ELECTRICAL PARTS
PARTS
NUMBERS
DESCRIPTION
QTY PER
MACHINE
PARTS
NUMBERS
DESCRIPTION
36920825
QTY PER
MACHINE
0–100 psi PRESSURE
TRANSDUCER
1
35578194
ENGINE GROUND
STRAP
1
54765946
0–500 psi PRESSURE
TRANSDUCER
1
54731427
FUEL LEVEL SENDER
1
22173579
WEDGE CONTROLLER
1
36898922
THERMISTOR PROBE
2
22199061
W1 CHASSIS HARNESS
1
36840841
SOLENOID VALVE
1*
22179659
STARTER AND INLET
HEATER RELAY
2
W1 CHASSIS HARNESS
DIAGRAM
N/A
36853521
36792083
FUSE 20 AMP BLADE
1
35610856
NEGATIVE BATTERY
CABLE
1
22071591
FUSE 10 AMP BLADE
1
35583582
POSITIVE BATTERY
CABLE
1
54475777
DIAGNOSTIC SWITCH
1
**
MACHINE ID PLUG
1
*
Quantity two (2) per machine on P600WIR (7/170) model only.
**
Part number 22201354 on models 7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), and 14/85 (VHP300AWIR).
Part number 22201362 on models 7/170 (P600WIR), 10/125 (HP450WIR), and 14/115 (VHP400WIR).
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
64
FAULT FINDING
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.
Check the fan belt
tension, battery and
cable connections.
Reduced cooling air
from fan.
Bad earth
connection.
Check the earth
cables, clean as
required.
Check the fan and the
drive belts. Check for
any obstruction inside
the cowl.
Faulty thermostat
Loose connection.
Locate and make the
connection good.
Check the thermostat
and
replace
if
necessary.
Fuel starvation.
Check the fuel level
and fuel system
components.
Replace the fuel filter
if necessary.
Engine
speed too
high.
Incorrect throttle arm
setting.
Check the engine
speed setting.
Engine
speed too
low.
Incorrect throttle arm
setting.
Check the
setting.
FAULT
CAUSE
REMEDY
No reaction
from
instrument
panel when
key turned
to (I)
position.
Batteries not
connected.
Connect batteries.
Fuse at starter motor
‘blown’.
Replace fuse.
Engine fails
to start.
Low battery charge.
Engine
stops while
in service or
is reluctant
to start.
Relay failed.
Replace the relay.
Blocked fuel filter.
Check and replace if
necessary.
Faulty stop solenoid
Check
the
solenoid
Blocked air filter.
Check and replace
the
element
if
necessary.
Incorrectly set
regulation system.
Reset the regulation
system. Refer to
SPEED
AND
PRESSURE
REGULATION
ADJUSTMENT in the
MAINTENANCE
section
of
this
manual.
Premature
unloading.
Check the regulation
system.
Low fuel level.
stop
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.
Electrical fault
Test the
circuits.
Low engine oil
pressure.
Check the oil level
and the oil filter(s).
Faulty relay
Check the relays.
Faulty key–switch
Check
key–switch.
Engine
starts but
will not run
or engine
shuts down
prematurely.
Electrical fault.
Test the
circuits.
Low engine oil
pressure.
Check the oil level
and oil filter(s).
Engine
starts but
will not run
or engine
shuts down
prematurely.
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.
Engine
starts but
stalls when
the switch
returns to
position I.
throttle
electrical
the
Excessive
vibration.
Engine speed too
low.
See ”Engine speed
too low”
Leaking oil
seal.
Improperly fitted oil
seal.
Replace the oil seal.
electrical
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 relays and
replace if necessary.
Refer also to the Engine Manufacturer’s Manual.
Air
discharge
capacity too
low.
65
Engine speed too
low.
See “Engine speed
too low”
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.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
FAULT FINDING
Compressor
overheats.
Excessive oil
present in
the
discharge
air.
Safety valve
operates.
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.
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.
Operating pressure
too high.
Refer to SPEED AND
PRESSURE
REGULATION
ADJUSTMENT in the
MAINTENANCE section of this manual.
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.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Oil is forced
back into the
air filter.
66
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
switch is
pressed.
Faulty load valve.
Replace the valve.
Faulty switch.
Test switch
Loose pipe/hose
connections.
Check all pipe/hose
connections.
OPTIONS
OPTIONS – Lubricator
PRIOR TO STARTING
Check the lubricator oil level and replenish as necessary.
(For units manufactured in North America)
MAINTENANCE
SAFETY
Check the lubricator oil level and replenish as necessary.
WARNING: Ensure that the lubricator filler cap is
re–tightened correctly after replenishing with oil.
FAULT FINDING
WARNING: Do not replenish the lubricator oil, or service
the lubricator without first making sure that the machine is
stopped and the system has been completely relieved of all
air pressure (Refer to STOPPING THE UNIT in the
OPERATING INSTRUCTIONS section of this manual).
CAUTION: If the nylon tubes to the lubricator are disconnected
then ensure that each tube is re–connected in its original
location.
FAULT
CAUSE
No oil flow.
Incorrect connection. Reverse the nylon
tube connections to
the lubricator.
REMEDY
GENERAL INFORMATION
Oil capacity:
1 QT Option –0.95 Litre (1qt)
2 QT Option –1.9 Litre (2qts)
Oil specification:
Refer to the Tool Manufacturer’s Manual.
OPERATING INSTRUCTIONS
COMMISSIONING
Check the lubricator oil level and fill as necessary.
67
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
OPTIONS
OPTIONS – Dual pressure
NOTICE:
Do not operate at temperatures less that 2C (35F) unless
equipped with low ambient IQ option.
SAFETY
OPERATING INSTRUCTIONS
Starting and use:
WARNING: Any pneumatic equipment that is, or may be
connected to the machine must be suitable for use with at
least the higher, rated pressure.
Select desired air type using diverter valve and start machine
normally.
Using diverter valve, toggle between standard air and IQ air as
required.
OPERATING INSTRUCTIONS
COMMISIONING
Check that switch and solenoid are functioning correctly.
TO AFTERCOOLER
Switch handle up: Lower pressure selected
Standard
Operation
Switch handle right: Higher pressure selected
FROM FILTERS
STARTING AND USE
Select higher pressure setting with valve handle (handle to
right) and start machine normally.
If lower pressure is required then turn handle to up position.
SERVICE AIR
Toggle between high and low pressure as required.
OPTIONS – IQ SYSTEM
SAFETY
TO AFTERCOOLER
CAUTION: The compressor regulation system is adjusted to
maintain regulated pressure at the separator tank. DO NOT
adjust regulation to provide full regulation pressure at the
service valve when the IQ System is enabled. This will result
inC operation at excessive horsepower levels, causing
overheating, reduced engine life, and reduced airend life.
FROM FILTERS
Standard
Operation
SERVICE AIR
CAUTION: Excessively restricted filter elements may cause an
increase in the amount of aerosol water and oil carryover, which
could result in damage to downstream equipment. Normal
service intervals should not be exceeded.
CAUTION: Blockage of the condensate will result in flooding of
the vessels. If flooding occurs, excessive condensate may
enter the air stream and could result in damage to downstream
equipment.
CAUTION: Do not remove u–bolts from both filters at the same
time. Removing both u–bolts will place excessive stress on the
aftercooler.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
68
OPTIONS
MAINTENANCE
Daily maintenance:
Verify, during full–load (maximum compressed air delivery) that
the IQ system filter restriction indicators do not show excessive
restriction.
Restriction indicators for primary and secondary filters are
located on the filter heads. If so equipped, an automatic
restriction indicator is located behind the filter mounting bracket
and will shut down the compressor if restriction exceeds
recommended values.
Weekly Maintenance:
Verify that the piping from the water separator and filters to
the exhaust system is not clogged.
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 on the filter
heads. If so equipped, an automatic restriction indicator located
behind the filters will shut down the compressor if restriction
exceeds recommended values.
Filter replacement.
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 be removed by hand after loosening, taking care
to prevent the housing from falling to the floor panel.
Lower the housing to floor panel. Remove and replace the
filter element, being careful not to damage outer wrap.
Put a small amount of petroleum jelly or other non–synthetic
grease on the element o–ring to aid installation into the filter
head.
Replace housing making sure not to overtighten.
Repeat the above procedure on the remaining filter element.
Rec onnect all wires and hoses to drains on bottom of each
filter housing.
69
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
PARTS ORDERING
A series of illustrations show each part distinctly
and in location relative to the other parts in the
assembly. The part number, the description of the
part and the quantity of parts required are shown
on each illustration or on adjacent page. The
quantities specified are the number of parts used
per one assembly and are not necessarily the total
number of parts used in the machine. Where no
quantity is specified the quantity is assumed to be
one.
GENERAL
This publication, which contains an illustrated
parts breakdown, has been prepared as an aid in
locating those parts which may be required in the
maintenance of the unit. All of the compressor
parts, listed in the parts breakdown, are
manufactured with the same precision as the
original equipment. For the greatest protection
always insist on genuine Ingersoll–Rand
Company parts for your compressor.
Each description of a part is based upon the “noun
first” method, i.e., the identifying noun or item
name is always the first part of the description.
The noun name is generally followed by a single
descriptive modifier. The descriptive modifier
may be followed by words or abbreviations such
as upper, lower, inner, outer, front, rear, RH, LH,
etc. when they are essential.
NOTICE
Ingersoll–Rand Company can bear no
responsibility for injury or damages resulting
directly from the use of non–approved repair
parts.
Ingersoll–Rand Company service facilities and
parts are available worldwide.
There are
Ingersoll–
Rand
Company
Construction
Equipment Group Sales Offices and authorized
distributors located in the principal cities of the
United States. In Canada our customers are
serviced by the Canadian Ingersoll–Rand
Company,
Limited.
There are also
Ingersoll–Rand
International
autonomous
companies and authorized distributors located in
the principal cities throughout the free world.
In referring to the rear, the front or to either side
of the unit, always consider the drawbar end of
the unit as the front. Standing at the rear of the
unit facing the drawbar (front) will determine the
right and left sides.
FASTENERS
Both SAE/inch, ISO/metric hardware have been
used in the design and assembly of these units.
In the disassembly and reassembly of parts,
extreme care must be taken to avoid damaging
threads by the use of wrong fasteners. In order to
clarify the proper usage and for exact
replacement parts, all standard fasteners have
been identified by part number, size and
description. This will enable a customer to obtain
fasteners locally rather than ordering from the
factory. These parts are identified in tables that
will be found at the rear of the parts illustrations.
Any fastener that has not been identified by both
part number and size is a specially engineered
part that must be ordered by part number to obtain
the exact replacement part.
Special order parts may not be included in this
manual. Contact the Mocksville Parts Department
with the unit serial number for assistance with
these special parts.
DESCRIPTION
The illustrated parts breakdown illustrates and
lists the various assemblies, subassemblies and
detailed parts which make up this particular
machine. This covers the standard models and
the more popular options that are available.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
70
e.
MARKINGS AND DECALS
NOTICE
In the event parts are being returned to your
nearest sales office, autonomous company or
authorized distributor, for inspection or repair, it is
important to include the serial number of the unit
from which the parts were removed.
Do not paint over safety warnings or
instructional decals. If safety warning decals
become
illegible,
immediately
order
replacements from the factory.
Part numbers for original individual decals
and their mounting locations are shown
within Parts List Section. These are available
as long as a particular model
is
in
production.
TERMS AND CONDITIONS ON PARTS
ORDERS
Acceptance: Acceptance of an offer is expressly
limited to the exact terms contained herein. If
purchaser’s order form is used for acceptance of
an offer, it is expressly understood and agreed
that the terms and conditions of such order form
shall not apply unless expressly agreed to by
Ingersoll–Rand Company (“Company”) in writing.
No additional or contrary terms will be binding
upon the Company unless expressly agreed to in
writing.
Afterwards, service sets of exterior decals and
current production safety warning decals are
available. Contact the Product Support Group at
Mocksville for your particular needs and
availability.
HOW TO USE PARTS LIST
a.
Turn to Parts List.
b.
Locate the area or system of the
compressor in which the desired part is used
and find illustration page number.
c.
Locate the desired part on the illustration by
visual identification and make note of part
number and description.
Taxes: Any tax or other governmental charge
now or hereafter levied upon the production, sale,
use or shipment of material and equipment
ordered or sold is not included in the Company’s
price and will be charged to and paid for by the
Purchaser.
Shipping dates shall be extended for delays due
to acts of God, acts of Purchaser, acts of
Government, fires, floods, strikes, riot, war,
embargo, transportation shortages, delay or
default on the part of the Company’s vendors, or
any other cause beyond the Company’s
reasonable control.
HOW TO ORDER
The satisfactory ordering of parts by a purchaser
is greatly dependent upon the proper use of all
available information. By supplying your nearest
sales office, autonomous company or authorized
distributor, with complete information, you will
enable them to fill your order correctly and to avoid
any unnecessary delays.
Should Purchaser request special shipping
instruction, such as exclusive use of shipping
facilities, including air freight when common
carrier has been quoted and before change order
to purchase order can be received by the
Company, the additional charges will be honored
by the Purchaser.
In order that all avoidable errors may be
eliminated, the following instructions are offered
as a guide to the purchaser when ordering
replacement parts:
a.
Always specify the model number of the unit
as shown on the general data decal
attached to the unit.
b.
Always specify the serial number of the unit.
THIS IS IMPORTANT. The serial number of
the unit will be found stamped on a plate
attached to the unit. (The serial number on
the unit is also permanently stamped in the
metal of the frame side rail.)
c.
Always specify the number of the parts list
publication.
d.
Always specify the quantity of parts
required.
Always specify the part number, as well as
the description of the part, or parts, exactly
as it is given on the parts list illustration.
Warranty: The Company warrants that parts
manufactured by it will be as specified and will be
free from defects in materials and workmanship.
The Company’s liability under this warranty shall
be limited to the repair or replacement of any part
which was defective at the time of shipment
provided Purchaser notifies the Company of any
such defect promptly upon discovery, but in no
event later than three (3) months from the date of
shipment of such part by the Company. The only
exception to the previous statement is the
extended warranty as it applies to the special
airend exchange program.
Repairs and replacements shall be made by the
Company F.O.B. point of shipment.
The
Company shall not be responsible for costs of
transportation, removal or installation.
71
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
Warranties applicable to material and equipment
supplied by the Company but wholly
manufactured by others shall be limited to the
warranties extended to the Company by the
manufacturer which are able to be conveyed to
the Purchaser.
AIREND EXCHANGE PROGRAM
Ingersoll–Rand offers an airend exchange
program to benefit portable compressor users.
On the airend exchange program the exchange
price is determined by the age and condition of the
airend.
Delivery: Shipping dates are approximate. The
Company will use best efforts to ship by the dates
specified; however, the Company shall not be
liable for any delay or failure in the estimated
delivery or shipment of material and equipment or
for any damages suffered by reason thereof.
Your nearest sales office, autonomous company
or authorized distributor must first contact the
Parts Service Department at the factory at which
your portable air compressor was manufactured
for an airend exchange number. The airend must
be tagged with this preassigned number and
returned to the factory prepaid. The airend must
be intact, with no excluded parts, otherwise the
exchange agreement may be cancelled. The
warranty on an exchange or factory rebuilt airend
is 365 days.
Airends being returned to the factory in
connection with a WARRANTY CLAIM must be
processed through the Customer Service
Department. If returned without a Warranty MRR
(Material Return Request) Number, no warranty
claim will be considered.
The company makes no other warranty or
representation of any kind whatsoever,
expressed or implied, except that of title, and all
implied warranties, including any warranty of
merchantability and fitness for a particular
purpose, are hereby disclaimed.
Limitation of Liability:
The remedies of the Purchaser set forth herein
are exclusive, and the total liability of the
Company with respect to this order whether
based on contract, warranty, negligence,
indemnity, strict liability or otherwise, shall not
exceed the purchase price of the part upon which
such liability is based.
The Company shall in no event be liable to the
Purchaser, any successors in interest or any
beneficiary of this order for any consequential,
incidental, indirect, special or punitive damages
arising out of this order or any breach thereof, or
any defect in, or failure of, or malfunction of the
parts hereunder, whether based upon loss of use,
lost profits or revenue, interest, lost goodwill, work
stoppage, impairment of other goods, loss by
reason of shutdown or non– operation, increased
expenses of operation or claims of customers of
Purchaser for service interruption whether or not
such loss or damage is based on contract,
warranty, negligence, indemnity, strict liability or
otherwise.
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
72
For information on how to order parts or information regarding your local distributor
(Europe, Middle East, Africa) please contact:
Facility:
Portable Power Aftermarket ESA
Ingersoll–Rand European Sales Ltd
Swan Lane, Hindley Green
Wigan WN2 4 EZ
United Kingdom
Telephone:
+44 (0) 1942 257 171
Emergency order telephone # +44 (0) 777 617 0921
Fax:
+44 (0) 1942 523 417
Office hours: Monday – Friday 8:00 a.m. to 4:30 p.m. (GMT)
73
7/120 (P425AWIR), 9/110 (XP375AWIR), 10/105 (HP375AWIR), 14/85 (VHP300AWIR),
7/170 (P600WIR), 10/125 (HP450WIR), 14/115 (VHP400WIR)
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