Ingersoll-Rand HP935WCU Operating, Maintenance And Parts Manual
Ingersoll-Rand HP935WCU is a powerful and versatile portable compressor designed for a variety of applications. With its rugged construction and reliable performance, the HP935WCU is ideal for use in construction, mining, and other demanding environments. This compressor is powered by a diesel engine and features a two-stage air compressor with an intercooler. It has a maximum pressure of 125 psi and a flow rate of 935 cfm. The HP935WCU is also equipped with a variety of safety features, including an automatic shutdown system and a low-oil pressure sensor.
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OPERATING, MAINTENANCE,
PARTS MANUAL
COMPRESSOR MODELS
VHP825WCU
HP935WCU
XP1050WCU
HP825WCU
XP900WCU
Code: Code: D
!
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
Portable Power
P.O. Box 868 -- 501 Sanford Ave
Mocksville, N.C. 27028
Book 35393560 (12/02)
QUALITY POLICY
We will supply products and services that consistently meet the requirements of our customers and each other.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Book 35393560 (12/02)
Foreword
Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European common market countries requires that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. 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:
Book 35393560 (12/02)
Declaration of Conformity
WITH EC DIRECTIVE
98/37/EC
89/336/EEC
Ingersoll--Rand Company
P.O. Box 868
501 Sanford Avenue
Mocksville, North Carolina 27028
We
Represented In EC By:
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)
HP1300WCU
XP1400WCU
P1600WCU
XP900WCU
NXP1300WCU
VHP825WCU
HP935WCU
XP1050WCU
HP825WCU
NHP1500WCU
XHP900WCAT
XHP650WCAT
XHP750WCAT
XHP825WCAT
XHP1070CAT
VHP750WCAT
VHP850WCAT
HP900WCAT
XP1000WCAT
10/425
XHP1170WCU
XHP1070WCU
HP1600WCU
HP1300WCU
XHP1170SCAT
To which this declaration relates, is (are) in conformity with the provisions of the above directives using the following principal standards
EN1012--1, EN29001, EN292, EN60204--1
PN8NTC2, EN 50081, EN50082
Issued at Hindley Green on 1--1--95
Issued at Mocksville on 1--1--95
________________________________
Ric Lunsford
Manager of Quality Control
________________________________
H. Seddon, Q.A. Manager
Book 35393560 (12/02)
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.
This manual contains instructions and technical data to cover all routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be referred to an authorized Ingersoll--Rand service department.
All components, accessories, pipes and connectors added to the compressed air system should be:
S of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by
Ingersoll--Rand.
S clearly rated for a pressure at least equal to the machine maximum allowable working pressure.
S compatible with the compressor lubricant/coolant.
S accompanied with instructions for safe installation, operation and maintenance.
Details of approved equipment are available from Ingersoll--Rand Service departments.
The use of repair parts 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.
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.
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.
If in doubt, consult supervision.
This machine has been designed and supplied for above ground operation to be used for compression of normal ambient air containing no additional gases, vapors or particles within the ambient temperature range specified in the general data section of this manual.
This machine should not be used:
A. For direct or indirect human consumption of the compressed air.
B. Outside the ambient temperature range specified in the general data section of this manual.
C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists.
D. With other than Ingersoll--Rand approved components.
E. With guards, or controls or switches missing or disabled.
F. For storage or transportation of materials inside or on the enclosure.
This company accepts no responsibility for errors in translation of this manual from the original English version.
You as the customer are expected to provide certain service and maintenance items. Your Ingersoll--Rand dealer will provide all other more detailed service and maintenance items on a special preventive maintenance schedule for each machine. It is very important that the minimum service and maintenance requirements explained in this manual be performed at the required intervals. Exceeding these intervals may reduce the reliability of the machine.
The purpose of this manual is to train the operator with functions, operation, and basic service and maintenance requirements of the compressor. During the preparation of this manual, every effort was made to ensure the adequacy and accuracy of the contents.
Book 35393560 (12/02)
Your Ingersoll--Rand dealer will assist with setup and initial startup of the compressor. He will also provide brief operating and service instructions and will insure that a copy of this manual is included with the machine. Before starting the compressor, this manual and instructions should be carefully read to obtain a thorough knowledge of the duties to be performed. Please take pride in the compressor, keep it clean, and in good mechanical condition.
To enable proper maintenance records, Ingersoll--Rand provides a Noise Emission Control Maintenance Log
Book (PCD Form 685) with each compressor shipped from the factory. This Log Book contains a recommended schedule and space so that the serviceman can note what service and maintenance was done, by whom, where, and when.
Book 35393560 (12/02)
TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . .
SAFETY
SECTION 2 . . . . . . . . . . . . . . .
WARRANTY/REGISTRATION
SECTION 3 . . . . . . . . . . . . . . .
NOISE EMISSION
SECTION 4 . . . . . . . . . . . . . . .
GENERAL DATA
SECTION 5 . . . . . . . . . . . . . . .
OPERATION
SECTION 6 . . . . . . . . . . . . . . .
MAINTENANCE
SECTION 7 . . . . . . . . . . . . . . .
LUBRICATION
SECTION 8 . . . . . . . . . . . . . . .
TROUBLESHOOTING
SECTION 9 . . . . . . . . . . . . . . .
PARTS ORDERING
SECTION 10 . . . . . . . . . . . . . .
PARTS LIST
SECTION 11 . . . . . . . . . . . . . .
OPTIONS PARTS LIST
SECTION 12 . . . . . . . . . . . . . .
ENGINE (operation, maintenance, lubrication, troubleshooting)
Book 35393560 (12/02)
SECTION 1-- SAFETY
SAFETY PRECAUTIONS
General Information
Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.
Compressed air must not be used for a feed to any form of breathing apparatus or mask.
The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible.
Ensure that the Operation and Maintenance manual, and the manual holder if equipped, are not removed permanently from the machine.
Ensure that maintenance personnel are adequately trained, competent and have read the manuals.
Make sure that all protective covers are in place and that the canopy/doors are closed during operation.
If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided.
When using compressed air, always use appropriate personal protective equipment.
All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the
Manual instructions.
The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas. If such an application is required then all local regulations, codes of practice and site rules must be observed. To ensure that the machine can operate in a safe and reliable manner, additional equipment such as gas detection, exhaust spark arrestors, and intake
(shut--off) valves may be required, dependent on local regulations or the degree of risk involved.
Avoid bodily contact with compressed air.
Air discharged from this machine may contain carbon monoxide or other contaminants which will cause serious injury or death. Do not breathe this air.
Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.
Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel.
All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine safety valve rating.
If more than one compressor is connected to one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidentally be pressurized or over pressurized by another.
Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine.
Never operate the engine of this machine inside a building without adequate ventilation. Avoid breathing exhaust fumes when working on or near the machine.
Do not alter or modify this machine.
A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water.
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 operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine.
Book 35393560 (12/02)
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.
High Pressure Air can cause serious injury or death.
Relieve pressure before removing filler plugs/caps, fittings or covers.
Air pressure can remain trapped in air supply line which can result in serious injury or death. Always carefully vent air supply line at tool or vent valve before performing any service.
This machine produces loud noise with the doors open or service valve vented. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open or service valve is vented.
Never inspect or service unit without first disconnecting battery cable(s) to prevent accidental starting.
Do not remove the pressure cap from a HOT radiator.
Allow radiator to cool down before removing pressure cap.
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).
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).
Hot pressurized fluid can cause serious burns. Do not open radiator while hot.
Rotating fan blade can cause serious injury. Do not operate without guard in place.
Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.).
Ether is an extremely volatile, highly flammable gas.
USE SPARINGLY! Do NOT use ETHER if unit has
GLOW Plug starting aid. Engine damage will result.
Never allow the unit to sit stopped with pressure in the receiver--separator system. As a precaution, open the manual blowdown valve.
Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, blow gun tips, etc. well away from moving parts.
Make sure wheels, tires and tow bar connectors are in safe operating condition and tow bar is properly connected before towing.
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.
Hazardous Substance Precaution
The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly.
Precaution: Avoid ingestion, skin contact and breathing fumes for the following substances:
Antifreeze, Compressor Oil, Engine Lubricating Oil,
Preservative Grease, Rust Preventative, Diesel Fuel and Battery Electrolyte.
The following substances may be produced during the operation of this machine and may be hazardous to health:
Avoid build--up of Engine Exhaust Fumes in confined spaces.
Avoid breathing Exhaust Fumes.
Avoid breathing Brake Lining Dust during maintenance .
Book 35393560 (12/02)
SAFETY LABELS
Look for these signs on machines shipped to international markets outside North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform you supervisor.
Corrosion risk Hot Surface
Lifting point
WARNING: Electrical shock risk.
Parking Brake
Diesel Fuel.
No open flame.
Do not operate the machine without guard being fitted.
No open flame
Lifting point
WARNING -- Flammable liquid .
When parking use prop stand, handbrake and wheel chocks.
Air/gas flow or Air discharge.
WARNING -- Hot and harmful exhaust gas.
Tie down point
Book 35393560 (12/02)
Do not breathe the compressed air from this machine.
Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken.
X,X
BAR
WARNING -- Maintain correct tire pressure.
(Refer to the GENERAL INFORMATION section of this manual).
WARNING: Consult the operation and maintenance manual before performing any maintenance.
Rough Service Designation
Wet Location Operation
Do not stack
Replace any cracked protective shield.
Do not use fork lift truck from this side
On (power).
Off (power).
Do not operate with the doors or enclosure open.
WARNING -- Before connecting the tow bar or when preparing to tow, consult the operation and maintenance manual.
Emergency stop.
Book 35393560 (12/02)
Oil Drain
XX
km/h
Do not exceed the speed limit.
0
_
C
WARNING -Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved.
Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken
WARNING -- For operating temperature below
0
_
C, consult the operation and maintenance manual.
Do not remove the Operating and
Maintenance manual and manual holder from this machine.
Pressurized vessel.
Use fork lift truck from this side only.
Pressurized component or system.
Book 35393560 (12/02)
Look for these signs on machines shipped to markets in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform you supervisor.
!
Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored.
(Red Background)
!
(Orange Background)
Indicates the presence of a hazard which CAN cause serious injury, death or property damage, if ignored.
Indicates the presence of a hazard which WILL or can cause injury or property damage, if ignored.
(Yellow Background)
Indicates important set--up, operating or maintenance information.
(Blue Background)
WARNING
Trapped air pressure.
Can cause serious injury or death.
Close service valve and operate tool to vent trapped air before performing any service.
DANGER
Discharged air can contain carbon monoxide or other contaminants.
Will cause serious injury or death.
Do not breathe this air.
WARNING
Hot pressurized fluid.
Can cause serious burns.
Do not open radiator while hot.
Book 35393560 (12/02)
WARNING
High pressure air.
Can cause serious injury or death.
Relieve pressure before removing filler plugs/caps, fittings or covers.
WARNING
Improper operation of this equipment.
Can cause serious injury or death.
Read Operator’s Manual supplied with this machine before operation or servicing.
Do not alter or modify this machine without the express written consent of the manufacturer.
WARNING
Rotating fan blade.
Can cause serious injury.
Do not operate without guard in place.
WARNING
Door under pressure.
Can cause serious injury.
Use both hands to open door when machine is running.
WARNING
CAUTION
DO NOT WELD.
ELECTRONIC DAMAGE
WILL OCCUR.
This engine is equipped with an electronic engine controller and other electronic components.
Book 35393560 (12/02)
105 km/h
WARNING
Collapsing jackstand.
Can cause serious injury.
Insert locking pin completely.
Excessive towing speed.
Can cause serious injury or death.
Do NOT exceed 65 mph
(105 km/hr.)
WARNING
Falling off machine.
Can cause serious injury or death.
Access lifting bail from inside machine.
WARNING
Disconnected air hoses whip.
Can cause serious injury or death.
When using air tools attach safety device
(OSHA Valve) at source of air supply for each tool.
WARNING
Combustible gas.
Can cause serious burns, blindness or death.
+
Keep sparks and open flames away from batteries.
CAUTION
DO NOT USE ETHER.
ENGINE DAMAGE WILL OCCUR.
This engine is equipped with an electric heater starting aid.
WARNING
High pressure air.
Can cause serious injury or death.
Relieve pressure before removing filler plugs/caps, fittings or covers.
USE DIESEL
FUEL ONLY
NOTICE
COOLANT FILL INSTRUCTIONS
Adding:
Do NOT remove radiator cap. Top off at overflow reservoir. Use same anti--freeze mixture as in radiator.
Replacing:
With system cool, remove radiator cap. Drain coolant and close drain. At radiator, refill system.
Replace radiator cap. At reservoir, fill to “Hot” level.
Run for 30 minutes. Stop and allow to cool.
At reservoir, add coolant as necessary to reach
“Cold” level.
FREE SAFETY DECALS!
To promote communication of Safety Warnings on products manufactured by the Portable Compressor
Division in Mocksville, N.C., Safety Decals are available
free
of charge. Safety decals are identified by the decal heading:
DANGER, WARNING or CAUTION.
Decal part numbers are on the bottom of each decal and are also listed in the compressor’s parts manual. Submit orders for Safety Decals to the Mocksville Parts Service
Department. The no charge order should contain only
Safety Decals. Help promote product safety! Assure that decals are present on the machines. Replace decals that are not readable.
Book 35393560 (12/02)
SECTION 2 -- Warranty
Ingersoll--Rand, through its distributor, warrants that each item of equipment manufactured by it and delivered hereunder to the initial user will be free of defects in material and workmanship for a period of three (3) months from initial operation or six (6) months from the date of shipment to the initial user, whichever occurs first.
With respect to the following types of equipment, the warranty period enumerated below will apply in lieu of the foregoing warranty period.
A.
Aftercoolers -- The earlier of nine (9) months from date of shipment to or six (6) months from start up by initial user.
B.
Portable Compressors, Portable Generator Sets (GENSET) 8KW, 11KW, 20KVA thru 575KVA, Portable Light Towers and Air Dryers -- The earlier of twelve (12) months from shipment to or the accumulation of
2,000 hours of service by the initial user.
3.5KW thru 7.0KW and 10KW – The earlier of twelve (12) months from shipment to or the accumulation of
2,000 hours of service by the initial user, whichever occurs first. Ingersoll--Rand will provide a new part or repaired part, at it’s election, in place of any part which is found to be defective in material or workmanship during the period described above. Labor cost to replace the part is the responsibility of the user.
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.
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:
1. The original air end is returned assembled and unopened.
2. Continued use of genuine Ingersoll--Rand parts, fluids, oil and filters.
3. Maintenance is performed at prescribed intervals.
Oil--Free airends are fee--based and may require a maintenance agreement. Formal enrollment is required.
D.
Genset Generators 8KW, 11KW, 20KVA thru 575KVA -The earlier of twenty--four (24) months from shipment to or the accumulation of 4,000 hours of service by the initial user.
3.5KW thru 7.0KW and 10KW -- The earlier of twelve (12) months from shipment to or the accumulation of 2,000 hours of service.
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.
Book 35393560 (12/02)
G.
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 (airend drive belts are not included). The optional warranty is automatically available when meeting the following conditions:
1.
The original airend is returned assembled and unopened.
2. Continued use of genuine Ingersoll--Rand parts, fluids, oil and filters.
3. Maintenance is performed at prescribed intervals.
It is the obligation of the user to provide verification that these conditions have been satisfied when submitting warranty claims.
F.
Spare Parts – Six (6) months from date of shipment.
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 above warrantees do 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.
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 FOR A PARTICULAR
PURPOSE.
Book 35393560 (12/02)
GENERAL WARRANTY
Portable Compressor
GENERAL WARRANTY INFORMATION
Extended Coverage
Package
Airend
1 year/2000 hrs
2 yrs/4000 hrs 5 yrs/10,000 hrs
Limited warranty, major components
(refer to operator’s manual).
Portable Genset 8kW, 11KW,
20KVA thru 575KVA
Portable Genset 3.5KW thru
7.0KW and 10KW
Light Tower
Package
Generator
Package
Generator
Package
Generator
1 yr/2000 hrs
2 yrs/4000 hrs
1 yr/2000 hrs (parts only)
1 yrs/2000 hrs (parts only)
1 yr/2000 hrs
1 yr/2000 hrs
None
None
None
None
2 years/4000 hours, for Lightsource introduced 8/16/99.
ENGINES
CATERPILLAR
CUMMINS
JOHN DEERE (in compressors)
(in generators as of 1/1/01)
DEUTZ
INGERSOLL--RAND
KUBOTA (North America only)
(Western Europe & Oceania)
(Central & South America, Asia, Middle East &
Africa)
MITSUBISHI
VOLVO
HONDA
VANGUARD
PARTS
Ingersoll--Rand
Months
6
24
24
12
24
24
24
12
24
24
24
Months
12
24
24
Hours unlimited
2000
2000
2000
2000
4000
2000
2000
1000
2000
2000 unlimited unlimited
Extended Coverage
Available at dealer
Major components 3 yrs/10,000 hrs
Available at dealer
5 yrs/5000 hrs using OEM fluids and filters with
$250 deductible
2 yrs/4000 hrs using IR fluids and filters
Available at dealer
5 yrs/10,000 hrs when using genuine Ingersoll--
Rand fluids and parts. Refer to operator’s manual.
Major components 36 mo/3000 hrs (parts only)
None
None
2 yrs/4000 hrs using IR fluids & filters
2 yrs/4000 hrs using ir fluids & filters
None
None
Hours
No Limit
Coverage
Parts Only
AIREND EXCHANGE
Airend
Months
12
Hours
2000 hours
Extended Coverage
2 yrs/4000 hrs -- available from
IR.
Note: Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with each new product.
Book 35393560 (12/02)
WARRANTY REGISTRATION
Complete Machine Registration
Machines shipped to locations within the United States do not require a warranty registration unless the machine status changes (i.e. change of ownership).
Machines shipped outside the United States require notification be made to initiate the machine warranty.
Fill out the Warranty Registration Form in this section, keep a copy for your records and mail form to:
Ingersoll--Rand Company
Portable Compressor Division
P.O. Box 868
Mocksville, North Carolina 27028
Attn: Warranty Department
Note: Completion of this form validates the warranty.
Book 35393560 (12/02)
Selling Distributor
Name
Address
City
County
State
Zip Code
Telephone
Servicing Distributor
Name
Address
City
County
State
Zip Code
Telephone
Construction--Heavy
(highway, excavation, etc.)
Complete the Applicable Blocks
Owner/User Type of Business (check one only)
Asphalt Contractor
Coal Mining
Construction--Light
(carpentry, plumbing, pools, mason, etc.)
Rental
(rental center, rental fleet, etc.)
Government
(municipal, state, county, etc.)
Building Contractor
Quarry
Waterwell
Industrial (plant use) Other specify __________
Exploration
WARRANTY REGISTRATION
Owner/User Name
Address
City
County
State
Zip Code
Telephone
Other Mining
Shallow Oil & Gas
Utility Company
(gas, electric, water, etc.)
Utility Contractor
Model
Unit--Hours
Unit S/N
Airend S/N
Engine S/N
Truck S/N
Date Delivered
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.
Book 35393560 (12/02)
t en artm Dep ivision a27028 y olin rD an mp
Car ranty
Co rth presso om and
868
No
War leC l-R ntion:
Box rsol rtab Po
Inge
P .O.
Mocksville,
Atte
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
fold
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
Book 35393560 (12/02)
SECTION 3 -- NOISE EMISSION
This section pertains only to machines distributed within the United States.
WARNING
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof:
(1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the compressor after such device or element of design has been removed or rendered inoperative by any person.
Among those acts included in the prohibition against tampering are these:
Removal or rendering inoperative any of the following: the engine exhaust system or parts thereof the air intake system or parts thereof enclosure or parts thereof
Removal of any of the following: fan shroud vibration mounts sound absorption material
Operation of the compressor with any of the enclosure doors open.
Compressor Noise Emission Control Information
A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of design incorporated into this compressor in compliance with the noise control act;
B. The use of this compressor after such device or element of design has been removed or rendered inoperative.
Note: the above information applies only to units that are built in compliance with the U.S. Environmental
Protection Agency.
Ingersoll--Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.
The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor.
Book 35393560 (12/02)
NOISE EMISSION CONTROL
MAINTENANCE LOG
COMPRESSOR MODEL
SERIAL NO.
USER UNIT NO.
UNIT IDENTIFICATION
Engine Make & Model:
Serial No.:
Purchaser or Owner:
Address:
DEALER OR DISTRIBUTOR FROM
WHOM PURCHASED:
Date Purchased:
The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations, specifically the following acts or the causing thereof:
(1) the removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the compressor after such device or element of design has been removed or rendered inoperative by any person.
NOISE EMISSION WARRANTY
The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built and equipped to conform at the time of sale to the first retail purchaser, with all applicable U.S.
EPA Noise Control Regulations.
This warranty is not limited to any particular part, component, or system of the air compressor. Defects in the design, assembly or in any part, component, or system of the compressor which, at the time of sale to the first retail purchaser, caused noise emissions to exceed Federal Standards are covered by this warranty for the life of the air compressor.
INTRODUCTION
The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air Compressors.
The purpose of this book is to provide (1) the Maintenance Performance Schedule for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when. The Maintenance Schedule and detailed instructions on the maintenance items are given on following page.
Book 35393560 (12/02)
MAINTENANCE SCHEDULE
ITEM
I.
J.
E.
F.
G.
H.
A.
B.
C.
D.
AREA
Compressed Air Leaks
Safety and Control Systems
Acoustic Materials
Fasteners
Enclosure Panels
Air Intake & Engine Exhaust
Cooling Systems
Isolation Mounts
Engine Operation
Fuels & Lubricants
A. Compressed Air Leaks
Correct all compressed air leaks during the first shutdown period after discovery. If severe enough to cause serious noise problems and efficiency loss, shut down immediately and correct the leak(s).
B. Safety and Control Systems
Repair or replace all safety and control systems or circuits as malfunction occurs. No compressor should be operated with either system bypassed, disabled, or nonfunctional.
C. Acoustic Materials
In daily inspections, observe these materials. Maintain all acoustic material as nearly as possible in its original condition. Repair or replace all sections that have: 1) sustained damage, 2) have partially separated from panels to which they were attached, 3) are missing, or have otherwise deteriorated due to severe operating or storage conditions.
D. Fasteners
All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be inspected for looseness after each 100 hours of operation. They should be retightened, repaired, or if missing, replaced immediately to prevent subsequent damage and noise emission increase.
E. Enclosure Panels
Enclosure panels should also be inspected at 100 hour operational intervals. All panels that are warped, punctured, torn, or otherwise deformed, such that their noise containment function is reduced, should be repaired or replaced before the next operation interval. Doors, access panels, and hatch closures especially, should be checked and adjusted at this time to insure continuous seating between gasket or acoustic material and the mating frame.
PERIOD
As Detected
As Detected
Daily
100 hours
100 hours
100 hours
250 hours
250 hours
See Operator’s Manual
See Operator’s Manual
F. Air Intake and Engine Exhaust
Engine and compressor air intake and engine exhaust systems should be inspected after each 100 hours of operation for loose, damaged, or deteriorated components. Repairs or replacements should be made before the next period of use.
G. Cooling Systems
All components of the cooling system for engine water and compressor oil should be inspected every 250 hours of use. Any discrepancies found should be corrected before placing the unit back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at all times during operation.
H. Isolation Mounts
Engine/airend isolation mounts should be inspected after each 250 hours of operation. Those mounts with cracks or splits in the molded rubber, or with bent or broken bolts due to operation or storage in severe environments, all should be replaced with equivalent parts.
I. Engine Operation
Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer.
J. Fuels and Lubricants
Use only the types and grades of fuels and lubricants recommended in the Ingersoll--Rand Company and
Engine Manufacturer’s Operator and Maintenance
Manuals.
Book 35393560 (12/02)
ITEM NO.
MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY
DESCRIPTION OF WORK HOURMETER
READING
MAINT/
INSPECT DATE
LOCATION CITY/
STATE
WORK DONE BY
(NAME)
Book 35393560 (12/02)
SECTION 4 -- GENERAL DATA
Model
Rated Delivery: cfm litres/sec
Rated Pressure:
-- psi
-- kPa
Safety Valve
Setting:
-- psi
-- kPa
Engine Model:
Cummins M11
VHP825WCU
825
389
200
379
250
723
335
HP935WCU
935
441
150
1034
200
1379
335
XP1050WCU
1050
496
125
862
200
1379
335
HP825WCU
825
389
150
1034
200
1379
335
XP900WCU
900
425
125
862
200
1379
335
AMBIENT OPERATING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*10 _ F to 120 _ F (--12 _ C to 49 _ C)
*Operation below 10 _ F (--12 _ C) requires optional equipment and lubricants.
ENGINE (Diesel)
Full Load Speed -- rpm
No Load Speed -- rpm
Electrical System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1800
1200
24 VDC
FLUID CAPACITIES -- gallons (litres)
Compressor Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lube (including filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 (98.4)
9 (34.1)
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank (Clean DIESEL fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.8 (52.2)
142 (538)
Notice: Above 15 _ F (--9 _ C) Use No. 2 Diesel Fuel with sulfur content not greater than 0.5% and minimum cetane number of 42.
UNITS MEASUREMENTS/WEIGHTS -- inch (mm)
Overall Length (incl. drawbar) Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steerable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
205 (5207)
218 (5537)
Overall Height
Overall Width
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gross Weight (all fluids) pounds (kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92 (2237)
79.6 (2022)
10,400 (4717))
RUNNING GEAR
Track Width -- inch (mm)
Tire Size/Load Range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65.6 (1667)
LT215/85R16/E
Inflation Pressure (Cold) -- psi (kPa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towing Speed (Maximum) Tandem -- mph (km/hr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steerable -- mph (km/hr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80 (551)
65 (105)
20 (32)
CAUTION: Any departure from the specifications may make this equipment unsafe.
Book 35393560 (12/02)
SECTION 5 -- OPERATION
WARNING
YELLOW -- TOO HIGH
OPTIMUM OIL LEVEL
(EITHER SIDE)
Do not climb on top of unit. The lifting eye can be reached through the roof door ONLY from
INSIDE of the unit.
DISCONNECT and SET -- UP
S Place the unit in an open, well--ventilated area.
Position as level as possible. The design of these units permits a 15 degree sidewise limit on out--of--level operation.
When the unit is to be operated out--of--level it is important:
(1) To keep the engine crankcase oil level near the high level mark (with the unit level),
(2) To have the compressor oil level gauge show no more than mid--scale.
COMPRESSOR MOUNTING
Portable compressors, which are modified to remove the running gear and mount the machine direct to trailers, truck beds or frames, etc. may experience failure of the enclosure, frame, and/or other components. It is necessary to isolate the compressor package from the carrier base with a flexible mounting system. Such a system must also prevent detachment of the package from the carrier base in the event the isolators fail.
Contact Ingersoll--Rand representative for flexible mounting kits.
Warranty does not cover failures attributable to mounting of the compressor package to the carrier base unless it is an Ingersoll--Rand provided system.
COMPRESSOR OIL LEVEL
The oil level should be checked before the unit is started. Always check the oil level while the unit is level, the engine off, and there is zero pressure in the separator tank. The optimum oil level is with the pointer at the top of the green section on the level gage. Add oil if the pointer reaches the bottom of the green section.
Note: The oil level gage will not read properly while the engine is running.
GREEN -- OK
RED
TOO LOW
ADD OIL LEVEL
(EITHER SIDE)
Do not overfill either the engine crankcase or the compressor.
DISCONNECT
Engage parking brakes and chock wheels of both tow vehicle and compressor.
Stand aside while:
S Withdraw pin, swing jack down and fully insert pin to lock in down position.
S Disconnect safety chains from tow vehicle.
S
Disconnect brake actuator chain from tow vehicle.
S If so equipped, disconnect running light plug from the tow vehicle.
S Operate drawbar jack to raise pintle eye from hitch of tow vehicle.
BEFORE TOWING
Units equipped with hydraulic brakes:
Check brake fluid level. Top off as required with DOT
3 brake fluid.
Check condition of brake lines, hoses and cables.
Repair or replace damaged parts.
Attach brake actuator breakaway chain above hitch on towing vehicle.
Book 35393560 (12/02)
TOWING
Tandem Axle Units
These units are designed to be highway towable. Do
NOT exceed 65 mph towing speed.
WARNING
Excessive towing speed can cause serious injury or death. Do NOT exceed 65 mph.
Steerable Axle Units
These units are not designed to be highway towable.
Do NOT tow on highway. Do NOT exceed 20 mph towing speed.
WARNING
Excessive towing speed can cause serious injury or death. Do NOT exceed 20 mph.
• Open service valve (s) to ensure pressure is relieved in receiver--separator system.
S Close valve (s) in order to build up full air pressure and ensure proper oil circulation.
• Check battery for proper connections and condition.
COMBUSTIBLE GAS CAN CAUSE SEVERE
BURNS, BLINDNESS OR DEATH. KEEP SPARKS
AND OPEN FLAME AWAY FROM BATTERY.
S
Check the compressor and engine lubricating oil levels.
The oil level should be checked before the unit is started. Always check the oil level while the unit is level, the engine off, and there is zero pressure in the separator tank. The optimum oil level is with the pointer at the top of the green section on the level gage. Add oil if the pointer reaches the bottom of the green section.
Note: The oil level gage will not read properly while the engine is running.
If necessary, Refer to Lubrication Section for recommended lubricant.
Note: Use a tow vehicle whose towing capacity is greater than the gross weight of this machine.
CAUTION
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.
WARNING
Unrestricted air flow from a hose will result in a whipping motion of the hose which can cause serious injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure in case of hose failure or other sudden pressure release. Reference: OSHA regulation 29 CFR Section 1926.302 (b).
BEFORE STARTING --
All checks should be made while unit is level.
Book 35393560 (12/02)
WARNING
Hot pressurized fluid can cause serious burns.
Do not open radiator while hot.
Check engine coolant level by removing the radiator top cap and looking for coolant in the filler neck of the radiator. Add coolant as required. Insure that radiator cap is installed properly and tightened.
NOTICE: If the appropriate mixture of antifreeze is not used during freezing temperatures, failure to drain the engine may cause costly engine damage. Never use water only as corrosion inhibitors are required in engine coolant fluid.
CAUTION
No smoking, sparks, or open flame near fuel.
Check the fuel level. Add only CLEAN DIESEL fuel for maximum service from the engine. Refer to the Engine Section for fuel specifications.
A fuel level gauge reading can be obtained by turning the power switch to “ON”.
NOTICE
To minimize condensation (water) in the fuel tank, fill the tank at the end of each day.
WARNING
This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve (s) are open.
Close the side doors to maintain a cooling air path and to avoid recirculation of hot air. This will maximize the life of the engine and compressor and protect the hearing of surrounding personnel.
Make sure no one is IN or ON the compressor unit.
STARTING --
CAUTION
Exercise caution when using a booster battery charger to start.
To jump--start, connect the positive booster/charger cable to the 24VDC positive (+) terminal of the battery.
Then connect the negative booster/charger cable to the engine block...Not to the negative (--) terminal of the weak battery. After starting, disconnect the negative (--) cable from engine block; then from the booster battery/charger. Disconnect positive (+) cable from both batteries.
S Flip the POWER switch to “ON”. All diagnostics lamps will light (glow) for two (2) seconds. Then all lamps should go off except for ALTERNATOR NOT
CHARGING and LOW ENGINE OIL PRESSURE.
S In freezing weather, flip HEATERS switch “ON” and wait sixty (60) seconds. This applies heat to the control system components for easier starting. Leave this switch “ON” while operating at these temperatures.
If equipped with 24 volt compressor (Cold Start
Option)
Press and hold the BYPASS button for ten (10) to fifteen (15) seconds. This operates the 24 volt compressor which pressurizes the inlet valve and holds it closed for easier starting.
Book 35393560 (12/02)
In cold weather:
Open manual blow down valve and, if so equipped, press the ETHER INJECT button once and release.
Then, while cranking, press and release button once every five (5) seconds. This injects a measured amount of ETHER to the engine.
Press both the START and the BYPASS buttons to crank the engine. DO NOT OPERATE THE START-
ER MOTOR FOR MORE THAN TEN (10) SECONDS
WITHOUT ALLOWING AT LEAST ONE MINUTE
COOLING TIME BETWEEN START ATTEMPTS.
CAUTION
ETHER is an extremely volatile, highly flammable gas. Use sparingly! If too much is injected, the engine may be damaged.
Release the START button when the engine starts and sustains running.
Release BYPASS button when the engine speed reaches 1000 rpm. The engine oil pressure should be above 20 psi. If the engine oil pressure does not rise within five (5) seconds, stop the unit and refer to
Engine Operator’s Manual.
Once running, All DIAGNOSTIC lamps should be off.
If not, stop the machine and investigate.
Observe the gauges while the unit warms up for five
(5) to ten (10) minutes or until the coolant temperature reaches 140 ° F (60 ° C).
Push the SERVICE AIR button. The engine should go to full speed and the discharge pressure rise to slightly over rated pressure. If there is no air being consumed, the compressor will unload (intake should be throttled or closed) and the engine speed drop to the no load speed.
Compressor is now ready to furnish air when the service valve is opened.
AFTERCOOLER OPTION
1. Do NOT operate when the ambient temperature is 32 ° F (0 ° C) or below.
2. BEFORE STARTING, insure ALL water is drained from aftercooler, water separator and filter
(if so equipped).
3. If compressor is running, close service valve.
4. Locate aftercooler bypass valve at top inlet to aftercooler, inside front door. Turn valve handle fully as follows.
THRU Aftercooler..... CLOCKWISE (To Right)
BYPASS Aftercooler...COUNTERCLOCKWISE
5. Open service valve.
6. After use, insure ALL water is drained from aftercooler, water separator, and filter before leaving or storing machine.
NOTICE: Dispose of condensate from aftercooler, water separator and filter in accordance with local, state and federal regulations.
CAUTION
Never allow the unit to sit stopped with pressure in the receiver--separator system.
As a precaution, open the manual blowdown valve.
WARNING
Even after pressure is relieved from the receiver--separator system, any air supply line from the compressor to a tool or machine could remain under pressure and cause very serious personal injury or death.
After the compressor stops, carefully open a valve at any tool or machine to exhaust the pressure in any line prior to removal or servicing.
STOPPING
• Close air service valve (s).
• Allow the unit to run at “no load” for 3 to 5 minutes to reduce the engine temperatures
• Flip all toggle switches to “Off”.
EQUIPMENT PROTECTION
NOTICE
Do NOT wire around or bypass a shutdown sensor or switch.
All units in this family of machines are protected by five
(5) sensors or switches at the following locations:
NOTICE
Failure to allow turbo cool down prior to stopping can cause turbocharger damage.
Once the engine stops, the automatic blowdown valve will begin to relieve all pressure from the receiver--separator system.
(1) High engine COOLANT temperature in the engine.
(2) Low engine oil pressure, in the engine.
(3) Low Fuel Level. (First, the light on the control panel will come on as a warning).
High Discharge AIR Temperature
(4) At the airend outlet.
(5) In the safety valve connection on the side of the separator tank.
All sensors will automatically reset when the problem condition is corrected.
Book 35393560 (12/02)
Automatic Shutdown/Diagnostics
Should any of these problem situations occur, the unit will automatically shutdown and stop.
BEFORE restarting the unit or flipping the POWER switch to
“Off”, check the DIAGNOSTICS area on the instrument panel.
In a shutdown situation, the function of the panel lamps is to indicate what specific failure caused the unit to shut down. These lamps will remain illuminated until the Power Switch is turned “OFF”.
Note: None of the panel lamps should be glowing when machine is operating. If they are, shut unit down and investigate.
The upper four (4) lamps are electronically “latched” to only respond to the first or primary signal for a shutdown. In other words, if the automatic shutdown is the result of one of these four problems, only that particular problem lamp will be lit. And the lamp will remain lit as long as the batteries provide power.
Refer to OPERATING CONTROLS AND
INSTRUMENTS for the various problem signal criteria ( ° F, psi, etc.). The indicated problem area should be inspected for a physical cause (low fluid, broken fan belt, evidence of excessive heat, etc.) and corrections made.
Sensors (1) through (5) will automatically reset when the problem condition is corrected.
Other possible causes for an unexpected shutdown are listed on the Trouble Shooting Chart.
Book 35393560 (12/02)
OPERATING CONTROLS & INSTRUMENTS
Control Panel
1
5
9
10
11
12
13
14
15
2
6
3
7
4
8
16 17 18 19
20 21 22
DIAGNOSTICS/AUTO SHUTDOWN
9.
High Compressor Temperature --
248 _ F (120 _ C) or more.
10. Low Engine Oil Pressure -12 psi or less
11. High Engine Temperature --
Coolant above 215 _ F (102 _ C).
12. Low Fuel Level --
Comes on first as a warning and eventually triggers a shutdown. Must add fuel to operate.
13. Alternator Not Charging -needs attention.
14. Low Coolant Level --
Needs attention. Must add coolant.
15. Air Filters Restricted --
Needs servicing.
Operating Controls/Instruments (Standard)
1.
Compressor Discharge Pressure Gauge --
Indicates pressure in receiver tank, normally from 0 psi (kPa) to the rated pressure of the machine.
2.
Discharge Air Temp. Gauge --
Indicates in
_
F and
_
C. Normal operating range:
185
_
F/85
_ to 248
_
F/120
_
C.
3.
Engine Oil Pressure Gauge --
Indicates engine oil pressure (psi (kPa). See engine for normal range.
4.
Engine Speed Gauge --
Indicates engine speed in RPM from zero when stopped to full speed.
5.
Hourmeter --
Records running time for maintenance purposes.
6.
Fuel Level Gauge --
Indicates amount of fuel in tank.
7.
Engine Water Temp. Gauge --
Indicates coolant temperature, with normal operating range from 180
_
F (82
_
C) to 210
_
F (99
_
C).
8.
Voltmeter --
Indicates battery condition.
Book 35393560 (12/02)
CONTROLS
16. Power Switch --
Flip “ON” to activate systems prior to Starting. Flip
“Off” to stop engine.
17. Lights Switch --
Operates Lamps within Gauges. Hourmeter does not have a lamp.
18. Heaters Switch --
Activates control system heaters for operation below
32
_
F (0
_
C).
19. Service Air Button --
After warm up, PUSH. Provides full air pressure at the service outlet.
21. Start Button --
Activates the Engine Starter. PRESS to crank engine.
Release when engine sustains firing.
22. Bypass Button --
PRESS while engine is starting. Bypasses automatic shutdown circuit. Release after 2--3 seconds.
OPTIONAL CONTROLS
20. Ether Inject Button --
Injects a measured shot.
USE SPARINGLY.
Normally, regulation requires no adjusting, but if proper adjustment is lost, proceed as follows:
Before Starting Unit --
1.
At engine governor, (EG), check the position of throttle arm (A) on governor shaft (B). This is done by loosening nut (C) that clamps the throttle arm (A) to the shaft (B). Rotate shaft (B) counterclockwise as far as possible. Rotate throttle arm until it is vertical. Tighten nut (C).
2.
3.
Speed and Pressure Regulation
Adjust jam nut (D) on throttle spring rod (E) to fully relieve tension on two compression springs (F).
Atop separator cover at pressure regulator
(PR) loosen locknut (G) counterclockwise. Turn adjustment screw counterclockwise on full turn.
After Starting Unit --
4.
Allow unit to warm up, then push “Service Air” button on control panel.
5.
Open and adjust service valve on outside of the unit to obtain the rated operating pressure on the discharge pressure gauge.
Note: If the rated operating pressure cannot be maintained with engine at full load speed and rod (M) fully extended, turn regulator adjustment screw (H) clockwise until throttle arm (A) moves against governor stop.
6.
Insure that pressure is maintained at rated pressure, then turn regulator adjustment screw (H) counterclockwise until throttle arm (A) just begins to move.
Note: Turning regulator adjustment screw (H) clockwise will raise pressure at full speed.
7.
8.
Adjust jam nut (D) on throttle spring rod (E) until distance “X” between spring mount (J) and rod guide (K) is 2.88 in. (73 mm).
Close service valve (engine will slow to no load or idle speed). Loosen jam nut (L) at air cylinder (AC) shaft. Rotate air cylinder shaft (M) to adjust speed to no load rpm. If unable to obtain no load rpm, loosen nut (C) and rotate throttle arm (A) as required.
Moving throttle arm (A) clockwise increases idle speed. Tighten nut (C) and, if necessary, finely adjust idle speed by rotating air cylinder shaft (M). Then tighten jam nut (L).
If necessary, repeat steps 5 and 6.
9.
10.
At pressure regulator (PR) tighten lock nut
(G).
11.
Limit full load engine speed by adjusting the collar (N) on the end of the throttle spring rod (E).
12.
To obtain maximum CFM at any pressure between 80 PSI (550 kPa) and the rated operating pressure, turn adjustment screw
(H) of pressure regulator (PR) to obtain desired discharge pressure at full load engine speed. Always lock and protect pressure setting of adjusting screw (H) with locknut
(G).
13.
Ensure unloader solenoid (US) acts to hold pressure in inlet unloader (IU) after shutdown. After start--up, a pressure switch will open unloader solenoid (US).
Book 35393560 (12/02)
IQ System
The IQ System is a complete, self--contained system which provides cooler, cleaner air than from a standard portable compressor. The system utilizes an integral aftercooler, high--efficiency filtration, and a patented condensate disposal system to provide the cool, clean air. The condensate disposal system injects all liquid condensed from the moisture separator and filters into the engine exhaust system where it is vaporized by heat. This eliminates the need for collecting the condensate, and the added cost of disposing of the condensate, which is often regulated by local, state, and/or federal regulations.
When equipped with the optional low ambient feature, the IQ System automatically adjusts movable louvers to control airflow through the aftercooler, ensuring that the compressed air temperature always remains above freezing temperatures (typically 45ºF) at any ambient temperature down to --20ºF. This prevents the need for 120V AC heat tracing systems, or any manual adjustment to prevent freezing of the compressed air system. All drain points for the condensate handling system are heated with 24VDC heat tracing, which is integral to the compressor heater system.
Theory of Operation
The compressed air exits the separator tank through the top cover piping, and can then travel along one of two paths, selectable via manual valving.
Refer to Illustration 36534774.
One path allows Standard Operation, which bypasses the IQ System, and delivers air quality equivalent to a standard oil--flooded portable compressor. If the IQ
System is enabled by proper setting of the 3--way valve, the compressed air first enters the aftercooler.
The aftercooler is cooled by the incoming compressor package air, which is controlled by movable louvers mounted on the aftercooler (if equipped with low ambient option). At most conditions, the louvers are fully open, and maximum aftercooling is available. The compressed air and condensate (water with a small amount of compressor lubricant) exits the aftercooler and enters the moisture separator, where most of the condensate is removed. The compressed air then flows through two stages of filtration, where the aerosol water and oil is removed down to approximately
0.01 ppm, and all particulates are removed down to
0.01 micron.
Book 35393560 (12/02)
At the bottom of the moisture separator and both filters are strainers and constant--bleed orifices, which are sized to allow the maximum flow of condensate while minimizing compressed air loss.
The condensate lines are then piped together, and the condensate is injected at a single point into the muffler.The compressed air then travels through the minimum pressure valve, and out through the service air valve. The air pressure gauge on the instrument panel indicates the pressure inside the separator tank. A service air pressure gauge is located inside the front door of the compressor on the filter support.
If the IQ System is bypassed (Standard Operation selected), the delivered air pressure will be approximately equal to the separator tank pressure. If the IQ System operation is selected, the delivered air pressure will be slightly less, depending on the restriction of the filters.
CAUTION
The compressor regulation system is adjusted to maintain regulated pressure at the separator tank.
DO NOT adjust regulation to provide full regulation pressure at the service valve when the IQ System is enabled. This will result in operation at excessive horsepower levels, causing overheating, reduced engine life, and reduced airend life.
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.
Weekly Maintenance:
S Remove Y--strainer screens at the bottom of the moisture separator and both filters and clean out any residue.
S Verify that the orifices below the Y--strainers are not clogged.
S
Verify that the piping from the orifice purge points to the exhaust system is not clogged.
Low Ambient Option Operation
When the ambient temperature falls to the point that the aftercooler outlet temperature is approaching
45ºF, the Temperature Control Unit (TCU), mounted on the rear of the control panel, will automatically adjust the louvers to control the cooling airflow through the aftercooler.
In the event that the unit is operating under abnormal conditions (i.e., an enclosure door open) which would cause excessive cooling of the aftercooler, a temperature sensor in the aftercooler outlet header will signal the TCU to further close the louvers if the compressed air temperature falls to approximately 36ºF or lower.
There are no user selectable or serviceable components in the TCU. Contact Ingersoll--Rand Service if any abnormal operation of the freeze protection control system occurs.
MAINTENANCE
Daily Maintenance:
Verify, during full--load (maximum compressed air delivery) that the IQ System filter restriction indicators do not show excessive restriction. Restriction indicators for the filters are mounted on the filter support inside the front door, and will shut down the compressor if restriction exceeds recommended values.
CAUTION
Blockage of the Y--strainers, orifices, or piping can result in flooding of the vessels with condensate. If flooding occurs, excessive condensate may enter the air stream and could result in damage to downstream equipment.
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 support inside the front door, and will shut down the compressor if restriction exceeds recommended values.
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.
Book 35393560 (12/02)
Filter Replacement
S Remove all wires and hoses connected to drains on bottom of each filter housing. Inspect fittings and hoses for any blockage. Clean if necessary.
S 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.
S
Lower the housing to floor panel and lean it against the airend. Remove and replace the filter element, being careful not to damage outer wrap.
Verify the part number of new element vs. old element, as the two IQ filters are of different media.
S
Put a small amount of petroleum jelly or other non--synthetic grease on the element o--ring to aid installation into the filter head.
S
Replace housing making sure to not overtighten.
S Repeat the above procedure on the remaining filter element.
S Reconnect all wires and hoses to drains on bottom of each filter housing.
Book 35393560 (12/02)
GENERAL
SECTION 6 -- MAINTENANCE
S The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting appropriate anti--start devices.
In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance.
Servicing may consist of pre--operation and post--operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need for repair.
Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining your unit and keeping it clean at all times will facilitate servicing.
Refer to the engine Operator’s Manual furnished in this manual for the specific requirements on preventive maintenance for the engine.
S All residual electrical power sources (mains and battery) are isolated.
Prior to opening or removing panels or covers to work inside a machine ensure that:
S
Anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts.
Prior to attempting any maintenance work on a running machine, ensure that:
S The work carried out is limited to only those tasks which require the machine to run.
This section refers to the various components which require periodic and replacement.
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.
S
All hazards present are know (e.g. pressurized components, electrical live components, removed panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving parts, safety valve discharge, etc.).
S Appropriate personal protective equipment is worn.
Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance
Manuals.
Prior to attempting any maintenance work, ensure that:
S Loose clothing, jewelry, long hair etc., is made safe.
S
Warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen.
Upon completion of maintenance tasks and prior to return the machine into service, ensure that:
S 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.
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.
S The machine is suitably tested.
S All guards and safety protection devices are refitted.
S
All panels are replaced, canopy and doors closed.
S Hazardous materials are effectively contained and disposed of.
This pressure must be relieved carefully by: a. Disconnecting any downstream equipment.
b. Opening the discharge valve to atmosphere. (Use hearing protection if necessary).
SCHEDULED MAINTENANCE
The maintenance schedule is based on normal operation of the unit. This page can be reproduced and used as a checklist by the service personnel. In the event unusual environmental operating conditions exist, the schedule should be adjusted accordingly.
Book 35393560 (12/02)
COMPRESSOR OIL LEVEL
Check the compressor and engine lubricating oil levels.
The oil level should be checked before the unit is started. Always check the oil level while the unit is level, the engine off, and there is zero pressure in the separator tank. The optimum oil level is with the pointer at the top of the green section on the level gage. Add oil if the pointer reaches the bottom of the green section.
Note: The oil level gage will not read properly while the engine is running.
YELLOW -- TOO HIGH
GREEN -- OK
OPTIMUM OIL LEVEL
(EITHER SIDE)
RED
TOO LOW
ADD OIL LEVEL
(EITHER SIDE)
Do not overfill either the engine crankcase or the compressor.
If necessary, Refer to Lubrication Section for recommended lubricant.
AIR CLEANER
This unit is equipped with an AIR FILTERS
RESTRICTED lamp on the instrument panel, covering both the engine and the compressor.
This should be checked daily during operation. If the lamp glows (red) with the unit operating at full speed, servicing of the cleaner element is necessary.
Also weekly squeeze the rubber valve (precleaner dirt dump) on each air cleaner housing to ensure that they are not clogged.
NOTICE: Holes or cracks downstream of the air cleaner housing will cause the restriction indicators to be ineffective.
The air filters restricted sensor will automatically reset after the main power switch is flipped to “OFF.”
Book 35393560 (12/02) a
5.
To service the air cleaners on all units proceed as follows:
1.
2.
3.
4.
6.
7.
Loosen outer wing nut and remove with outer element. Remove loose inner wing nut and inner (safety) element.
Inspect air cleaner housing for any condition that might cause a leak and correct as necessary.
Wipe inside of air cleaner housing with a clean, damp cloth to remove any dirt accumulation, especially in the area where the element seals against the housing.
Inspect the primary element by placing a bright light inside and rotating slowly. If any holes or tears are found in the paper, discard this element. If no ruptures are found, the element can be cleaned by one of the following procedures.
Do not clean the safety element. Replace it with new element.
Check new air filter elements for any shipping damage.
Install cleaned or new elements in the reverse order to the above. Tighten wing nuts firmly.
Inspect to ensure that the end cap seals tightly
360 degrees around the air cleaner body.
In the event that the filter element must be reused immediately, compressed air cleaning (as follows) is recommended since the element must be thoroughly dry. Direct compressed air through the element in the direction opposite to the normal air flow through the element.
Move the nozzle up and down while rotating the element. Be sure to keep the nozzle at least one inch
(25.4 mm) from the pleated paper.
NOTICE
To prevent damage to the element, never exceed a maximum air pressure of 100 psi (700 kPa).
The air cleaner system (housing and piping) should be inspected every month for any leakage paths or inlet obstructions. Make sure the air cleaner mounting bolts and clamps are tight. Check the air cleaner housing for dents or damage which could lead to a leak. Inspect the air transfer tubing from the air cleaner to the compressor and the engine for holes.
Make sure that all clamps and flange joints are tight.
COMPRESSOR OIL FILTER ELEMENTS
The compressor lubrication and cooling oil system includes dual spin--on, throw away type oil filters, each with an internal bypass valve. With a clean, new filter element, all of the oil flows through the full element area, from the outside/inside. As each element becomes contaminated with dirt, a pressure differential is created in the filter housing between the oil inlet and outlet ports. As this differential approaches 25 psi (175 kPa), the bypass valve starts to open, thus permitting a small quantity of oil to bypass the filter. As the contaminants continue to build up, more and more of the oil bypasses the filter media itself.
This does not provide any filtration but does allow a maximum flow of compressor lubricating and cooling oil to preclude any possible damage from loss of oil.
Also the design of the filter prevents any washing--off of any dirt during oil bypassing.
NOTICE
The oil filter must be replaced every 500 hours of operation. On new or overhauled units, replace the element after the first 50 and 150 hours of operation; thereafter, service the oil filter every 500 hours.
To service the oil filters, it will first be necessary to shut the unit down. Wipe off any external dirt and oil from the exterior of the filter to minimize any contamination from entering the lubrication system.
WARNING
High pressure air can cause serious injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system.
1. Open the service air valve(s) and manual blowdown valve to ensure that system is relieved of all pressure. Close the valve(s).
2. Turn the spin--on filter element counterclockwise to remove it from the filter housing. Inspect the filter element and then discard.
NOTICE
If there is any indication of formation of varnishes, shellacs or lacquers on the oil filter element, it is a warning the compressor lubricating oil has improper characteristics and should be immediately changed.
3. Inspect the oil filter head to be sure the gasket was removed with the oil filter element. Clean the gasket seal area on the oil filter head.
Installing a new oil filter element when the old gasket remains on the oil filter head will cause an oil leak and can cause property damage.
4. Lubricate the new filter gasket with the same oil being used in the machine.
5. Install new filter by turning element clockwise until gasket makes initial contact. Tighten the filter one half turn.
6. Start unit and allow to build up to rated pressure.
Check for leaks before placing unit back into service.
GAUGES
The instruments or gauges are essential for safety, maximum productivity and long service life of the machine. Inspect the gauges and test any diagnostic lamps prior to start--up. During operation observe the gauges and any lamps for proper functioning. Refer to
Operating Controls & Instruments for the normal readings.
FUEL TANK
This unit is equipped with tank that can be filled from front of unit. Using clean fuel in the fuel tank is vitally important and every precaution should be taken to ensure that only clean fuel is either poured or pumped into the tank.
Every six months the drain valve should be opened so that any sediment or accumulated condensate may be drained. When closing the valve, make sure it is fully closed and does not leak.
Book 35393560 (12/02)
BATTERY
Keep the battery posts--to--cable connections clean, tight and lightly coated with a grease. Also the electrolyte level in each cell should cover the top of the plates.
If necessary, top--up with clean distilled water.
TIRES
A weekly inspection is recommended. Tires that have cuts or cracks or little tread should be repaired or replaced. Monthly check the wheel lug nuts for tightness.
SWITCHES
The discharge air temperature switches will require approximately 248 ° F (120 ° C) to actuate. The engine coolant temperature switch will require approximately
215 ° F (102 ° C) to actuate. Replace any defective switch before continuing to operate the unit.
A low oil pressure switch may be tested by removing it and connecting it to a source of controlled pressure while monitoring an ohmmeter connected to the switch terminals. As pressure is applied slowly from the controlled source, the switch should close at 12 psi
(.84 kgf per cm 2) and show continuity through the contacts. As the pressure is slowly decreased to 8 psi
(0.56 kgf per cm2) the contacts should open and the ohmmeter should show lack of continuity (infinite ohms) through the contacts. Replace a defective switch before continuing to operate the unit.
COMPRESSOR OIL COOLER
The compressor lubricating and cooling oil is cooled by means of the fin and tube--type oil cooler, located beside the radiator. The lubricating and cooling oil, flowing internally through the core section, is cooled by the air stream from the cooling fan flowing past the core section. When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler, its efficiency is impaired.
Each month it is recommended that the oil cooler be cleaned by directing compressed air which contains a nonflammable safety solvent through the core of the oil cooler. This should remove the accumulation of grease, oil and dirt from the exterior surfaces of the oil cooler core so that the entire cooling area can transmit the heat of the lubricating and cooling oil to the air stream.
NOTICE
Do not clean with caustic solutions. Aluminum Heat
Exchangers will be damaged.
In the event foreign deposits, such as sludge and lacquer, accumulate in the oil cooler to the extent that its cooling efficiency is impaired, a resulting high discharge air temperature is likely to occur, causing shut down of the unit. To correct this situation it will be necessary to clean it using a cleaning compound in accordance with the manufacturer’s recommendations. After completing the cleaning procedure, the oil cooler must be flushed before returning to service.
RADIATOR
WARNING
Do not remove the cap from a HOT engine radiator. The sudden release of pressure from a heated cooling system can result in serious personal injury.
The engine cooling system is filled at the factory with a
50/50 mixture of water and ethylene glycol. This permanent type antifreeze contains rust inhibitors and provides protection to --35 ° F (--37 ° C). The use of such a mixture is recommended for both summer and winter operation. When using water alone, be sure to add a reputable brand of rust inhibitor to prevent internal corrosion.
It is recommended to test the freezing protection of the coolant every six months or prior to freezing temperatures. Replenish with a fresh mixture every twelve months. A drain for the system is located in the bottom radiator tank. An alternate method would be to disconnect a bottom radiator hose.
Book 35393560 (12/02)
Each month, inspect the radiator exterior for obstructions (dirt, bugs, etc.). If present, blow water or compressed air containing a nonflammable solvent between the fins in a direction opposite the normal air flow. Should the radiator be clogged internally, standard automotive practices should be followed.
ENGINE CORROSION RESISTOR ELEMENT
Replace as recommended in engine operation manual.
HOSES
Each month it is recommended that all of the intake lines to and from the air cleaners, the engine cooling system hoses and all of the flexible hoses used for air, oil, and fuel be inspected.
To ensure freedom from air leaks, all rubber hose joints and the screw--type hose clamps must be absolutely tight. Regular inspection of these connections for wear or deterioration is a definite “must” if regulator servicing of the air cleaners is not to prove futile. Premature wear of both the engine and compressor is AS-
SURED whenever dust--laden air is permitted to enter the engine’s combustion chamber or the compressor intake practically unfiltered.
The flexible hoses used in the fuel, oil and air lines on these units are primarily used for their ability to accommodate relative movement between components. It is extremely important they be periodically inspected for wear and deterioration. Clamps are used to prevent hose cover abrasion through vibration. This abrasion may occur when two hose lines cross, or when a hose line rubs against a fixed point; therefore, it is necessary that all clamps be replaced if missing. It is also important the operator does not use the hoses as convenient hand hold or steps. Such use can cause early cover wear and hose failure.
NOTICE
Piping systems operating at less than 150 psi
(1050 kPa) may use a special nylon tubing. The associated fittings are also of a special “push--in” design. If so, features are as follows:
Pulling on the tubing will cause the inner sleeve to withdraw and compress, thus tightening the connection. The tubing can be withdrawn only while holding the sleeve against the fitting. The tubing can be removed and replaced numerous times without losing its sealing ability.
To install the nylon tubing, make a mark (with tape or grease pencil) approximately 7/8 inch from the end of the tubing. Insert the tubing into the sleeve and
“push--in” past the first resistance to the bottom. The mark should be approximately 1/16 inch from the sleeve, for the 3/8 inch O.D. tubing; 1/8 inch for the
0.25 inch O.D. tubing. This will ensure that the tubing is fully engaged in the sealing mechanism.
FASTENERS
Visually check entire unit in regard to bolts, nuts and screws being properly secured. Spot check several capscrews and nuts for proper torque. If any are found loose, a more thorough inspection must be made.
Take corrective action.
Note: For Nyloc Nuts, IF REMOVED, replace with new ones.
Book 35393560 (12/02)
COMPRESSOR OIL
The lubricating and cooling oil must be replaced every
1000 hours of operation or six (6) months, whichever comes first.
Check the compressor and engine lubricating oil levels.
The oil level should be checked before the unit is started. Always check the oil level while the unit is level, the engine off, and there is zero pressure in the separator tank. The optimum oil level is with the pointer at the top of the green section on the level gage. Add oil if the pointer reaches the bottom of the green section.
Note: The oil level gage will not read properly while the engine is running.
YELLOW -- TOO HIGH
OPTIMUM OIL LEVEL
(EITHER SIDE)
GREEN -- OK
RED
TOO LOW
ADD OIL LEVEL
(EITHER SIDE)
Do not overfill either the engine crankcase or the compressor.
RUNNING GEAR
Every month or 500 miles, tighten the wheel lug nuts to
85 -- 95 lbs.--ft. Every six months the wheel bearings, grease seals and axle spindles should be inspected for damage (corrosion, etc.) or excessive wear. Replace any damaged or worn parts. Repack wheel bearings. Use a wheel bearing grease conforming to specification MIL--G--10924 and suitable for all ambient temperatures.
Grease can be replaced in a wheel bearing using a special fixture or by hand as follows.
Before installing bearing, place a light coat of grease on the bearing cups which are pressed in the hub.
Place a spoonful of grease in the palm of one hand and take the bearing in the other hand. Push a segment of the wider end of the bearing down into the outer edge of the grease pile closest to the thumb. Keep lifting and pushing the bearing down into the edge of the grease pile until grease oozes out both from the top and from between the rollers. Then rotate the bearing to repeat this operation on the next segment. Keep doing this until you have the entire bearing completely filled with grease.
NOTICE
Excessive grease in the hub or grease cap serves no purpose due to the fact that there is no way to force the grease into the bearing. The manufacturer’s standard procedure is to thoroughly pack the inner and outer bearing with grease and then to apply only a very small amount of grease into the grease cap.
Book 35393560 (12/02)
If bearing adjustment is required or the hub has been removed for any reason, the following procedure must be followed to ensure a correct bearing adjustment of
0.001 to .012 free play.
1.
2.
While rotating hub slowly to seat the bearings, tighten spindle nut to approximately 15 lbs.--ft.
Grasp the tire at the top and bottom and rock, in and out. There should be no evidence of looseness (free play) at the bearing.
Loosen nut to remove preload torque. Do not rotate hub.
3.
4.
5.
6.
7.
Finger tighten nut until just snug. Loosen nut until the first nut castellation lines up with cotter pin hole in spindle. Insert cotter pin.
Ensure a definite but minimal amount of free play by rocking the tire.
Bend over cotter pin legs to secure nut and clear grease cap.
Nut should be free to move with only restraint being the cotter pin.
Inspect Leaf Springs and Retaining Bolts/Nuts.
RECEIVER--SEPARATOR SYSTEMS
WARNING
High pressure air can cause serious injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system.
* Open service valve and manual blowdown valve at end of machine.
* Ensure pressure is relieved, with BOTH:
-- Discharge air pressure gauge reads zero
(0).
-- No air discharging from service valve or manual blowdown valve.
* When draining oil, use valve at bottom of separator tank.
* When adding oil, remove and replace (make tight) plug on side of separator tank.
In the compressor lubricating and cooling system, separation of the oil from the compressed air takes place in the receiver--separator tank. As the compressed air enters the tank, the change in velocity and direction drop out most of the oil from the air.
Additional separation takes place in the oil separator element which is located in the top of the tank.
Any oil accumulation in this separator element is continuously drained off by means of a scavenge tube which returns the accumulated oil to the system.
The life of the oil separator element is dependent upon the operating environment (soot, dust, etc.) and should be replaced every twelve months or 2000 hours. To replace the element proceed as follows:
* Ensure the tank pressure is zero.
* Disconnect the hose from the scavenge tube.
* Remove scavenge tube from tank cover.
* Disconnect service line from cover.
* Remove (20) cover mounting screws.
* Remove cover, element and inner shell.
* Remove any gasket material left on cover or tank.
* Install new gasket, inner shell and new element.
NOTICE
Do not remove staples from the elementgasket.
The staples provides continuity between the mating components.
Book 35393560 (12/02)
*Place a straightedge across top of element and measure from bottom of straightedge to bottom of element (See Fig. 4.1).
*Replace scavenge tube in cover (cover is still off of tank).
*Remove scavenge tube.
* Reposition cover (use care not to damage gaskets).
*Measure from bottom of cover to end of scavenge tube (See Fig. 4.2). Measurement should be from
1/8” to 1/4” less than the element measurement. If not, cut to size, being sure to cut in an approximate
45 _ angle.
*Replace cover mounting screws: tighten in a crisscross pattern to 166 lbs.--ft.
*Reconnect service line. Replace scavenge tube.
Re--connect hose.
*Close service valve. Start unit and look for leaks.
When replacing the element, the scavenge lines, orifice, filter, and check valve should be thoroughly cleaned and the oil changed.
cut line if necessary
Book 35393560 (12/02)
SCAVENGE LINE
WARNING
High pressure air can cause serious injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system.
The
NOTICE
Excessive oil carry--over may be caused by an oil-logged separator element. Do not replace element without first performing the following maintenance procedure:
2.
scavenge
Thoroughly clean scavenge line, any orifice and check valve.
line originates at the receiver--separator tank cover and terminates at the compressor airend through an orifice.
Once a year or every 2000 hours of operation, whichever comes first, remove this line and any orifice, thoroughly clean, then reassemble.
1.
Check oil level. Maintain as indicated earlier in this section.
3.
4.
Assure minimum pressure valve is holding
65--70 psi.
Run unit at rated operating pressure for 30 to 40 minutes to permit element to clear itself.
5.
6.
7.
EXTERIOR FINISH CARE
This unit was painted and heat cured at the factory with a high quality, thermoset polyester powder coating. The following care will ensure the longest possible life from this finish.
1.
If necessary to remove dust, pollen, etc. from housing, wash with water and soap or dish washing liquid detergent. Do not scrub with a rough cloth, pad, etc.
2.
If grease removal is needed, a fast evaporating alcohol or chlorinated solvent can be used. Note: This may cause some dulling of the paint finish.
3.
If the paint has faded or chalked, the use of a commercial grade, non--abrasive car wax may partially restore the color and gloss.
Field Repair of Texture Paint
1.
2.
3.
4.
The sheet metal should be washed and clean of foreign material and then thoroughly dried.
Clean and remove all grease and wax from the area to be painted using Duponts 3900S
Cleaner prior to sanding.
Use 320 grit sanding paper to repair any scratches or defects necessary.
Scuff sand the entire area to be painted with a red scotch brite pad.
Wipe the area clean using Duponts 3900S.
Blow and tack the area to be painted.
Apply a smooth coat of Duponts 1854S
Tuffcoat Primer to all bare metal areas and allow to dry.
Book 35393560 (12/02)
8.
9.
Apply 2 medium -- wet coats of Duponts
222S Adhesion Promoter over the entire area to be painted, with a 5 minute flash in between coats.
To apply the texture coat, use Duponts
1854S Tuffcoat Primer.
The proper technique to do this is to spray the Tuffcoat
Primer using a pressure pot and use about
2--5 pounds of air pressure. This will allow the primer to splatter causing the textured look. Note: You must be careful not to put too much primer on at one time, this will effect the amount of texture that you are trying to achieve. Allow the texture coat to flash for 20 minutes or until dry to touch.
10.
Apply any of Duponts Topcoat Finishes such as Imron t or Centari t according to the label instructions.
Note: To re--topcoat the textured surfaces when sheet metal repairs are not necessary, follow steps 1, 2, 4, 5, 6, 8 and 10.
COOLING FAN DRIVE
The heat exchanger or cooling fan is driven by a belt arrangement directly from the engine. Inspect the engine fan belt weekly or at 50 hour intervals. Refer to engine section for proper belt adjustment procedures.
BRAKE SYSTEMS (Hydraulic Only)
This compressor is equipped with mechanical parking brakes and hydraulic surge brakes. The maintenance of these brake systems is required to ensure safe operation of this compressor.
Every six months visually check the brake shoes for proper operation and deterioration. The common automotive standards and procedures would apply in replacing the brake shoes.
When replacing brake cables it is necessary to adjust the brake shoes before adjusting the parking brake system. To adjust the shoes, remove the rubber hole plug in the brake backing plate and rotate the star adjusting nut until you cannot rotate the wheel by hand.
Then back off the adjustment ten to twelve (10--12) notches.
Note: Always rotate wheel in direction of forward travel only. Replace hole plug and proceed to next wheel and repeat procedure.
Adjust parking brakes after all brake shoes have been adjusted by:
1. Turning knob on brake lever until lever is perpendicular to bracket when in “OFF” position. Wheels should turn freely.
2. With lever in “OFF” position, adjust brake cables until each has approximately the same tension. Wheels should turn freely.
3. Move lever to “ON” position. Check each wheel to see that it will not rotate. If all wheels will rotate, adjust knob on lever until brakes are fully applied. If one or two wheels will still rotate, adjust the cables for those wheels and recheck.
4. After brakes are adjusted, move lever to “ON” position and apply grease to cable strands from conduit six inches toward lever. This is to prevent dirt from getting into the conduit.
NOTE: New cables will stretch and therefore should be readjusted after the first week of use.
Every six months, apply a multi--purpose grease to the fittings on the brake actuator.
Before servicing the hydraulic surge brake system, the actuator, reservoir, wheels and underside of frame should be cleaned to prevent dirt and other contaminants from entering the hydraulic system.
Whenever a brake line hose, tube or fitting is removed/ replaced, the hydraulic brake system must be bled of air to ensure proper brake operation. Bleed the brakes, at each wheel cylinder, in the following order:
RH rear; LH rear; RH front; LH front (front is the hitch end; instrument panel is on LH side), while maintaining brake fluid level in reservoir. Use brake fluid conforming to DOT 3 or DOT 4 specifications.
Book 35393560 (12/02)
BRAKE SYSTEMS -- (Non Hydraulic)
This compressor may be equipped with mechanical parking brakes or electric brakes. The maintenance of these brake systems is required to ensure safe operation of this compressor.
Parking Brakes:
Every six months visually check the brake shoes for proper operation and deterioration. The common automotive standards and procedures would apply in replacing the brake shoes.
When replacing brake cables it is necessary to adjust the brake shoes before adjusting the parking brake system. To adjust the shoes, remove the rubber hole plug in the brake backing plate and rotate the star adjusting nut until you cannot rotate the wheel by hand.
Then back off the adjustment ten to twelve (10--12) notches. Note: always rotate wheel in direction of forward travel only. Replace hole plug and proceed to next wheel and repeat procedure.
Adjust parking brakes after all brake shoes have been adjusted by:
1. Turning knob on brake lever until lever is perpendicular to bracket when in “OFF” position. Wheels should turn freely.
2. With lever in “OFF” position, adjust brake cables until each has approximately the same tension. Wheels should turn freely.
3. Move lever to “ON” position. Check each wheel to see that it will not rotate. If all wheels will rotate, adjust knob on lever until brakes are fully applied. If one or two wheels will still rotate, adjust the cables for those wheels and recheck.
4. After brakes are adjusted, move lever to “ON” position and apply grease to cable strands from conduit six inches toward lever. This is to prevent dirt from getting into the conduit.
Electric Brake Adjustment:
Brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have
“seated”, (2) at 3000 mile intervals, (3) or as use and performance requires. The brakes should be adjusted in the following manner:
1. Jack up trailer and secure on adequate capacity jack stands. Check that the wheel and drum rotate freely.
2. Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate.
3. With a screwdriver or standard adjusting tool, rotate the starwheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn.
4. Then rotate the starwheel in the opposite direction until the wheel turns freely with a slight lining drag.
5. Replace the adjusting hole cover and lower the wheel to the ground.
6. Repeat above procedures on all brakes.
NOTE: New cables will stretch and therefore should be readjusted after the first week of use.
Every six months, apply a multi--purpose grease to the fittings on the brake actuator.
Book 35393560 (12/02)
CAUTION
Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty.
If performing more than visual inspections, disconnect battery cables and open manual blowdown valve.
Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.).
Never operate this machine with any guards removed.
Inch and metric hardware was used in the design and assembly of this unit. Consult the parts manual for clarification of usage.
Notice: Disregard any maintenance pertaining to components not provided on your machine.
Book 35393560 (12/02)
MAINTENANCE SCHEDULE
These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty or wet).
SMALL UNITS (P100--P600)
LARGE UNITS (HP600--P1600)
**Hydraulic Oil Level
Compressor Oil Level
Engine Oil Level
**Radiator Coolant Level
Gauges/Lamps
Air Cleaner Service Indicators
Fuel Tank (fill at end of day)
**Fuel/Water Separator
Air Cleaner Precleaner Dumps
Fan/Alternator Belts
Battery Connections/Electrolyte
**Tire Pressure and Surface
**Wheel Lug Nuts
Hoses (oil, air, intake, etc.)
Automatic Shutdown System
Air Cleaner System
DRAIN
Compressor Oil Cooler
**Engine Radiator
Fasteners, Guards
Air Cleaner Elements
** Fuel/Water Separator Element
*Compressor Oil Filter Element
*Compressor Oil
**Wheels (bearings, seals, etc)
Engine Coolant
Shutdown Switch Settings
Test
Test
Scavenge Orifice & related parts
Oil Separator Element
**Lights (running, brake, & turn)
**Pintle Eye Bolts
Engine (oil changes, oil & fuel filters, etc)
Test
Visual
Exterior
Exterior
Daily
C
C
C
C
C
C
C
CBT
CBT
Weekly Monthly 3 MOS .
6 MOS.
12 MOS.
C
C
C
C
C
C
C
C
C
C
C
250 hours
500 hours
CLEAN
CLEAN
C
WI
B
R
500 hours 1000 hours
1000 hours 2000 hours
R
DRAIN
R
A
R
C
C
C
R
C
CLEAN
R
**Disregard if not appropriate for this particular machine.
*NXP Units -- consult manual
R =replace, C =check (adjust if necessary), WI =OR when indicated, CBT = check before towing.
A = Small Units
B = Large Units
Refer to specific sections of the operator’s manual for more information.
Book 35393560 (12/02)
SECTION 7 -- LUBRICATION
GENERAL INFORMATION
Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit require more frequent lubrication than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures.
The Preventive Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed. A regular service program should be developed to include all items and fluids.
These intervals are based on average operating conditions. In the event of extremely severe
(hot, cold, dusty or wet) operating conditions, more frequent lubrication than specified may be necessary.
Details concerning lubrication of the running gear are in Maintenance Section.
All filters and filter elements for air and compressor lubricant must be obtained through Ingersoll--Rand to assure the proper size and filtration for the compressor.
If the unit has been operated for the time/ hours mentioned above, it should be completely drained of oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier change period may be necessary as oil deteriorates with time as well as by operating conditions.
WARNING
High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. Ensure the following conditions are met:
-- Discharge air pressure gauge reads zero (0).
-- No air discharging from an “open” manual blowdown valve.
An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.
Completely drain the reservoir, piping, and cooler. If the oil is drained immediately after the unit has been run for some time, most of the sediment will be in suspension and, therefore, will drain more readily. However, the fluid will be hot and care must be taken to avoid contact with the skin or eyes.
COMPRESSOR OIL CHANGE
These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit for approximately 6 months or 1000 hours, whichever comes first. If a unit has been completely drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to specifications in Lubrication Table.
NOTICE
Some oil types are incompatible when mixed and result in the formation of varnishes, shellacs, or lacquers which may be insoluble. Such deposits can cause serious troubles including clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different brands. A type or brand change is best made at the time of a complete oil drain and refill.
After the unit has been completely drained of all old fluid, close the drain valve, install new oil filter elements. Add oil in the specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil. Check the oil level. DO NOT OVER-
FILL.
NOTICE
Ingersoll--Rand provides compressor oil specifically formulated for Portable Compressors and requires the use of these fluids in order to obtain extended limited airend warranty.
Book 35393560 (12/02)
COMPRESSOR
LUBRICATION
RATED OPERATING PRESSURE
100 -- 300 PSI
125
_
F
350 PSI
50 _ C
40
_
C
Portable Compressor Fluid Chart
Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change.
30
_
C
IR
PER FORMANCE
500
IR
PRO--TEC t
20
_
C
10 _ C
0
_
C
--10
_
C
--20
_
C
--30 _ C
104 _ F
IR
XHP505
86 _ F
65
_
F
50
_
F
32 _ F
14 _ F
10
_
F
--10 _ F
--22 _ F
IR
PERFORMANCE
500
500 PSI
IR
XHP 1001
IR
XHP1001
IR
XHP505
Design Operating
Pressure
100 psi to 300 psi
100 psi to 300 psi
350 psi
Ambient
Temperature
Specification
--10
_
F to 125
_
F
(--23
_
C to 52
_
C)
IR Pro--Tec t
Mil –PRF 2104G SAE 10W
--40
_
F to 125
_
F
(--40 _ C to 52 _ C)
IR Performance 500
Mil--L--46167
--10 _ F to 125 _ F
(--23 _ C to 52 _ C)
IR XHP 505
--40
_
C --40
_
F consult factory
IR XHP1001 65
_
F to 125
_
F
(18
_
C to 52
_
C)
--40 _ F to 65 _ F
(--40 _ C to 18 _ C)
IR Performance 500
Mil--L--46167
500 psi
50
_
F to 125
_
F
(10
_
C to 52
_
C)
10
_
F to 65
_
F
(--12
_
C to 18
_
C)
IR XHP1001
IR XHP 505 below 10
(--12 _ C)
_ F Consult Factory
Recommended Ingersoll--Rand Fluids -- Use of these fluids with original I--R filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your I--R representative.
Recommended Fluid
IR Pro--Tec t
IR XHP 505
IR Performance 500
IR XHP1001
1 Gal. (3.8 Litre) 5 Gal. (19.0 Litre) 55 Gal. (208.2 Litre)
36899698
35382928
36899706
35365188
35382936
35612738
36899714
35365170
35382944
35300516
Premium grade oils API, CG --4 or CH--4 are recommended for the QSX15 engine.
Book 35393560 (12/02)
SECTION 8 -- Trouble Shooting
INTRODUCTION
Trouble shooting for a portable air compressor is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction.
The trouble shooting chart that follows includes some of the problems that an operator may encounter during the operation of a portable compressor.
B. Do The Simplest Things First
Most troubles are simple and easily corrected. For example, most complaints are “low capacity” which may be caused by too low an engine speed or “compressor over-- heats” which may be caused by low oil level.
Always check the easiest and most obvious things first; following this simple rule will save time and trouble.
The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the answers for correction of the problems.
The chart does give those problems that are most apt to occur. To use the trouble shooting chart:
A.
Find the “complaint” depicted as a bold heading.
B.
Follow down that column to find the potential cause or causes. The causes are listed in order (1,2,3 etc.) to suggest an order to follow in trouble shooting.
Note : For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in Parts List
Section.
C. Double Check Before Disassembly
The source of most compressor troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a compressor can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly.
Check again to be sure an easy solution to the problem has not been overlooked.
ACTION PLAN
A. Think Before Acting
Study the problem thoroughly and ask yourself these questions:
(1) What were the warning signals that preceded the trouble?
(2) Has a similar trouble occurred before?
(3) What previous maintenance work has been done?
(4) If the compressor will still operate, is it safe to continue operating it to make further checks?
D. Find And Correct Basic Cause
After a mechanical failure has been corrected, be sure to locate and correct the cause of the trouble so the same failure will not be repeated. A complaint of “premature breakdown” may be corrected by repairing any improper wiring connections, but something caused the defective wiring. The cause may be excessive vibration.
Book 35393560 (12/02)
TROUBLE SHOOTING CHART
Bold Headings depict the COMPLAINT -- Subheadings suggest the CAUSE
Note: Subheadings suggest sequence to follow troubleshooting.
1.
Unit Shutdown:
*
Out of Fuel
Compressor Oil Temp. Too High
Engine Water Temp. Too High
Engine Oil Pressure Too Low
Broken Engine Fan Belt
Loose Wire Connection
Low Fuel Level Shutdown Switch
Defective Discharge Air Temp. Switch
Defective Engine Oil Pressure Switch
Defective Shutdown Solenoid
Malfunctioning Relay
< 16 Volts at Shutdown Solenoid
Blown Fuse
Engine Malfunctioning
Airend Malfunctioning
Corrective Action
Add CLEAN diesel Fuel
See Complaint 10
Check coolant level. If necessary, Add.
See Complaint 3 and Complaint 4.
Replace fan belt.
Wiggle wires at switches & connector blocks. Make repairs.
Replace switch.
Replace switch.
Replace switch.
Replace solenoid.
Replace relay.
Check battery and alternator. Make repairs.
Replace fuse.
See Trouble Shooting in Engine Manual.
See Complaint 10.
2.
Won’t Start/Run:
*
Low Battery Voltage
<16 Volts at Shutdown Solenoid
Blown Fuse
Malfunctioning Start Switch
Defective Safety Bypass Switch
Clogged Fuel Filters
Out of Fuel
Compressor Oil Temp. Too High
Engine Water Temp. Too High
Engine Oil Pressure Too Low
Loose Wire Connection
Defective Discharge Air Temp. Switch
Defective Engine Oil Pressure Switch
Defective Shutdown Solenoid
Malfunctioning Relay
Engine Malfunctioning
Airend Malfunctioning
3.
Engine Temperature Lamps Stays On:
*
*
Broken Engine Fan Belt
Malfunctioning Circuit Board
Ambient Temp. >125 _ F (52 _ C)
Dirty Operating Conditions
Dirty Cooler
Out of Level >15 degrees
Operating Pressure Too High
Recirculation of Cooling Air
Loose Wire Connection
Malfunctioning circuit board.
Check electrolyte level. Check connections.
Charge battery and alternator. Make repairs.
Replace fuse.
Replace switch.
Replace switch.
Service filters. See Engine Operator’s Manual.
Add CLEAN fuel.
See Complaint 10.
Check fluid level. If necessary, Add.
See Complaint 3 and Complaint 4.
Repair or replace connection.
Replace switch.
Replace switch.
Replace solenoid.
Replace relay.
See Trouble Shooting in Engine Manual.
See Complaint 10.
Replace fan belt set.
Replace circuit board.
Above spec limit.
Move unit to cleaner environment.
Clean exterior of cooler.
Relocate or reposition unit.
Reduce pressure to spec.
Close side doors.
Repair or replace.
Replace circuit board.
* : > = greater than, < = less than
Book 35393560 (12/02)
4.
Engine Oil Pressure Lamp Stays On:
Low Oil Level
Out of Level >15 degrees
Wrong Lube Oil
Clogged Oil Filter Element(s)
Engine Malfunctioning
Loose Wire Connection.
Malfunctioning circuit board
5.
Engine Temperature Lamps Stays Off:
Bulb Burned Out
Malfunctioning circuit board
6.
Engine Oil Pressure Lamp Stays Off:
Bulb Burned Out
Malfunctioning circuit board
7.
Alternator Lamp Stays On:
Loose or Broken Belts
Loose Wire Connection
Low Battery Voltage
Malfunctioning Alternator
Malfunctioning circuit board
Corrective Action
Add oil.
Relocate or reposition.
See Engine Oil Spec. Change oil.
Replace element(s).
See Trouble Shooting in Engine Manual.
Repair or replace.
Replace circuit.
Replace circuit board.
Replace circuit board.
Replace circuit board.
Replace circuit board.
Tighten or replace belt set.
Repair or replace connection.
Check electrolyte level. Add if necessary.
Check connectors. Clean & tighten.
Recharge battery.
Repair or replace alternator.
Replace circuit board.
8.
Alternator Lamp Stays Off:
Bulb Burned Out
Loose Wire Connection
Malfunctioning circuit board
Replace circuit board.
Repair or replace connector.
Replace circuit board.
9.
Unit Fails To Shutdown:
Defective Low Fuel Shutdown Switch
Defective Discharge Air Temperature Switch
Defective Engine Oil Pressure Switch
Defective Shutdown Solenoid
Malfunctioning Relay
Defective Safety Bypass Switch
Pull wire off shutdown solenoid. Replace switch.
Pull wire off. Replace switch.
Pull wire off. Replace switch.
Carefully block air inlet to stop engine.
Replace solenoid.
Pull wire off shutdown solenoid. Replace relay.
Pull wire off shutdown solenoid. Replace defective item.
Book 35393560 (12/02)
10.
Excessive Compressor Oil Temperature:
Ambient Temp. > 125 _ F (52 _ C)
Out of Level > 15 degrees
Low Oil Level
Wrong Lube Oil
Dirty Cooler
Dirty Operating Conditions
Clogged Oil Filter Elements
Loose or Broken Belts
Operating Pressure Too High
Recirculation Of Cooling Air
Malfunctioning Thermostat
Malfunctioning Fan
Defective Oil Cooler Relief Valve
Defective Minimum Pressure Valve
Blocked or Restricted Oil Lines
Airend Malfunctioning
11.
Engine RPM Down:
Clogged Fuel Filter
Operating Pressure Too High
Incorrect Pressure Regulator Adjustment
Malfunctioning Pressure Regulator
Incorrect Linkage Adjustment
Dirty Air Filter
Malfunctioning Air Cylinder
Wrong Air Filter Element
Defective Separator Element
Engine Malfunctioning
Airend Malfunctioning
Corrective Action
Above spec limit.
Relocate or reposition unit.
Add oil. Look for any leaks.
Check spec in this manual.
Clean exterior surfaces.
Move unit to cleaner environment.
Replace elements. Change oil.
Tighten or replace belt set.
Reduce pressure to spec.
Close side doors. Replace belly pan.
Replace thermostat in bypass valve.
Check fan belt tension. Tighten or replace belt set.
Replace valve.
Repair or replace valve.
Clean by flushing or replace.
See Complaint 11, 12, 13, 15, 16 or 18.
Clean primary filter. Replace final filter. Drain tanks.
Add CLEAN fuel.
Reduce pressure to spec limit.
See Section 6 in this manual.
Replace regulator.
See Section 6 in this manual.
Clean or replace elements.
Replace air cylinder and adjust per Section 6.
Install correct element.
Install new element per page 21.
See Trouble Shooting in Engine Manual.
Refer to Airend Rebuild Manual.
12.
Excessive Vibration:
Rubber Mounts, Loose or Damaged
Defective Fan
Drive Coupling Defective
Engine Malfunctioning
Airend Malfunctioning
Anti--rumble valve not working.
Engine idle speed too low.
13.
Low CFM:
Dirty Air Filter
Incorrect Linkage Adjustment
Incorrect Pressure Regulator Adjustment
Malfunctioning Pressure Regulator
Malfunctioning Inlet Unloader/Butterfly Valve
Malfunctioning Air Cylinder
Defective Minimum Pressure Valve
Defective Separator Element
Wrong Air Filter Element
Tighten or replace.
Replace fan.
Replace coupling.
See Trouble Shooting in Engine Manual.
See Complaint 15 and 17.
Repair or Replace.
Raise “No Load” speed per Section 6.
Clean or replace elements.
See Section 6 in this manual.
See Section 6 in this manual.
Replace regulator.
Inspect valve. Make adjustment per Section 6.
Replace air cylinder.
Repair or replace valve.
Install new element per Page 21.
Install correct element.
Book 35393560 (12/02)
14.
Short Air Cleaner Life:
Dirty Operating Conditions
Inadequate Element Cleaning
Incorrect Stopping Procedure
Wrong Air Filter Element
Oil Pump Drive Coupling
Corrective Action
Move unit to cleaner environment.
Install new element.
Read procedure in this manual.
Install proper element.
Inspect coupling. If necessary, replace coupling.
15.
Excessive Oil In Air:
High Oil Level
Out of Level > 15 degrees
Clogged Scavenge Orifice
Scavenge Tube Blocked
Defective Scavenge Check Valve
Sep. Tank Blow Down Too Quickly
Defective Minimum Pressure Valve
16.
Oil Seal Leak:
Contaminated Lube Oil
Blocked or Restricted Oil Line(s)
Malfunctioning Seal
Scored Shaft
Read procedure in this manual.
Relocate or reposition unit.
Remove scavenge orifice. Clean and Replace.
Remove scavenge tube. Clean and Replace.
Remove check valve. Replace with new valve.
Allow unit to blow down automatically.
Remove valve. Repair valve and replace.
Drain and flush system. Add new CLEAN oil.
Remove, clean and replace line(s).
Refer to Airend Rebuild Manual.
See instructions in new seal kit.
17.
Will Not Unload:
Leak in Regulator Piping
Incorrect Pressure Regulator Adjustment
Malfunctioning Pressure Regulator
Malfunctioning Inlet Butterfly Valve
Ice in Regulation Lines/Orifice
Find and repair leak(s).
Refer to Section 6 in this manual.
Replace regulator.
Inspect valve fit. Readjust per Section 6.
Apply heat to line(s) and or orifice.
18.
Oil In Air Cleaner:
Incorrect Stopping Procedure
Oil Pump Drive Coupling
Discharge Check Valve Faulty
Read Procedure in this manual.
Inspect coupling. Replace if necessary.
Replace.
19.
Safety Valve Relieves:
Operating Pressure Too High
Leak In Regulator Piping
Incorrect Pressure Regulator Adjustment
Malfunctioning Pressure Regulator
Malfunctioning Inlet Unloader/Butterfly Valve
Defective Safety Valve
Defective Separator Element
Ice in Regulation Lines/Orifice
Reduce pressure to spec limit.
Repair leak(s).
Refer to Section 6 in this manual.
Replace regulator.
Inspect valve fit. Readjust per Section 6.
Replace safety valve.
Remove element. Install new.
Apply heat to lines and/or orifice.
Book 35393560 (12/02)
GENERAL
SECTION 9 -- PARTS ORDERING
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.
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.
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.
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.
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.
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 and 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.
Book 35393560 (12/02)
MARKINGS AND DECALS
NOTICE
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.
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.
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.
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.)
Book 35393560 (12/02) d.
e.
c.
Always specify the number of the parts list publication.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Book 35393560 (12/02)
AIREND EXCHANGE PROGRAM
Your Ingersoll--Rand Company Construction Equipment Group Sales Offices and authorized distributors as well as Ingersoll--Rand International autonomous companies and authorized distributors now have 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 and may be classified by one of the following categories.
Category “A”: The airend must not be over two years old and must have reusable rotor housing(s) and rotor(s).
Category “B”: The airend must be between two and five years old and returned with two or more reusable major castings.
Category “C” : The airend must be over five years old.
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.
Book 35393560 (12/02)
Book 35393560 (12/02)
SECTION 10
PARTS LIST INDEX
Frame & Running Gear, Sht 1
Frame & Running Gear, Sht 2
Frame & Running Gear,
Frame & Running Gear,
Sht 3
Sht 4
Jack Assembly, Sht 1
Jack Assembly, Sht 2
Brake Actuator Assembly, Sht 1
Brake Actuator Assembly, Sht 2
Running Gear Complete, Sht 1
Running Gear Complete, Sht 2
( Fast Track )
( Fast Track )
Running Gear Complete, Sht 1 ( Steerable )
Running Gear Complete, Sht 2 ( Steerable )
Running Gear Complete, Sht 3
Running Gear Complete, Sht 4
( Steerable )
( Steerable )
Engine Complete, Sht 1
Engine Complete, Sht 2
Exhaust Complete, Sht 1
Exhaust Complete, Sht 2
Airend Complete, Sht 1
Airend Complete, Sht 2
Unloader Assembly, Sht 1
Unloader Assembly, Sht 2
Air End Assembly, Sht 1
Air End Assembly, Sht 2
Air End Assembly,
Air End Assembly,
Air End Assembly,
Air End Assembly,
Air End Assembly,
Air End Assembly,
Air End Assembly,
Air End Assembly,
Sht 3
Sht 4
Sht 5
Sht 6
Sht 7
Sht 8
Sht 9
Sht 10
Air End Assembly,
Air End Assembly,
Air End Piping,
Air End Piping,
Air End Piping,
Sht 1
Sht 2
Sht 11
Sht 12
Sht 3
Air End Piping, Sht 4
Radiator & Oil Cooler Assembly,
Radiator & Oil Cooler Assembly,
Radiator Piping,
Radiator Piping,
Parking Brakes,
Parking Brakes,
Brake Line Piping,
Brake Line Piping,
Sht 1
Sht 2
Sht 1
Sht 2
Separator Assembly,
Separator Assembly,
Sht 1
Sht 2
Sht 1
Sht 2
Sht 1
Sht 2
-- 1 --
SECTION 11
PARTS LIST INDEX
Minimum Pressure Valve,
Minimum Pressure Valve,
Oil Filter Assembly, Sht 1
Sht 1
Sht 2
Oil Filter Assembly, Sht 2
Fuel Tank Complete, Sht 1
Fuel Tank Complete,
Air Piping, Sht 1
Air Piping, Sht 2
Sht 2
Oil Piping,
Oil Piping,
Starting Aid,
Starting Aid,
Sht 1
Sht 2
Sht 1
Sht 2
Air Intake Complete,
Air Intake Complete,
Sht 1
Sht 2
Battery & Mounting Complete,
Battery & Mounting Complete,
Instr./Control Panel & Mounting,
Instr./Control Panel & Mounting,
Instr./Control Panel & Mounting,
Instr./Control Panel & Mounting,
Enclosure Assembly,
Enclosure Assembly,
Sht 1
Sht 2
Sht 1
Sht 2
Sht 1
Sht 2
Sht 3
Sht 4
Enclosure Assembly,
Enclosure Assembly,
Sht 3
Sht 4
Enclosure Assembly,
Enclosure Assembly,
Belly Pans,
Belly Pans,
Sht 1
Sht 2
Acoustic Panels,
Acoustic Panels,
Sht 1
Sht 2
Sht 5
Sht 6
Sht 3 Acoustic Panels,
Acoustic Panels,
Decal Location,
Decal Location,
Sht 4
Sht 1
Sht 2
Decal Location, Sht 3
Wiring Diagram & Parts, Sht 1
Wiring Diagram & Parts,
Wiring Diagram & Parts,
Sht 2
Sht 3
Wiring Diagram & Parts, Sht 4
Enclosure & Acoustics ( EEC ), Sht 1
Enclosure & Acoustics ( EEC ), Sht 2
Enclosure & Acoustics ( EEC ), Sht 3
Enclosure & Acoustics ( EEC ), Sht 4
Book 35393560 (12/02) -- 2 --
A4 A5 A6 A9
STARTS AT SERIAL NO.
291411
V
FAST TRACK RUNNING GEAR
U
Y A2 A3 A7
J K
E F G H
L M A9
C D
T
Z A2 A3 A7 A8
B
S
A1 A2 A3 A7
N P Q R
X
W
A
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
3--00 WAP FRAME AND RUNNING GEAR ASSY.
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--2 3--00/B
Book 35393560 (12/02) -- 3 --
A7
A8
A5
A6
A9
Y
Z
A1
V
W
X
R
S
P
Q
T
U
D
E
F
G
H
J
M
N
K
L
A
B
C
A2
A3
A4
36895225
35326966
36877793
35304047
36893733
36763670
35297340
95935003
36895225
95935011
36894061
36882785
35148204
35385434
36891794
36891786
36892701
35304666
95922910
35326958
36870111
35609544
35610377
35369800
36734879
35605187
35376094
96700885
35272558
35356526
36893725
36763670
36042893
Book 35393560 (12/02)
JACK
PIN
CHAIN
COUPLING
ACTUATOR , BRAKE
EYE , PINTLE
SCREW
NUT
( 2 REQD )
( 4 REQD )
SCREW
NUT , LOCK
DRAWBAR
SCREW
( 6 REQD )
( 6 REQD )
( 8 REQD )
TIRE & WHEEL ASSY.
TIRE
WHEEL
STEM , VALVE
KIT , EQUALIZER
FRONT AXLE ASSEMBLY
REAR AXLE ASSEMBLY
FRAME
STEP
NUT ( 4 REQD )
HANGER , FRONT
HANGER , CENTER
HANGER , REAR
SCREW
NUT
( 12 REQD )
( 12 REQD )
LIFTING BAIL
SCREW
NUT
WASHER
EQUALIZER
WASHER
( 4 REQD )
( 4 REQD )
( 12 REQD )
( 2 REQD )
FAST TRACK RUNNING GEAR
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
3--00 WAP
FRAME AND RUNNING GEAR ASSY.
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--3 3--00/B
-- 4 --
K L M
STEERABLE RUNNING GEAR
H J
N P
G
Book 35393560 (12/02)
E F
A B C D
-- 5 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
3--00 WAP FRAME AND RUNNING GEAR ASSY.
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--4 3--00/B
STEERABLE RUNNING GEAR
95922910
36893733
36763670
35297340
95930723
35374453
36042893
36894061
36882785
35148204
36891513
36895399
36892719
35304666
A
D
E
B
C
H
J
F
G
K
L
M
N
P
TIRE & WHEEL ASSY.
TIRE
WHEEL
VALVE STEM
FRONT AXLE ASSEMBLY
REAR AXLE ASSEMBLY
FRAME
STEP
NUT
LIFTING BAIL
( 4 REQD )
( 4 REQD ) SCREW
NUT ( 4 REQD )
SCREW
NUT
( 16 REQD )
( 16 REQD )
Book 35393560 (12/02) -- 6 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
3--00 WAP FRAME AND RUNNING GEAR ASSY.
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--5 3--00/B
A
B
C
D
E
Book 35393560 (12/02)
G
M N
H
F
-- 7 --
K
J
L
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
3--00 WAP
JACK ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--6 3--00/B
Book 35393560 (12/02) -- 8 --
Book 35393560 (12/02) -- 9 --
Book 35393560 (12/02) -- 10 --
Z
A
A1
A2
A3
B
D
C
E
F
H
G
T U
V W
J
K Y
X
A4
Book 35393560 (12/02)
R
S
L
Q
P
N
M
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
RUNNING GEAR ( FAST TRACK )
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--10 1--00/B
-- 11 --
A
B
C
D
35315357 NUT
35315340 BOLT
35359389 PLATE , TIE
35359397 NUT ( 32 REQD )
E
H
J
K
L
F
G
M
N
P
36891794
36891786
35385392
FRONT AXLE ASSEMBLY
REAR AXLE ASSEMBLY
SPRING
35315365 BOLT
35315373 NUT
35356922 U--BOLT ( 2 REQD )
35385236
35385244
HUB
STUD ( 12 REQD )
BEARING , OUTER 35385293
35385277 CUP , OUTER
35356914 WASHER
Q
R
35315217 NUT
S
V
W
X
T
U
Y
Z
A3
A4
A1
A2
35379395
35379387
CAP , GREASE
CAP , E--Z LUBE
35315225 PIN , COTTER
35359413 SHOE , FRONT
35359421 SHOE , REAR
36895241
36895258
35356864
L.H. BRAKE ASSEMBLY
R.H. BRAKE ASSEMBLY
WASHER ( 5 REQD )
35356872 NUT ( 4 REQD )
35359405 KIT , WHEEL CYLINDER
35316876 BEARING , INNER
35316884 CUP , INNER
35316868 SEAL , GREASE
35385251 NUT ( 12 REQD )
Book 35393560 (12/02) -- 12 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
RUNNING GEAR ( FAST TRACK )
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--11 1--00/B
E
F
G
D
C
B
A5
A6
A7
Book 35393560 (12/02)
X
V
W
Y
K L
N
M
J
Z
H
A4
A B1
A2
A3
Q
P
A1
R
A8 A9
U
T
S
-- 13 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
RUNNING GEAR ( STEERABLE )
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--12 1--00/B
V
W
X
T
U
R
S
P
Q
A7
A8
A5
A6
A9
B1
A1
A2
A3
A4
Y
Z
A
B
C
F
G
D
E
H
J
K
L
M
N
11A13C66E
36719169
36719466
36719177
35111590
250A10X1613C
35588755
25A13C298
12A5D13Z1
36719557
35107168
11A13C83E
36753242
35588953
35140722
36719219
35141167
25A13C332
36851376
36845766
36853042
36504389
36140730
35588961
W86707
36753259
25A13C283
W86707
25A13C301
95239927
36851566
36851574
25A13C281
35319045
ROD , TIE
NUT , JAM
BALL JOINT , OUTER
FITTING , LUBE
AXLE , FRONT
PIN , ROLL
FITTING , LUBE
PIN , ROLL
WASHER
L.H. KNUCKLE ASSEMBLY
R.H. KNUCKLE ASSEMBLY
PIN , ROLL
PIN , KING
PIN , COTTER
BRACKET
SPRING
BRACKET
BOLT , SHACKLE
FITTING , LUBE
PIN , CENTER
PIN , ROLL
WASHER
DRAWBAR
PIN , HINGE
PIN , COTTER
ARM , CENTER
BALLJOINT , INNER
NUT , JAM
LATCH
SPRING
PIN , ROLL
FRONT AXLE ASSEMBLY
REAR AXLE ASSEMBLY
TIE ROD ASSEMBLY
( INCLUDES A,B,C,A3,A4 )
1--00
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
WAP
DESCRIPTION
RUNNING GEAR ( STEERABLE )
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--13 1--00/B
Book 35393560 (12/02) -- 14 --
G
F
H
S
T
E
D
C
B
Book 35393560 (12/02)
J
K
L
N
P
M
Q R
U
V
W
X
-- 15 --
A Y
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
RUNNING GEAR ( STEERABLE )
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--14 1--00/B
V
W
X
T
U
P
Q
R
S
Y
D
E
F
G
H
J
K
L
M
N
A
B
C
Book 35393560 (12/02)
35106806
35608360
35379916
36764983
35308352
250A10X1613C
35111590
36719177
35589241
11A13C66E
36719169
35588839
36719466
36777209
35834621
35111566
35589126
36851608
36851590
35106814
11A13C413E
36776821
36776813
AXLE , REAR
U--BOLT
NUT
SEAL
BEARING
BEARING
WASHER
PIN , COTTER
NUT
CAP , GREASE
NUT
OUTER RACE
HUB ASSEMBLY ( INCLUDES B, D, E )
STUD
INNER RACE
FITTING , LUBE
BOLT
BRACKET
PLATE , CLAMP
PIN , COTTER
BRACKET
RIVET
SPRING
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
RUNNING GEAR ( STEERABLE )
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--15 1--00/B
-- 16 --
A2
A1
STARTS AT SERIAL NO.
291411
B1 B2 B3 B4 B5 B6 B7
Z
A9
A8
A7
A6
Y
X
W
V
S T
U
N
P
A4
J K L
H
E
F
D
G
A3
A5
Q
M
R
P
N
C
A
B
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ENGINE COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--16 1--00/B
Book 35393560 (12/02) -- 17 --
A
K
L
H
J
M
N
B
C
D
E
F
G
R
S
P
Q
T
U
V
36893709
36877793
36761476
95326609
35288885
35594225
35322445
95923108
35300532
95245288
35322452
35601475
35144492
35144492
35322635
35145242
95043196
95076741
35322429
95098356
FAN , 44 INCH
SCREW
SCREW
SCREW
BUSHING
CYLINDER
GUIDE
NUT
BEARING
NUT
BUSHING
LEVER
NUT
NUT
JOINT , BALL
SCREW
WASHER
NUT
ROD
NUT
A4
A5
A6
A7
A8
A9
Y
Z
A1
W
X
A2
A3
B4
B5
B6
B7
B1
B2
B3
36893519
35378546
35357268
36893314
95930301
19A7J19Z1
95930301
35322437
35322411
35329721
35324664
95923314
35855089
SPACER
35145242
35297340
35273812
36894012
35273937
96700919
MOUNT
SPRING
SPRING
COLLAR
NUT
BRACKET
SCREW
NUT
MOUNT , RUBBER
BRACKET , ENGINE
WASHER
SCREW
ENGINE , M11--335
ELEMENT , ENG. LUBE
FILTER , FUEL
FILTER , WATER
BUSHING ( ABOVE STARTER )
NIPPLE
BUSHING
Book 35393560 (12/02) -- 18 --
1--00
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
WAP
DESCRIPTION
ENGINE COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--17 1--00/B
B
C
H
H
STARTS AT SERIAL NO.
291411
F
G
E
D
A
J
Book 35393560 (12/02)
K
-- 19 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
EXHAUST COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--18 1--00/B
A
D
E
F
G
B
C
H
J
K
36893717
TO ENGINE TURBO
35602796
35279025
36893675
35857036
35127653
36897783
36897791
35279023
TUBE , EXHAUST FLEX
CLAMP , V--BAND
SCREW ( 5 REQD )
MUFFLER
CAP , RAIN
SEALCLAMP
SUPPORT , EXHAUST TUBE
COVER
SCREW ( 8 REQD )
Book 35393560 (12/02) -- 20 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
EXHAUST COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--19 1--00/B
P
STARTS AT SERIAL NO.
N
291411
J
M
K
L
H
Book 35393560 (12/02)
G
F
Q
E
D
C
B
A
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP AIREND COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--20 1--00/B
-- 21 --
A
D
E
B
C
H
J
F
G
K
L
M
N
95923363
35599950
35273937
95934253
36894087
35358274
35834795
35103852
95220604
36881704
36046456
36043461
36046464
36043479
36043487
36786572
NUT ( 2 REQD )
MOUNT , RUBBER
WASHER
SCREW
( 2 REQD )
( 2 REQD )
( 2 REQD )
BRACKET , A/E MOUNTING
SCREW ( 4 REQD )
COUPLING , DRIVE
BUSHING
SCREW ( 8 REQD )
SCREW ( 12 REQD )
AIR END ASSEMBLY
AIR END ASSEMBLY
HP825
VHP825
AIR END ASSEMBLY
AIR END ASSEMBLY
AIR END ASSEMBLY
GASKET
UNLOADER ASSEMBLY
SCREW
SCREW
( 6 REQD )
( 2 REQD )
XP900
HP935
XP1050
36734515
35272558
96700901
Q 35101476 WASHER ( 2 REQD )
AIR END ASSEMBLY
AIR END ASSEMBLY
AIR END ASSEMBLY
AIR END ASSEMBLY
AIR END ASSEMBLY
36046456
36043461
36046464
36043479
36043487
HP825
VHP825
XP900
HP935
XP1050
EXCHANGE AIREND OPTION: INGERSOLL--RAND OFFERS FACTORY REMANUFACTURED
AIRENDS THAT ARE BUILT TO THE LATEST DESIGNS. MEANING IT WILL REFLECT ALL THE
ENGINEERING UPGRADES AND PERFORMANCE ENHANCEMENTS MADE TO THAT SIZE UNIT.
ALL EXCHANGE AIRENDS COME WITH A ONE YEAR WARRANTY. THESE BENEFITS MAKE A
FACTORY REBUILT AIREND THE ONLY COST EFFECTIVE OPTION. CALL YOUR LOCAL IR
DEALER FOR MORE DETAILS. PLEASE PROVIDE YOUR AIREND SERIAL NUMBER.
Book 35393560 (12/02) -- 22 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIREND COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--21 1--00/B
226WW AIR END COMPLETE
F
G
BEGINNING WITH SERIAL NO.299248
H
E
J
K
D
C
N
B
A
ITEM
A
B
C
D
E
F
L
M
N
P
Q
R
G
H
J
K
CPN QTY DESCRIPTION
35364975
35103852
36865574
95934253
35273927
35358274
35599950
1
2
1
1
2
4
2
KEY
BUSHING
35834787
35834795
95220604
36880995
35272558
96700901
36734515
1
1
8
12
6
2
1
COUPLING ( METEOR--ACE/DEUCE )
COUPLING ( ACE/DEUCE )
SCREW
SCREW
SCREW
SCREW
UNLOADER
36786572 1 GASKET
AIR END ASSEMBLY ( SEE CHART )
36894087 1 BRACKET , MOUNTING ( METEOR )
BRACKET , MOUNTING ( ACE/DEUCE )
SCREW
WASHER
SCREW
35101476
95923363
2
2
MOUNT , RUBBER
WASHER
NUT
ITEM CPN QTY
Q
UNIT / CFM
HP--600
XP--750
HP--750
VHP--750
XP--825
HP--825
VHP--825
VHP--850
XP--900
HP--900
HP--915
HP--935
XP--1000
XP--1050
MANUAL NO.
DRAWING NO. DATE / REV:
35393560 21A 8/02 A
Book 35393560 (12/02) -- 23 --
DESCRIPTION
226WW
A/E ASSY. NO.
36047454
36047462
36047470
36046910
36047488
36046472
36046472
36046472
36046480
36046928
36046480
36043503
36046936
36043511
P
R
L
M
A
B
C
D
G
E
H
K
L
M
N
P
F
Q
Book 35393560 (12/02)
J
W
V
U
T
S
R
-- 24 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
UNLOADER ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--22 1--00/B
Book 35393560 (12/02)
A 35331586 GROMMET
B
C
36897148 VALVE , ANTI--RUMBLE
( DO NOT USE 35328210 ON VHP UNITS )
35331578 GROMMET
D 35328236 ADAPTER
H
J
E
F
G
95928255
36734507 BODY
35597509
PLUG
VALVE ASSEMBLY
35328269 BUSHING ( 2 REQD )
35332691 SPRING
K
P
Q
L
M
N
R
S
35328228
35328244 SEAL
35328251 GASKET
36722460 HOUSING
35374842
35374834
SCREW ( 12 REQD )
SCREW ( 8 REQD )
35591189 COVER , PISTON
95934642
BUSHING
SCREW
T
U
35327204 WASHER
35592534 DIAPHRAGM
V
W
35591163 PISTON
35332683 SPRING
UNLOADER ASSEMBLY
PART NO. 36734515
-- 25 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
UNLOADER ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--23 1--00/B
HP--825 / HP--935 & XP--900 / XP--1050
T
S
A
B
V
U
W
M
L
C
D
E
F
N
P
R
J
K
E
H
G
Q
Book 35393560 (12/02) -- 26 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--24 1--00/B
HP--825 / HP--935 & XP--900 / XP--1050
A 35375385 SCREW ( 12 REQD )
B 35611359 GASKET
C 92367663 SCREW
D 35255819 PLATE , CLAMP
E GEAR SET
36740546
35296011
36893360
93488732
NO.
F 35299346 SPACER
UNIT
HP--825
XP--900
HP--935
XP--1050
G 36851681 SPACER
H 36846418
J 36846426
SPACER
M 36851459
BEARING , TAPERED ROLLER
K 36854925 BEARING , TAPERED ROLLER
L 17A13A289 PIN , DOWEL
CASE , GEAR
N 35364975 KEY
P 35361328 KEY
Q 35223145 RING , RETAINING
R 36846400
S 35593508
SHAFT , DRIVE
SEAL , SHAFT
T 95358164 O--RING
U 36507515 COVER
V 96712187
W 36846442
SCREW
SHIM SET
( 6 REQD )
36798361
36798346
GUARD
GUARD
Book 35393560 (12/02) -- 27 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--25 1--00/B
HP--825 / HP--935 & XP--900 / XP--1050
B
A
S
C
D
E
F
N
Q
G
H
J
K
M
L
L
P
T
R
Book 35393560 (12/02) -- 28 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--26 1--00/B
HP--825 / HP--935 & XP--900 / XP--1050
A 35299296 SPACER
D
E
B
C
35299262 BEARING , ROLLER
35272541 SCREW ( 17 REQD )
36711620 HOUSING , FRONT BEARING
36506699 GASKET
H
J
F
G
35361310 KEY
36794287 HOUSING , ROTOR
35611342 GASKET
95239927 PIN , LOCATING
K
L
36005023 ROTOR SET
95239919 PIN , LOCATING
SCREW ( 16 REQD )
P
Q
M
N
96706429
35299312 SPACER
35299270 BEARING , ROLLER
35364728 SPRING SET
R
S
35299338 RING , SNAP
35365261 PIN , LOCATING
T 35364710 SPRING , SET
Book 35393560 (12/02) -- 29 --
1--00
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
WAP
DESCRIPTION
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--27 1--00/B
HP--825 / HP--935 & XP--900 / XP--1050
A
B
J
C
D
K
H
F
G
H
F
J
C
D
K
B
E
Book 35393560 (12/02) -- 30 --
1--00
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
WAP
DESCRIPTION
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--28 1--00/B
HP--825 / HP--935 & XP--900 / XP--1050
A
B
96706429 SCREW
35299361 SHIM SET
( 16 REQD )
G
H
J
E
F
K
C
D
35299320 PLATE , CLAMP
35293869 SCREW ( 3 REQD )
36866069 HOUSING , REAR BEARING
35272533
35278555 PLUG
SCREW
35579309 COVER , REAR BEARING
35299254 BEARING , ROLLER
95358198 O--RING
( 3 REQD )
Book 35393560 (12/02) -- 31 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--29 1--00/B
VHP--825
A
B
U
C
D
E
F
P
N
E
G
A1
W
V
H
J
K
Y
X
Book 35393560 (12/02)
L
S
-- 32 --
T
M
R
Q
Z
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--30 1--00/B
VHP--825
A 35272541
B 39482138
SCREW
GASKET
C 96706254 SCREW
D 35255819 PLATE , CLAMP
E GEAR SET
36740546
NO.
UNIT
VHP -- 825
( 14 REQD )
F 39485982
G 39314679
H 36846426
J 95239919
K 39861851
L 35364975
M 35361328
SPACER
SPACER , BEARING
BEARING , ROLLER
PIN , DOWELL
CASE , GEAR
KEY
KEY
N 39481734
P 39141825
CLAMP
SCREW
Q 35336304 SCREW
R
36764785 CAP
S 36854925 BEARING
T 36846400 SHAFT , DRIVE
U 35365261 PIN
V 35593508 SEAL , SHAFT
W 20A11C2M252 0--RING
X 36507515 COVER
( 3 REQD )
Y 96712187 SCREW ( 6 REQD )
Z 39314687
A1 36846442
SPACER
SHIM SET
Book 35393560 (12/02) -- 33 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--31 1--00/B
VHP--825
B
C
D
E
G
G
M
H
K
A
P
L
J
M
Book 35393560 (12/02)
N
-- 34 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--32 1--00/B
VHP--825
E
F
G
H
J
A
B
39481783
35272541
C
D
39801857
35597723
35361310 KEY
39779467
BEARING , ROLLER
SCREW ( 17 REQD )
HOUSING , FRONT BEARING
GASKET
HOUSING , ROTOR
35611342 GASKET
36005981
39481791
ROTOR SET
BEARING , ROLLER
M
N
P
K
L
161A13S625
95096806
35365261
39180542
39180526
36798361
36798346
RING , RETAINING
RING , SNAP
PIN , LOCATING
SCREW ( 4 REQD )
( 2 REQD ) SCREEN
GUARD
GUARD
Book 35393560 (12/02) -- 35 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--33 1--00/B
VHP--825
A
B
M
R
G H
J
L
F
B
P
N
C
D
S
Q
K
H
E
Book 35393560 (12/02) -- 36 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--34 1--00/B
VHP--825
A 96706429 SCREW ( 16 REQD )
B 35299361 SHIM SET
K
L
H
J
F
G
C
D
39457486
35293869
E 39853163
39436977
39774583
35273341
95938213
39774591
35605203
PLATE , CLAMP
SCREW
HOUSING , REAR BEARING
PLATE , CLAMP
SCREW
PLUG
( 6 REQD )
COVER , REAR BEARING
( 8 REQD )
COVER , REAR BEARING
BEARING , ROLLER
M 95024312 O--RING
N
P
Q
R
S
T
39438221
39437686
39437009
39437017
39437025
39457544
39457551
39457569
39457577
95023370
39457502
39457510
39457528
39457536
BEARING , ROLLER
BEARING , ROLLER
SHIM .001”
SHIM .003”
SHIM .010”
SHIM .001”
SHIM .003”
SHIM .005”
SHIM .010”
O--RING
SHIM .001”
SHIM .003”
SHIM .005”
SHIM .010”
Book 35393560 (12/02) -- 37 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--35 1--00/B
226WW AIR END ASSEMBLY
K
G
J
E
D
C
B
A
ITEM
A
E
F
G
B
C
D
M
N
K
L
H
J
R
S
P
Q
T
U
V
W
CPN QTY DESCRIPTION
96712187
36507515
36846442
35593508
95938205
36798346
6
1
1
1
1
1
SCREW
COVER , SHAFT SEAL
GASKET , COVER
SEAL
PLUG
GUARD , BOTTOM
95358164
36851459
96716162
36798361
1
1
14
1
O--RING
CASE , GEAR
SCREW
GUARD , TOP
35364975
36846426
36846400
1
1
1
KEY
BEARING , SHAFT
SHAFT , DRIVE
36846418
35361328 1 KEY
GEAR SET ( SEE CHART )
36851681
1
1
SPACER
SPACER
36764785
35336304
1
1
PLATE , CLAMP
SCREW
36854925
39253992
1
1
BEARING
O--RING
L
MANUAL NO.
DRAWING NO. DATE / REV:
35393560 35A 8/02 A
Book 35393560 (12/02)
H
Q
R
BEGINNING WITH SERIAL NO.299248
W
V U
T
S
P
N
M
F
ITEM CPN QTY
UNIT / CFM
HP--600
XP--750
HP--750
VHP--750
XP--825
HP--825
VHP--825
VHP--850
XP--900
HP--900
HP--915
HP--935
XP--1000
XP--1050
-- 38 --
GEAR SET
PART NO.
35269117
35298132
35335363
36893394
35334853
36740546
36740546
36740546
35296011
36893386
35296011
36893360
36893378
93488732
DESCRIPTION
226WW
A/E ASSY. NO.
36047454
36047462
36047470
36046910
36047488
36046472
36046472
36046472
36046480
36046928
36046480
36043503
36046936
36043511
226WW AIR END ASSEMBLY
A3
A2
A1
BEGINNING WITH SERIAL NO.299248
X
W
S
Z
R
Y
D
M
N
Q P
H
J
K
L
C
B
A
ITEM CPN QTY DESCRIPTION
M
N
K
L
H
J
A
B
C
D
E
F
G
P
Q
R
S
96716105
39326749
39322706
39889720
39925367
39326756
6
1
1
1
2
2
SCREW
PLATE , CLAMP
BEARING
HOUSING , ROTOR
GASKET
COVER
96712179
35295336
35262963
95096806
39437686
39436977
8
1
1
1
4
2
SCREW
DOWEL
SPACER
RING , SNAP
35313568
96706254
35255819
1
1
1
BEARING
SCREW
CLAMP , PLATE
39326483 1 SPACER
GEAR SET ( SEE CHART )
35361310 1 KEY
36005031
35299361
1
1
SET , ROTOR
SET , SHIM
BEARING
CLAMP , PLATE
T
U
V
W
X
96705983
39253984
6
Y
Z
A1
A2
A3
39890553
96706262
39891486
96712179
39326806
MANUAL NO.
DRAWING NO. DATE / REV:
35393560 35B 8/02 A
1
1
14
2
10
1
SCREW
O--RING
HOUSING , REAR BEARING
SCREW
COVER , REAR BEARING
SCREW
SET , SHIM
Book 35393560 (12/02)
E
F
G
ITEM
UNIT / CFM
HP--600
XP--750
HP--750
VHP--750
XP--825
HP--825
VHP--825
VHP--850
XP--900
HP--900
HP--915
HP--935
XP--1000
XP--1050
-- 39 --
CPN QTY
GEAR SET
PART NO.
35269117
35298132
35335363
36893394
35334853
36740546
36740546
36740546
35296011
36893386
35296011
36893360
36893378
93488732
T
U
V
DESCRIPTION
226WW
A/E ASSY. NO.
36047454
36047462
36047470
36046910
36047488
36046472
36046472
36046472
36046480
36046928
36046480
36043503
36046936
36043511
STARTS AT SERIAL NO.
291411
C
A
B
Book 35393560 (12/02) -- 40 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--36 1--00/B
STARTS AT SERIAL NO.
291411
A
B
C
95959607
39911284
95959730
CONNECTOR
TUBE ASSEMBLY
ELBOW , TUBE
Book 35393560 (12/02) -- 41 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--37 1--00/B
STARTS AT SERIAL NO.
291411
C
B
A
Book 35393560 (12/02) -- 42 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--38 1--00/B
STARTS AT SERIAL NO.
291411
A
B
C
35279827
39911292
95974663
ELBOW , TUBE
TUBE ASSEMBLY
CONNECTOR
Book 35393560 (12/02) -- 43 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR END PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--39 1--00/B
A3 A4 A5
A2
A1
U V W X Y Z
G H J K
Book 35393560 (12/02) -- 44 --
R S T
L M N P Q
D E F
A B C
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP RADIATOR AND OIL COOLER ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--40 1--00/B
36879302
36879211
36894806
36797652
35346741
36894814
35371558
36880995
36879195
35279025
35279025
36891703
36891687
35335140
36894848
36797652
36797652
35279025
36893550
35144336
35371558
36881886
36894830
36797652
35279025
36895308
36797652
36894822
35371558
35371558
V
W
X
T
U
R
S
P
Q
Y
Z
A1
A2
A3
A4
A5
A6
A
F
G
D
E
H
J
B
C
K
L
M
N
Book 35393560 (12/02)
PANEL , BOTTOM
SCREW ( 9 REQD )
SCREW ( 4 REQD )
BRACKET , FUEL TANK
SCREW ( 2 REQD )
SCREW
GUARD , FAN
SCREW
( 2 REQD )
( 8 REQD )
SCREW
NUT
( 6 REQD )
( 6 REQD )
SUPPORT , RADIATOR
SCREW ( 5 REQD )
SCREW ( 2 REQD )
SCREW ( 2 REQD )
NUT
PLATE , ORIFICE
( 2 REQD )
SCREW
NUT
( 10 REQD )
( 8 REQD )
SUPPORT , OIL COOLER
SCREW ( 5 REQD )
( 5 REQD )
( 5 REQD )
SCREW
NUT
SCREW
SCREW
OIL COOLER
( 3 REQD )
RADIATOR
CAP , RADIATOR
SUPPORT , ROOF
SCREW
SCREW
( 5 REQD )
( 4 REQD )
-- 45 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP RADIATOR AND OIL COOLER ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--41 1--00/B
U
S
R
P
Q
N
M
L
C
E
J K
D
B
A
C
T
H
F
G
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
RADIATOR PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--42 1--00/B
Book 35393560 (12/02) -- 46 --
Book 35393560 (12/02)
A
H
J
F
G
D
E
B
C
K
L
M
N
S
T
U
P
Q
R
TO ENGINE , NEAR WATER OUTLET
36840627 ADAPTER
35296342
35286772
CLAMP
HOSE
ADAPTER
( 58 INCHES )
35369511
THRU BELLY PAN
( 74 INCHES ) 35360775
36845592
35135458
95235131
TUBING
CLAMP
HOSE
CLAMP
( 47 INCHES )
( 2 REQD )
35222017
35330570
36894772
CLAMP
HOSE
TUBE
( 8 REQD )
( 3 REQD )
TO BOTTOM OF ENGINE
TO TOP OF ENGINE
35356534 HOSE
36894764 TUBE
TO LOW COOLANT LEVEL SENSOR
TO VENT LINE
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
RADIATOR PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--43 1--00/B
-- 47 --
T
W
W
U
V
J
J T
Z
S
R Q P
F
Book 35393560 (12/02)
N
X
M
L
K
J
Y
G
E
C
B
H
D
A
B
A
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
PARKING BRAKES
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--44 1--00/B
-- 48 --
P
Q
R
S
T
U
V
W
X
Y
Z
A
K
L
H
J
M
N
D
E
F
G
B
C
36847440
35603208
35602846
35118728
35603182
35603216
95928867
95934998
35145077
92304674
95934998
36763704
35603224
35857382
36847432
95935136
35357151
LEVER
BRACKET , R.H.
SCREW
PIN
36895407
35602895
CABLE
CLIP
35602903 SPACER
SCREW 35279025
95935086 NUT
NUT 96700877
36896900 BRACKET , MOUNTING
( STEERABLE UNIT ONLY )
PIN , COTTER
WASHER
NUT
WASHER
WASHER
SCREW
SPACER
BRACKET , L.H.
CLEVIS
BRACKET
NUT
ROD , LINK
CLEVIS
Book 35393560 (12/02) -- 49 --
36043396 -- PARKING BRAKE COMPLETE
( STEERABLE UNIT )
36043362 -PARKING BRAKE COMPLETE
( TANDEM UNIT )
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
PARKING BRAKES
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--45 1--00/B
R
F
B
D
T
J
U
C
H
F
Q
C
S
H
G
N
H
J
P
L
J
L
K
M
K
E
D
A
C
B
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
BRAKE LINE PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--46 1--00/B
Book 35393560 (12/02) -- 50 --
36043354 -- BRAKE ASSEMBLY
A
B
C
K
L
M
H
J
F
G
D
E
Q
R
N
P
S
T
U
TO L.H. SIDE / REAR AXLE
35356419 TUBE ASSEMBLY
35356328 TEE
36867471
TO R.H. SIDE / REAR AXLE
BRACKET , TEE
36894665 TUBE ASSEMBLY
35356377
35356310
35356302
HOSE , FLEX
BRACKET , HOSE MOUNTING
CLIP , HOSE
36894681
X1182T23
35356336
TUBE ASSEMBLY
CLAMP , TUBE
UNION
35356369
36734879
TO R.H. SIDE / FRONT AXLE
TO L.H. SIDE / FRONT AXLE
36894673
35356377
36894699
HOSE , FLEX
BRAKE ACTUATOR ASSEMBLY
TUBE ASSEMBLY
TUBE ASSEMBLY
TUBE ASSEMBLY
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
BRAKE LINE PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--47 1--00/B
Book 35393560 (12/02) -- 51 --
P
B
A
H
C
R
STARTS AT SERIAL NO.
M
S
K
L
291411
J
D E
G
F
Book 35393560 (12/02)
Q
-- 52 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP SEPARATOR TANK ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--48 1--00/B
A
D
E
B
C
F
35375377
95252409
36879302
95280541
95252409
36785012
36893691
36765121
35575570
35579630
35279942
36891307
36898476
36879302
36891083
36891315
36891323
35602325
G
H
J
K
L
M
N
R
S
P
Q
SCREW
PLUG
SCREW
O--RING
PLUG
BRACKET
HOSE , DISCHARGE
SCREW ( 8 REQD )
( 2 REQD ) GASKET
PLUG
O--RING
TANK , SEPARATOR ( STANDARD )
TANK , SEPARATOR ( EEC )
SCREW
GAGE , OIL LEVEL
ELEMENT
( 3 REQD )
COVER
SPRING
( 16 REQD )
( 2 REQD )
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
SEPARATOR TANK ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--49 1--00/B
Book 35393560 (12/02) -- 53 --
D
C
B
A
J
H
G
F
E
Book 35393560 (12/02) -- 54 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
MINIMUM PRESSURE VALVE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--50 1--00/B
OIL PIPING
6
1
1
L
E
R
C
O
O
O
I
L
10
20 21
20 21
2
18 19
4
17
5
3 4
7
4
8
33
R
A
T
O
R
P
A
S
E
N
K
T
A
9
13
24
25
2X
36
53
BEGINNING WITH SERIAL NO.299248
12
31
14
15
16
22
23
52
30
26
24
32
27
23
4
29
28
SCAVENGE OIL TO OIL FILTER
(XP750CWCU,XP750WJD,HP600CWCU,HP600W
SCAVENGE OIL TO COMPRESSOR INLET
(XP825CWCU,XP825WJD,HP750CWCU,HP750W
39
11
JD)
JD)
38
4
39
51
50
48
TOP PORT
49
BOTTOM PORT
47
MANUAL NO. DRAWING NO. DATE / REV:
35389923 50A 8/02 A
Book 35393560 (12/02)
46
39
35
-- 55 --
37
40
34
45
41
42
41
43
44
A
B
C
D
E
H
J
F
G
35367341
35367390
11A5D6Z1
35367366
35367374
35367325
35367358
35367317
35367333
MINIMUM PRESSURE CHECK VALVE ASSEMBLY
CAP
INSERT
WASHER
SPRING
O--RING
PISTON
SPRING
CHECK VALVE ASSEMBLY
BODY
PART NUMBER 35598770
Book 35393560 (12/02) -- 56 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
MINIMUM PRESSURE VALVE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--51 1--00/B
F
E
D
Book 35393560 (12/02)
C
-- 57 --
B
A
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
OIL FILTER ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--52 1--00/B
A
B
C
D
E
F
95942553
36788982
36860336
36756120
95923033
36893766
SCREW
BINDER , 3--RING
( 2 REQD )
ELEMENT , FILTER
FILTER HEAD ASSEMBLY
NUT ( 2 REQD )
SUPPORT , A/E AIR CLEANER
Book 35393560 (12/02) -- 58 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
OIL FILTER ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--53 1--00/B
M
L
K
E
F
D
G
C
H
J
P
N
B
Book 35393560 (12/02) -- 59 --
A
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
FUEL TANK COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--54 1--00/B
A
D
E
F
G
H
J
B
C
K
L
M
N
P
36893667
36845014
35286756
35136548
FUEL SUPPLY
FUEL RETURN
36881928
35283118
35369347
35356484
35369339
35322395
36893949
36842102
TANK , FUEL
CAP , FUEL TANK
ELBOW , 90
HOSE ASSEMBLY
HOSE ASSEMBLY
ELBOW , 90
CONNECTOR
TUBING
CONNECTOR
MUFFLER
SENDER , FUEL
( 2 REQD )
( 2 REQD )
( 2 REQD )
SCREW ( 5 REQD )
Book 35393560 (12/02) -- 60 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
FUEL TANK COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--55 1--00/B
43 STARTS AT SERIAL NO.
291411
SPEED CONTROL
AIR CYLINDER
41
36 35
24
33
10
30
31
29
10
19
34
50
OUT
27
11
25
IN
28
10
9
42
OUT IN
14
37
13 12
11 6
7
8
SEPARATOR TANK
17
44
DISCH PRESS GA
PRESS SW
26
15
16
5
2
1
4
3
22
AIREND
23
UNLOADER
39
40
38
18
19
21
20
48
45
44
47
49
24V COMPRESSOR
51
50
52
53
46
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--56 1--00/B
Book 35393560 (12/02) -- 61 --
PART NO.
35287937
35857176
35279850
36840460
95954038
36881944
95940748
95944575
95954194
95944690
35284082
36843464
36046308
35301126
36844074
35311471
95667341
35302314
35141902
35282953
95953808
35598770
35335124
36893923
35248145
95946281
95944658
35602473
35306687
35283258
95930301
95953444
35284082
35368927
36840841
35290147
35283084
35326503
35127083
35301225
35322379
35322346
35283134
35287929
95954269
95928040
35576115
95928172
35313287
95944625
35283050
35367846
36896892
36854495
36854149
Book 35393560 (12/02)
ITEM NO.
3
4
5
2
1
8
9
6
7
31
32
33
34
28
29
30
35
36
37
38
25
26
27
22
23
24
19
20
21
16
17
18
10
11
12
13
14
15
46
47
48
49
50
51
52
53
39
40
41
42
43
44
45
PART DESCRIPTION
TEE, STREET .75 NPT
NIPPLE, CLOSE .75 NPT
VALVE, BALL .75 NPT
ELBOW , STREET 90 .75 NPT
ADAPTER, .75 NPT X --8 JIC
BUSHING, .50 NPT X .25 NPT
TEE, RUN .25 NPT X --6 JIC
NUT, SWIVEL --6 JIC X .25 NPT
VALVE, PRESSURE REGULATOR 200 PSI (VHP UNITS ONLY)
VALVE, PRESSURE REGULATOR 150 PSI (HP UNITS ONLY)
VALVE, PRESSURE REGULATOR 100 PSI (XP UNITS ONLY)
CONNECTOR, .25 NPT X --6 JIC
SWIVEL, FEMALE .38 NPT X --6 JIC
VALVE, SOLENOID 24V -- .38 NPT
CONNECTOR, .38 NPT X --6 JIC
TEE, RUN, SWIVEL NUT --6 JIC
TEE, .125 NPT X --4 JIC
HOSE, --04 JIC X 72.00 LONG
ELBOW , 90 .125 NPT X --4 JIC
VALVE, BLOWDOWN
CONNECTOR, ORIFICE .156
CONNECTOR, .25 NPT X --8 JIC
TEE, RUN, SWIWEL NUT, --8 JIC
ELBOW , 90 .56 --18X --8 JIC
TUBE, FLARED --8 JIC
TEE, RUN, .56--18 X --6 JIC
VALVE, RELIEF/CHECK .040 ORIFICE
PLUG, .25 NPT
VALVE, SOLENOID, START/RUN
BUSHING, .38 NPT X .25 NPT
NIPPLE, CLOSE .25 NPT
TEE, .25 NPT
TEE, STREET .25 NPT
CONNECTOR, .25 NPT X --6 JIC
TUBE, FLARED --38 JIC
KIT, COMPRESSOR 24 VOLT
ELBOW , 90 .125 NPT X --6 JIC
HOSE, --6 JIC X 52.00 LONG
HOSE, --6 JIC X 30.00 LONG
NIPPLE, CLOSE .25 NPT
ADAPTER
HOSE, --8 JIC X 50.00 LONG
HOSE, --6 JIC X 11.00 LONG
NIPPLE, 2.00 NPT X 3.00 LONG
VALVE, CHECK 2.00 NPT , MINIMUM PRESSURE
CONNECTOR, MALE --32 JIC X 2.00 NPT
TUBE, SERVICE
VALVE, CHECK .25 NPT
ELBOW , 90 2.00 NPT
NIPPLE, 2.00 NPT X 12.00 LONG
VALVE, BALL 2.00 NPT
ELBOW , 90 .125 NPT X --4 JIC
HOSE, --4 JIC X 34.00 LONG
BUSHING, REDUCING .25 NPT X .12 NPT
COUPLING, .25 NPT
-- 62 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--57 1--00/B
AIR PIPING
BEGINNING WITH SERIAL NO.299248
55
32
HIGH
9
150 OR
200 PSI
LOW
58
31
8
55
62
41
11
55
14
41
OUT IN
TO
UNLOADER
VALVE
13
12
TO
SEPARATOR
TANK
DUAL REGULATION OPTION
6
54
7
56
10
9
9
100 PSI
8
13
42
SPEED CONTROL
AIR CYLINDER
41
57
43
44
14
37
13
OUT IN
12
11 6
7
8
SEPARATOR
TANK
26
17
PRESS
SW
DISCH
PRESS GA
15
16
2
5
1
4
3
36 35
24
33
10
30
31
29
10
19
34
50
OUT
IN
27
11
25
28
22
AIREND
23
UNLOADER
39
38
40
21
20
18
59
60
24V
COMPRESSOR
(STANDARD ON
XP UNITS AND
OPTIONAL ON
OTHER UNITS)
51
50
52
53
46
19
61
MANUAL NO.
DRAWING NO. DATE / REV:
35393560 57A 8/02 A
Book 35393560 (12/02) -- 63 --
48
45
44
47
49
AIR PIPING
ITEM NO.
3
4
5
1
2
8
9
6
7
54
55
56
49
50
51
52
53
57
58
59
60
61
46
47
48
43
44
45
37
38
39
40
41
42
62
MANUAL NO.
DRAWING NO. DATE / REV:
35393560 57B 8/02 A
Book 35393560 (12/02)
31
32
33
28
29
30
34
35
23
24
25
20
21
22
26
27
17
18
19
14
15
16
10
11
12
13
36
PART NO.
36844074
35289578
35311471
95667341
35302314
35141902
35282953
95953808
35598770
35335124
36893923
35248145
95946281
95944658
35857176
35279850
36840460
95954038
36881944
95940748
95944575
95954194
95944690
35284082
36843464
36046308
35301126
95381158
35602473
35306687
35283258
95930301
95953444
35283068
35279934
36864684
35282979
35282961
35369347
35356484
35369339
35290253
36840841
35290147
35283084
35326503
35127083
35301225
35322379
35322346
35283134
35287929
35287937
95954269
95928040
35576115
95928172
35313287
95944625
35283050
35367846
36896892
36854495
36854149
35284082
35368927
BEGINNING WITH SERIAL NO.299248
PART DESCRIPTION
TEE, STREET .75 NPT
NIPPLE, CLOSE .75 NPT
VALVE, BALL .75 NPT
ELBOW, STREET 90 .75 NPT
ADAPTER, .75 NPT X --8 JIC
BUSHING, .50 NPT X .25 NPT
TEE, RUN .25 NPT X --6 JIC
NUT, SWIVEL --6 JIC X .25 NPT
VALVE, PRESSURE REGULATOR 175/200 PS
VALVE, PRESSURE REGULATOR 150 PSI (H
VALVE, PRESSURE REGULATOR 100/125 PS
CONNECTOR, .25 NPT X --6 JIC
SWIVEL, FEMALE .38 NPT X --6 JIC
VALVE, SOLENOID 24V -- .38 NPT
CONNECTOR, .38 NPT X --6 JIC
TEE, RUN, SWIVEL NUT --6 JIC
TEE, .125 NPT X --4 JIC
HOSE, --04 JIC X 72.00 LONG
ELBOW, 90 , .125 NPT X --4 JIC
VALVE, BLOWDOWN
CONNECTOR, ORIFICE .156
CONNECTOR, .25 NPT X --8 JIC
TEE, RUN, SWIWEL NUT, --8 JIC
ELBOW, 90 .56--18 X --8 JIC
I (VHP UNITS ONLY)
P UNITS ONLY)
I (XP UNITS ONLY)
TUBE, FLARED --8 JIC
TEE, RUN, .56--18 X --6 JIC
VALVE, RELIEF/CHECK .040 ORIFICE
PLUG, .25 NPT
VALVE, SOLENOID, START/RUN
BUSHING, .38 NPT X .25 NPT
NIPPLE, CLOSE .25 NPT
TEE, .25 NPT
TEE, STREET .25 NPT
CONNECTOR, .25 NPT X --6 JIC
TUBE, FLARED --38 JIC
KIT, COMPRESSOR 24 VOLT
ELBOW, 90 .125 NPT X --6 JIC (CU UNITS ONLY)
ADAPTER, .125 NPT X 9/16 -- 18 JIC (C AT UNITS ONLY)
HOSE, --6 JIC X 52.00 LONG (CU UNITS
HOSE, --6 JIC X 69.00 LONG (CAT UNITS
HOSE, --6 JIC X 30.00 LONG
NIPPLE, CLOSE .25 NPT
ADAPTER
HOSE, --8 JIC X 50.00 LONG
HOSE, --6 JIC X 11.00 LONG
NIPPLE, 2.00 NPT X 3.00 LONG
ONLY)
ONLY)
VALVE, CHECK 2.00 NPT , MINIMUM PRES
CONNECTOR, MALE --32 JIC X 2.00 NPT
TUBE, SERVICE
VALVE, CHECK .25 NPT
ELBOW, 90 2.00 NPT
NIPPLE, 2.00 NPT X 12.00 LONG
SURE
VALVE, BALL 2.00 NPT
ELBOW, 90 .125 NPT X --4 JIC
HOSE, --4 JIC X 34.00 LONG
BUSHING, REDUCING .25 NPT X .12 NPT
COUPLING, .25 NPT
ELBOW, 90 --6 JIC SWIVEL
ELBOW, 90 .25 NPT X --6 JIC
VALVE, 3 WAY
HOSE, --6 JIC X 21.00 LONG
HOSE, --6 JIC X 13.00 LONG
CONNECTOR, .25 NPT X .38 TUBING
TUBING, .38 SYNFLEX
CONNECTOR, .25 NPT X .38 TUBING
ELBOW, 45 .25 NPT X --6 JIC
-- 64 --
STARTS AT SERIAL NO.
10
11
12
DETAIL A
291411
18
TO REAR OF
ROTOR HOUSING
UNDER UNLOADER
}
17
19
28 29
15
16
6
1
1
30
14
51 23
SEPARATOR
TANK
21
20
22
31
SEE DETAIL A
FOR CONFIGURATION
OF VHP 825 UNITS
} 32 33 34
24
25
26 27
30
1
E
R
C
O
O
L
O
I
L
2 1
1 3
4 5
7 8 9
35
BOTTOM PORT
TOP PORT
50
49
39
47
48
Book 35393560 (12/02)
AIREND
39 38
41
41
46
36
37
-- 65 --
45 44 43
39
40
42
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
OIL PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--58 1--00/B
49
50
46
47
48
40
41
42
43
44
45
PART NO.
35296409
36894749
36894731
95431292
36893824
35130863
95867933
36756120
35296425
95294336
95487773
43205269
95037347
35329309
36781227
36840437
36840411
35127034
35579630
35279942
36795680
36891083
36893691
35575570
36765121
35130871
35286954
36866531
36865889
35283076
36866564
36865897
35305622
35305648
36865921
35356450
35856251
39578950
95365094
95954277
95940912
36865756
36897627
39225511
95953311
36764389
36764884
35192178
35305648
36865905
35283068
35283068
36893741
36894780
95974663
36866564
32
33
34
35
36
37
38
39
28
29
30
31
24
25
26
27
18
19
20
21
22
23
NO.
1
2
3
7
8
9
10
12
13
4
5
6
14
15
16
17
DESCRIPTION
STRAIGHT CONN 1.88--12 X --24 JIC, W/O--RING
TUBE ASSY -- UPPER
TUBE ASSY -- LOWER
ELBOW , 90 1.88--12X --24 JIC, W/O--RING
OIL TEMPERATURE BYPASS VALVE
HOSE ASSY
UNION, 1.88--12 X --24 JIC, W/O--RING
DUAL FILTER ASSY
ELBOW , 45 1.88--12X --24 JIC, W/O--RING
CHECK VALVE, 1.50 NPT (VHP UNITS ONLY)
NIPPLE, 1.25 NPT X 2.00 (VHP UNITS ONLY)
ADAPTER, 1.88--12 X 1.50 NPT (VHP UNITS ONLY)
BUSHING, .50 NPT X .38 NPT
LENZ FITTING
TUBE ASSY
CHECK VALVE .062 (VHP UNITS ONLY)
CHECK VALVE .25 (HP AND XP UNITS ONLY)
HOSE ASSY
ELBOW , 90 .44--20X --4 JIC W/O--RING
STREET TEE, 1.25 NPT
BUSHING, 1.25 NPT X .50 NPT
TEMPERATURE SWITCH
SAFETY VALVE, 250 PSI (VHP UNITS ONLY)
SAFETY VALVE, 200 PSI (HP AND XP UNITS ONLY)
STREET ELBOW , 90 1.50 NPT
TUBE ADAPTER, 1.50 PIPE X 2.00 TUBE
VENT TUBE
SADDLE CLAMP, 2.00
VENT PLUG, 1.62--12
O--RING
DRAIN VALVE, W/O--RING
OIL LEVEL GAGE ASSY
DISCHARGE HOSE ASSY
GASKET
HEX SCREW, M16--2.00 X 55LG
HOSE ASSY
STRAIGHT CONN .88--14 X --10 JIC, W/O--RING
MANIFOLD, W/O--RING
TUBE ASSY
STRAIGHT CONN .56--18 X --6 JIC, W/0--RING
STRAIGHT CONN .44--18 --6 JIC, W/O--RING
TUBE ASSY
ELBOW , 90 .75--16X --10 JIC , W/O--RING
ELBOW , SWIVEL 90 .75 --16X --10 JIC
TUBE ASSY
TEE SWIVEL .88--14 X --10 JIC
TUBE ASSY
TUBE ASSY
( XP & HP UNITS )
( VHP UNITS )
ELBOW , 90 .75 --16X --10 JIC
TUBE ASSY
ELBOW 90 .56 --18X --6 JIC
ELBOW 90 .56 --18X --6 JIC
( VHP UNITS )
( XP & HP UNITS )
TUBE ASSY (VHP UNITS ONLY)
TUBE ASSY (HP AND XP UNITS ONLY)
STRAIGHT CONN .88--14 X --6 JIC, W/0--RING (VHP UNITS ONLY)
STRAIGHT CONN .44--20 X --6 JIC, W/O--RING
( HP AND XP UNITS ONLY )
( VHP UNITS )
( XP & HP UNITS )
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
OIL PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--59 1--00/B
Book 35393560 (12/02) -- 66 --
OIL PIPING
13
10
11
12
18
TO REAR OF
ROTOR HOUSING
UNDER UNLOADER
}
17
19
28 29
16
15
20
14
BEGINNING WITH SERIAL NO.299248
51
23 24
22
25
26 27
SEPARATOR
TANK
21
DETAIL A
SEE DETAIL A
FOR CONFIGURATION
OF VHP UNITS
}
6
1
1
30
31
32 33 34
30
1
C
O
O
L
E
R
O
I
L
2 1
4 5
7
1 3
8 9
35
50
49
BOTTOM PORT 48
TOP PORT
39
47
MANUAL NO. DRAWING NO. DATE / REV:
35393560 59A 8/02 A
Book 35393560 (12/02)
AIREND
39
46
36
37
-- 67 --
38
41
41
45 44
39
40
43 42
OIL PIPING
ITEM NO.
3
4
1
2
5
6
7
8
9
10
11
12
13
14
15
16
17
28
29
30
31
32
24
25
26
27
33
34
35
36
37
38
39
40
41
42
43
44
45
18
19
20
21
22
23
46
47
48
49
50
51
MANUAL NO. DRAWING NO. DATE / REV:
35393560 59B 8/02 A
Book 35393560 (12/02)
PART NO.
36865756
36897627
39225511
95953311
36764389
36764884
35192178
35579630
35279942
36795680
36891083
36893691
35575570
36765121
35130871
35286954
36866531
36865889
35283076
36866564
36865897
35305622
35305648
36865921
35356450
39578950
35856251
35305648
36865905
35283068
36893741
36894780
95974663
36866564
95928230
43205269
35357813
95037347
35329309
36781227
36840437
36840411
35127034
95365094
95954277
95940912
35296409
36894749
36894731
95431292
36893824
35130863
95867933
36756120
35296425
95294336
95487773
BEGINNING WITH SERIAL NO.299248
PART DESCRIPTION
STRAIGHT CONN 1.88--12 X --24 JIC, W/
TUBE ASSY -- UPPER
TUBE ASSY -- LOWER
O--RING
OIL TEMPERATURE BYPASS VALVE
HOSE ASSY
UNION, 1.88--12 X --24 JIC, W/O--RING
DUAL FILTER ASSY
ELBOW, 45 1.88--12 X --24 JIC, W/O--RING
CHECK VALVE, 1.50 NPT (VHP UNITS ON LY)
NIPPLE, 1.50 NPT X 1.75 (VHP UNITS
ADAPTER, 1.88--12 X 1.50 NPT (VHP UN
ADAPTER, 1.50 X --24 JIC (VHP UNITS
BUSHING, .50 NPT X .38 NPT
LENZ FITTING
TUBE ASSY
CHECK VALVE .062 (VHP UNITS ONLY)
CHECK VALVE .25 (HP AND XP UNITS ON
ONLY)
ITS ONLY)
ONLY)
LY)
HOSE ASSY
ELBOW, 90 .44--20 X --4 JIC W/O--RING
STREET TEE, 1.25 NPT
BUSHING, 1.25 NPT X .50 NPT
TEMPERATURE SWITCH
SAFETY VALVE, 250 PSI (VHP UNITS ON
SAFETY VALVE, 200 PSI (HP AND XP UN
STREET ELBOW, 90 1.50 NPT
TUBE ADAPTER, 1.50 PIPE X 2.00 TUBE
VENT TUBE
SADDLE CLAMP, 2.00
LY)
ITS ONLY)
VENT PLUG, 1.62--12
O--RING
DRAIN VALVE, W/O--RING
OIL LEVEL GAGE ASSY
DISCHARGE HOSE ASSY
GASKET
HEX SCREW, M16--2.00 X 55LG
HOSE ASSY
STRAIGHT CONN .88--14 X --10 JIC, W/O
MANIFOLD, W/O--RING
TUBE ASSY
STRAIGHT CONN .56--18 X --6 JIC, W/0--
STRAIGHT CONN .44--20 X --6 JIC, W/0--
TUBE ASSY
ELBOW, 90 .75--16 X --10 JIC, W/O--RING
ELBOW,SWIVEL 90
TUBE ASSY
$ .75 --16 X --10 JIC
TEE SWIVEL .88--14 X --10 JIC
TUBE ASSY (VHP UNITS ONLY)
TUBE ASSY (HP & XP UNITS ONLY)
ELBOW , 90 .75--16 X --10 JIC
TUBE ASSY
ELBOW 90 .56--18 X --6 JIC
TUBE ASSY (VHP UNITS ONLY)
TUBE ASSY (HP AND XP UNITS ONLY)
STRAIGHT CONN .88--14 X --6 JIC, W/0--
STRAIGHT CONN .44--20 X --6 JIC, W/O--
PLUG, .25 NPT
--RING
RING (VHP UNITS ONLY)
RING (XP & HP UNITS ONLY)
RING (VHP UNITS ONLY)
RING (HP AND XP UNITS ONLY)
-- 68 --
J
C
D
E
F
G
H
B
Book 35393560 (12/02)
A
-- 69 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
STARTING AID
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--60 1--00/B
35103498
35132166
35602812
35322908
35103506
14A5C55
92304500
35357961
35112911
35357052
H
J
F
G
C
D
E
K
A
B
ELBOW , 90
TUBING
ATOMIZER
SCREW
CLAMP
WASHER
NUT
( 4 REQD )
( 4 REQD )
( 4 REQD )
VALVE & BRACKET ASSEMBLY
CYLINDER , ETHER
STARTING AID KIT COMPLETE
Book 35393560 (12/02) -- 70 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
STARTING AID
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--61 1--00/B
P
A4
M N A3
A1
Z
Y
W
X
A
B
Book 35393560 (12/02)
C E
B
K
A5
H
A6
Z
A1
A2
Z
A9
Z
T
V
L M N
U
U
H J
R
S
P Q
A7
G
B F
D
B
C
A8
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR INTAKE COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--62 1--00/B
-- 71 --
V
W
X
T
U
P
Q
R
S
A2
A3
Y
Z
A1
A4
A
D
E
B
C
H
J
F
G
K
L
M
N
A5
A6
A7
A8
A9
36867786
36893840
36867794
36876019
36893857
36896579
35116615
35117605
35596493
36893758
36867778
36867794
36866242
36893832
TO ENGINE TURBO
35279553
35274406
35161025
36895639
35116615
35281328
36895647
TO UNLOADER INLET
35119858 CLAMP
ELBOW 35598838
35112648 TUBE
ELBOW 35315894
35123496 CLAMP
SCREW 36880995
35863638 BAND , MOUNTING
BAND , MOUNTING 35502608
36879195
VHP--825 / HP--940
VHP--825 / HP--940
( 8 REQD )
NUT ( 8 REQD )
SUPPORT , A/E AIR CLEANER
VHP--825 / HP--940
XP--1050
36893766
36880995
36879195
SCREW
NUT
( 8 REQD )
( 8 REQD )
AIR CLEANER ASSY.
AIR CLEANER ASSY.
VHP--825 / HP--940
XP--1050
CLAMP
REDUCER
CLAMP
TUBE
CLAMP
ELBOW
TUBE
CLAMP
ELBOW
TUBE
SUPPORT , ENG. AIR CLEANER
EJECTOR , DUST VHP--825 / HP--940
NUT , WING
ELEMENT , PRIMARY
ELEMENT , PRIMARY
NUT , WING
ELEMENT , SAFETY
ELEMENT , SAFETY
CLAMP
VHP--825 / HP--940
VHP--825 / HP--940
XP--1050
VHP--825 / HP--940
VHP--825 / HP--940
XP--1050
XP--1050
Book 35393560 (12/02) -- 72 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AIR INTAKE COMPLETE
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--63 1--00/B
K
H
G
STARTS AT SERIAL NO.
J
F
291411
E
C
D
B
Book 35393560 (12/02)
A
-- 73 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
BATTERY AND MOUNTING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--64 1--00/B
F
G
D
E
H
J
K
A
B
C
36894798
35279025
36793545
36892523
35579143
35128982
35512425
36860005
36853265
36895456
95923298
TRAY , BATTERY
SCREW ( 4 REQD )
BATTERY ( 2 REQD )
BATTERY
CABLE , NEGATIVE
( 2 REQD )
CABLE , JUMPER
CABLE , POSITIVE
J--BOLT
WASHER
( 4 REQD )
( 4 REQD )
HOLD DOWN
NUT ( 4 REQD )
( 2 REQD )
( WET )
( DRY )
Book 35393560 (12/02) -- 74 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
BATTERY AND MOUNTING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--65 1--00/B
L M N P
K
J
H
G
F
E
Q
R
S
T
U
V
Book 35393560 (12/02)
D C B A
-- 75 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP INSTR / CONTROL PANEL & MOUNTING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--66 1--00/B
T
U
V
Q
R
N
P
S
J
K
G
H
E
F
C
D
A
B
L
M
35255561
35255553
35255553
36771434
36775484
36842656
35337435
36841245
35604099
36844124
35369180
35314582
36891216
35377878
36789535
SWITCH , BY--PASS
SWITCH , START
SWITCH , ETHER INJECTION
MODULE , 7 LIGHT
RIVET , PLASTIC
PANEL , INSTRUMENT / CONTROL
SWITCH , ON / OFF POWER
GAGE , HOURMETER
GAGE , FUEL LEVEL
STUD , 1/4 TURN ( 3 REQD )
RETAINER
RECEPTACLE
GAGE , DISCHARGE PRESSURE
GAGE , DISCHARGE PRESSURE
GAGE , DISCHARGE PRESSURE
( 3 REQD )
( 3 REQD )
--VHP825
-- 940
-- XP1050
35604115
36841146
36870590
35372416
35604115
36841153
SWITCH , ACCESSORY
35255561
35337435
35144328
35144492
GAGE , DISCHARGE AIR TEMPERATURE
KIT , RESISTOR / BULB
GAGE , ENGINE OIL PRESSURE
TACHOMETER
GAGE , ENGINE WATER TEMP.
GAGE , VOLTMETER
( OPTIONAL )
SWITCH , SERVICE AIR
SWITCH , LIGHT
SCREW
NUT
( 3 REQD )
( 3 REQD )
36891455
36892370
36842128
Book 35393560 (12/02)
PANEL HARNESS
MODULE , LOW WATER
BULB , GAGE ( 6 REQD )
-- 76 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
INSTR / CONTROL PANEL & MOUNTING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--67 1--00/B
T
M
P
S
R
Q
D
INGERSOLLRAND
--
L
A
B C
E F G
J
K
H
N
Book 35393560 (12/02) -- 77 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP INSTR / CONTROL PANEL & MOUNTING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--68 1--00/B
S
T
D
E
F
G
H
J
K
L
M
N
A
B
C
P
Q
R
36845394
36845733
35356617
36842656
36845725
35144328
35144492
35603349
95935037
35273366
35327303
95923314
35327311
95923314
35577873
36878361
36892362
36892370
36844595
DOOR , CONTROL PANEL
HINGE
RIVET ( 3 REQD )
PANEL , INSTRUMENT / CONTROL
HINGE
SCREW
NUT
HOLDER
( 3 REQD )
( 3 REQD )
( 2 REQD ) WASHER
NUT
EYEBOLT
WASHER
SPRING
( 2 REQD )
NUT
SWITCH , MAG.
RELAY , 24 VOLT
RELAY , 24 VOLT ( 4 REQD )
MODULE , LOW WATER
ENCLOSURE , INSTRUMENT PANEL
Book 35393560 (12/02) -- 78 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP INSTR / CONTROL PANEL & MOUNTING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--69 1--00/B
A1
Z
Y
A2
P
Q
R
S
T
U
A
M L
K
V
N
H
Book 35393560 (12/02)
W X
B C D E F G
J
A
-- 79 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ENCLOSURE ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--70 1--00/B
V
W
X
T
U
R
S
P
Q
Y
Z
A1
A2
D
E
F
G
H
J
M
N
K
L
A
B
C
Book 35393560 (12/02)
36894590
36894467
36501500
35327303
35327311
95934998
95923314
36849925
36894434
36894459
36740421
36894400
36894475
36894442
36894418
36894368
36894384
36894400
36894376
36894350
36894426
36793602
35130707
35374834
36769743
PANEL , R.H. FRONT
DOOR
PANEL , R.H. REAR
PANEL , R.H. REAR
DOOR
PANEL , L.H. REAR
PANEL , L.H. REAR SIDE
DOOR
LATCH , DOOR
HOLD , HAND
SCREW
NUT
STEPS , REAR
ANGLE , MOUNTING
DOOR , FUEL FILLER
HINGE
EYEBOLT
SPRING
WASHER
NUT
LATCH , DOOR
PANEL , L.H. FRONT
PANEL , L.H. FRONT
HINGE
DOOR
( 4 REQD )
PANEL , R.H. FRONT SIDE
SIDE
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ENCLOSURE ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--71 1--00/B
-- 80 --
G
G
G
G
C
E
D
F
Book 35393560 (12/02)
B
A
-- 81 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ENCLOSURE ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--72 1--00/B
A
D
E
F
G
B
C
36894533
36894525
36894392
36894533
36894525
36894483
36755742
RAIL , L.H. TOP
RAIL , L.H. LONG
RAIL , REAR TOP
RAIL , R.H. REAR
RAIL , R.H. LONG
RAIL , FRONT TOP
STRIP , CONNECTOR
Book 35393560 (12/02) -- 82 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ENCLOSURE ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--73 1--00/B
Q
P
G
L
H
N
M
K J
E
F
C
Book 35393560 (12/02)
D
B
-- 83 --
A
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ENCLOSURE ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--74 1--00/B
A
B
C
H
J
F
G
D
E
K
L
M
N
P
Q
36894558
36894574
36894566
36894541
36883421
36894582
36894491
36894509
36879104
36894517
35305416
35131051
36771186
36798635
36756773
BAFFLE , L.H. INTAKE
BAFFLE , R.H. INSIDE INTAKE
BAFFLE , R.H. INTAKE
BAFFLE , EXHAUST
RETAINER , ROOF
GUTTER
( 8 REQD )
( 4 REQD )
PANEL , FRONT ROOF
PANEL , MIDDLE ROOF
COVER , COOLER
PANEL , REAR ROOF
PLATE , STRIKER
LATCH , DOOR
CABLE
DOOR , ROOF
HINGE
Book 35393560 (12/02) -- 84 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ENCLOSURE ASSEMBLY
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--75 1--00/B
STARTS AT SERIAL NO.
291411
B
F
D
E
Book 35393560 (12/02)
G
E
A
C
-- 85 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
BELLY PANS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--76 1--00/B
A
B
C
D
E
F
G
36895555
36895621
36895597
36895571
36880623
36895589
36895605
PAN , A/E FRONT BELLY
PAN , EXHAUST BELLY
PAN , ENGINE FRONT BELLY
PAN , R.H. FRONT BELLY
COVER , FLEX
PAN , R.H. MIDDLE BELLY
PAN , ENGINE REAR BELLY
Book 35393560 (12/02) -- 86 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
BELLY PANS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--77 1--00/B
H
J
K
P
G
E
M
N
M
E
F
L
D
C
B
A
Book 35393560 (12/02) -- 87 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ACOUSTIC PANELS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--78 1--00/B
H
J
K
E
F
G
L
M
N
C
D
A
B
P
36894947
36894871
36894889
36894897
36894954
36894962
36894905
36894939
36894921
36894913
36894988
36894970
36846822
36894996
PANEL , L.H. FRONT
PANEL , L.H. FRONT ENDCAP
PANEL , R.H. FRONT ENDCAP
PANEL , R.H. FRONT ENDCAP
PANEL , FRONT ROOF
PANEL , MIDDLE ROOF
PANEL , R.H. FRONT
PANEL , R.H. SIDE
PANEL , R.H. MIDDLE
PANEL , R.H. REAR
PANEL , REAR ROOF
PANEL , R.H. & L.H. ROOF
PANEL , ROOF DOOR
PANEL , REAR ENDCAP
Book 35393560 (12/02) -- 88 --
1--00
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
WAP
DESCRIPTION
ACOUSTIC PANELS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--79 1--00/B
)
F
K
L
D
J
H
G
E
Book 35393560 (12/02)
C
-- 89 --
B
A
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ACOUSTIC PANELS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--80 1--00/B
A
D
E
F
G
H
J
B
C
K
L
36895035
36895027
36895019
36895001
36895050
36895043
36894855
36894863
36854040
36854065
36854024
PANEL , OUTSIDE BAFFLE
PANEL , INSIDE BAFFLE
PANEL , L.H. INTAKE
PANEL , R.H INTAKE
PANEL , R.H. INTAKE BAFFLE
PANEL , R.H. INTAKE BAFFLE
PANEL , L.H. EXHAUST BAFFLE
PANEL , R.H. EXHAUST BAFFLE
PANEL , DOOR BOTTOM
PANEL , DOOR MIDDLE
PANEL , DOOR TOP
Book 35393560 (12/02) -- 90 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ACOUSTIC PANELS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--81 1--00/B
Book 35393560 (12/02) -- 91 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
DECAL LOCATION
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--82 1--00/B
Book 35393560 (12/02) -- 92 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
DECAL LOCATION
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--83 1--00/B
Book 35393560 (12/02) -- 93 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
DECAL LOCATION
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--84 1--00/B
WHT RED/
WHT
BLK RED/
LU DKB
BLK RED/
RED/
BRN
BRN
ORN LU/ DKB
ED YEL/R
/YEL BLU DK
K YEL/BL
U YEL/BL
L YE RED/
RED E-ABL YC BATTER
RED RED
GRN LU/ DKB
RED RED
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
WIRING DIAGRAM & PARTS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--85 1--00/B
Book 35393560 (12/02) -- 94 --
VIO
DULE FU
HT VIO/W
VIO
RED
DULE U3
VIO
HT /W BRN HT /W BRN
BRN
RN /G LU LTB
BRN
BRN
BRN
BRN
BRN
Book 35393560 (12/02)
K YEL/BL
-- 95 --
K /BL BLU LT
BRN
HOUR METER M5
BRN
BRN
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
DESCRIPTION
1--00 WAP
WIRING DIAGRAM & PARTS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--86 1--00/B
Book 35393560 (12/02)
VIO
VIO/BLK
VIO/WHT
VIO/WHT
VIO/BLK
VIO/BLK
VIO/BLK
VIO/WHT
VIO/WHT
VIO/WHT
ORN/RED
ORN/YEL
ORN/BLU
ORN/WHT
-- 96 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
WIRING DIAGRAM & PARTS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--87 1--00/B
BRN
BRN
BRN
BRN
BRN
BRN
BRN
BRN
BRN
BRN
Book 35393560 (12/02) -- 97 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
WIRING DIAGRAM & PARTS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--88 5--00/C
L
K
H
J
Book 35393560 (12/02)
D
E F G
C
B
-- 98 --
A
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ENCLOSURE AND ACOUSTICS ( EEC )
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--89 1--00/B
36898591
36898609
36898617
36898625
36898757
36740421
36849925
36898575
36898633
36898583
36898567
A
K
L
H
J
D
E
F
G
B
C
BAFFLE , BOTTOM FRONT EXHAUST
BAFFLE , BOTTOM REAR EXHAUST
BAFFLE , EXHAUST
REAR END CAP , R.H.
DOOR , REAR
HINGE
LATCH
PANEL , REAR ROOFL.H.
RAIL , REAR TOP
PANEL , ROOF REAR R.H.
PANEL , ROOF REAR
Book 35393560 (12/02) -- 99 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
ENCLOSURE AND ACOUSTICS ( EEC )
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--90 1--00/B
T
R
S
Q
P
N
K
L
M
J
H
Book 35393560 (12/02)
F
G
E
B
A
-- 100 --
D
C
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP ENCLOSURE AND ACOUSTICS ( EEC )
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--91 1--00/B
A
D
E
F
G
H
J
B
C
M
N
K
L
P
Q
R
36898906
36898708
36898872
36898880
36898716
36898898
36898682
36898690
36898724
36898641
36898674
36898740
36898732
36898658
36898666
36898914
PANEL , BOTTOM REAR
PANEL , BAFFLE BOTTOM FRONT
PANEL , SIDE REAR
PANEL , SIDE REAR
PANEL , BAFFLE BOTTOM REAR
PANEL , REAR FRAME ( 3 REQD )
PANEL , BAFFLE EXHAUST
PANEL , BAFFLE EXHAUST
PANEL , LOUVER R.H.
PANEL , ROOF REAR
PANEL , END CAP BOTTOM
PANEL , LOUVER LOWER
PANEL , LOUVER UPPER ( 3 REQD )
PANEL , LOUVER REAR
PANEL , LOUVER BOTTOM
PANEL , TOP RAIL
( 4 REQD )
( 4 REQD )
( 10 REQD )
Book 35393560 (12/02) -- 101 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
DESCRIPTION
1--00 WAP
ENCLOSURE AND ACOUSTICS ( EEC )
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--92
1--00/B
Book 35393560 (12/02) -- 102 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AFTER COOLER OPTION
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--93 1--00/B
Y
Z
A1
V
W
X
S
T
U
P
Q
R
A2
A3
A
L
M
N
H
J
K
F
G
D
E
B
C
35598770
95953790
95944682
36786127
35335124
35114859
36897502
95037354
39240858
95940946
39240411
39240726
36893295
95037404
95048906
36895936
36895910
36866010
36866028
95920708
36866028
95953972
36895498
36895928
35356443
36856045
95953816
Book 35393560 (12/02)
BUSHING
NIPPLE
ADAPTER
TUBE
FLANGE , SPLIT
O--RING
SCREW
O--RING
SCREW
AFTERCOOLER
TUBE
HOSE ASSEMBLY
VALVE , 3--WAY
NIPPLE
NIPPLE
TEE
ELBOW
CONNECTOR
HOSE
TUBE , SERVICE
BUSHING
FILTER , 3RD STAGE
NIPPLE
FILTER , 2ND STAGE
FILTER , 1ST STAGE
SEPARATOR , WATER
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AFTER COOLER OPTION
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--94 1--00/B
-- 103 --
Book 35393560 (12/02) -- 104 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AFTER COOLER OPTION
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--95 1--00/B
A
B
C
D
36897536
36897510
36897551
36897528
BRACE , FILTER SUPPORT
BRACKET , FILTER
BRACKET , WATER SEPARATOR
SUPPORT , FILTER
Book 35393560 (12/02) -- 105 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AFTER COOLER OPTION
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--96 1--00/B
SECTION 11
OPTIONS PARTS LIST INDEX
EEC Option,
EEC Option,
Sht 1
Sht 2
EEC Option,
EEC Option,
Sht 3
Sht 4
After Cooler Option
After Cooler Option
After Cooler Option
After Cooler Option
,
,
,
Sht 1
Sht 2
Sht 3
Sht 4
,
IQ
IQ
Filter Drain Piping , Sht 1
Filter Drain Piping ,
IQ Indicator Piping ,
IQ Indicator Piping ,
IQ Aftercooler Piping ,
Sht 2
Sht 1
IQ Aftercooler Piping ,
IQ Filter Piping ,
IQ Filter Piping ,
Sht 2
Sht 1
Sht 2
IQ Filter Brackets ,
IQ Filter Brackets ,
Sht 1
Sht 2
Sht 1
Sht 2
Autostart / Stop Option
Book 35393560 (12/03) -- 106 --
L
K
H
J
Book 35393560 (12/03)
D
E F G
C
B
A
-- 107 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
EEC OPTION
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP1 1--00/B
Book 35393560 (12/03)
95245353
95772562
36844579
95245346
37081528
35114545
35279934
35321223
95452025
36882223
35283464
35282904
36920304
36920205
35321983
35315407
95279527
A
K
L
H
J
M
N
D
E
F
G
B
C
P
Q
R
S
ADAPTER
NIPPLE
Y--STRAINER
BUSHING
ORIFICE
TEE , STREET
ELBOW , 90
ELBOW , 45
NIPPLE
TEE
ELBOW
HOSE
HOSE
TUBE
UNION
HOSE
ELBOW
-- 108 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
EEC OPTION
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--OP2 1--00/B
T
R
S
Q
P
N
K
L
M
J
H
Book 35393560 (12/03)
F
B
A
G
-- 109 --
E
D
C
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
EEC OPTION
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP3
1--00/B
F
G
D
E
H
J
K
L
M
N
A
B
C
P
Q
R
36898906
36898708
36898872
36898880
36898716
36898898
36898682
36898690
36898724
36898641
36898674
36898740
36898732
36898658
36898666
36898914
PANEL , BOTTOM REAR
PANEL , BAFFLE BOTTOM FRONT
PANEL , SIDE REAR
PANEL , SIDE REAR
PANEL , BAFFLE BOTTOM REAR
PANEL , REAR FRAME ( 3 REQD )
PANEL , BAFFLE EXHAUST
PANEL , BAFFLE EXHAUST
PANEL , LOUVER R.H.
PANEL , ROOF REAR
PANEL , END CAP BOTTOM
PANEL , LOUVER LOWER
PANEL , LOUVER UPPER ( 3 REQD )
PANEL , LOUVER REAR
PANEL , LOUVER BOTTOM
PANEL , TOP RAIL
( 4 REQD )
( 4 REQD )
( 10 REQD )
Book 35393560 (12/03) -- 110 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
EEC OPTION
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--OP4 1--00/B
Book 35393560 (12/03) -- 111 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AFTER COOLER OPTION
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP5 1--00/B
Y
Z
A1
V
W
X
S
T
U
P
Q
R
A2
A3
A
L
M
N
H
J
K
F
G
D
E
B
C
35598770
95953790
95944682
36786127
35335124
35114859
36897502
95037354
39240858
95940946
39240411
39240726
36893295
95037404
95048906
36895936
36895910
36866010
36866028
95920708
36866028
95953972
36895498
36895928
35356443
36856045
95953816
Book 35393560 (12/03)
BUSHING
NIPPLE
ADAPTER
TUBE
FLANGE , SPLIT
O--RING
SCREW
O--RING
SCREW
AFTERCOOLER
TUBE
HOSE ASSEMBLY
VALVE , 3--WAY
NIPPLE
VALVE , MIN. PRESS. CHECK
NIPPLE
TEE
ELBOW
CONNECTOR
HOSE
TUBE , SERVICE
BUSHING
FILTER , 3RD STAGE
NIPPLE
FILTER , 2ND STAGE
FILTER , 1ST STAGE
SEPARATOR , WATER
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AFTER COOLER OPTION
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP6 1--00/B
-- 112 --
Book 35393560 (12/03) -- 113 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AFTER COOLER OPTION
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP7 1--00/B
A
B
C
D
36897536
36897510
36897551
36897528
BRACE , FILTER SUPPORT
BRACKET , FILTER
BRACKET , WATER SEPARATOR
SUPPORT , FILTER
Book 35393560 (12/03) -- 114 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AFTER COOLER OPTION
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP8 1--00/B
HP--935 ONLY STARTS AT SERIAL NO.
295452
Book 35393560 (12/03) -- 115 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
IQ FILTER DRAIN PIPING
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP9 1--00/B
Book 35393560 (12/03)
95245353
95772562
36844579
95245346
37081528
35114545
35279934
35321223
95452025
36882223
35283464
35282904
36920304
36920205
35321983
35315407
95279527
A
K
L
H
J
M
N
D
E
F
G
B
C
P
Q
R
S
ADAPTER
NIPPLE
Y--STRAINER
BUSHING
ORIFICE
TEE , STREET
ELBOW , 90
ELBOW , 45
NIPPLE
TEE
ELBOW
HOSE
HOSE
TUBE
UNION
HOSE
ELBOW
-- 116 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
IQ FILTER DRAIN PIPING
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP10 1--00/B
A
B
C
D
35315357 NUT
35315340 BOLT
35359389 PLATE , TIE
35359397 NUT ( 32 REQD )
E
H
J
K
L
F
G
M
N
P
36891794
36891786
35385392
35315365 BOLT
FRONT AXLE ASSEMBLY
REAR AXLE ASSEMBLY
SPRING
35315373 NUT
35356922 U--BOLT ( 2 REQD )
35385236
35385244
35385293
HUB
STUD ( 12 REQD )
BEARING , OUTER
35385277 CUP , OUTER
35356914 WASHER
Q
R
35315217 NUT
35379395
35379387
CAP , GREASE
CAP , E--Z LUBE
V
W
X
Y
Z
S
T
U
35315225 PIN , COTTER
35359413 SHOE , FRONT
35359421 SHOE , REAR
36895241 L.H. BRAKE ASSEMBLY
36895258
35356864
R.H. BRAKE ASSEMBLY
WASHER ( 5 REQD )
35356872 NUT ( 4 REQD )
35359405 KIT , WHEEL CYLINDER
A1
A2
35316876 BEARING , INNER
35316884 CUP , INNER
A3 35316868 SEAL , GREASE
A4 35385251 NUT ( 12 REQD )
Book 35393560 (12/03) -- 117 --
RUNNING GEAR ( FAST TRACK )
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--11 1--00/B
Book 35393560 (12/03)
H
J
F
G
D
E
K
L
M
N
A
B
C
P
36899599
36898401
35321231
35284496
INDICATOR , 20 PSI
ADAPTER , BULKHEAD
HOSE
ELBOW , 45
TO SECONDARY FILTER
36899615 INDICATOR , 25 PSI
35283266
TO PRIMARY FILTER
HOSE
35283464 ELBOW
TO MINIMUM PRESS. CHECK VALVE
35315431
95010906
35306687
HOSE
COUPLING
ELBOW
36891216 GAGE , PRESSURE
-- 118 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
IQ INDICATOR PIPING
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP12 1--00/B
HP--935 ONLY STARTS AT SERIAL NO.
295452
E
L
D
C
B
A
F J
AFTERCOOLER
A
B
C
D
F
G
H
M
E
L
K
J
Book 35393560 (12/03) -- 119 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
IQ AFTRECOOLER PIPING
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP13 1--00/B
A
B
C
K
L
M
H
J
D
E
F
G
95929998
95667341
BUSHING
NIPPLE
35322379
35322346
VALVE , BLOWDOWN
ORIFICE
ELBOW 35369354
35321223 ELBOW , 45
TEE , STREET 35114545
35283472 CONNECTOR
HOSE 35283498
95365094
35356484
TO AIR END INTAKE
ELBOW
TUBE , NYLON
Book 35393560 (12/03) -- 120 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
IQ AFTERCOOLER PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--OP14 1--00/B
HP--935 ONLY STARTS AT SERIAL NO.
G
295452
H
E F
D
L
J
B
A1
C
A3
A2
A
B
B
T
U
Q
Q
A5
P
N
R
S
X
V
Z
V
W
X
Y
M
K
G
G
F A4
Book 35393560 (12/03) -- 121 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
IQ FILTER PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--OP15 1--00/B
Book 35393560 (12/03)
Y
Z
A1
V
W
X
S
T
U
P
Q
R
A2
A3
A
L
M
N
H
J
F
G
K
D
E
B
C
A4
A5
36866028
36895498
36895936
95048906
95037404
36893295
36920189
95953816
36786127
36856045
35356443
36895928
36866010
NIPPLE
ELBOW
3--WAY VALVE
HOSE ASSEMBLY
TUBE , INLET
FLANGE , SPLIT
O--RING
AFTERCOOLER
ADAPTER
NIPPLE
BUSHING
SEPARATOR , WATER
ADAPTER
36893220
95940946
36920171
36920163
95037354
36856920
35355124
36920221
95953790
95944674
ADAPTER
NIPPLE
FILTER , FIRST STAGE
FILETR , SECOND STAGE
BUSHING
HOSE
CONNECTOR
VALVE , CHECK
NIPPLE
ELBOW , STREET
95944682
36920130
TEE
VALVE , MIN. PRESS. CHECK
36897502
TO SEPARATOR TANK
TUBE
36895910
95358040
TUBE
O--RING
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
IQ FILTER PIPING
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--OP16 1--00/B
-- 122 --
HP--935 ONLY
A E
STARTS AT SERIAL NO.
295452
C B
Book 35393560 (12/03)
C
D
-- 123 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
IQ FILTER BRACKETS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR 35393560--OP17 1--00/B
A
B
C
D
36897528
36897551
36897510
SUPPORT , FILTER
BRACKET , WATER SEPARATOR
BRACKET , FILTER
BRACE , FILTER SUPPORT 36897536
E 36920213 BRACKET , INDICATOR
IQ PARTS NOT ILLUSTRATED
36899839 WIRING HARNESS
36899607
36892362
36534634
36534675
36534774
24 VOLT RED LAMP
24 VOLT RELAY
DECAL
IQ VALVE DECAL
IQ VALVE OPERATION DECAL
IQ DECAL 36534758
36764736 BAFFLE BRACKET
36920460
36898310
36920247
36898922
36841526
36920643
36892362
36897890
36897908
ACOUSTIC PANEL
BAFFLE PANEL
INTAKE BAFFLE 36896611
36897882 INTAKE BAFFLE
LOW AMBIENT OPTION
36899631
36920452
LOUVER
LOUVER MOUNTING BRACKET
ACTUATOR MOUNTING BRACKET
LINEAR ACTUATOR
24 VOLT HEATER HARNESS
TEMPERATURE
24 VOLT HEATER
SENSOR
TEMP. CONTROL ASSEMBLY
24 VOLT RELAY
Book 35393560 (12/03) -- 124 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
IQ FILTER BRACKETS
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
35393560--OP18 1--00/B
TEST PROCEDURE
EQUIPMENT/TOOLS REQUIRED:
--ADJUSTABLE WRENCH
--SMALL (MICRO) CROSS--HEAD AND FLAT BLADE SCREWDRIVERS
--VOLTMETER WITH 6--FOOT LONG LEADS
--SPST SWITCH WITH MALE AND FEMALE 1/4 QUICK--CONNECT TERMINAL LEADS
--10MM DEEP SOCKET
--9/32 INCH SOCKET
1.
COMPLETE THE INSTALLATION USING INSTRUCTIONS ON SHEET 2.
BE CAREFUL -- DO NOT OVERTIGHTEN OR STRIP THE ADJUST
POTS -- THEY TURN EASILY.
> SET LARGE SWITCH (INSIDE AUTOSTART BOX) TO MANUAL.
> SET SMALL SWITCH (INSIDE) TO OFF.
> TEMPORARILY MOVE WIRE ON INPUT 12 (TERM 14) TO
INPUT 8 (TERM 10).
> ADJUST POT 7 FULLY COUNTER--CLOCKWISE.
> ADJUST POT 8 FULLY CLOCKWISE.
2.
UNPLUG EXTERNAL WIRE LEADS 48 AND 49 FROM EACH OTHER
AND CONNECT THEM TO A TEMPORARY SPST SWITCH AS THE REMOTE
START SWITCH. LEAVE SWITCH IN OFF (OPEN) POSITION.
3.
TURN ON POWER SWITCH ON THE COMPRESSOR PANEL.
> VERIFY NORMAL COMPRESSOR OPERATION FROM THE FRONT
PANEL (AS WITHOUT AUTOSTART), INCLUDING HEATER CIRCUIT.
”AUTO--MODE” LIGHT ON FRONT OF COMPRESSOR SHOULD BE OFF.
> TURN UNIT OFF.
4.
DISCONNECT THE POWER WIRE (GRAY) FROM THE FUEL SOLENOID.
Book 35393560 (12/03)
5.
SET AND VERIFY CRANK DISCONNECT, OVERCRANK, TIMES
CRANK DISCONNECT
> CONNECT A TEST LIGHT OR METER ACROSS THE ETHER
VALVE FOR MONITORING.
> PRESET CRANK DISCONNECT POT 6 TO FULLY CLOCKWISE.
TURN ON POWER SWITCH.
> SET LARGE SWITCH (INSIDE AUTOSTART BOX) TO AUTOMATIC.
> SET SMALL SWITCH (INSIDE) TO TEST.
> WHEN ENGINE CRANKS, SLOWLY TURN POT 6 COUNTER--CLOCKWISE
UNTIL ENGINE STOPS CRANKING.
(DO THIS AND NEXT 2 STEPS QUICKLY, WITHIN 8 SECONDS)
> TURN POT 6 CLOCKWISE 1/8 TO 1/4 TURN.
THE CRANK DISCONNECT IS NOW SET. SET THE SMALL SWITCH
TO ”OFF” AND THEN BACK TO ”TEST”. THIS WILL ACCEPT THE
CHANGE AND ALLOW YOU TO CONTINUE WITH THE NEXT STEP.
> VERIFY ENGINE CRANKS FOR 8--12 SECONDS. THEN CRANK
DISCONNECT IS CORRECTLY SET.
(4--30 SECOND RANGE, ADJUST POT 2, ABOUT 1/4 TURN)
OVERCRANK AND CRANK/REST TIME
> VERIFY REST TIME BETWEEN CRANKS IS 20--30 SECONDS (10--60 RANGE,
ADJUST POT 3 TO MIDDLE).
> VERIFY ETHER INJECTION IS POWERED (24 VDC) FOR 1--3 SECONDS ON
EACH CRANK BY OBSERVING TEST LAMP OR METER.
> VERIFY MACHINE CRANKS FOR THREE CYCLES (1--5 CRANKS, ADJUST
POT 4 TO MIDDLE).
> VERIFY AN OVERCRANK ALARM AFTER 3 CRANKS.
OVERCRANK WILL CAUSE A LIGHT ON OUTPUT 2 AND A CONSTANT
ALARM. RESET UNIT BY SWITCHING TO MANUAL OR OFF ON ANY ONE OF
THE SWITCHES.
6. TURN SWITCHES OFF, RECONNECT FUEL SOLENOID, REMOVE ETHER LAMP OR METER.
7. VERIFY CHARGER OPERATION
> PLUG IN BATTERY CHARGER.
> VERIFY BATTERY CHARGER IS CHARGING BY OBSERVING
CURRENT ON METER.
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
DESCRIPTION
1--00 WAP
INSTALLATION & TEST PROCEDURE / AUTOSTART
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--1A 1--00/A
-- 125 --
TEST PROCEDURE
8. OPERATION
> CONNECT A TEST LIGHT OR METER ACROSS THE UNLOADER VALVE
SOLENOID FOR MONITORING.
TURN ON POWER SWITCH.
> SET LARGE SWITCH (INSIDE AUTOSTART BOX) TO AUTOMATIC.
> SET SMALL SWITCH (INSIDE) TO AUTO.
> VERIFY ”AUTO--MODE” LIGHT ON FRONT OF COMPRESSOR IS ON.
> TURN HEATER/ACCESSORY SWITCH ON COMPRESSOR PANEL TO ON.
> VERIFY UNLOADER VALVE HEATER IS OFF (0 VDC) BY FEELING
HEATER ON VALVE.
> CONNECT REMOTE START SWITCH WIRES 48 AND 49, OR SET
REMOTE START SWITCH TO ON.
9. CRANKING
> VERIFY 10 SECOND PRE--ALARM DELAY (5 ON/OFF PULSES)
BEFORE CRANK.
> VERIFY UNLOADER VALVE IS NOT POWERED BY OBSERVING
TEST LIGHT OR METER.
10. ENGINE STARTS
> VERIFY STARTER DISCONNECTS.
AFTER BYPASS TIME DELAY OF 12--18 SECONDS (0--60 RANGE,
ADJUST POT 5 ABOUT 1/8 TURN):
NOTE: IF ENGINE DOES NOT CATCH, TURN POT 6 1/4 TURN CLOCKWISE AND
RETRY. YOU MUST TURN THE SMALL SWITCH TO ”OFF” AND
BACK TO ”AUTO” TO ACCEPT THE ADJUSTMENT TO POT 6.
REPEAT THIS PROCEDURE UNTIL ENGINE CATCHES.
> VERIFY UNLOADER VALVE IS ON BY OBSERVING TEST LIGHT
OR METER.
> VERIFY UNLOADER VALVE HEATER IS ON BY FEEL OF HEAT.
11. ENGINE RUNNING
> VERIFY WARMUP DELAY OF 50--70 SECONDS, THEN COMPRESSOR LOADS.
(0--10 MINUTE RANGE IN SECOND INCREMENTS. SET SECONDS
ON ADJUST POT 7, SET MINUTES ON INPUTS 8 TO 16)
> VERIFY BATTERY CHARGER IS NOT CHARGING WHILE RUNNING BY
OBSERVING CURRENT ON METER.
12. SHUTDOWN
> DISCONNECT REMOTE START SWITCH WIRES 48 AND 49, OR SET REMOTE
START SWITCH TO OFF.
> SET AND VERIFY COOLDOWN DELAY OF 4--5 MINUTES BEFORE SHUTDOWN.
AFTER 5 MINUTES SLOWLY ADJUST POT 8 COUNTER--CLOCKWISE UNTIL
ENGINE STOPS.
(0--30 RANGE, ADJUST POT 8)
13.
FINAL SETTINGS
> TURN POWER SWITCH OFF.
> SET LARGE SWITCH (INSIDE AUTOSTART BOX) TO MANUAL.
> SET SMALL SWITCH (INSIDE) TO OFF.
> RECONNECT THE WIRE CONNECTED TO INPUT 8 (TERM 10) TO INPUT 12
(TERM 14).
(THIS SETS WARM UP DELAY TO 5 MINUTES).
> DISCONNECT (UNPLUG) REMOTE START SWITCH FROM WIRES 48 AND 49.
> TURN HEATER/ACCESSORY SWITCH TO OFF.
14.
MANUAL OPERATION
> VERIFY NORMAL COMPRESSOR OPERATION WITHOUT AUTOSTART ENABLED.
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
DESCRIPTION
1--00 WAP
INSTALLATION & TEST PROCEDURE / AUTOSTART
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--1B 1--00/A
Book 35393560 (12/03) -- 126 --
INSTALLATION:
THIS SYSTEM IS DESIGNED TO WORK WITH THE STANDARD MANUAL CONTROLS ON THE
PORTABLE COMPRESSOR AND DOES NOT REQUIRE ANY ADDITIONAL PARTS IN THE MANUAL
CONTROL PANEL. THE WIRING WILL BE CONNECTED BY PLUGGING THE PANEL WIRE
HARNESS INTO THE CONTROL PANEL CABLE CONNECTOR, CONNECTING 2 WIRES FROM
THE AUTOSTART CONTROLLER WIRE HARNESS INSIDE THE CONTROL PANEL,
ATTACHING 2 WIRES IN THE MAGNETIC PICKUP CABLE TO THE TERMINALS
ON THE MAGNETIC PICKUP, CONNECTING 2 WIRES TO THE AUTO MODE LIGHT, AND
THE BATTERY CHARGER.
CONNECTING
THE CONTROL PACKAGE INCLUDES THE FOLLOWING PARTS:
(1) AUTOSTART CONTROLLER MOUNTED IN A NEMA 3 ENCLOSURE WITH
INSTALLATION WIRE HARNESS.
(1) MAGNETIC PICKUP ASSEMBLY (MAGNETIC PICKUP WITH RUBBER TERMINAL COVER
(1) AUTO MODE LIGHT AND NOTICE DECAL THAT MACHINE CAN START UNEXPECTEDLY.
(1) BATTERY CHARGER.
(1) CHARGER WIRING HARNESS.
(1) CHARGER RELAY.
(5) AUTO START DECAL
(1) OPERATING INSTRUCTION DECAL.
(1) INSTALLATION AND OPERATING MANUAL.
(1) WIRING DIAGRAM.
AFTER OPENING THE PACKAGE, INPECT THE CONTENTS TO INSURE THAT ALL OF THE
COMPONENTS ARE INCLUDED AND NO DAMAGE HAS OCCURRED DURING SHIPPING. IF ANY
OF THE COMPONENTS ARE DAMAGED, ADVISE THE SHIPPER AT ONCE.
BOOT).
AFTER IDENTIFYING EACH PART, THE INSTALLATION CAN BEGIN.
1. DISCONNECT THE LOAD FROM THE COMPRESSOR AND STOP THE ENGINE BY TURNING
THE POWER SWITCH TO THE OFF POSITION.
2. OPEN ENCLOSURE SIDE DOORS AND DISCONNECT THE BATTERY CABLES.
3. MOUNT THE AUTOSTART CONTROLLER.
4. MOUNT THE AUTO MODE LIGHT AND AUTO MODE NOTICE DECAL ABOVE THE
COMPRESSOR CONTROL PANEL.
5. MOUNT AN AUTOSTART DECAL DECAL ABOVE EACH COMPRESSOR DOOR LATCH.
6. MOUNT THE OPERATING INSTRUCTIONS DECAL OUTSIDE OF THE COMPRESSOR
CONTROL PANEL DOOR.
7. LOCATE THE HEX HEAD PLUG WITH THE SCREW DRIVER SLOT IN THE ENGINE
FLYWHEEL HOUSING AND REMOVE IT FROM THE ENGINE.
8. REMOVE THE MAGNETIC PICKUP FROM THE PACKAGE. REMOVE THE RUBBER BOOT
FROM THE PICKUP BY TWISTING AND PULLING IT OFF. RUN THE LOCKNUT UP THE
MAGNETIC PICKUP TOWARD THE TERMINAL HEAD AS FAR AS IT WILL GO.
Book 35393560 (12/03) -- 127 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP INSTALLATION & TEST PROCEDURE / AUTOSTART
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
AUTOS--2 A 1--00/A
INSTALLATION:
9. THREAD THE PICKUP INTO THE FLYWHEEL HOUSING UNTIL IT STOPS IN CONTACT
WITH THE TEETH ON THE RING GEAR. (YOU MAY HAVE TO BUMP--CRANK THE ENGINE
THEN FEEL WITH YOUR FINGER TO ENSURE A TOOTH IS DIRECTLY BELOW THE
AND RUN THE LOCKNUT DOWN UNTILIT CONTACTS THE SURFACE OF THE
TIGHTEN THE LOCKNUT SECURELY WITH AN OPEN END WRENCH.
PICKUP
AND
HOLE.) NOTE THE POSITION OF THE TERMINAL STUDS ON TOP OF THE PICKUP AND
ROTATE THE PICKUP COUNTERCLOCKWISE 1/4 TURN; THIS SETS THE AIR GAP
THE RING GEAR TEETH AND THE PICKUP AT .015”. HOLD THE PICKUP IN
BETWEEN
THAT POSITION
FLYWHEEL HOUSING.
CAUTION: BE SURE THE PICKUP DOES NOT ROTATE. DAMAGE WILL OCCUR IF
PICKUP CONTACTS THE RING GEAR TEETH WHILE ENGINE IS RUNNING.
THE
10. RUN THE SMALL 2--WIRE CABLE FROM THE AUTOSTART CONTROLLER TO THE
MAGNETIC PICKUP, ROUTING IT SO IT CAN BE SECURED WITH WIRE
TIES FOR SUPPORT. THIS IS THE WIRING FOR THE MAGNETIC PICKUP.
11. THREAD THE TWO WIRES THROUGH THE SMALL HOLE IN THE MAGNETIC PICKUP
RUBBER BOOT AND CONNECT THEM TO THE TERMINAL STUDS ON THE PICKUP.
CONNECT THE RED WIRE TO THE (+) TERMINAL AND THE BLACK WIRE
TO THE (--) TERMINAL. PUSH THE BOOT DOWN OVER THE TERMINAL
HEAD UNTIL IT LOCKS IN PLACE AND WILL NOT COME OFF WITH LIGHT PULLING FORCE.
12. RUN THE REMAINING CABLE FROM AUTOSTART CONTROLLER TO THE CONTROL PANEL
ALONG AN AREA WHERE IT CAN BE TIED DOWN AND SUPPORTED TO PREVENT VIBRATION
AND CHAFING OF THE HARNESS COVERING.
13. DISCONNECT THE CHASSIS WIRE HARNESS CONNECTOR FROM THE CONTROL PANEL
CONNECTOR AND PLUG IN BOTH ENDS OF THE CABLE FROM THE AUTOSTART CONTROLLER.
14. WIRES 54 & 55 WILL BE CONNECTED INSIDE OF THE CONTROL PANEL TO
THE LOAD SWITCH, S--16. ROUTE THE 2--WIRE HARNESS INTO THE CONTROL PANEL.
15. REMOVE THE BLU/ORN WIRE FROM S--16 AND PLUG THE MALE BLADE TERMINAL
FROM THE AUTOSTART CABLE INTO THE BLU/ORN CONNECTOR.
16. CONNECT THE FEMALE TERMINAL TO THE VACANT CONTACT ON S--16 SWITCH.
17. WIRES 41 & 48 WILL OF CONNECTED TO THE AUTO MODE LIGHT MOUNTED ABOVE
THE CONTROL PANEL.
18. CONNECT THE GREEN GROUND WIRE TO THE ENGINE STARTER NEGATIVE GROUND
19. MOUNT THE BATTERY CHARGER.
20. CONNECT THE CHARGER HARNESS SMALL RED LUG TO THE CHARGER (+) TERMINAL,
BLACK LUG TO THE (--) TERMINAL.
POINT.
AND
21. PLUG THE CHARGER RELAY INTO THE HARNESS AND MOUNT THE RELAY.
22. CONNECT THE GRAY HARNESS WIRE TO THE ENGINE FUEL SOLENOID TERMINAL.
23. CONNECT THE HARNESS LARGE RED LUG TO THE BATTERY (+) TERMINAL, AND
THE BLACK LUG TO THE BATTERY (--) GROUND TERMINAL.
24. THE INSTALLATION IS NOW COMPLETE. BEFORE PROCEEDING, DOUBLE CHECK ALL
WIRE CONNECTIONS TO BE SURE THAT THEY ARE IN THE CORRECT LOCATION AND
TIGHTENED. CHECK ALL MOUNTING NUTS AND BOLTS TO BE SURE THEY ARE
SECURELY
TIGHT, INCLUDING
THE LOCKNUT ON THE MAGNETIC PICKUP.
Book 35393560 (12/03) -- 128 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP INSTALLATION & TEST PROCEDURE / AUTOSTART
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
AUTOS--2 B 1--00/A
OPTIONAL
ETHER
BOTTLE
-+
THERMO--
STAT
(RED/WHITE)
+
(BRN)
GND
CHASSIS
HARNESS
C1
(RED)
+
BATTERY
CHARGER
--
C2
( BRN )
CHARGER
RELAY
B1
+
(RED)
--
B2 ( BRN )
(GRAY)
F1
ENGINE
FUEL
SOL
BATTERY
Book 35393560 (12/03) -- 129 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
INSTALLATION & TEST PROCEDURE / AUTOSTART
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--3A 1--00/A
AUTOSTART
CONTROLLER
41
48
AUTO
MODE
LIGHT
AUTO--MODE DECAL
STANDARD
COMPRESSOR
CONTROL
PANEL
54
55
LOAD
SWITCH
( GRN )
48
CUSTOMER
CONNECTION
49
GROUND
POINT
P1A J1
ETHER
SWITCH
J1A
P1
--
(RED)
+
CHASSIS
HARNESS
MAGNETIC
SPEED
PICKUP
SENSOR
RING GEAR
TEETH
Book 35393560 (12/03) -- 130 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
INSTALLATION & TEST PROCEDURE / AUTOSTART
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--3B 1--00/A
NOTES:
1. INTERPRET DIMENSIONING AND TOLERANCING
IAW ASME Y14.5M--1994
3. SPECIFICATIONS, INCLUDING THOSE PERTAINING
TO FORM, FIT, FUNCTION, FINISH, RELIABILITY
OR DURABILITY, SHALL BE EQUAL TO OR BETTER
THAN THOSE REQUIRED FOR THE ORIGINAL ITEM
APPROVED BY INGERSOLL--RAND COMPANY.
4. SPECIFICATIONS:
4.1 LOCATION OF CONTROLS AND COMPRESSOR INTERFACE
THE AUTOSTART/STOP CONTROLS (ASSC) SHOULD BE LOCATED NEXT TO THE
COMPRESSOR MAIN CONTROL PANEL, AND INTERFACE CONNECTIONS SHOULD BE
MADE BY UTILIZING THE EXISTING HARNESS CONNECTORS AS PICKUP POINTS.
ASSC MATING CONNECTORS OR TERMINALS MUST BE COMPATIBLE WITH EXISTING
COMPRESSOR CONNECTORS.
4.2 PHYSICAL AND ENVIRONMENTAL DESIGN
THE ASSC MUST BE SUITABLE FOR OPERATION IN A DIESEL ENGINE COMPARTMENT
FROM --20 F TO +140 F AMBIENT TEMPERATURE.
THE ASSC MUST BE HOUSED IN A NEMA 12 ENCLOSURE THAT CAN BE READILY
OPENED AND CLOSED. ANY CMOS, MOS, OR OTHER ELECTRONIC OR SENSITIVE
COMPONENTS MUST BE CONFORMALLY COATED OR OTHERWISE PROTECTED FROM
AIRBORNE CONTAMINANTS AND HUMIDITY.
REFER TO THE LAYOUT DRAWING FOR PHYSICAL DIMENSIONS, MOUNTING, AND
WIRING REQUIREMENTS.
4.3 CIRCUIT PROTECTION
THE ASSC MUST BE PROTECTED BY AN OVERCURRENT DEVICE.
4.4 OPERATION SEQUENCE -- AUTOMATIC MODE
WHEN THE SELECTOR SWITCH INSIDE THE ASSC BOX IS TURNED TO THE
”AUTOMATIC” POSITION AND THE SWITCH ON THE COMPRESSOR MAIN CONTROL
PANEL IS TURNED ON,THE AUTO MODE LIGHT WILL BE ACTIVATED AND THE UNIT
WILL OPERATE AS FOLLOWS:
A-- THE ASSC WILL REMAIN IN A STANDBY CONDITION WITH THE COMPRESSOR
OFF UNTIL THE PRESSURE OR OTHER TRANSFER SWITCH (INSTALLED BY THE
CUSTOMER) CONTACTS CLOSE. WHEN THE SWITCH CLOSES, THE ASSC WILL
PROCEED AS FOLLOWS:
B-- DURING AN INITIAL FIXED DELAY OF 10 SECONDS, A ”PULSED” ALARM WILL
SOUND AND THE UNLOADER COMPRESSOR MOTOR WILL BE ACTIVATED. THE
INITIAL DELAY ALSO PROTECTS AGAINST SHORT TERM RIPPLES IN THE MAIN
AIR SUPPLY.
C-- AFTER THE INITIAL ALARM DELAY, THE UNIT WILL BEGIN ITS NORMAL
CRANK CYCLE. CONCURRENT WITH THE START OF EACH CRANK, A 2 SECOND
PULSED OUTPUT MUST BE PROVIDED FOR ETHER INJECTION. IMMEDIATELY
PRIOR TO CRANK, THE START/RUN VALVE MUST BE ENERGIZED AND REMAIN
SO UNTIL THE COMPRESSOR IS LOADED (STEP G). THE UNLOADER COMPRES--
SOR MOTOR MUST REMAIN ACTIVATED DURING CRANK. AN ADDITIONAL
DRY CONTACT MUST BE INSERTED IN SERIES WITH THE HEATER SWITCH
(S11) AND CLOSE ONLY DURING UNIT STARTING AND RUN OPERATION. THE
DRY CONTACT WILL BE ENERGIZED TO AN OPEN STATE DURING STANDBY AND
DEFAULT TO CLOSED UPON LOSS OF POWER OR MANUAL MODE OPERATION.
D-- THE CRANK PERIOD SHOULD BE ADJUSTABLE FROM 4 -- 30 SECONDS
(FACTORY PRESET TO 10 SECONDS). THE REST PERIOD SHOULD BE ADJUSTABLE
FROM 10 -- 60 SECONDS (FACTORY PRESET TO 25 SECONDS). THE NUMBER OF CRANK
CYCLES SHOULD BE SETTABLE FOR 1 -- 5 CYCLES (FACTORY PRESET TO 3
IF THE UNIT FAILS TO START AFTER THE SET NUMBER OF CYCLES, AN
CYCLES).
OVERCRANK
CONDITION SHOULD BE INDICATED AND A CONTINUOUS ALARM WILL SOUND.
THE ASSC WILL NOT ATTEMPT TO START AGAIN UNLESS POWER IS RECYCLED
OR A RESET BUTTON IS PUSHED.
Book 35393560 (12/03) -- 131 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AUTOSTART / STOP CONTROL
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
AUTOS--4A 1--00/A
SPECIFICATIONS (CONT.)
E-- AS THE UNIT STARTS DURING A CRANK CYCLE, AT A SET FLYWHEEL
SPEED AS SENSED BY A MAGNETIC SPEED PICKUP, CRANK DISCONNECT
OCCURS AND THE ASSC GOES TO THE RUN MODE. AT THIS TIME A
PROTECTION BYPASS TIME DELAY PERIOD BEGINS WHICH ALLOWS THE
ENGINE OIL PRESSURE TO RISE SUFFICIENTLY TO SATISFY THE
COMPRESSOR ENGINE PROTECTION CIRCUIT. THIS PREVENTS PREMATURE
SHUTDOWN. THE PROTECTION BYPASS TIMER SHOULD BE ADJUSTABLE
FROM 0 -- 60 SECONDS (FACTORY PRESET TO 15 SECONDS). THE
SPEED CRANK DISCONNECT ADJUST RANGE SHOULD BE FROM 20 -- 2000 HZ.
INSTRUCTIONS ON SETTING THIS SHOULD BE PROVIDED.
F-- ONCE THE ENGINE REACHES A NORMAL RUNNING CONDITION, THE UNIT
REQUIRES A WARMUP PERIOD PRIOR TO LOADING THE COMPRESSOR
TO ITS NORMAL OUTPUT PRESSURE. THIS WARMUP PERIOD SHOULD BE
ADJUSTABLE FROM 0 -- 10 MINUTES IN 10 SECOND INCREMENTS
(FACTORY PRESET TO 5 MINUTES).
G-- AFTER THE WARMUP PERIOD, THE ASSC WILL AUTOMATICALLY LOAD
THE COMPRESSOR BY DEACTIVATING THE START/RUN VALVE. THIS
ENABLES THE COMPRESSOR TO DELIVER RATED PRESSURE AND FLOW
FOR NORMAL OPERATION.
H-- THE UNIT MAY BE SHUT OFF AT ANY TIME WHILE RUNNING IN
AUTOMATIC MODE BY EITHER SWITCHING THE ASC TO ”OFF”
OR TURNING THE COMPRESSOR ON/OFF SWITCH TO ”OFF ON
THE FRONT OPERATOR PANEL. THIS WILL SHUT DOWN THE
COMPRESSOR IMMEDIATELY.
J-- ONCE THE CUSTOMER TRANSFER SWITCH OPENS, THE UNIT WILL BEGIN
A COOL--DOWN PERIOD. THE COOL--DOWN PERIOD SHOULD BE ADJUSTABLE
FROM 0 -- 30 MINUTES (FACTORY PRESET TO 5 MINUTES).
K-- AT THE END OF THE COOL--DOWN PERIOD THE UNIT WILL AUTOMATICALLY
SHUT DOWN AND RETURN TO THE STANDBY MODE AS IN 4.4 A.
5. OPERATION SEQUENCE -- MANUAL MODE
WHEN THE SELECTOR SWITCH INSIDE THE ASSC BOX IS TURNED TO THE ”MANUAL”
POSITION ALL AUTOMATIC FUNCTIONS WILL BE DISABLED. THE COMPRESSOR
MUST BE ABLE TO BE OPERATED MANUALLY FROM THE COMPRESSORS MAIN
CONTROL PANEL. THE COMPRESSOR MUST SHUT DOWN IMMEDIATELY IF, WHILE
COMPRESSOR IS RUNNING IN AUTOMATIC MODE, THE SELECTOR SWITCH IS
SWITCHED TO MANUAL OR OFF. IF THE ON/OFF SWITCH ON THE COMPRESSORS
MAIN CONTROL PANEL IS TURNED ”OFF” THE UNIT WILL IMMEDIATELY SHUT DOWN.
6. OPERATION SEQUENCE -- OFF MODE
WHEN THE SELECTOR SWITCH INSIDE THE ASSC BOX IS TURNED TO THE ”OFF”
POSITION DURING ANY MODE OF OPERATION, THE UNIT WILL IMMEDIATELY SHUT
DOWN. IF THE SWITCH ON THE COMPRESSORS MAIN CONTROL PANEL IS TURNED
”OFF”, THE UNIT WILL ALSO IMMEDIATELY SHUT DOWN.
7. OUTPUT SPECIFICATIONS:
ALARM 24 VDC, 0.5 AMPERE
UNLOADER COMPRESSOR
START/RUN VALVE
STARTER AUXILIARY RELAY
ETHER INJECTION VALVE
HEATER DRY CONTACT
AUTO MODE LIGHT
24 VDC, 10 AMPERES
24 VDC, 2 AMPERES
24 VDC, 2 AMPERES
24 VDC, 2 AMPERES
NO, 2 AMPERES
24 VDC, 0.5 AMPERES
8 LABEL WIRE TERMINATIONS AS #48 AND #49.
9 MAGNETIC PICKUP INPUT VOLTAGE REQUIRED: 1.8 VRMS MINIMUM.
Book 35393560 (12/03) -- 132 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AUTOSTART / STOP CONTROL
MODEL NO.
DATE/REV:
METEOR
MANUAL NO.
AUTOS--4B 1--00/A
2
1
ITEM
3
2
6
5
4
11
10
9
8
7
1
QTY
1
1
31
1
31
1
4
1
2
2
INSTALLATION
TERM, RING #8 FULL INSUL
BOX, WEATHERPROOF
& OPERATION MANUAL
TERM, MALE .25 SPADE FULL INSUL
TERM, FEM .25 SPADE FULL INSUL
PIN, CONTACT
CONNECTOR, CHASSIS
SOCKET, CONTACT 18--16 AWG
CONNECTOR, PANEL
ALARM
NEMA 12 ENCLOSURE 8X10X4
DESCRIPTION
PARTS LIST
ALARM LOCATION TO BE
APPROXIMATELY AS SHOWN
--
--
36774818
35306141
36844520
0460--202--16141
HDP24--24--31PT
0462--201--16141
HDP26--24--31ST
36773109
PART NO.
--
4.12
14.37
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
--
--
MFG
--
--
--
--
--
2/A5
2/D7
2/C8
SHT/Z
2/B3
2/B4
2/B6
--
2/C4--C6
2/D4
2/A5--B4
2/A4--B4
9
.32
10.24
11.50
10.74
1
2.00
6.00
8.24
2.25
COMPRESSOR INTERFACE
PIGTAIL AND CUSTOMER
CONNECTION IN THIS AREA
60.0
GND
6X .31
2X 10
AUTO MODE
LIGHT
41
48
2X 2.0
62.0
60.0
10.0
60.O
2X 5.0
2X 2.0
48
49
CUSTOMER CONNECTION
8
RPT.QTY
7
RPT.QTY
8
2X 12.0
6
10 2X
MAGNETIC PICKUP 9
4.26
P1A
CONNECTOR
4
9.5
J1A
5
3
8
2X 4.5
54 55
S 16
LOAD SWITCH
7
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP
AUTOSTART / STOP CONTROL
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--5 1--00/A
Book 35393560 (12/03) -- 133 --
Book 35393560 (12/03) -- 134 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
DESCRIPTION
1--00 WAP
AUTOSTART / STOP CONTROL
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--6 1--00/A
NOTES:
1. INTERPRET DIMENSIONING AND TOLERANCING
IAW ASME Y14.5M--1994.
2 MANUFACTURER: AMP
3 MANUFACTURER: PACKARD
4. HARNESS TO MEET TOLERANCES PER I--R 35387968.
5. HARNESS SHALL BE TAPED AT ALL BREAKOUTS.
6. COMPLETED HARNESS TO BE TAGGED WITH PART NO.,
LATEST E/C NO., MFG AND DATE.
7. HEAT SHRINK TUBING SHALL BE APPLIED TO ALL
UNINSULATED TERMINALS.
8 WIRE: TYPE GXL STRANDED WIRE. MEETS
OR EXCEEDS SAE J1128 SPEC, LATEST REVISION.
9. ALL CRIMP TERMINATIONS SHALL MEET THE PULL
TEST OR OTHER TEST SPECIFICATIONS OF THE
TERMINAL MANUFACTURER. ENSURE THAT NO
LOOSE WIRE STRANDS REMAIN AT TERMINAL
AFTER CRIMPING.
10. VISUALLY INSPECT EACH WIRE AND REJECT ANY
WITH DAMAGE TO THE INSULATION SUCH AS CUTS
OR ABRAIDED AREAS.
11. TEST EACH HARNESS USING STANDARD MEASURING
AND TEST EQUIPMENT.
A. CONTINUITY: EACH WIRE TERMINATION TO IT’S
OPPOSITE END TERMINATION PER THE WIRE TABLE.
1
WIRE NO.
3
2
5
4
WIRE
14
14
14
14
14
AWG
RED
BRN
BRN
GRY
BRN
COLOR
C1
K1--85
K1--87A
K1--86
K1--30
REF
FROM
2
ITEM
2
2
5
2
1
ITEM
3
2
6
5
4
A/R
2
1
2
4
1
QTY
CONVOLUTED TUBING
TERMINAL, .25 RING
TERMINAL, #10 RING
TERMINAL, .50 RING
TERMINAL, FEMALE
CONNECTOR RELAY, SEALED 5 WAY
DESCRIPTION
PARTS LIST
Book 35393560 (12/03)
B1
B2
C2
F1
B2
REF
TO
3
W/WIRE 1
3
ITEM
5
4
R--68235
34124
34123
35135
12066614
12077993
PART NO.
COMMENTS
3
3
MATL
2
2
3
2 C1,C2
F1
B1,B2
K1
K1
SHT/Z
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP BATTERY CHARGER HARNESS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--7A 1--00/A
-- 135 --
1
2
2
1
Book 35393560 (12/03)
4
1
4
1
-- 136 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP BATTERY CHARGER HARNESS
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--7B 1--00/A
WHT RED/ WHT RED/ WHT RED/
BLK RED/
LU DKB
BLK RED/ BLK RED/
BRN
BRN
ORN LU/ DKB
ED YEL/R
K YEL/BL
ED YEL/R
/YEL BLU DK L YE LU/ DKB
RED E-ABL YC BATTER
RED
D/YEL RE
RED
U YEL/BL
RED RED
GRN LU/ DKB
Book 35393560 (12/03) -- 137 --
1--00
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
WAP
DESCRIPTION
AUTOSTART / STOP WIRING DIAGRAM
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--8 1--00/A
VIO
PNK PNK
Book 35393560 (12/03)
VIO
RED
VIO
HT VIO/W
BRN/WHT BRN/WHT
BRN
BLU/GRN LT
BRN
HT GRY
BRN
BRN
BRN
BRN
BLK BLU/ LT
BRN
LK YEL/B
-- 138 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY:
DESCRIPTION
1--00 WAP
AUTOSTART / STOP WIRING DIAGRAM
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--9 1--00/A
VIO/WHT
VIO
RESISTOR
R1
RESISTOR
R2
RESISTOR
R3
RESISTOR
R4
B
P1--17
GAGE
LIGHT
DS3
G
FUEL
LEVEL
GAGE
M3
GAGE
LIGHT
DS4
COMPR
TEMP
GAGE
M8
G
P1--18
GAGE
LIGHT
DS5
ENGINE
TEMP
GAGE
M4
G
P1--19
GAGE
LIGHT
DS6
G
VOLT
METER
M7
GAGE
LIGHT
DS7
ENGINE OIL
PRESS
GAGE
M2
G
P1--22
COMPR
TEMP
SENDER
RT1
ENGINE
TEMP
SENDER
RT2
ENGINE
OIL PRESS
SENDER
RP1
Book 35393560 (12/03) -- 139 --
INGERSOLL--RAND COMPANY
PORTABLE COMPRESSOR DIVISION
DATE/DWN BY: DESCRIPTION
1--00 WAP AUTOSTART / STOP WIRING DIAGRAM
MODEL NO.
MANUAL NO.
DATE/REV:
METEOR AUTOS--10 1--00/A
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Key Features
- Powerful diesel engine
- Two-stage air compressor with intercooler
- Maximum pressure of 125 psi
- Flow rate of 935 cfm
- Rugged construction
- Reliable performance
- Automatic shutdown system
- Low-oil pressure sensor