Ingersoll-Rand 25/300 XHP1070DWCAT Operating & Maintenance Manual

Operating & Maintenance Manual
Compressor Models
25/300
XHP1070AWCAT
XHP1070DWCAT
25/330
XHP1170WCAT
XHP1170BWCAT
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.
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
Book 22481881 (12/05)
Revised (10-12)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
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.
Foreword
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Operation & Maintenance Manual
Foreword
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:
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Foreword
25/330
XHP1070AWCAT
XHP1070DWCAT
22481881
Operation & Maintenance Manual
25/300
XHP1170WCAT
XHP1170BWCAT
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Operation & Maintenance Manual
Foreword
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:
•
of good quality, procured from a reputable manufacturer and, wherever possible, be
of a type approved by Ingersoll-Rand.
•
clearly rated for a pressure at least equal to the machine maximum allowable working
pressure.
•
compatible with the compressor lubricant/coolant.
•
accompanied with instructions for safe installation, operation and maintenance.
Details of approved equipment 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, IngersollRand 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.
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Foreword
Operation & Maintenance Manual
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 can 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.
Before starting the compressor, this manual and instructions should be carefully read to obtain
a thorough knowledge of the duties to be performed. Please take pride in the compressor,
keep it clean, and in good mechanical condition.
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Foreword
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TABLE OF CONTENTS
Manual-Name
TITLE
PAGE
SECTION 1 - INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
HOW THIS MANUAL IS ORGANIZED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Where To Find Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
DANGER, WARNING, CAUTION, NOTICE and NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURE WHEN RECEIVING THE T3W WATERWELL DRILL . . . . . . . . . . . . . . . . . .
IDENTIFICATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T3W WATERWELL DRILL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
1-5
1-6
1-7
1-8
1-9
1-10
T3W WATERWELL DRILL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
DERRICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
OPERATORS CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SERVICEABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
STANDARD FEATURES ON T3W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
DRILL LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
SECTION 2 - SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 - SAFETY AND HEALTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
GENERAL SAFETY AND HEALTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety And Health Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 - SAFETY PRECAUTIONS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
DRILL APPLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
PERSONNEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
GENERAL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
GENERAL RULES FOR INGERSOLL-RAND DRILLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
PRE-START INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
OPERATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
WARNING OF SPECIAL DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
1-1
TABLE OF CONTENTS
Manual-Name
TITLE
PAGE
INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 - INSTRUMENTS AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
T3W INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
UPPER CONSOLE, 900/350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
UPPER CONSOLE, 1070/350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
MIDDLE CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
LOWER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
UNDER CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
HELPER'S CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
IN/OUT BOX ACTUATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
SERVICE PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
RECEIVER OIL LEVEL GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
HYDRAULIC TANK GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
FUEL TANK GAUGE AND FILLER CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
SECTION 6 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 - SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 - MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3 - REFILL CAPACITIES AND SUBSTANCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
FILTER ELEMENTS AND KITS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
FLUID CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
1-2
Section A - Safety
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Safety
Safety
SAFETY PRECAUTIONS
General Information
Ensure that the operator reads and
understands the decals and consults the
manuals before maintenance or operation.
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.
Ensure that the Operation and Maintenance
manual, and the manual holder if equipped,
are not removed permanently from the
machine.
2
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.
Compressed air must not be used for a feed
to any form of breathing apparatus or mask.
Ensure that maintenance personnel are
adequately trained, competent and have
read the manuals.
The discharged air contains a very small
percentage of compressor lubricating oil and
care should be taken to ensure that
downstream equipment is compatible.
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.
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.
When using compressed air, always use
appropriate personal protective equipment.
All pressure containing parts, especially
flexible hoses and their couplings, must be
regularly inspected, be free from defects and
be replaced according to the Manual
instructions.
Avoid bodily contact with compressed air.
Never operate unit without first observing all
safety warnings and carefully reading the
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Safety
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.
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.
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Operation & Maintenance Manual
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.
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Operation & Maintenance Manual
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.
4
Safety
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.
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Operation & Maintenance Manual
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 your supervisor.
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Safety
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Safety
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Operation & Maintenance Manual
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Operation & Maintenance Manual
Safety
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 your
supervisor.
!
DANGER
Indicates the presence of a hazard which WILL cause
serious injury, death or property damage, if ignored.
(Red Background)
!
WARNING
Indicates the presence of a hazard which CAN cause
serious injury, death or property damage, if ignored.
(Orange Background)
!
CAUTION
Indicates the presence of a hazard which WILL or can
cause injury or property damage, if ignored.
(Yellow Background)
NOTICE
Indicates important set-up, operating or maintenance
information.
(Blue Background)
8
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Safety
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Section B - Warranty
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Operation & Maintenance Manual
Warranty
Warranty
Ingersoll-Rand, through its distributors, warrants to the initial user that each portable air
compressor manufactured by it, will be free of defects in material and workmanship for a
period of the earlier of twelve (12) months from shipment to or the accumulation of 2,000 hours
of service by the initial user.
Portable compressor airends will be free of defects in material and workmanship for a period
of the earlier of twenty four months from shipment to or the accumulation of 4,000 hours of
service by the initial user. The warranty against defects will include replacement of the
complete airend, provided the original airend is returned assembled and unopened.
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.
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 warranty does not apply to failures occurring as a result of abuse; misuse, negligent
repairs, corrosion, erosion and normal wear and tear, alterations or modifications made to the
product without express written consent of Ingersoll-Rand; or failure to follow the
recommended operating practices and maintenance procedures as provided in the product’s
operating and maintenance publications.
Accessories or equipment furnished by Ingersoll-Rand, but manufactured by others, including,
but not limited to, engines, 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.
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GENERAL WARRANTY INFORMATION
GENERAL WARRANTY
Portable Compressor
Portable Genset 8kW, 11KW,
20KVA thru 575KVA
Portable Genset 3.5KW thru
7.0KW and 10KW
Light Tower
Extended Coverage
Package
1 year/2000 hrs
Airend
2 yrs/4000 hrs
5 yrs/10,000 hrs
Limited warranty, major components
(refer to operator’s manual).
Package
1 yr/2000 hrs
None
Generator
2 yrs/4000 hrs
None
Package
1 yr/2000 hrs (parts only)
None
Generator
1 yr/2000 hrs (parts only)
None
Package
1 yr/2000 hrs
Generator
1 yr/2000 hrs
2 years/4000 hours, for Lightsource
introduced 8/16/99.
ENGINES
CATERPILLAR
Months Hours
Extended Coverage
12
unlimited Available at dealer
CUMMINS
24
2000
Major components 3 yrs/10,000 hrs Available at
dealer
JOHN DEERE (in compressors)
24
2000
5 yrs/5000 hrs using OEM fluids and filters with
$250 deductible
(in generators as of 1/1/01)
24
2000
2 yrs/4000 hrs using IR fluids and filters
DEUTZ
24
2000
Available at dealer
INGERSOLL-RAND
24
4000
5 yrs/10,000 hrs when using genuine Ingersoll-Rand
fluids and parts. Refer to operator’s manual.
KUBOTA (North America only)
24
2000
Major components 36 mo/3000 hrs (parts only)
(Western Europe & Oceania)
24
2000
None
(Central & South America, Asia, Middle East & Africa) 12
1000
None
MITSUBISHI
24
2000
2 yrs/4000 hrs using IR fluids and filters
VOLVO
24
2000
2 yrs/4000 hrs using IR fluids and filters
HONDA
12
unlimited None
VANGUARD
24
unlimited None
PARTS
Ingersoll-Rand
Months Hours
Coverage
6
Parts Only
No Limit
AIREND EXCHANGE
Airend
Months Hours
Extended Coverage
12
2 yrs/4000 hrs - available from IR.
2000
NOTE: Actual warranty times may change. Consult the manufacturer’s
warranty policy as shipped with each new product.
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Operation & Maintenance Manual
Warranty
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.
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Selling Distributor
Servicing Distributor
WARRANTY REGISTRATION
Name____________________
Name ____________________
Owner/User Name__________
Address __________________
Address __________________
Address __________________
City _____________________
City _____________________
City _____________________
County ___________________
County ___________________
County ___________________
State ____________________
State ____________________
State ____________________
Zip code__________________
Zip code__________________
Zip code__________________
Telephone ________________
Telephone ________________
Telephone ________________
Complete the Applicable Blocks
Owner/User Type of Business (check one only)
Construction-Heavy
(highway, excavation, etc.)
Asphalt Contractor
Coal Mining
Other Mining
Construction-Light
(carpentry, plumbing,
pools, mason, etc.)
Government
(municipal, state, county, etc.)
Quarry
Shallow Oil & Gas
Rental (rental center,
rental fleet, etc.)
Building Contractor
Water well
Utility Company
(gas, electric, water, etc.)
Industrial
(plant use)
Other
specify __________________
Exploration
Utility Contractor
Model S/N
Unit S/N
Engine S/N
Date delivered
Unit-Hours
Airend S/N
Truck S/N
Truck Engine S/N
SERVICING DISTRIBUTOR / USER ACKNOWLEDGEMENT
1.
The Purchaser has been instructed and/or has read the manual and understands proper
preventative maintenance, general operation and safety precautions.
2.
The warranty and limitation of liability has been reviewed and understood by the owner/user.
3.
In the event that this unit is to be used within a nuclear facility, the owner/user shall notify
Ingersoll-Rand of such use so that Ingersoll-Rand may arrange for appropriate nuclear liability
protection from the owner-licensee of the facility.
4.
Ingersoll-Rand reserves the right to make design changes or modifications of Ingersoll-Rand
products at anytime without incurring any obligation to make similar changes or modifications
on previously sold units.
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6
Warranty
22481881
Section C - Noise Emission
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Noise Emission
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:
1. Removal or rendering inoperative any of the following:
a. the engine exhaust system or parts thereof
b. the air intake system or parts thereof
c. enclosure or parts thereof
2. Removal of any of the following:
a. fan shroud
b. vibration mounts
c. sound absorption material
3. Operation of the compressor with any of the enclosure doors open.
Compressor Noise Emission Control Information
A. The removal or rendering inoperative, other than for the purpose 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.
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NOISE EMISSION CONTROL
MAINTENANCE LOG
COMPRESSOR MODEL_________________________
SERIAL NO. __________________________________
USER UNIT NO. _______________________________
UNIT IDENTIFICATION
Engine Make & Model:_________________
DEALER OR DISTRIBUTOR FROM
WHOM PURCHASED:
Serial No.:__________________________
__________________________________
Purchaser or Owner:__________________
__________________________________
Address: ___________________________
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.
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Operation & Maintenance Manual
Noise Emission
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.
MAINTENANCE SCHEDULE
ITEM
AREA
PERIOD
A.
Compressed Air Leaks
As Detected
B.
Safety and Control Systems
As Detected
C.
Acoustic Materials
Daily
D.
Fasteners
100 hours
E.
Enclosure Panels
100 hours
F.
Air Intake & Engine Exhaust
100 hours
G.
Cooling Systems
250 hours
H.
Isolation Mounts
250 hours
I.
Engine Operation
See Operator’s Manual
J.
Fuels & Lubricants
See Operator’s Manual
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.
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Operation & Maintenance Manual
D. Fasteners
All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be
inspected for looseness after each 100 hours of operation. They should be retightened,
repaired, or if missing, replaced immediately to prevent subsequent damage and noise
emission increase.
E. Enclosure Panels
Enclosure panels should also be inspected at 100 hour operational intervals. All panels that
are warped, punctured, torn, or otherwise deformed, such that their noise containment
function is reduced, should be repaired or replaced before the next operation interval. Doors,
access panels, and hatch closures especially, should be checked and adjusted at this time to
insure continuous seating between gasket or acoustic material and the mating frame.
F. Air Intake and Engine Exhaust
Engine and compressor air intake and engine exhaust systems should be inspected after each
100 hours of operation for loose, damaged, or deteriorated components. Repairs or
replacements should be made before the next period of use.
G. Cooling Systems
All components of the cooling system for engine water and compressor oil should be inspected
every 250 hours of use. Any discrepancies found should be corrected before placing the unit
back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at
all times during operation.
H. Isolation Mounts
Engine/airend isolation mounts should be inspected after each 250 hours of operation. Those
mounts with cracks or splits in the molded rubber, or with bent or broken bolts due to operation
or storage in severe environments, all should be replaced with equivalent parts.
I. Engine Operation
Inspect and maintain engine condition and operation as recommended in the manuals
supplied by the engine manufacturer.
J. Fuels and Lubricants
Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand
Company and Engine Manufacturer’s Operator and Maintenance Manuals.
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Noise Emission
MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY
ITEM NO.
6
DESCRIPTION OF WORK
HOURMETER MAINT/ INSPECT LOCATION
READING
DATE
CITY/ STATE
WORK DONE
BY (NAME)
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Section D - General Data
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General Data
General Data
UNIT MODELS ......................................... XHP1070 ............................................ 1170WCAT
Air Delivery - cfm (litres/sec) ..................... 1070 (505) .......................................... 1170 (553 )
COMPRESSOR
Rated Operating Pressure - psi (kPa)....................................................... 150-350 (1034-2412)
ENGINE (Diesel)
Manufacturer ............................................................................................................ Caterpillar
Model ................................................................................................................................. C15
Rated Horsepower at 1800 rpm ................. 475 ................................................................. 525
Electrical System .......................................................................................................... 24 VDC
Full Load Speed - rpm ...................................................................................................... 1800
No Load Speed - rpm ....................................................................................................... 1350
FLUID CAPACITIES - U.S. Gallons (litres)
Compressor Lubricant ................................................................................................. 55 (208)
Engine Lube (including filter) ...................................................................................... 10.5 (40)
Engine Coolant (Radiator) ....................................................................................... 15.2 (57.5)
Fuel Tank (Clean DIESEL fuel) ................................................................................. 230 (870)
UNITS MEASUREMENTS/WEIGHTS .......... HSRG ................... Wagon RG ............ LRG
Feet (Meters)
Overall Length ............................................... 24.3 (7.42) .............19.2 (5.85) ......... 19.2 (5.85)
Overall Height ................................................ 8.33 (2.54) ............ 8.33 (2.54) ........ 7.25 (2.21)
Overall Width ................................................. 7.5 (2.29) .............. 7.5 (2.29) ............. 7.5 (2.29)
Gross Weight - pounds (kg) .......................... 16,700 (7590) ....... 16,000 (7258) .15,300 (6940)
RUNNING GEAR
Tire Size ........................................................ 215/75R17.5H ...... 215/75R17.5H ............... NA
Towing Speed (Maximum) mph ..................... 65 ......................... 20 .................................. NA
Inflation Pressure .......................................... 125 psig ................ 125 psig ......................... NA
EXPENDABLE SERVICE PARTS
Part Number
Description
Where Used
Quantity
36860336 ....................... Filter, Oil .................................... Airend ................................2
36762250 ....................... Separator, Oil HP ...................... Airend ................................1
36864361 ....................... Filter, Inlet Primary .................... Engine & AE inlet ...............2
36864379 ....................... Filter, Inlet Secondary ................ Engine & AE inlet ...............2
35362235 ....................... Filter Oil, Engine ........................ C15 ....................................1
35362268 ....................... Filter Coolant, Engine ................ C15 ....................................1
22090534 ....................... Filter Fuel Engine-Primary ......... C15 ....................................1
22090526 ....................... Filter, Fuel Engine-Secondary ... C15 ....................................1
22090542 ....................... Filter Cup, Fuel - Primary .......... C15 ....................................1
!
CAUTION
Any departure from the specifications may make this equipment unsafe.
2
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Section E - Operating Instructions
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Operating Instructions
Operating Instructions
OPERATING CONTROLS AND INSTRUMENTS
The operating controls and instruments are arranged on the control panel as shown above. A
description of each panel device is as follows:
1. Panel Light: Illuminates instrument and control panel. Controlled by Switch 14.
2. High Compressor Temp: Fault indicator lamp. Indicates shutdown due to high
compressor temperature.
3. Low Radiator Coolant Level: Alarm indicator lamp. Indicates engine coolant
needs service.
4. Low Engine Oil Pressure: Fault indicator lamp. Indicates shutdown due to low
engine oil pressure.
5. Restricted Air Filter: Alarm indicator lamp. Indicates engine/compressor air
inlet filters need service.
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6. High Engine Coolant Temp: Fault indicator lamp. Indicates shutdown due to
high engine water temperature.
7. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to dirty
IQ air filters (if equipped).
8. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to low fuel level.
Lamp blinks at low fuel warning.
9. Compressor Malfunction: Fault indicator lamp. Indicates shutdown due to
compressor system fault. Refer to Fault Code List.
10. Low Battery Voltage: Alarm indicator lamp. Indicates battery or charging
system requires service.
11. Engine Malfunction: Engine Fault code. Refer to service card or engine
manual for codes and service requirements.
12. Malfunction Code (4 Digit): Compressor or engine fault. Refer to manual for
list of codes and service requirements.
13. Ether Inject: Injects a measured shot of ether for aid in cold weather starting
of engine.
!
CAUTION
Use Sparingly.
14. Panel Light Switch: Controls panel lamp # 1.
15. Pressure Control: Momentary contact switch. Allows engine to warm up at low
compressor pressure.
16. Main Power Control Switch: ON/OFF Start Switch.
17. Heaters: ON/OFF Power Switch for regulation and IQ heaters. Prevents freeze
up in cold weather.
18. Hourmeter: Indicates machine operating hours.
19. E-STOP: Emergency Stop Push Button (ESA units only). Push to stop, turn to
release.
20. Discharge Air Pressure Gage: Indicates pressure in receiver tank, normally
from 0 psi(kPa) to the rated pressure of the machine.
21. Engine Tachometer: Indicates engine speed in RPM from 0 when stopped to
full speed.
22. Engine Water Temp
23. Fuel Level Gauge: Not used on “S” Models.
24. Compressor Oil Temp
25. Engine Oil Pressure
26. Battery Voltage
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Operating Instructions
LIFTING UNIT
The lifting bail can be reached through the roof door only from inside the machine.
Use hoist or crane capable of lifting machine gross weight (see General Data).
BEFORE TOWING
Ensure that the tires, wheels and running gear are in good condition and secure.
Wagon Style Running Gear
•
Do not tow this unit in excess of 20 mph (32km/hr).
•
Use a tow vehicle whose towing capacity is greater than the gross weight of this unit.
(see general data).
•
Machine is not designed to be Highway Towable.
•
Set parking brake or chock wheels before disconnecting from towing vehicle.
•
Optional Parking Brake - located beside towbar on front of unit, if equipped.
•
Push lever down to apply brake.
High Speed Running Gear
•
Use jack to raise or lower lunette eye.
•
Use tow vehicle whose towing capacity is greater than the gross weight of this unit
(see general data).
•
Do not tow this unit in excess of 65 mph.
•
Place wheel chocks under tires before disconnecting from towing vehicle.
•
When raising or lowering lunette eye, always stand to one side.
Wheel Chock - HSRG
— Located inside of front towbar
— Secure unit with chocks before disconnecting drawbar from tow vehicle.
SETTING UP (ALL UNITS)
Place the unit in an open, well-ventilated area. Position as level as possible. The design of
these units permits a maximum 10 degree limit on out-of-level operation.
Chock wheels or set parking brake.
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Operation & Maintenance Manual
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.
!
WARNING
Do not connect the air discharge on this unit onto a common header with
any other unit of any description, or any other source of compressed air,
without first making sure a check-valve is used between the header and
the unit. If this unit is connected in parallel with another unit of higher
discharge pressure and capacity, a safety hazard could occur in a backflow condition.
!
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).
Air hose restraining cable installation:
Secure hose restraining cable at each end to prevent accidental hose whipping. At the
machine-side of the air hose, install and secure one end of the hose restraining cable on the
3” nipple on the inlet side of the 3” service valve. Install the other end of the hose restraining
cable over the main hose connector.
Install suitable 3” air hose between service valve on unit and point of air use. The air hose must
be rated for outdoor use and for pressurized air service. Minimum rating is 250°F (121°C) and
200 psig (HP) or 425 psig (XHP).
BEFORE STARTING
Open manual blowdown valve to ensure the separator has been vented of all pressure. Close
the valve before starting.
Inspect the complete installation including remote fuel lines (if any) and air hose routing and
connections.
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Operating Instructions
Check battery for proper connections and condition.
!
WARNING
Combustible gas can cause severe burns, blindness or death. Keep
sparks and open flame away from battery.
•
Check the compressor fluid level. Maintain the fluid level between bottom and
midway of the sight glass on the separator tank.
•
Check engine oil level. The proper level is labeled on the engine dipstick. Add oil
when required. Do not overfill.
•
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.
!
WARNING
Do not remove the cap from a HOT engine radiator. The sudden release
of pressure from a heated cooling system can result in a loss of coolant
and possible severe personal injury.
Check coolant to assure coolant level is at minimum level when the unit is cold.
Check engine coolant level on coolant recovery bottle on inside of rear door. Add coolant as
required.
NOTE: This machine will not allow engine starting if engine coolant is low.
!
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 Operator’s Section for fuel specifications.
NOTICE
To minimize condensation (water) in the fuel tank, it is recommended to
fill the tank at the end of each day.
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!
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 -
NOTICE
This unit is equipped with a battery disconnect switch which removes
power from the machine controller for long term storage. The switch is
located on the side of the engine near the battery.
This switch must be turned ON to provide power to the control panel for
starting this unit.
Close the air service valve to isolate the compressor from the compressed air tool until the
engine is warmed up.
1. Turn the keyswitch to the “ON” position (first position). All diagnostic lamps and
the LED display will light for two (2) seconds. All lamps should then go off and
ALTERNATOR NOT CHARGING and LOW ENGINE OIL PRESSURE lamps
will flash.
2. In freezing weather (below 32°F/0°C), 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.
3. When the keyswitch is turned to “START” the engine starter will be engaged.
Do not operate the engine starter motor for more than ten (10) seconds
without allowing at least one minute cooling time between start attempts.
!
CAUTION
Ether is an extremely volatile, high flammable gas. Use Sparingly! If too
much is injected, the uncontrolled explosion may result in costly damage
to the engine.
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Operating Instructions
4. In cold weather, as required, press the ETHER INJECT button once or twice
only while the engine is cranking. This injects a measured amount of ETHER
to the engine.
5. Following a successful start, the engine will accelerate to 1200 rpm initially,
then 1500 rpm for warm-up. Compressor discharge pressure will be maintained
at 60 psi during warm-up. After warm-up, rpm will maintain 1200 rpm idle.
6. Press the LOAD button. The engine will increase speed up to 1800 rpm until
the pressure reaches the desired set point.
After the engine has warmed up, open the service air valve to supply air to compressed air tool.
NORMAL OPERATION
The Operator may observe and monitor operating parameters using the gages on the panel.
In the event the machine controller detects a parameter outside normal operating limits, the
unit will shutdown.
In the event the machine controller detects a parameter at a dangerously high or low level, the
machine will be automatically be stopped with the cause of the SHUTDOWN shown on the
diagnostic lights and display.
STOPPING
•
Close air service valve(s).
•
Allow the unit to run at “IDLE” for 3 to 5 minutes to reduce the engine temperatures.
•
Turn the keyswitch to the “OFF” position.
NOTICE
Failure to allow turbo cool down prior to stopping can cause
turbocharger damage.
!
CAUTION
Machines with EMERGENCY STOP BUTTON - Use the Emergency Stop
Button only for emergency conditions. Do not use for normal machine
stopping. Button must be reset before starting can be accomplished.
NOTICE
Once the engine stops, the automatic blowdown valve will relieve
pressure from the separator tank.
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!
WARNING
Even after pressure is relieved from the piping system, any air supply line
from the compressor to a tool or machine could remain under pressure
and cause 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.
!
CAUTION
Never allow the unit to sit stopped with pressure in the receiver-separator
system. As a precaution, open the service valve.
IQ System
The optional 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, highefficiency 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.
A low ambient feature of 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 control orifice 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.
One path allows Standard Operation, which bypasses the IQ System, and delivers air quality
equivalent to a standard oil-flooded portable compressor.
If the IQ System is enabled by proper setting of the selector valve, the compressed air first
enters the aftercooler.
The aftercooler is cooled by the incoming compressor package air, which is controlled by
movable louvers mounted on the aftercooler. At most conditions, the louvers are fully open,
and maximum after cooling is available. The compressed air and condensate (water with a
small amount of compressor lubricant) exits the aftercooler and enters the moisture separator,
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Operating Instructions
where most of the condensate is removed. The compressed air then flows through two stages
of filtration, where the aerosol water and oil is removed down to approximately 0.01 ppm, and
all particulates are removed down to 0.01 micron.
At the bottom of the moisture separator and both filters are strainers and constant-bleed
orifices, which are sized to allow the maximum flow of condensate while minimizing
compressed air loss.
The condensate lines are then piped together, and the condensate is injected at a single point
into the engine exhaust piping. The compressed air then travels through the minimum
pressure valve, and out through the service air valve. The air pressure gauge on the
instrument panel indicates the pressure inside the separator tank. 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.
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Operating Instructions
Operation & Maintenance Manual
!
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.
Low Ambient Option Operation
When the ambient temperature falls to the point that the aftercooler outlet temperature is
approaching 45°F, 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
inside the control panel, and will shut down the compressor if restriction exceeds
recommended values.
Weekly Maintenance:
•
Remove Y-strainer screens at the bottom of the moisture separator and both filters
and clean out any residue.
•
Verify that the orifices below the Y-strainers are not clogged.
•
Verify that the piping from the orifice purge points to the exhaust system is not
clogged.
Confirm that water and air are being purged by loosening the condensate drain line fitting at
the muffler. Line is open if air and water escape.
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Operation & Maintenance Manual
!
Operating Instructions
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.
Filter Replacement
•
With engine stopped, ensure pressure is relieved from air system.
•
Remove all wires and hoses connected to drains on bottom of each filter housing.
Inspect fittings and hoses for any blockage. Clean if necessary.
•
Using a chain wrench or similar tool, loosen the housing. The housing should be
removed by hand after loosening, taking care to prevent the housing from falling to
the floor panel.
•
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.
12
•
Put a small amount of petroleum jelly or other non-synthetic grease on the element
o-ring to aid installation into the filter head.
•
Replace housing making sure to not overtighten.
•
Repeat the above procedure on the remaining filter element.
•
Reconnect all wires and hoses to drains on bottom of each filter housing.
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Operating Instructions
Operation & Maintenance Manual
SPEED AND PRESSURE REGULATION
Adjustment Instructions
The operating pressure of this unit was set at the factory to the maximum rating (at full speed).
See General Data. However, this pressure may be reset down to 150 psi (1050 kPa).
Normally, regulation requires no adjusting; but if proper adjustment is lost, proceed as follows:
1. WITH UNIT STOPPED, loosen nut (E) to relax spring (G).
2. Loosen nut (H). Turn rod (L) in Air Cylinder (AC) until approximately 3/4 inch
(20 mm) between nut (H) and flats on rod (L).
3. Turn rod (L) One round into rod end bearing. Tighten nut (H). Rotate butterfly
shaft/lever (C), open and close, several times to assure that linkage is not
binding.
4. With air cylinder rod (L) fully extended, take slack out of spring (G) by moving
nuts (E) and (F). Tighten nuts.
5. Start unit and allow to warm up for 3 to 5 minutes.
6. Push “Service Air” button on control panel.
7. With service air valve closed, adjust pressure regulator (PR) to rated pressure
(350 psi) plus 10 psi (70 kPa) as follows:
8. Loosen locknut (M) counterclockwise;. Turn adjustment cap (N) clockwise to
increase pressure, counterclockwise to decrease pressure.
9. Open service air valve and observe full load engine speed (*). Adjust regulator
to give rated operating pressure (*). Tighten locknut (M).
10. Close and slowly open service air valve. If engine speed surges, increase
tension on spring (G) by moving nuts (E) and (F).
11. To regulate to any pressure between 150 psi (1050 kPa) and maximum rating
(350 psi), make adjustments at the pressure regulator.
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14
Operating Instructions
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Section F - Maintenance
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Operation & Maintenance Manual
Maintenance
Maintenance
GENERAL
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.
•
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 extreme 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.
NOTE: Disregard any maintenance pertaining to components not
provided on your machine.
CONTAINMENT BASE
This unit uses a containment base large enough to hold the fluid contents of the engine oil,
coolant, fuel and compressor oil systems.
Drain plugs are located at strategic positions in this base to drain accumulated fluids and also
to allow access to system drain plugs in the fuel tanks and compressor oil reservoir for
flushing.
A central drain system is provided for normal service of engine, engine coolant, fuel, and
compressor fluid.
The containment base should be drained and flushed monthly or following any fluid discharge
into the base.
SCHEDULED MAINTENANCE
The maintenance schedule is based on normal operation of the unit. In the event unusual
environmental operating conditions exist, the schedule should be adjusted accordingly.
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COMPRESSOR FLUID LEVEL
Check the compressor fluid level daily. Check when the machine is not operating. Maintain the
fluid level between bottom and midway of the sight glass.
COMPRESSOR FLUID CHANGE
This machine was factory filled with an initial supply of Ingersoll-Rand fluid sufficient to allow
operation of the unit for approximately 6 months or 1000 hours, whichever comes first.
NOTICE
Some fluid 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. Do NOT mix
fluids 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.
Different fluids may have different carryover characteristics resulting in
more fluid being transferred downstream.
!
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.
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.
Operate the machine to circulate the oil. Check the oil level. Adjust as required.
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.
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Operation & Maintenance Manual
Maintenance
By continued use of Ingersoll-Rand compressor fluids and filters, optional warranty will be
extended for the base airend (rotors, housings, gears and bearings) when substantiated with
proof of conformance to recommended maintenance intervals and purchase of OEM IngersollRand filters and fluids.
Optional Warranty
The earlier of 60 months from shipment to, or the accumulation of 10,000 hours of service by
the initial user. The optional warranty is limited to defects in major components (rotors,
housings and bearings), and is automatically available to the original user when he meets the
following two conditions:
1. Submissions of proof that Ingersoll-Rand fluid, filters and separators have been
used. Refer to the Operation and Parts manual for the correct fluids, filters and
separator elements required.
2. Submission of proof that maintenance intervals have been followed.
The compressor fluid must be replaced every 1000 hours of operation or six (6) months,
whichever comes first.
Refer to the fluids and lubricants chart for ambient temperature ranges and specifications, in
the lubrication section of this manual.
NOTICE
The compressor oil filter must be replaced every 500 hours of operation.
To service the oil filters:
!
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.
1. Open the service air valve(s) to ensure that system is relieved of all pressure.
Close the valve(s).
2. Rotate filter elements counterclockwise to remove it from the filter housing.
Inspect the filter element and then discard.
NOTE: 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.
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Maintenance
Operation & Maintenance Manual
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 rotating clockwise until gasket makes initial contact. Tighten
an additional 1/2 to 3/4 turn.
6. Start unit and check for leaks before placing unit back into service.
AIR FILTERS
This unit is equipped with an AIR FILTER RESTRICTED lamp on the instrument panel.
When the lamp is on, the engine and airend filters should be replaced.
Each week, 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 filter housing will cause the
restriction indicators to be ineffective.
To service the air filters:
1. Loosen outer wing nut and remove with outer element. Remove wing nut and
inner (safety) element.
2. Inspect air filter housing for any condition that might cause a leak and correct
as necessary.
3. Wipe inside of air filter housing with a clean, damp cloth to remove any dirt
accumulation, especially in the area where the element seals against the
housing.
4. Check new filter closely for shipping damage.
5. Install new elements in the reverse order to the above. Tighten wing nuts firmly.
6. Inspect to ensure that the end cap seals tightly 360 degrees around the air filter
body.
The air filter system (housing and piping) should be inspected every month for any leakage
paths or inlet obstructions. Make sure the air filter mounting bolts and clamps are tight. Check
the air filter housing for dents or damage which could lead to a leak. Inspect the air transfer
tubing from the air filter to the compressor and the engine for holes. Make sure that all clamps
and flange joints are tight.
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Operation & Maintenance Manual
Maintenance
GAUGES
Inspect the gauges prior to start-up. During operation observe the gauges and any lamps for
proper functioning. Refer to Operating Controls for the normal readings. Refer to Section B for
Wedge Diagnostic Lamp testing.
FUEL TANK
Every precaution should be taken to ensure that only clean fuel is used.
Every six months the drain plugs should be removed from the tanks so that any sediment or
accumulated condensate may be drained.
BATTERY
Heavy-duty batteries were installed at the factory and should be inspected weekly. 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.
COMPRESSOR OIL AND FUEL COOLERS
Each month the coolers should be cleaned by directing compressed air which contains a
nonflammable solvent through the core of the coolers. This should remove the accumulation
of grease, oil and dirt.
!
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).
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.
Each month, inspect the radiator exterior for obstructions. If dirty, blow water or compressed
air containing a nonflammable solvent between the fins in a direction opposite the normal air
flow.
ENGINE CHARGE AIR COOLER
Each month, clean the cooler by directing compressed air with a nonflammable solvent
through the core of the cooler. This should remove the accumulation of grease, oil and dirt.
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Maintenance
Operation & Maintenance Manual
Ensure that the air connections do not leak. Leaks or loss of cooling will result in low engine
power.
HOSES
Each month, inspect all tubes and hoses for leaks and abrasion.
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 “pushin” design.
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 amark (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
Every 3 months, spot check several capscrews and nuts for proper torque. If any are found
loose, a more thorough inspection must be made. Take corrective action.
ENGINE COOLING FAN DRIVE
Inspect the cooling fan belt weekly.
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.
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Operation & Maintenance Manual
Maintenance
Field Repair of Texture Paint
1. The sheet metal should be washed and clean of foreign material and then
thoroughly dried.
2. Clean and remove all grease and wax from the area to be painted using
Duponts 3900S Cleaner prior to sanding.
3. Use 320 grit sanding paper to repair any scratches or defects necessary.
4. Scuff sand the entire area to be painted with a red scotch brite pad.
5. Wipe the area clean using Duponts 3900S.
6. Blow and tack the area to be painted.
7. Apply a smooth coat of Duponts 1854S Tuffcoat Primer to all bare metal areas
and allow to dry.
8. 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.
9. 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™ or Centari™
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.
Detailed engine maintenance is provided in the Operation and Maintenance Section of
manual.
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Maintenance
Operation & Maintenance Manual
MAINTENANCE SCHEDULE
These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty
or wet).
Daily Weekly Monthly
3 MOS.
500 hours
**Hydraulic Oil Level
C
Compressor Oil Level
6 MOS.
12 MOS.
1000 hours 2000 hours
R
C
Engine Oil Level
C
**Radiator Coolant Level
C
Gauges/Lamps
C
Air Cleaner Service Indicators
C
Fuel Tank (fill at end of day)
**Fuel/Water Separator
C
DRAIN
DRAIN
C
Air Cleaner Precleaner Dumps
C
Fan/Alternator Belts
C
Battery Connections/Electrolyte
C
**Tire Pressure and Surface
C
**Wheel Lug Nuts
C
Hoses (oil, air, intake, etc.)
C
Automatic Shutdown System
Test
C
Air Cleaner System
Visual
C
Compressor Oil Cooler
Exterior
C
CLEAN
**Engine Radiator
Exterior
C
CLEAN
Fasteners, Guards
C
Air Cleaner Elements
WI
** Fuel/Water Separator Element
R
*Compressor Oil Filter Element
R
*Compressor Oil
R
**Wheels (bearings, seals, etc.)
C
C
C
R
Engine Coolant
Test
Shutdown Switch Settings
Test
C
Scavenge Orifice & related parts
CLEAN
Oil Separator Element
R
**Lights (running, brake, & turn)
CBT
**Pintle Eye Bolts
CBT
Engine (oil changes, oil & fuel filters, etc.)
R
**Disregard if not appropriate for this particular machine.
R=replace, C=check (adjust if necessary), WI=OR when indicated, CBT = check before towing.
Refer to specific sections of the operator’s manual for more information.
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Operation & Maintenance Manual
10
Maintenance
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Section G - Lubrication
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Operation & Maintenance Manual
Lubrication
Lubrication
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.
NOTE: Fluids listed as “preferred” are
required for extended warranty.
Compressor oil carryover (oil consumption)
may be greater with the use of alternative
fluids.
Design Operating
Ambient
Pressure
Temperature
Specification
100 psi to 300 psi
-10°F to 125°F Preferred:
(-23°C to 52°C) IR Pro-Tec™
Alternate:
ISO Viscosity Grade 46
with rust and oxidation
inhibitors, designed for
air compressor service.
350 psi
-10°Fto 125°F Preferred:
(-23°C to 52°C) IR XHP 605
Alternate:
IR XHP405
ISO Viscosity Grade 68
Group 3 or 5 with rust and
oxidation inhibitors
65°Fto125°F designed for air
(-18°C to 52°C) compressor service.
Preferred:
XHP605
IR XHP1001
Preferred 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.
Ingersoll-Rand
1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Llitre)
Preferred Fluids
IR Pro-Tec™
2
36899698
36899706
36899714
36899722
IR XHP605
-
22252076
22252050
22252068
IR XHP1001
-
35612738
35300516
-
XHP405
-
22252126
22252100
22252118
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Section H - Trouble Shooting
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Trouble Shooting
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.
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.
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?
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.
NOTE: For trouble shooting electrical problems, refer to the Wiring
Diagram Schematic found in Parts List Section.
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Trouble Shooting
Operation & Maintenance Manual
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.
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.
Electrical/Electronic Troubleshooting
Refer to the Electrical/Electronic Service Manual for troubleshooting information and
diagnostic code descriptions.
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Operation & Maintenance Manual
Trouble Shooting
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
4
Low Fuel Level Shutdown
Defective Sensor
Malfunctioning Relay
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 fuel sender.
Replace sensor.
Replace relay.
Replace fuse.
See Trouble Shooting in Engine Manual.
See Complaint 10.
2. Won’t Start/Run:
Low Battery Voltage
Blown Fuse
Malfunctioning Start 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 Sensor
Malfunctioning Relay
Engine Malfunctioning
Airend Malfunctioning
Check electrolyte level. Check connections.
Replace fuse.
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 sensor.
Replace relay.
See Trouble Shooting in Engine Manual.
See Complaint 10.
3. High Engine Temperature
Broken Engine Fan Belt
*Ambient Temp. >115°F
Dirty Operating Conditions
Dirty Cooler
*Out of Level >15 degrees
Operating Pressure Too High
Recirculation of Cooling Air
Loose Wire Connection
Replace fan belt set.
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.
* : > = greater than, < = less than
4. Low Engine Oil Pressure
Corrective Action
22481881
Trouble Shooting
Low Oil Level
Out of Level >15 degrees
Wrong Lube Oil
Clogged Oil Filter Element(s)
Engine Malfunctioning
Loose Wire Connection.
5. Alternator Low Voltage
Loose or Broken Belts
Loose Wire Connection
Low Battery Voltage
Malfunctioning Alternator
Operation & Maintenance Manual
Add oil.
Relocate or reposition.
See Engine Oil Spec. Change oil.
Replace element(s).
See Trouble Shooting in Engine Manual.
Repair or replace.
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.
6. High Compressor Discharge Temperature:
Ambient Temp. > 115°F
Above spec limit.
Out of Level > 15 degrees
Relocate or reposition unit.
Low Oil Level
Add oil. Look for any leaks.
Wrong Lube Oil
Check spec in this manual.
Dirty Cooler
Clean exterior surfaces.
Dirty Operating Conditions
Move unit to cleaner environment.
Clogged Oil Filter Elements
Replace elements. Change oil.
Loose or Broken Belts
Tighten or replace belt set.
Operating Pressure Too High
Reduce pressure to spec.
Recirculation Of Cooling Air
Close side doors. Replace belly pan.
Malfunctioning Thermostat
Replace thermostat in bypass valve.
Malfunctioning Fan
Check fan belt tension. Tighten or replace belt set.
Defective Oil Cooler Relief Valve
Replace valve.
Defective Minimum Pressure Valve
Repair or replace valve.
Blocked or Restricted Oil Lines
Clean by flushing or replace.
Airend Malfunctioning
See Complaint 11, 12
7. Engine RPM Down:
Clogged Fuel Filter (primary)
Operating Pressure Too High
Dirty Air Filter
Wrong Air Filter Element
Engine Malfunctioning
Airend Malfunctioning
8. Excessive Vibration:
Rubber Mounts, Loose or Damaged
Defective Fan
Drive Coupling Defective
Engine Malfunctioning
Airend Malfunctioning
Engine idle speed too low.
9. Low CFM:
Dirty Air Filter
22481881
Replace primary filter. Replace final filter. Drain
tanks. Add CLEAN fuel.
Reduce pressure to spec limit.
Clean or replace elements.
Install correct element.
See Trouble Shooting in Engine Manual.
Refer to Factory.
Tighten or replace.
Replace fan.
Replace coupling.
See Trouble Shooting in Engine Manual.
See Complaint 11 and 12.
See Engine Manual.
Clean or replace elements.
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Operation & Maintenance Manual
6
Trouble Shooting
Incorrect Linkage Adjustment
Malfunctioning Inlet Unloader/Butterfly Valve
Wrong Air Filter Element
Make adjustment per Section 4.
Inspect valve. Make adjustment per Section 4.
Install correct element.
10. Short Air Cleaner Life:
Dirty Operating Conditions
Inadequate Element Cleaning
Incorrect Stopping Procedure
Wrong Air Filter Element
Move unit to cleaner environment.
Install new element.
Read procedure in this manual.
Install proper element.
11. Will Not Unload:
Malfunctioning Inlet Butterfly Valve
Ice in Regulation Lines/Orifice
Load Solenoid Leak
Plugged Vent Leak
Inspect valve fit. Re-adjust per Section 4.
Apply heat to line(s) and or orifice.
Replace load solenoid.
Clean and/or replace.
12. Safety Valve Relieves:
Operating Pressure Too High
Malfunctioning Inlet Unloader/Butterfly Valve
Defective Safety Valve
Unit Will Not Unload Fast Enough
Reduce pressure to spec limit.
Inspect valve fit. Readjust per Section 4.
Replace safety valve.
Apply heat to lines and/or orifice.
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Section I - Electrical
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Electrical
Electrical
WEDGE Controller
The WEDGE controller is the heart of the machine monitor and control system. It provides data
collection, alarming and control functions for compressor operations. It is a microcontroller
based unit with analog and digital inputs and outputs.
The WEDGE controller is attached to the back of the control panel. The LED annunciators are
part of the front panel of the WEDGE. They can be seen through the laminate on the front of
the control panel. The WEDGE is attached to the control panel with four #10 size nuts.
The first function of the WEDGE is to scan all analog and digital inputs at a fixed interval.
These inputs are scanned every 100 milliseconds. The analog values are then compared
against minimum and maximum values and an ALERT or SHUTDOWN is issued, if a value is
out of range. The various ALERTS and SHUTDOWNS are listed in section 7 of this manual.
The third function of the WEDGE controller is to communicate with the diesel engine via the
J1939 CAN network. The WEDGE provides the engine throttle setpoint (software versions 2.0
and greater) to the engine controller via the J1939 CAN Network and retrieves diagnostic
information from the engine.
Software versions under 2.0 use the frequency throttle to communicate with the engine. A
square wave frequency signal from 150 Hz to 375 Hz is sent from the WEDGE controller to
the engine controller. The signal is linear from 150 Hz at engine idle (1200 RPM) to 375 Hz at
maximum run speed (1800 RPM). The software version with frequency throttle does not
support engine diagnostics.
Figure 8-2 shows the signals between the engine ECM and the WEDGE ECM.
Sensors and Transducers
The electronics system contains sensors and transducers that are used to collect process data
from the compressor. The temperature sensors are thermistor devices. A change in
temperature causes a resistance change in the thermistor. This resistance change causes an
input voltage change to the WEDGE controller input and is interpreted as a temperature
change.
The electronics system also contains pressure transducers to measure process pressure
changes. These devices have an output signal of .45 VDC to 4.5 VDC, corresponding to 0 psi
and the maximum psi for a selected device. The maximum psi can be 100, 225, or 500 psi.
A5VDC excitation signal is provided to power the transducers. These are three wire devices:
excitation, signal and ground (return) connections.
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Operation & Maintenance Manual
Controller Outputs:
The WEDGE controller has three different types of outputs: frequency, pulse width modulated
(PWM) and 24 VDC digital (ON / OFF). The frequency out is used as a throttle signal for the
engine (software versions less than 2.0). The frequency signal is a 50% duty cycle square
wave at 24VDC, and varies from 150 Hz to 375 Hz.
The PWM signal is also used for engine throttle applications. It provides a duty cycle from 10%
to 90%, corresponding to 1200 to 1800 RPM engine speeds. Refer to the system diagrams to
determine which signal may be used.
The WEDGE controller provides 24 VDC digital outputs to control solenoids, DC heaters, etc.
These are 24 VDC ON and 0 VDC OFF. They are current limited and short circuit protected.
They may have a voltage level of .5 VDC to 1.4 VDC in the OFF state due to current leakage
of the darlington transistors in the output drivers.
Pressure Control
The discharge pressure is controlled by manipulating the engine speed and compressor inlet
valve position. The inlet valve position is controlled pneumatically and the engine speed
setpoint is determined by the WEDGE controller. The WEDGE measures the pneumatic
system regulation pressure and computes an engine speed setpoint. It sends this setpoint to
the electronically controlled engine, which controls engine speed to this setpoint.
Electronic Engine
The Viking machine family contains an emissions certified diesel engine. In order to meet the
emissions requirements, the engine has an electronic control system.
The control system handles all the monitor, alarm and control functions for the engine. The
WEDGE controller communicates with the engine controller over the J1939 CAN network.
The WEDGE controller sends throttle setpoints to the engine (software versions 2.0 and
greater) and receives diagnostic and run time data from the engine over the J1939 CAN
network. A frequency throttle interface with the engine is used for software versions earlier
than 2.0. Figure 8-2 shows the connections between the engine and WEDGE controller.
J1939 Data Link - The CAN network is a single pair shielded cable within the W1 main
harness. Figure 8-3 shows a layout of the CAN harness or backbone as it is referred to. The
termination resistors (Terminator) are important to prevent reflections on the transmission line
and must be in place for the network to function properly. The shield from the cable is
connected to the machine frame at the WEDGE controller end. It is very important that this
shield be connected and the connection be properly made to the frame.
The engine diagnostics connector is located on the left side of the engine at the engine ECM.
This is used to connect the engine manufacturers service tools to the CAN network. This
connector also provides 24 VDC power to these service tools.
There are two other CAN network nodes in the harness. One is for the Autostart option and
the other one is for future devices. Figure 8-3 shows these nodes.
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Operation & Maintenance Manual
Electrical
Electrical System
The electrical system consists of the wiring harnesses and associated electrical devices such
as relays, switches, lights, solenoids and alarm horns. The electrical system consists of the
wiring harnesses and associated electrical devices such as relays, switches, lights, solenoids
and alarm horn. There are two wiring harnesses in the Viking family of machines. They are as
follows:
54654918
W1 Chassis Main Wiring Harness
22108690
Control Panel Harness w/individual gages.
22060594
Control Panel Harness w/ 4 in one gages.
The schematic diagrams show the connections for these harnesses. Figure 8-1 is a system
diagram showing harness connection with devices and controllers.
The troubleshooting section includes information on how to make harness repairs and
information on the connectors used. The control panel harness is purchased with the entire
control panel assembly. It is not sold separately.
The electrical circuits are protected using ATC style fuses. A fuse should only be replaced with
one of the same rating. Replacing a fuse with one of a larger rating could lead to harness
damage. If a fault occurs and the circuit does not have the appropriate size fuse, wires could
be burned in the harness and damage other circuits.
When battery power is connected to the WEDGE by engaging the main power switch on the
unit control panel, it goes thru a start up sequence including a test of all lamps.
All diagnostic lamps and segments of the numeric display should be illuminated
simultaneously during the lamp test portion of WEDGE start up.
4
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Section J - Electrical Schematics
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Electrical Schematics
Electrical Schematics
2
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Electrical Schematics
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4
Electrical Schematics
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WORD INDEX
S
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Manual-Name
7-1
WORD INDEX
7-2
Manual-Name
©2004 Ingersoll-Rand Company, Printed in the USA
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