Ingersoll-Rand MHP825WCAT Operation & Maintenance Manual

Operation & Maintenance Manual
Compressor Models
XHP700WCAT
MHP825WCAT
VHP750WCAT
CODE: B
CODE: D
SHP750WCAT
CODE:
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 22560825 (2/05)
Revised (09-12)
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.
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE
PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Complete Machine Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Registration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Noise Emission Control Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A. Compressed Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B. Safety and Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C. Acoustic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D. Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
E. Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F. Air Intake and Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
G. Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
H. Isolation Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
I. Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
J. Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SAFETY SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine Starting Fluid (Ether) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
GENERAL INFORMATION - MSA (SRG/HRG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General Information – MSA (SRG/HRG). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sound Level Data (‘W’ model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Site Running Gear (SRG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High Speed Running Gear (HSRG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Prior to Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Operating Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wedge Diagnostic Display Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Caterpillar C–9 Engine
Diagnostic and Event Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Starting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inlet Heater/Wait to Start Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Emergency Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Re–Starting After an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Monitoring During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Maintenance Interval Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Protective Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Low Engine Fuel Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Compressor Oil Cooler and Engine Radiator Air Charge Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Air Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fuel Filter Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Charge Cooler Pipework:– . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Tyres/Tyre Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Running Gear/Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Engine Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Engine Lubricating Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Engine Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Compressor Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Running Gear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Speed and Pressure Regulation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Speed and Pressure Regulation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
MACHINE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Machine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Control System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
FAULT FINDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
IQ System Operating Instructions – 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
IQ System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
IQ System Operating Instructions – 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Low Ambient Option Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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PARTS ORDERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Markings and Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
How to Use Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
How to Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Airend Exchange Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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Foreword
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Operation & Maintenance Manual
Foreword
Foreword
The contents of this manual are considered to be proprietary and confidential to Ingersoll–
Rand and should not be reproduced without the prior written permission of Ingersoll–Rand.
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.
The design specification of this machine has been certified as complying with EC directives.
As a result:
(a) Any machine modifications are strictly prohibited, and will invalidate EC certification.
(b) This machine may be used in USA/Canada, when configured with components bearing the
appropriate certification. (Where ASME certification is valid).
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/lubricants/fluids other than those included within the Ingersoll–Rand
approved parts list may create hazardous conditions over which Ingersoll–Rand has no
control. Therefore Ingersoll–Rand cannot be held responsible for equipment in which non–
approved repair parts are installed.
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.
6
Foreword
Operation & Maintenance Manual
This machine has been designed and supplied for use only in the following specified
conditions and applications:
•
Compression of normal ambient air containing no known or detectable additional
gases, vapours or particles.
•
Operation within the ambient temperature range specified in the GENERAL
INFORMATION section of this manual.
The use of the machine in any of the situation types listed in table 1:–
a. Is not approved by Ingersoll–Rand,
b. May impair the safety of users and other persons, and
c. May prejudice any claims made against Ingersoll–Rand.
TABLE 1 – IMPROPER USES
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity checks.
Use of the machine outside the ambient temperature range
specified in the GENERAL INFORMATION SECTION of this manual.
Use of this machine in potentially explosive atmospheres, including situations
where flammable gases or vapours may be present.
Use of the machine fitted with non Ingersoll–Rand approved components/
lubricants/fluids.
Use of the machine with safety or control components missing or disabled.
Use of this machine in any underground application.
The company accepts no responsibility for errors in translation of this manual from the original
English version.
7
**Always use Ingersoll-Rand Replacement parts!**
8
Warranty
9
Operation & Maintenance Manual
Warranty
Warranty
Ingersoll–Rand Portable Compressor 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.
10
Warranty
Operation & Maintenance Manual
General Warranty Information
COMMENTS
PORTABLE COMPRESSOR PACKAGE
2.5kVA–8kVA
GENERATORS
AIREND
24 MONTHS/4,000
HOURS
ENGINE
SEE BELOW
PACKAGE
12 MONTHS/2,000
HOURS
ALTERNATOR
12 MONTHS/2,000
HOURS
ENGINE
LIGHT TOWER
12 MONTHS/2000
HOURS
CONTACT IR NETWORK
FOR WARRANTY (PARTS
ONLY NO LABOUR).
CONTACT IR NETWORK
FOR WARRANTY (PARTS
ONLY NO LABOUR).
SEE BELOW
PACKAGE
12 MONTHS/2,000
HOURS
ALTERNATOR
12 MONTHS/2,000
HOURS
ENGINE
COVERS CONTROLS,
SWITCHES, SHEET METAL,
RADIATOR, OIL COOLER,
RECEIVER, PIPEWORK,
ELECTRICAL CIRCUIT ETC.
60 MONTHS/10,000 HOURS.
EXTENDED LIMITED
WARRANTY AVAILABLE ON
MAJOR COMPONENTS.
REFER TO OPERATOR’S
MANUAL.
COVERS CONTROLS,
SWITCHES, SHEET METAL,
ELECTRICAL CIRCUIT ETC.
EXTENDED WARRANTY OF
24 MONTHS/4,000 HRS.
FOR LIGHTSOURCE
INTRODUCED
8/16/99.
SEE BELOW
11
Operation & Maintenance Manual
Warranty
ENGINES
MONTHS
CATERPILLAR
12
CUMMINS
24
PERKINS
12
COMMENTS
2,000
EXTENDED WARRANTY
PROVIDED VIA ENGINE
SUPPLIER’S OWN
APPROVED NETWORK AT
TIME OF PURCHASE.
UNLIMITED IF UNDER 500 HOURS IN
FIRST YEAR THEN BELOW
APPLIES.
24
1,000
ALL COMPONENTS
COVERED EXCLUDING
INJECTORS.
JOHN DEERE (IN COMPRESSORS)
24
2,000
5 YRS/5000 HRS USING OEM
FLUIDS AND FILTERS WITH
$250 DEDUCTABLE
(IN GENERATORS)
24
2,000
24 MONTHS/4,000 HRS.
AVAILABLE FROM IR WITH
USE OF GENUINE IR PARTS
AND OILS AT PRESCRIBED
SERVICE INTERVALS.
CONTACT IR NETWORK.
DEUTZ
12
HOURS
UNLIMITED EXTENDED WARRANTY
PROVIDED VIA ENGINE
SUPPLIER’S OWN
APPROVED NETWORK AT
TIME OF PURCHASE.
0 – 12
UNLIMITED ALL COMPONENTS
COVERED.
13 – 24
UNLIMITED MAJOR COMPONENTS
COVERED. FURTHER
EXTENDED WARRANTY ON
MAJOR COMPONENTS
PROVIDED VIA ENGINE
SUPPLIER’S OWN
APPROVED NETWORK AT
TIME OF PURCHASE.
INGERSOLL-RAND
24
4,000
EXTENDED WARRANTY OF
60 MONTHS/10,000 HRS.
WHEN USING GENUINE
INGERSOLL–RAND FLUIDS
AND PARTS ON MAJOR
COMPONENTS.
KUBOTA (North America only)
24
2,000
EXTENDED WARRANTY OF
36 MONTHS/3,000 HRS. ON
MAJOR COMPONENTS,
PARTS ONLY, AVAILABLE
FROM KUBOTA.
Warranty
Operation & Maintenance Manual
(Western Europe & Oceania)
24
2,000
NO EXTENDED WARRANTY
AVAILABLE.
(Central & South America, Asia, Middle
East & Africa)
12
1,000
NO EXTENDED WARRANTY
AVAILABLE.
MITSUBISHI
24
2,000
2 YRS/4,000 HRS USING IR
FLUIDS AND FILTERS
VOLVO
24
2,000
2 YRS/4,000 HRS USING IR
FLUIDS AND FILTERS
PARTS
MONTHS
INGERSOLL–RAND
6
HOURS
COMMENTS
UNLIMITED PARTS ONLY AVAILABLE FROM
IR NETWORK.
AIREND EXCHANGE
AIREND
MONTHS
HOURS
60
10,000
COMMENTS
24 MONTHS/4,000 HRS.
AVAILABLE FROM IR
NETWORK.
CONSTRUCTION TOOLS
CONSTRUCTION TOOLS
MONTHS
HOURS
12
N/A
COMMENTS
OPTIONAL 36 MONTHS
EXTENDED WARRANTY
AVAILABLE FROM IR. ALL
WARRANTY COVERS PARTS
ONLY REPLACEMENT.
NOTE: Actual warranty times may change.
Consult the Manufacturer’s warranty policy as shipped with each new
product.
13
Operation & Maintenance Manual
Warranty
Warranty Registration
For Units Sourced From Mocksville, USA
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.
Engine Registration:
I–R powered machines do not require separate engine registration.
John Deere requires a separate engine registration be completed and mailed direct to John
Deere.
Separate engine registration material is included with this literature package for John Deere
powered machines.
All other engine manufacturers do not require a separate engine registration.
You MUST present proof of in–service date at time of requesting engine warranty service.
14
Warranty
Operation & Maintenance Manual
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
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.
15
Operation & Maintenance Manual
16
Warranty
Noise Emission
17
Operation & Maintenance Manual
Noise Emission
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 a 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.(40FR204.58–1).
18
Noise Emission
Operation & Maintenance Manual
Introduction
The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for
Noise Emissions, applicable to Portable Air Compressors.
The purpose of this book is to provide (1) the Maintenance Performance Schedule 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.
19
Operation & Maintenance Manual
Noise Emission
D. Fasteners
All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be
inspected for looseness after each 100 hours of operation. They should be retightened,
repaired, or if missing, replaced immediately to prevent subsequent damage and noise
emission increase.
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 sealing 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.
20
Noise Emission
Operation & Maintenance Manual
MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY
ITEM NO.
DESCRIPTION OF WORK OR
COMMENTS
HOURMETER
READING
MAINT/
INSPECT DATE
LOCATION
CITY/STATE
WORK DONE
BY (NAME)
21
**Always use Ingersoll-Rand Replacement parts!**
22
Safety Symbols
23
Operation & Maintenance Manual
Safety Symbols
Safety Symbols
Look for these signs on machines manufactured in North America, which point out
potential hazards to the safety of you and others. Read and understand thoroughly.
Heed warnings and follow instructions. If you do not understand, inform your
supervisor.
!
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
(Blue Background)
24
Indicates important set-up, operating or maintenance
information.
Safety Symbols
Operation & Maintenance Manual
25
Operation & Maintenance Manual
26
Safety Symbols
Safety Symbols
Operation & Maintenance Manual
27
Operation & Maintenance Manual
Safety
General Information
Ensure that the operator reads and
understands the decals and consults the
manuals before maintenance or operation.
Ensure that the Operation and Maintenance
manual, and the manual holder, are not
removed permanently from the machine.
Ensure that maintenance personnel are
adequately trained, competent and have
read the Maintenance manuals.
Make sure that all protective covers are in
place and that the canopy/doors are closed
during operation.
The specification of this machine is such that
the machine is not suitable for use in
flammable gas risk areas. If such an
application is required then all local
regulations, codes of practice and site rules
must be observed. To ensure that the
machine can operate in a safe and reliable
manner, additional equipment such as gas
detection, exhaust spark arrestors, and
intake (shut-off) valves may be required,
dependent on local regulations or the degree
of risk involved.
A weekly visual check must be made on all
fasteners/fixing screws securing mechanical
parts. In particular, safety–related parts such
as coupling hitch, drawbar components,
road–wheels, and lifting bail should be
checked for total security.
All components which are loose, damaged or
unserviceable, must be rectified without
delay.
Compressed Air
Compressed air can be dangerous if
incorrectly handled. Before doing any work
on the unit, ensure that all pressure is vented
from the system and that the machine cannot
be started accidentally.
28
Safety Symbols
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 rated pressure.
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.
The discharged air contains a very small
percentage of compressor lubricating oil and
care should be taken to ensure that
downstream equipment is compatible.
If the discharged air is to be ultimately
released into a confined space, adequate
ventilation must be provided.
When using compressed air, always use
appropriate personal protective equipment.
All pressure containing parts, especially
flexible hoses and their couplings, must be
regularly inspected, be free from defects and
be replaced according to the Manual
instructions.
Avoid bodily contact with compressed air.
The safety valve located in the separator
tank must be checked periodically for correct
operation.
Materials
The following substances may be produced
during the operation of this machine:
•
brake lining dust
•
engine exhaust fumes
Safety Symbols
Operation & Maintenance Manual
Avoid Inhalation
and that connections are secure.
Ensure that adequate ventilation of the
cooling system and exhaust gases is
maintained at all times.
DO NOT ATTEMPT TO SLAVE START A
FROZEN BATTERY SINCE THIS MAY
CAUSE IT TO EXPLODE.
The following substances are used in the
manufacture of this machine and may be
hazardous to health if used incorrectly:
Radiator
•
anti-freeze
•
compressor lubricant
•
engine lubricant
•
preservative grease
•
rust preventative
•
diesel fuel
•
battery electrolyte
Avoid Ingestion, Skin Contact and
Inhalation of Fumes
Should compressor lubricant come into
contact with the eyes, then irrigate with water
for at least 5 minutes.
Should compressor lubricant come into
contact with the skin, then wash off
immediately.
Consult a physician if large amounts of
compressor lubricant are ingested.
Consult a physician if compressor lubricant is
inhaled.
Never give fluids or induce vomiting if the
patient is unconscious or having
convulsions.
Safety data sheets for compressor and
engine lubricants should be obtained from
the lubricant supplier.
Battery
Batteries contain corrosive liquid and
produce explosive gas. Do not expose to
naked lights. Always wear personal
protective clothing when handling. When
starting the machine from a slave battery
ensure that the correct polarity is observed
Hot engine coolant and steam can cause
injury. Ensure that the radiator filler cap is
removed with due care and attention.
Engine Starting Fluid (Ether)
Do not use ETHER.
Engines are fitted with inlet air heaters.
Avoid Ingestion, Inhalation, Hot Surfaces
and Naked Lights
Transport
When loading or transporting machines
ensure that the specified lifting and tie down
points are used.
When loading or transporting machines
ensure that the towing vehicle, its size,
weight, towing hitch and electrical supply are
all suitable to provide safe and stable towing
at speeds either, up to the legal maximum for
the country in which it is being towed or, as
specified for the machine model if lower than
the legal maximum.
Before towing the machine, ensure that:–
•
the tyres and towing hitch are in a
serviceable condition.
•
the canopy is secure.
•
all ancillary equipment is stored in a
safe and secure manner.
When parking always use the handbrake
and, if necessary, suitable wheel chocks.
29
**Always use Ingersoll-Rand Replacement parts!**
30
General Information - MSA (SRG/
HRG)
31
Operation & Maintenance Manual
General Information - MSA (SRG/HRG)
General Information – MSA (SRG/HRG)
32
General Information - MSA (SRG/HRG)
Operation & Maintenance Manual
33
Operation & Maintenance Manual
MODEL
General Information - MSA (SRG/HRG)
MHP825
SHP750
XHP700
VHP750
cfm
(m3/min)
825
(23,3)
750
(21,5)
700
(20,1)
750
(21,5)
Normal operating
discharge pressure.
psi
(bar)
175
(12)
250
(17)
300
(21)
200
(14)
Safety valve setting.
psi
(bar)
217
(15)
362
(25)
362
(25)
250
(17)
Whisperized (W)
operating ambient
temperature range.
°F
(°C)
14/115
(-10/+46)
14/115
(-10/+46)
14/115
(-10/+46)
14/115
(-10/+46)
14/122
(-10/+50)
14/122
(-10/+50)
14/122
(-10/+50)
14/122
(-10/+50)
248
(120)
248
(120)
248
(120)
248
(120)
COMPRESSOR
Actual free air delivery.
High Ambient (HA)
operating ambient
temperature range.
°F
(°C)
Maximum discharge
temperature.
°F
(°C)
COMPRESSOR
Cooling system.
Oil capacity.
Oil Injection
Gallons/
Litres
18.5
(70)
19.8
(75)
19.8
(75)
18.5
(70)
Maximum oil system
temperature.
°F
(°C)
248
(120)
248
(120)
248
(120)
248
(120)
Maximum oil system
pressure.
psi
(bar)
217
(15)
362
(25)
362
(25)
250
(17)
SEE
NOTE -1
Protec
Protec
Protec
Protec
MHP825
SHP750
XHP700
VHP750
LUBRICATING OIL
SPECIFICATION (for
the specified ambient
temperatures).
ENGINE
MODEL
Whisperized (W)
Engine Type
Displacement.
/litre
CAT
C–9
(9)
CAT
C–9
(9)
CAT
C–9
(9)
CAT
C–9
(9)
Type/Displacement
(HA).
/litre
NA
NA
NA
NA
6
6
6
6
Number of cylinders.
34
Oil capacity.
gal
(litre)
6.3
(24)
6.3
(24)
6.3
(24)
6.3
(24)
Speed at full load.
RPM
1800
1800
1800
1800
Speed at idle.
RPM
1200
1350
1350
1200
Electrical system.
V DC
24
24
24
24
General Information - MSA (SRG/HRG)
MODEL
Operation & Maintenance Manual
MHP825
SHP750
XHP700
VHP750
Power available at
rated speed.
hp
(KW)
275
(205)
275
(205)
275
(205)
275
(205)
Fuel tank capacity.
gal
(litre)
145
(550)
145
(550)
145
(550)
145
(550)
Coolant capacity.
gal
(litre)
12.7
(48)
12.7
(48)
12.7
(48)
12.7
(48)
Max. gross weight.
lb
10,560
10,560
10,560
10,560
Shipping weight.
lb
9460
9460
9460
9460
NOTE: – 1
Refer to Compressor Lubrication Chart.
NA = not available
35
Operation & Maintenance Manual
General Information - MSA (SRG/HRG)
Sound Level Data (‘W’ model)
A. To Pneurop code PN8NTC2.
Equivalent continuous sound pressure level.*
. Rated load
83 dB(A) Estimated
(Operator position : 1m from machine)
B. In compliance with 86/188/EEC.
Average sound pressure level at 10m
to 79/113/EEC.*
72dB(A)
(*Machine only :– at maximum load in open site conditions)
C. US EPA 76dB(A)
Site Running Gear (SRG)
Number of wheels.
4
Tire size.
750x16 LT/E
Tire pressure.
90 psi (6.2 bar)
Maximum towing speed
20mph (35kph)
High Speed Running Gear (HSRG)
Number of wheels:
4
Tire size
8–14.5 LT/G
Tire pressure
110 psi (7.6 bar)
Maximum Towing Speed
65 mph (105kph)
Further information may be obtained by request through Ingersoll–Rand customer services
department.
36
Operating Instructions
37
Operation & Maintenance Manual
Operating Instructions
Operating Instructions
Commissioning
Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to
the instructions given below in PRIOR TO STARTING.
Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
Ensure that the position of the emergency stop device is known and recognised by its
markings. Ensure that it is functioning correctly and that the method of operation is known.
Before towing the unit, ensure that the tyre pressures are correct (refer to the GENERAL
INFORMATION section of this manual) and that the handbrake is functioning correctly (refer
to the MAINTENANCE section of this manual). Before towing the unit ensure that the lights
are functioning correctly (where fitted).
Ensure that all transport and packing materials are discarded.
Ensure that the correct fork lift truck slots or marked lifting/tie down points are used whenever
the machine is lifted or transported.
When selecting the working position of the machine ensure that there is sufficient clearance
for ventilation and exhaust requirements, observing any specified minimum dimensions (to
walls, floors etc.).
Adequate clearance needs to be allowed around and above the machine to permit safe access
for specified maintenance tasks.
Ensure that the machine is positioned securely and on a stable foundation. Any risk of
movement should be removed by suitable means, especially to avoid strain on any rigid
discharge piping.
Attach the battery cables to the battery(s) ensuring that they are tightened securely. Attach the
negative cable before attaching the positive cable.
!
WARNING
All air pressure equipment installed in or connected to the machine must
have safe working pressure ratings of at least the machine rated
pressure, and materials compatible with the compressor lubricant (refer
to the GENERAL INFORMATION section).
38
Operating Instructions
Operation & Maintenance Manual
!
WARNING
If more than one compressor is connected to one common downstream
plant, effective check valves and isolation valves must be fitted and
controlled by work procedures, so that one machine cannot accidently be
pressurised/over pressurised by another.
!
WARNING
If flexible discharge hoses are used, it is recommended that safety
retaining wires are used on the hoses.
Prior to Starting
1. Place the unit in a position that is as level as possible. The design of the unit
permits a 15 degree lengthways and sideways limit on out of level operation.
When the unit has to be operated out of level, it is important to keep the engine
oil level near the high level mark (with the unit level).
!
CAUTION
Do not overfill either the engine or the compressor with oil.
2. Check the engine lubrication oil in accordance with the operating instructions
in the Engine Operator’s Manual.
3. Check the compressor oil level in the sight glass located on the separator tank.
Liquid level should be in the green zone.
4. Check the diesel fuel level. A good rule is to top up at the end of each working
day. This prevents condensation from occurring in the tank.
!
CAUTION
Use only a No. 2–D diesel fuel oil with a minimum octane number of 45
and a sulphur content not greater than 0.5%.
39
Operation & Maintenance Manual
!
Operating Instructions
CAUTION
When refuelling:–
•
switch off the engine.
•
do not smoke.
•
extinguish all naked lights.
•
do not allow the fuel to come into contact with hot surfaces.
•
wear personal protective equipment.
5. Drain fuel filter water separator of water ensuring that any released fuel is
safely contained.
6. Check the radiator coolant level (with the unit level).
7. Open the service valve(s) to ensure that all pressure is relieved from the
system. Close the service valve(s).
!
CAUTION
8. Do not operate the machine with the canopy/doors in the open position
as this may cause overheating and operators to be exposed to high noise
levels.
9. Check the emergency stop. Rotate knob as indicated to release.
10. Close the manual relief valve inside the service door near the emergency stop.
When starting or operating the machine in temperatures below or approaching
0°C (32°F), ensure that the operation of the regulation system, the unloader
valve, the safety valve, and the engine are not impaired by ice or snow, and that
all inlet and outlet pipes and ducts are clear of ice and snow.
40
Operating Instructions
Operation & Maintenance Manual
41
Operation & Maintenance Manual
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 the instrument 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.
6. High Engine Coolant Temp: Fault indicator lamp. Indicates shutdown due to
high engine water temperature.
42
Operating Instructions
Operation & Maintenance Manual
7. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to high
pressure in “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. Inlet Heater/Wait to Start Lamp: Indicates engine manifold pre heater is
energized. Wait until lamp extinguishes before engaging starter.
14. Panel Light Switch: Controls panel lamp # 1.
15. Service Air Switch: Momentary contact switch. Allows engine to warm up at
low compressor pressure.
16. ON/OFF Start Switch: Main Power Control Switch.
17. Heater Switch: 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. Fuel Level Gage: Indicate fuel level in tank.
23. Engine Water Temp Gage
24. Compressor Oil Temp Gage
25. Engine Oil Pressure Gage
26. Battery Voltage Gage
43
Operation & Maintenance Manual
Operating Instructions
Wedge Diagnostic Display Codes
1. High Compressor Temp: Fault indicator lamp. Indicates shutdown due to high
compressor temperature.
2. Low Engine Oil Pressure: Fault indicator lamp. Indicates shutdown due to low
engine oil pressure.
3. High Engine Coolant Temp: Fault indicator lamp. Indicates shutdown due to
high engine water temperature.
4. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to low fuel level.
Lamp blinks at low fuel warning.
5. Low Battery Voltage: Alarm indicator lamp. Indicates battery or charging
system requires service.
6. Low Radiator Coolant Level: Alarm indicator lamp. Indicates engine coolant
needs service.
44
Operating Instructions
Operation & Maintenance Manual
7. Restricted Air Filter: Alarm indicator lamp. Indicates engine/compressor air
inlet filters need service.
8. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to high
pressure in “IQ” air filters (if equipped).
9. Compressor Malfunction: Fault indicator lamp. Indicates shutdown due to
compressor system fault. Refer to Fault Code List.
10. Engine Malfunction: Engine Fault code. Refer to service card or engine
manual for codes and service requirements.
11. Malfunction Code (4 Digit): Compressor or engine fault. Refer to manual for
list of codes and service requirements.
ALERT
SHUTDOWN
CODE
LIGHT
STEADY
DELAY
(sec)
Engine Speed <Min. RPM
1
CPRSR
Malfunction.
30
Engine Speed >Max. RPM
2
CPRSR
Malfunction.
30
Engine Crank Time Exceeded
3
CPRSR
Malfunction.
0
CODE
LIGHT BLINKS
*Engine Oil Temperature > 252
deg. F
5
CPRSR
Malfunction.
*Intake Manifold Temperature >180
deg. F
6
CPRSR
Malfunction.
*Water In Fuel - CUMMINS
8
CPRSR
Malfunction.
Engine Not Responding To Throttle
command
10
CPRSR
Malfunction.
45
Operation & Maintenance Manual
Operating Instructions
ALERT
SHUTDOWN
CODE
LIGHT
STEADY
DELAY
(sec)
Too Many Crank Attempts During
Autostart
11
CPRSR
Malfunction.
0
Engine Shut Itself Down: reason
unknown
29
CPRSR
Malfunction.
0
Low AE Oil Pressure
31
CPRSR
Malfunction.
20
Disch. Temp (RT2)
Sensor Fault
32
CPRSR
Malfunction.
10
Separator Tank Pressure >20 PSI
During Start Attempt (Engine Will Not
Crank)
34
CPRSR
Malfunction.
0
Machine Over Pressure
35
CPRSR
Malfunction.
1
Safety Valve Open
36
CPRSR
Malfunction.
2
Separator Tank Temp >
(247 deg.F)
50
CPRSR
Malfunction.
3
Machine ID Not Valid
51
CPRSR
Malfunction.
0
Sep. Tank Temp (RT1)
Sensor Fault
53
CPRSR
Malfunction.
10
55
CPRSR
Malfunction.
3
Fuel Level
3
CODE
Sep. Tank Pressure (PT1) Sensor Fault
33
LIGHT BLINKS
CPRSR
Malfunction.
*CAN derived data
Reg. System Pressure (PT2) Sensor
Fault
54
CPRSR
Malfunction.
Estop Button Pushed
55
CPRSR
Malfunction.
Serial Comm. Problem
70
CPRSR
Malfunction.
CAN Bus Problem
71
CPRSR
Malfunction.
Communication With Autostart Module
Lost
73
CPRSR
Malfunction.
Dedicated Lights:
Low Fuel Level
Air Filter Restriction
46
Fuel Level
Soiled Filter
Operating Instructions
Operation & Maintenance Manual
ALERT
SHUTDOWN
LIGHT
STEADY
DELAY
(sec)
*Engine Coolant Temperature
> = 220 deg. F
High Engine
Temp.
10
IQ Filter Restriction
IQ Filt. Rest
3
High Discharge Temp. (RT2>247
deg. F)
High Comp
Temp.
3
CODE
Low Battery Voltage
LIGHT BLINKS
Battery
Charging
Condition
*Engine Oil Pressure <18 PSI
Low Engine Oil
Pressure
*Low Coolant Level - CUMMINS
Engine Coolant
Level
*Engine Coolant Temperature
> = 215 deg. F
CODE
High Engine
Temp.
*CAN derived data
47
Operation & Maintenance Manual
Operating Instructions
Caterpillar C–9 Engine
Diagnostic and Event Flash Codes
Flash codes are used to represent diagnostic codes in the electronic system in order to alert
the operator that a problem exists.
Event codes refer to engine operating conditions and usually indicate a mechanical rather than
an electrical system problem.
NOTE: Flash codes can represent more than one failure mode indicator.
Use the engine manufacturers service tool to view failure modes.
DIAGNOSTIC
Description of Code
Flash Code
15
Injector Actuation Pressure Sensor Loss of signal
Injector Actuation Pressure open/short to +batt
Injector Actuation Pressure open/short to ground
17
High Injection Actuation Pressure
18
Injection Actuation Control Valve open/short
21
5 Volt Sensor DC Power Supply short to +batt
5 Volt Sensor DC Power Supply short to ground
Digital Sensor Supply short to +batt
Digital Sensor supply short to ground
24
Engine Oil Pressure open/short to +batt
Engine Oil Pressure short to ground
25
Turbo Outlet Pressure above normal
Turbo Outlet Pressure open/short to +batt
Turbo Outlet Pressure short to ground
26
Atmospheric Pressure open/short to +batt
Atmospheric Pressure short to ground
27
Engine Coolant Temperature open short to +batt
Engine Coolant Temperature short to ground
48
28
Throttle Position calibration required
32
Throttle Position signal abnormal
Operating Instructions
Operation & Maintenance Manual
DIAGNOSTIC
Description of Code
Flash Code
34
Speed/Timing Sensor Loss of signal
Speed/Timing Sensor mechanical failure
Loss of Secondary Engine Speed signal
Secondary Engine Speed Sensor mechanical failure
37
Engine Oil Temperature open/short to +batt
Engine Oil Temperature open/short to ground
38
Intake Manifold Air Temp open/short to +batt
Intake Manifold Air Temp short to ground
39
Injector Actuation Press Sensor mechanical failure
42
Engine Timing calibration required
51
System Voltage intermittent/erratic
53
Electronic Control Module error
56
Personality Module mismatch
Check Programmable Parameters
58
J1939 Data Link communications
72
Injector Cylinder #1 fault
Injector Cylinder #2 fault
73
Injector Cylinder #3 fault
Injector Cylinder #4 fault
74
Injector Cylinder #5 fault
Injector Cylinder #6 fault
49
Operation & Maintenance Manual
Operating Instructions
EVENT
Description of Code
Flash Codes
35
Engine Overspeed Shutdown
63
Fuel Filter Restriction Derate
Fuel Filter Restriction Shutdown
61
High Engine Coolant Temperature Derate
High Engine Coolant Temperature Shutdown
High Engine Coolant Temperature Warning
64
High Inlet Air Temperature Derate
High Inlet Air Temperature Warning
46
Low Engine Oil Pressure Derate
Low Engine Oil Pressure Shutdown
62
Low Engine Coolant Level Derate
Low Engine Coolant Level Shutdown
Low Engine Coolant Level Warning
50
63
Fuel Filter Restriction Warning
46
Low Engine Oil Pressure Warning
35
Engine Overspeed Warning
Operating Instructions
Operation & Maintenance Manual
Starting the Machine
Ensure emergency stop button is reset.
!
WARNING
Under no circumstances should volatile fluids such as ether be used for
starting this machine.
All normal starting functions are incorporated in the key operated switch.
Turn the keyswitch to (position 1);
— The auxiliary start compressor will operate to close the inlet valve.
— The wedge controller will execute a lamp test.
— The low engine oil pressure and low battery lamps will flash indicating proper
communication between wedge and engine ECM.
Inlet Heater/Wait to Start Light
•
Turn the key switch to on (position 1) until the inlet heater warning light 13
extinguishes.
NOTE: Position 2 is not used
•
Turn the key switch to crank position 3 (engine start position).
•
Release to on (position 1) when the engine starts. The engine will now be running at
a reduced speed.
•
During warm up, the engine will idle at 1500RPM. After warm up the engine will idle
at a lower speed.
51
Operation & Maintenance Manual
Operating Instructions
NOTE: In order to allow the machine to start at a reduced load, a valve,
which is operated by a service air switch located on the instrument panel,
is incorporated in the regulation system. (The valve automatically returns
to the start position when the machine is switched off and air pressure
relieved from the system).
•
Allow the engine to reach its operating temperature–then press the pressure control
button 15.
•
At this point in the operation of the machine it is safe to apply full load to the engine.
!
CAUTION
If the engine does not start, repeat the above procedure after waiting for
a minimum of one minute.
If the engine fails to start, refer to the MAINTENANCE section of this manual, and to the
ENGINE MANUFACTURER’S MANUAL.
Stopping the Machine
•
Close the service valve.
•
Allow the machine to run unloaded for a short period of time to reduce the engine
temperature.
•
Turn the ON/OFF start switch to the 0 (off) position.
NOTE: As soon as the engine stops, the automatic blowdown valve will
relieve all pressure from the system, except for the discharge pipe/
manifold area. This area should be depressurised by opening the
discharge valve, keeping clear of any airflow from it.
If the automatic blowdown valve fails to operate, then pressure must be relieved from the
system by means of the service valve(s).
!
WARNING
When relieving system pressure by means of the service valve(s), a small
amount of pressure will remain in the system. No maintenance work
should be carried out if this situation exists. Relieve this pressure by
opening the manual blowdown valve.
52
Operating Instructions
Operation & Maintenance Manual
!
CAUTION
Never allow the machine to stand idle with pressure in the system.
Emergency Stopping
In the event that the unit has to be stopped in an emergency, PRESS THE EMERGENCY
STOP SWITCH ON THE FRONT OF THE MACHINE.
If the unit is not fitted with an emergency stop switch, rotate the start switch to the (0) off
position.
Re–Starting After an Emergency
Disengage emergency stop control from engaged (depressed) position. (IF FITTED)
If the machine has been switched off because of a machine malfunction, then identify and
correct the fault before attempting to re–start.
If the machine has been switched off for reasons of safety, then ensure that the machine can
be operated safely before re–starting.
Refer to the PRIOR TO STARTING and STARTING THE UNIT instructions earlier in this
section before re–starting the machine.
Monitoring During Operation
Should any of the safety shut-down conditions occur, the unit will stop.
Refer to the wedge diagnostic display codes table for a listing of shutdown conditions.
!
CAUTION
CAUTION: To ensure an adequate flow of oil to the compressor at low
temperature, never allow the discharge pressure to fall below 3.5 bar.
53
Operation & Maintenance Manual
Operating Instructions
Decommissioning
When the machine is to be permanently decommissioned or dismantled, it is important to
ensure that all hazard risks are either eliminated or notified to the recipient of the machine. In
particular:–
54
•
Do not destroy batteries or components containing asbestos without containing the
materials safely.
•
Do not dispose of any pressure vessel that is not clearly marked with its relevant data
plate information or rendered unusable by drilling, cutting etc.
•
Do not allow lubricants or coolants to be released into land surfaces or drains.
•
Do not dispose of a complete machine without documentation relating to instructions
for its use.
Maintenance
55
Operation & Maintenance Manual
Maintenance
Maintenance
Maintenance Interval Chart
Maintenance Interval Chart
Initial
500
miles
/850 km
56
Daily
Compressor Oil Level
C
Engine Oil Level
C
*Radiator Coolant
Level
C
Gauges/Lamps
C
*Air Cleaner Service
Indicators
C
Fuel Tank (Fill at end
of day)
C
*Fuel/Water
Separator Drain
C
Oil Leaks
C
Fuel Leaks
C
Drain Water From
Fuel Filters
D
Coolant Leaks
C
Radiator Filler Cap
C
Weekly
Monthly
3
Monthly.
500 hrs.
6
Monthly.
1000 hrs.
D
Air Cleaner
Precleaner Dumps
C
Fan/Alternator Belts
C
Battery Connections/
Electrolyte
C
Tire Pressure and
Surface
C
*Wheel Lug Nuts
C
Hoses (Oil, Air,
Intake, etc.)
C
Automatic Shutdown
System
C
12
Monthly.
2000 hrs.
Maintenance
Operation & Maintenance Manual
Maintenance Interval Chart
Initial
500
miles
/850 km
Daily
Weekly
Monthly
Air Cleaner System
C
Compressor Heat
Exchanger Exterior
C
* Engine Heat
Exchanger Exterior
C
Fasteners, Guards
3
Monthly.
500 hrs.
6
Monthly.
1000 hrs.
12
Monthly.
2000 hrs.
C
Air Cleaner Elements
R/WI
*Disregard if not appropriate for this particular machine.
(1) or 3000 miles/5000km whichever is the sooner
(2) or as defined by local or national legislation
C = Check (adjust, clean or replace as necessary)
CBT = Check before towing.
CR = Check and report
D = Drain
G = Grease
R= Replace
T = Test
WI = or when indicated if earlier.
Refer to specific sections of the operator’s manual for more information.
57
Operation & Maintenance Manual
Maintenance
Maintenance Interval Chart
Initial
500
miles
/850
km
Daily
Weekly
Monthly
250
hrs
3
Monthly
500 hrs
Engine Coolant
Conditioner
R
*Fuel/Water
Separator Element
R
Compressor Oil
Filter Element
R
6
Monthly
1000 hrs
12
Monthly
1500
hrs
R
Compressor Oil
Engine Oil Change
R
CAT
Engine Oil Filter
R
CAT
*Water Pump
Grease.
R
*Wheels (Bearings,
Seals, etc.)
C
C
*Engine Coolant
Fuel Filter Element
(Service interval
varies with fuel
quality)
R
R
CAT
*Injection Nozzle
Check
C
Shutdown Switch
Settings
T
Scavenger Orifice &
Related Parts
C
Oil Separator
Element
R
Lights (running,
brake, & turn)
CBT
Pintle Eye Bolts
CBT
*Brakes
CBT
*Brake Linkage
Emergency Stop
58
12
Monthly
2000
hrs
C
T
Maintenance
Operation & Maintenance Manual
Maintenance Interval Chart
Initial
500
miles
/850
km
Daily
Weekly
Monthly
250
hrs
Fasteners
C
Running Gear
Linkage
G
Running Gear
Bolts(1)
C
3
Monthly
500 hrs
6
Monthly
1000 hrs
12
Monthly
1500
hrs
12
Monthly
2000
hrs
*Disregard if not appropriate for this particular machine.
(1) or 3000 miles/5000km whichever is the sooner
(2) or as defined by local or national legislation
C = Check (adjust, clean or replace as necessary)
CBT = Check before towing.
CR = Check and report
D = Drain
G = Grease
R= Replace
T = Test
W I = or when indicated if earlier.
Refer to specific sections of the operator’s manual for more information.
59
Operation & Maintenance Manual
Initial 500
miles /850
km
Maintenance
Daily
Weekly
Monthly
3
Monthly.
500 hrs.
C
Lubricator (Fill) *
2 Yrs
4 Yrs
6 Yrs
C
Hoses
R
Separator tank (2) interior
C
*Disregard if not appropriate for this particular machine.
(1) or 3000 miles/5000km whichever is the sooner
(2) or as defined by local or national legislation
C = Check (adjust, clean or replace as necessary)
CBT = Check before towing.
CR = Check and report
D = Drain
G = Grease
R= Replace
T = Test
W I = or when indicated if earlier.
Refer to specific sections of the operator’s manual for more information.
60
12
Monthly.
2000 hrs
CR
Separator tank (2) exterior
Safety valve
6
Monthly.
1000 hrs
Maintenance
Operation & Maintenance Manual
Routine Maintenance
This section refers to the various components which require periodic maintenance and
replacement.
The SERVICE MAINTENANCE INTERVAL CHART indicates the various components’
descriptions and the intervals when maintenance has to take place. Oil capacities, etc., can
be found in the GENERAL INFORMATION section of this manual.
For any specification or specific requirement on service or preventative maintenance for the
engine, refer to the Engine Manufacturer’s Manual.
Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit,
ensure that all pressure is vented from the system and that the machine cannot be started
accidentally.
If the automatic blowdown fails to operate, then pressure must be gradually relieved by
operating the manual blowdown valve. Suitable personal protective equipment should be
worn.
Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenance Manuals.
Prior to attempting any maintenance work, ensure that:–
•
all air pressure is fully discharged and isolated from the system. If the automatic
blowdown valve is used for this purpose, then allow enough time for it to complete
the operation.
NOTE: Pressure will always remain in the part of the system between the
minimum pressure valve and the discharge valve after operation of the
auto blowdown valve.
THIS PRESSURE MUST BE RELIEVED BY CAREFULLY:
a. DISCONNECTING ANY DOWNSTREAM EQUIPMENT.
b. OPENING THE DISCHARGE VALVE TO ATMOSPHERE.
(USE HEARING PROTECTION IF NECESSARY).
•
the machine cannot be started accidently or otherwise, by posting warning signs and/
or fitting appropriate anti–start devices.
•
Disconnect batteries.
Prior to opening or removing panels or covers to work inside a machine, ensure that:–
•
anyone entering the machine is aware of the reduced level of protection and the
additional hazards, including hot surfaces and intermittently moving parts.
•
the machine cannot be started accidently or otherwise, by posting warning signs and/
or fitting appropriate anti–start devices.
61
Operation & Maintenance Manual
Maintenance
Prior to attempting any maintenance work on a running machine, ensure that:–
•
the work carried out is limited to only those tasks which require the machine to run.
•
the work carried out with safety protection devices disabled or removed is limited to
only those tasks which require the machine to be running with safety protection
devices disabled or removed.
•
all hazards present are known (e.g. pressurised components, electrically live
components, removed panels, covers and guards, extreme temperatures, inflow and
outflow of air, intermittently moving parts, safety valve discharge etc.).
•
appropriate personal protective equipment is worn.
•
loose clothing, jewellery, long hair etc. is made safe.
•
warning signs indicating that Maintenance Work is in Progress are posted in a
position that can be clearly seen.
Upon completion of maintenance tasks and prior to returning the machine into service,
ensure that:–
•
the machine is suitably tested.
•
all guards and safety protection devices are refitted.
•
all panels are replaced, canopy and doors closed.
•
hazardous materials are effectively contained and disposed of.
Protective Shutdown System
Refer to the Wedge diagnostic display codes table for a listing of shutdown conditions.
Low Engine Fuel Level Switch
At three month intervals, test the low engine fuel level switch circuit as follows:
•
Start the machine.
NOTE: Do not press the load button.
•
Disconnect the switch, the machine should shutdown.
•
Re–connect the switch.
At twelve month intervals, test the low engine fuel level switch by removing and operating the
float manually.
62
Maintenance
Operation & Maintenance Manual
!
CAUTION
Never remove or replace switches when the machine is running.
Scavenge Line
The scavenge line runs from the combined orifice/drop tube in the separator tank, to the orifice
fitting located in the airend.
Examine the orifice, check valve and hoses at every service or in the event of oil carryover into
the discharge air.
It is good preventative maintenance to check that the scavenge line and tube are clear of any
obstruction each time the compressor lubricant is changed as any blockage will result in oil
carryover into the discharge air.
Compressor Oil Filter
Refer to the MAINTENANCE INTERVAL CHART in this section for the recommended
servicing intervals.
Removal
!
WARNING
Do not remove the filter(s) without first making sure that the machine is
stopped and the system has been completely relieved of all air pressure.
(Refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS
section of this manual).
Clean the exterior of the filter housing and remove the spin–on element by turning it in a
counter–clockwise direction.
63
Operation & Maintenance Manual
Maintenance
Inspection
Examine the filter element.
!
CAUTION
If there is any indication of the formation of varnishes, shellacs or
lacquers on the filter element, it is a warning that the compressor
lubricating and cooling oil has deteriorated and that it should be changed
immediately. Refer to LUBRICATION later in this section.
Reassembly
Clean the filter gasket contact area and install the new element by screwing in a clockwise
direction until the gasket makes contact with the filter housing. Tighten a further 1/2 to 3/4 of
a revolution.
!
CAUTION
Start the machine (refer to PRIOR TO STARTING and STARTING THE
UNIT in the OPERATING INSTRUCTIONS section of this manual) and
check for leakage before the machine is put back into service.
Compressor Oil Separator Element
Refer to the SERVICE MAINTENANCE INTERVAL CHART in this section for service
intervals.
Removal
!
WARNING
Do not remove the filter(s) without first making sure that the machine is
stopped and the system has been completely relieved of all air pressure.
(Refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS
section of this manual).
Disconnect all hoses and tubes from the separator tank cover plate. Remove the drop–tube
from the separator tank cover plate and then remove the cover plate. Remove the separator
element.
64
Maintenance
Operation & Maintenance Manual
Inspection
Examine the filter element. Examine all hoses and tubes, and replace if necessary.
Reassembly
Thoroughly clean the orifice/drop tube and filter gasket contact area before reassembly. Install
the new element.
!
WARNING
Do not remove the staple from the anti–static gasket on the separator
element since it serves to ground any possible static build–up. Do not
use gasket sealant since this will affect electrical conductance.
Reposition the cover plate, taking care not to damage the gasket, and replace the cover plate
screws tightening in a criss–cross pattern to the recommended torque (refer to the TORQUE
SETTING TABLE later in this section).
Replace the drop–tube and reconnect all hoses and tubes to the separator tank cover plate.
Replace the compressor oil (refer to LUBRICATION later in this section).
!
CAUTION
Start the machine (refer to PRIOR TO STARTING and STARTING THE
UNIT in the OPERATING INSTRUCTIONS section of this manual) and
check for leakage before the machine is put back into service.
Compressor Oil Cooler and Engine Radiator Air Charge Cooler
When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator,
the efficiency is impaired. It is recommended that each month the oil cooler and radiator be
cleaned by directing a jet of compressed air, (carrying if possible a non–flammable cleaning
solvent) over the exterior core of the cooler/radiator. This should remove any accumulation of
oil, grease and dirt from the exterior core of the cooler so that the entire cooling area can
radiate the heat of the lubricating and cooling oil/water into the air stream.
65
Operation & Maintenance Manual
!
Maintenance
WARNING
Hot engine coolant and steam can cause injury. When adding coolant or
antifreeze solution to the engine radiator, stop the engine at least one
minute prior to releasing the radiator filler cap. Using a cloth to protect
the hand, slowly release the filler cap, absorbing any released fluid with
the cloth. Do not remove the filler cap until all excess fluid is released and
the engine cooling system fully depressurised.
!
WARNING
Follow the instructions provided by the antifreeze supplier when adding
or draining the antifreeze solution. It is advisable to wear personal
protective equipment to prevent skin and eye contact with the antifreeze
solution.
Air Filter Element
The air filter should be inspected regularly (refer to the SERVICE MAINTENANCE INTERVAL
CHART) and the element replaced when the restriction indicator lamp illuminates. The dust
collector box(es) should be cleaned daily (more frequently in dusty operating conditions) and
not allowed to become more than half full.
Removal
!
CAUTION
Never remove and replace element(s) when the machine is running.
Clean the exterior of the filter housing and remove the filter element by releasing the nut.
If the safety element is to be renewed, thoroughly clean the interior of the filter housing prior
to removing the safety element.
66
Maintenance
Operation & Maintenance Manual
Inspection
Check for cracks, holes or any other damage to the element by holding it up to a light source,
or by passing a lamp inside.
!
CAUTION
If inspection reveals damage to the main element, the safety element
must be replaced.
Check the seal at the end of the element and replace if any sign of damage is evident.
Reassembly
Assemble the new element into the filter housing ensuring that the seal seats properly.
Secure the element in the housing by hand tightening the nut.
Assemble the dust collector box parts, ensuring that they are correctly positioned.
Before restarting the machine, check that all clamps are tight.
Ventilation
Always check that the air inlets and outlets are clear of debris etc.
!
CAUTION
NEVER clean by blowing air inwards.
Cooling Fan Drive
Periodically check that the fan mounting bolt in the fan hub has not loosened. If, for any reason,
it becomes necessary to remove the fan or re–tighten the fan mounting bolt, apply a good
grade of commercially available thread locking compound to the bolt threads and tighten to the
torque value shown in the TORQUE SETTING TABLE later in this section.
The fan belt(s) should be checked regularly for wear and correct tensioning.
Fuel System
The fuel tank should be filled daily or every eight hours. To minimise condensation in the fuel
tank(s), it is advisable to top up after the machine is shut down or at the end of each working
day. At six month intervals drain any sediment or condensate that may have accumulated in
the tank(s).
67
Operation & Maintenance Manual
Maintenance
Fuel Filter Water Separator
The fuel filter water separator contains a filter element which should be replaced at regular
intervals (see the SERVICE/MAINTENANCE CHART).
Caterpillar powered units are equipped with primary and secondary fuel filters.
Charge Cooler Pipework:–
Inspect all hoses and clips on the charge cooler pipe work.
Engine damage will occur if the charge cooling system leaks.
Hoses
All components of the engine cooling air intake system should be checked periodically to keep
the engine at peak efficiency.
At the recommended intervals, (see the SERVICE MAINTENANCE INTERVAL CHART),
inspect all of the intake lines to the air filter, and all flexible hoses used for air lines, oil lines
and fuel lines.
Periodically inspect all pipework for cracks, leaks, etc. and replace immediately if damaged.
Electrical System
!
Always disconnect the
maintenance or service.
WARNING
battery
cables
before
performing
any
Inspect the safety shutdown system switches and the instrument panel relay contacts for
evidence of arcing and pitting. Clean where necessary.
Check the mechanical action of the components.
Check the security of electrical terminals on the switches and relays i.e. nuts or screws loose,
which may cause local hot spot oxidation.
Inspect the components and wiring for signs of overheating i.e. discolouration, charring of
cables, deformation of parts, acrid smells and blistered paint.
68
Maintenance
Operation & Maintenance Manual
Battery
!
Always disconnect the
maintenance or service.
WARNING
battery
cables
before
performing
any
Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to
prevent corrosion.
The retaining clamp should be kept tight enough to prevent the battery from moving.
Pressure System
At 3 month intervals it is necessary to inspect the external surfaces of the system (from the
airend through to the discharge valve(s)) including hoses, tubes, tube fittings and the
separator tank, for visible signs of impact damage, excessive corrosion, abrasion, tightness
and chafing. Any suspect parts should be replaced before the machine is put back into service.
Tire Pressure
See the GENERAL INFORMATION section of this manual.
Running Gear/Wheels
Check the wheel nut torque 20 miles (30 kilometres) after refitting the wheels. Refer to the
TORQUE SETTING TABLE later in this section.
The bolts securing the running gear to the chassis should be checked periodically for tightness
(refer to the SERVICE/MAINTENANCE CHART for frequency) and re–tightened where
necessary. Refer to the TORQUE SETTING TABLE later in this section.
Lubrication
The engine is initially supplied with engine oil sufficient for a nominal period of operation (for
more information, consult The Engine Manufacturer’s Manual).
!
CAUTION
Always check the oil levels before a new machine is put into service.
If, for any reason, the unit has been drained, it must be re–filled with new oil before it is put
into operation.
69
Operation & Maintenance Manual
Maintenance
Engine Lubricating Oil
The engine oil should be changed at the engine manufacturer’s recommended intervals. Refer
to the SERVICE/MAINTENANCE CHART.
Engine Lubricating Oil Specification
Refer to the Engine Manufacturer’s Manual or Portable Compressor Fluid Chart.
Engine Oil Filter Element
The engine oil filter element should be changed at the engine manufacturer’s recommended
intervals. Refer to the SERVICE/MAINTENANCE CHART..
Compressor Lubricating Oil
Refer to the SERVICE/MAINTENANCE CHART in this section for service intervals.
NOTE: If the machine has been operating under adverse conditions, or
has suffered long shutdown periods, then more frequent service intervals
will be required.
!
WARNING
DO NOT, under any circumstances, remove any drain plugs or the oil filler
plug from the compressor lubricating and cooling system without first
making sure that the machine is stopped and the system has been
completely relieved of all air pressure (refer to STOPPING THE UNIT in the
OPERATING INSTRUCTIONS section of this manual).
Completely drain the receiver/separator system including the piping and oil cooler by removing
the drain plug(s) and collecting the used oil in a suitable container.
Replace the drain plug(s) ensuring that each one is secure.
NOTE: If the oil is drained immediately after the machine has been
running, then most of the sediment will be in suspension and will
therefore drain more readily.
70
Maintenance
Operation & Maintenance Manual
!
CAUTION
Some oil mixtures are incompatible and result in the formation of
varnishes, shellacs or lacquers which may be insoluble.
NOTE: Always specify INGERSOLL–RAND Pro–TecTM oil for use at all
ambient temperatures above –23°C.
For extended warranty use only IR fluids. Refer to portable compressor fluids chart.
Running Gear Wheel Bearings
Wheel bearings should be packed with grease every 6 months. The type of grease used
should conform to specification MIL–G–10924.
71
Operation & Maintenance Manual
Maintenance
MHP825, VHP750
Key
72
A
Adjusting screw
E
Orifice
I
Separator tank
B
Mini compressor
F
Regulation pressure
transducer
J
Manual blowdown valve
C
Auto blowdown
valve
G
Start/Run solenoid
K
Unloader
D
Unloader solenoid
H
Panel pressure gauge
Maintenance
Operation & Maintenance Manual
Speed and Pressure Regulation Adjustment
Normally, regulation requires no adjusting, but if correct adjustment is lost, proceed as follows:
Refer to the diagram above.
A Adjusting screw
Start the machine (Refer to STARTING INSTRUCTIONS in the OPERATING
INSTRUCTIONS section of this manual).
Adjust the service valve on the outside of the machine to maintain normal operating discharge
pressure (refer to GENERAL INFORMATION) and full speed position. If the tachometer
moves away from the full speed position before normal operating discharge pressure is
attained, then turn the adjusting screw ‘A’ clockwise to increase the pressure. Optimum
adjustment is achieved when the throttle just moves from its full speed position and the
pressure increases slightly.
Close the service valve. The engine will slow to idle speed.
!
CAUTION
Never allow the idle pressure to exceed
pressure(refer to GENERAL INFORMATION).
maximum
allowable
73
Operation & Maintenance Manual
Maintenance
XHP700, SHP750
Key:
74
1
Air cylinder
7
Regulation pressure
transducer
13
Pressure transducer
2
Butterfly valve
8
Start/Run solenoid
14
Minimum pressure valve
3
Mini compressor
9
Pressure regulator
15
Separator tank
4
Unloader Solenoid
10
Panel pressure guage
16
Auto blowdown valve
5
Relief valve
11
Manual blowdown valve
17
HR2 Airend
6
Orifice
12
Temperature sensor
18
Air inlet
Maintenance
Operation & Maintenance Manual
Speed and Pressure Regulation Adjustment
Normally, regulation requires no adjusting, but if correct adjustment is lost, proceed as follows:
Refer to the diagram above.
With the unit stopped, disconnect ballast spring ‘A’ from the butterfly lever. Loosen the two
screws securing bracket ‘C’ to main bracket ‘J’.
Loosen screw ‘D’ and rotate the butterfly valve pivot shaft ‘K’ fully clockwise until the valve is
closed. Position lever ‘L‘ approximately 10° after vertical and tighten screw ‘D’.
Keep the butterfly lever in the closed position and with the the air cylinder fully contracted
tighten the screws holding bracket ‘C’ to the main bracket ‘J’.
Allow the cylinder to return to its extended position and reconnect the ballast spring ‘A’.
IMPORTANT: Ensure all components are aligned and move freely.
Start engine: Note receiver pressure. Warm up pressure should be 3, 5–5, 0 bar (50–70 p.s.i.).
To increase the warm up pressure, turn the air cylinder rod in an anti–clockwise direction to
open the butterfly valve.
To reduce warm up pressure, turn air cylinder rod in clockwise direction to close butterfly
valve.
When the engine is warmed up, press the service air switch on the control panel to commence
normal regulation.
Set pressure by adjusting the screw ‘E’ on the pressure regulator ‘F’. Turn the screw clockwise
to increase pressure and anticlockwise to reduce pressure.
Rated Operating Pressure:
XHP700
300 psig
SHP750
300 psig
75
Operation & Maintenance Manual
Torque Values
76
Maintenance
Maintenance
Operation & Maintenance Manual
Wheel Torque Chart - Inch
1/2” lug nuts
Torque (FtLbs)
13” wheel
80-90
15” wheel
Wheel Torque Chart - Metric
Torque
(N-m)
Torque
(Ft-Lbs)
M12 bolts
85-95
62-70
105-115
M14 bolts
145-155
107-115
16” wheel
105-115
M16 bolts
175-185
129-137
16.5” wheel
105-115
M18 bolts
205-215
151-159
5/8” lug nuts
16” wheel
190-210
17” wheel
190-210
9/16” Clamp nuts/
Demountable Wheels
14.5” wheel
105-115
77
Operation & Maintenance Manual
Maintenance
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
Pressure
100 psi to 300 psi
Ambient Temperature
Specification
-10°F to 125°F
(-23°C to 52°C)
Preferred:
IR Pro–TecTM
Alternate:
ISO Viscosity Grade 46 with
rust and oxidation inhibitors,
designed for air compressor
service
350 psi
-10°F to 125°F
(-23°C to 52°C)
Preferred:
IR XHP 605
Alternate:
IR XHP405
ISO Viscosity Grade 68
Group 3 or 5 with rust and
oxidation inhibitors
designed for air compressor
service..
65°F to 125°F (18°C
to 52°C)
78
Preferred:
XHP605
IR XHP1001
Maintenance
Operation & Maintenance Manual
Recommended Ingersoll–Rand Fluids – Use of these fluids with original IR filters can extend
airend warranty. Refer to operator’s manual warranty section for details or contact your IR
representative.
Ingersoll–Rand
Preferred Fluids
1 gal.
(3.8 Litre)
5 gal.
(19.0 Litre)
55 gal. (208.2
Litre)
220 gal.
(836 Litre)
Preferred:
36899706
36899714
36899722
IR XHP605
22252076
22252050
22252068
IR XHP1001
35612738
35300516
XHP405
22252126
22252100
36875938
36866903
IR Pro–TecTM
Engine Oil
36899698
54480918
22252118
79
**Always use Ingersoll-Rand Replacement parts!**
80
Machine Systems
81
Operation & Maintenance Manual
Machine Systems
Control System Schematic
82
Machine Systems
Machine Systems
Operation & Maintenance Manual
Key
BAT
Battery
PT2
Pressure transducer, regulation
system 0-100 PSIG
BDS
Battery disconnect switch
PM
Plug, machine ID
CO
RS232C comms
RS
Relay-spst
ECON
Engine controller
RT1
Thermistor, separator tank
temperature -30-255°F
ES
Engine speed
RT2
Thermistor, airend discharge
temperature -30-255°F
CE
Caterpillar electronics ground
stud
ESTOP
Emergency stop
FT
Frequency throttle.
Range=500Hz Base frequency
10%-90% pwm, 1350-1800 RPM
at 24VDC
SC
Start compressor
G2
Flywheel magnetic pickup
SI
Switch inputs
POUT1
Engine key switch
SS
Starter solenoid
POUT2
Solenoid, start/run
SW1
IQ filter restriction
POUT3
Low fuel warning beacon
SW2
Alert, low fuel
POUT4
Spare
SW3
Low fuel shutdown
POUT5
Start relay
SW4
Switch, service air
POUT6
Start compressor
SW5
Air filter rest (option)
POUT7
Hour meter
SW6
Switch, airend oil pressure
(12PSI N.O.)
POUT8
Solenoid, unloader
SW7
Spare
PT1
Pressure transducer, separator
tank.
SW8
Switch, start
0-225 PSIG-9/235, 9270, 0/300, 12/235
SWB
Switch battery disconnect
0-225 PSIG-HP935, VHP750, MHP825,
XP1060
TE
Transducer excitation
0-500 PSIG-XHP750, XHP650, SHP825
WCON
Wedge controller
83
Operation & Maintenance Manual
5
55
500Hz Base Frequency: 10%-90% plom=1350-1800 rpm
84
Machine Systems
Machine Systems
Operation & Maintenance Manual
EMU CAT Low Pressure Electrical Parts MHP825, VHP750
PART
NUMBERS
DESCRIPTION
QUANTITY PER
MACHINE
22162572
IQ HARNESS OPTION
1
36899599
IQ FILTER SWITCH
1
36899615
IQ FILTER SWITCH
1
22102339
COOLANT LWL SWH
1
36896975
SW MASTER DISCONNECT
1
36920825
0–100 PRESS TRANS
1
54496773
0–225 PRESS TRANS
1
36892362
24V SEALED RELAY
2
36785319
MAG SPEED SENSOR
1
36898922
THERMISTOR PROBE
2
36840841
SOLENOID VALVE
2
36847838
AIR FILTER RESTRICTION INDICATOR
SWITCH
2
36870608
ENGINE OIL PRESS SENDER
1
36841138
COMP. & ENGINE TEMP SENDER
2
36757581
COMP. OIL PRESS SW
1
36850691
COMPRESSOR MOTOR
1
35577873
RELAY MAGNETIC 24 VOLT K1
1
36841526
CONTROL HEATER
2
36854677
REGULATOR HEATER
1
22319735
NEGATIVE BATTERY CABLE
1
22319743
POSITIVE BATTERY CABLE
1
54511282
POSITIVE JUMPER BATTERY CABLE
1
35128982
BATTERY JUMPER
1
22132153
FRAME GROUND STRAP
1
22132153
ENGINE GROUND STRAP
1
22094759
FUEL LEVEL SENDER
1
85
Operation & Maintenance Manual
PART
NUMBERS
86
Machine Systems
DESCRIPTION
QUANTITY PER
MACHINE
22173579
WEDGE CONTROLLER
1
22202337
W1 CHASSIS HARNESS
1
54734116
W1 CHASSIS HARNESS DIAGRAM
22101968
INLET HEATER BREAKER 120 AMPS
1
36853521
INLET HEATER RELAY
1
89303127
EMERGENCY STOP OPERATOR
1
89303135
NC E–STOP CONTACT BLOCK
2
N/A
Machine Systems
Operation & Maintenance Manual
EMU CAT High Pressure Electrical Parts SHP750, XHP700
PART
NUMBERS
DESCRIPTION
QUANTITY PER
MACHINE
22162572
IQ HARNESS OPTION
1
36899599
IQ FILTER SWITCH
1
36899615
IQ FILTER SWITCH
1
22102339
COOLANT LWL SWH
1
36896975
SW MASTER DISCONNECT
1
36920825
0–100 PRESS TRANS
1
54765946
0–500 PRESS TRANS
1
36892362
24V SEALED RELAY
2
36785319
MAG SPEED SENSOR
1
36898922
THERMISTOR PROBE
1
36842300
START/RUN SOLENOID VALVE
1
36842318
COMPRESSOR SOLENOID VALVE
1
36847838
AIR FILTER RESTRICTION INDICATOR
SWITCH
2
36870608
ENGINE OIL PRESS SENDER
1
36841138
COMP. & ENGINE TEMP SENDER
2
36757581
COMP. OIL PRESS SW
1
36850691
COMPRESSOR MOTOR
1
35577873
RELAY MAGNETIC 24 VOLT K1
1
36841526
CONTROL HEATER
2
22319735
NEGATIVE BATTERY CABLE
1
22319743
POSITIVE BATTERY CABLE
1
54511282
POSITIVE JUMPER BATTERY CABLE
1
35128982
BATTERY JUMPER
1
22132153
FRAME GROUND STRAP
1
22132153
ENGINE GROUND STRAP
1
22094759
FUEL LEVEL SENDER
1
87
Operation & Maintenance Manual
PART
NUMBERS
88
Machine Systems
DESCRIPTION
QUANTITY PER
MACHINE
22173579
WEDGE CONTROLLER
1
22202337
W1 CHASSIS HARNESS
1
54734116
W1 CHASSIS HARNESS DIAGRAM
22101968
INLET HEATER BREAKER 120AMPS
1
89303127
EMERGENCY STOP OPERATOR
1
89303135
NC E–STOP CONTACT BLOCK
2
N/A
Fault Finding
89
Operation & Maintenance Manual
Fault Finding
Fault Finding
Fault Finding
FAULT
CAUSE
REMEDY
No reaction
from
instrument
panel when
key turned to
(I) position.
Emergency stop actuated.
Reset emergency stop button.
Batteries not connected.
Connect batteries.
Fuse at starter motor
‘blown’.
Replace fuse.
Engine fails to
start.
Low battery charge.
Check the fan belt tension, battery and
cable connections.
Bad earth connection.
Check the earth cables, clean as required.
Loose connection.
Locate and make the connection good.
Fuel starvation.
Check the fuel level and fuel system
components. Replace the fuel filter if
necessary.
Relay failed.
Replace the relay.
Faulty stop solenoid
Check the stop solenoid
Low fuel level.
Fill fuel tank and bleed air from fuel system
if necessary. (Refer to MAINTENANCE
SECTION).
Safety shut-down system
in operation.
Check the safety shut-down switches.
Electrical fault.
Test the electrical circuits.
Low engine oil pressure.
Check the oil level and the oil filter(s).
Low water level.
Check if the low water lamp is
extinguished.
Faulty relay.
Check the relays.
Faulty key–switch.
Check the key–switch.
Engine stops
while in
service or is
reluctant to
start.
Engine starts
but stalls
when the
switch returns
to position I.
90
Fault Finding
Operation & Maintenance Manual
FAULT
CAUSE
REMEDY
Engine starts
but will not
run or engine
shuts down
prematurely.
Electrical fault.
Test the electrical circuits.
Low engine oil pressure.
Check the oil level and oil filter(s).
Safety shut-down system
in operation.
Check the safety shut-down switches.
Fuel starvation.
Check the fuel level and fuel system
components. Replace the fuel filter if
necessary.
Switch failure.
Test the switches.
High compressor oil
temperature.
Check the compressor oil level and oil
cooler. Check the fan drive.
Water present in fuel
system.
Check the water separator and clean if
required.
Faulty relay.
Check the relay in the holder and replace if
necessary.
Low water level.
Check the level and replenish if necessary.
Blocked radiator.
Stop the machine and clean the cooling
fins with compressed air or steam. Use
reduced pressure for cleaning the fins.
Reduced cooling air from
fan.
Check the fan and the drive belts. Check
for any obstruction inside the cowl.
Faulty thermostat.
Check the thermostat and replace if
necessary.
Blocked fuel filter.
Check and replace if necessary.
Blocked air filter.
Check and replace the element if
necessary.
Faulty regulator valve.
Check the regulation system.
Premature unloading.
Check the regulation and the operation of
the air cylinder.
Excessive
vibration.
Engine speed too low.
See “Engine speed too low”
Leaking oil
seal.
Improperly fitted oil seal.
Replace the oil seal.
Engine
Overheats.
Engine speed
too low.
91
Operation & Maintenance Manual
Fault Finding
Refer also to the Engine Manufacturer’s Manual.
FAULT
CAUSE
REMEDY
Air discharge
capacity too
low.
Engine speed too low.
Check the air cylinder and air filter(s).
Blocked air cleaner.
Check the restriction indicators and replace the
element(s) if necessary.
High pressure air
escaping.
Check for leaks.
Incorrectly set
regulation system.
Reset the regulation system. Refer to SPEED
AND PRESSURE REGULATION
ADJUSTMENT in the MAINTENANCE section
of this manual.
Low oil level.
Top up the oil level and check for leaks.
Dirty or blocked oil
cooler.
Clean the oil cooler fins.
Incorrect grade of oil.
Use Ingersoll–Rand recommended oil.
Defective by-pass
valve.
Check the operation of the element and replace
if necessary.
Recirculation of
cooling air.
Move the machine to avoid recirculation.
Reduced cooling air
from fan.
Check the fan and the drive belts. Check for
any obstruction inside the fan cowl.
Blocked scavenge line.
Check the scavenge line, drop tube and orifice.
Clean and replace.
Perforated separator
element.
Replace the separator element.
Pressure in the system
is too low.
Check the minimum pressure valve.
Operating pressure too
high.
Check the setting and operation of the regulator
valve piping.
Incorrect setting of the
regulator.
Adjust the regulator.
Faulty regulator.
Replace the regulator.
Inlet valve set
incorrectly.
Refer to SPEED AND PRESSURE
REGULATION ADJUSTMENT in the
MAINTENANCE section of this manual.
Compressor
overheats.
Excessive oil
present in the
discharge air.
Safety valve
operates.
92
Fault Finding
Operation & Maintenance Manual
Refer also to the Engine Manufacturer’s Manual.
FAULT
Oil is forced
back into the
air filter.
Machine goes
to full
pressure
when started.
Machine fails
to load when
the load
button is
pressed.
CAUSE
REMEDY
Loose pipe/hose
connections.
Check all pipe/hose connections.
Faulty safety valve.
Check the relieving pressure. Replace the
safety valve if faulty. DO NOT ATTEMPT A
REPAIR.
Incorrect stopping
procedure used.
Always employ the correct stopping procedure.
Close the discharge valve and allow the
machine to run on idle before stopping.
Faulty inlet valve.
Check for free operation of the inlet valve(s).
Inlet valve set
incorrectly.
(17/235, 21/215)
Refer to SPEED AND PRESSURE
REGULATION ADJUSTMENT in the
MAINTENANCE section of this manual.
(17/235, 21/215)
Faulty load valve.
Replace the valve.
Faulty load valve.
Replace the valve.
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Options
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Operation & Maintenance Manual
Options
Options
IQ System Operating Instructions – 1
Key
96
1
Three way valve
5
Filters
2
Ball valve 11/4”
6
Aftercooler
3
Ball valve 2”
7
Minimum pressure valve
4
Safety valve
8
Separator tank
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Operation & Maintenance Manual
IQ System
The IQ System is a complete, self–contained system which provides cooler, cleaner air than
from a standard portable compressor. The system utilizes an integral aftercooler, 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.
When equipped with the low ambient feature, the IQ System automatically adjusts movable
louvers to control airflow through the aftercooler, ensuring that the compressed air
temperature always remains above freezing temperatures (typically 45°F (7°C)) at any
ambient temperature down to –10°F (–23°C). This prevents the need for 120V AC heat tracing
systems, or any manual adjustment to prevent freezing of the compressed air system. All drain
points for the condensate handling system are heated with 24VDC heaters, which are integral
to the compressor heater system.
Standard Non–Louvered configuration not to be operated below freezing.
IQ System Operating Instructions – 2
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 (if equipped with low ambient option). At most
conditions, the louvers are fully open, and maximum aftercooling is available. The compressed
air and condensate (water with a small amount of compressor lubricant) exits the aftercooler
and enters the moisture separator, where most of the condensate is removed. The
compressed air then flows through two stages of filtration, where the aerosol water and oil is
removed down to approximately 0.01 ppm, and all particulates are removed down to 0.01
micron.
At the bottom of the moisture separator and both filters are strainers and constant–bleed
orifices, which are sized to allow the maximum flow of condensate while minimizing
compressed air loss.
The condensate lines are then piped together, and the condensate is injected at a single point
into the engine exhaust piping. The compressed air then travels through the minimum
pressure valve, and out through the service air valve. The air pressure gauge on the
instrument panel indicates the pressure inside the separator tank. 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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Operation & Maintenance Manual
Options
Low Ambient Option Operation
When the ambient temperature falls to the point that the aftercooler outlet temperature is
approaching 45°F (7°C), the Temperature Control Unit (TCU), mounted on the rear of the
control panel, will automatically adjust the louvers to control the cooling airflow through the
aftercooler.
In the event that the unit is operating under abnormal conditions (i.e., an enclosure door open)
which would cause excessive cooling of the aftercooler, a temperature sensor in the
aftercooler outlet header will signal the TCU to further close the louvers if the compressed air
temperature falls to approximately 36°F (2°C) or lower.
There are no user selectable or serviceable components in the TCU. Contact Ingersoll–Rand
Service if any abnormal operation of the freeze protection control system occurs.
Maintenance
Daily Maintenance:
Verify, during full–load (maximum compressed air delivery) that the IQ System filter restriction
indicators do not show excessive restriction. Restriction indicators for the filters are mounted
inside the control panel, and will shut down the compressor if restriction exceeds
recommended values.
Weekly Maintenance:
•
Remove Y–strainer screens at the bottom of the moisture separator and both 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.
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.
Filter Replacement
98
•
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.
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Operation & Maintenance Manual
Verify the part number of new element vs. old element, as the two IQ filters are of
different media.
Safety
!
CAUTION
The compressor regulation system is adjusted to maintain regulated
pressure at the separator tank. DO NOT adjust regulation to provide full
regulation pressure at the service valve when the IQ System is enabled.
This will result in operation at excessive horsepower levels, causing
overheating, reduced engine life, and reduced airend life.
!
CAUTION
Excessively restricted filter elements may cause an increase in the
amount of aerosol water and oil carryover, which could result in damage
to downstream equipment. Normal service intervals should not be
exceeded.
!
CAUTION
Blockage of the condensate will result in flooding of the vessels. If
flooding occurs, excessive condensate may enter the air stream and
could result in damage to downstream equipment.
NOTICE
Do not operate at temperatures less that 2°C (36°F) unless equipped with
low ambient IQ option.
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**Always use Ingersoll-Rand Replacement parts!**
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Parts Ordering
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Operation & Maintenance Manual
Parts Ordering
Parts Ordering
General
This publication, which contains an illustrated parts breakdown, has been prepared as an aid
in locating those parts which may be required in the maintenance of the unit. All of the
compressor parts, listed in the parts breakdown, are manufactured with the same precision as
the original equipment. For the greatest protection always insist on genuine Ingersoll–Rand
Company parts for your compressor.
NOTICE
Ingersoll–Rand Company can bear no responsibility for injury or
damages resulting directly from the use of non–approved repair parts.
Ingersoll–Rand Company service facilities and parts are available
worldwide. There are Ingersoll–Rand Company Construction Equipment
Group Sales Offices and authorized distributors located in the principle
cities of the United States. In Canada our customers are serviced by the
Canadian Ingersoll–Rand Company, Limited. There are also Ingersoll–
Rand International autonomous companies and authorized distributors
located in the principle cities throughout the free world.
Special order parts may not be included in this manual. Contact the
Mocksville Parts Department with the unit serial number for assistance
with these special parts.
Description
The illustrated parts breakdown illustrates and lists the various assemblies, subassemblies
and detailed parts which make up this particular machine. This covers the standard models
and the more popular options that are available.
A series of illustrations show each part distinctly and in location relative to the other parts in
the assembly. The part number, the description of the part and the quantity of parts required
are shown on each illustration or on adjacent page. The quantities specified are the number
of parts used per one assembly and are not necessarily the total number of parts used in the
machine. Where no quantity is specified the quantity is assumed to be one.
Each description of a part is based upon the “noun first” method, i.e., the identifying noun or
item name is always the first part of the description. The noun name is generally followed by
a single descriptive modifier. The descriptive modifier may be followed by words or
abbreviations such as upper, lower, inner, outer, front, rear, RH, LH, etc. when they are
essential.
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In referring to the rear, the front or to either side of the unit, always consider the drawbar end
of the unit as the front. Standing at the rear of the unit facing the drawbar (front) will determine
the right and left sides.
Fasteners
Both SAE/inch, ISO/metric hardware have been used in the design and assembly of these
units. In the disassembly and reassembly of parts, extreme care must be taken to avoid
damaging threads by the use of wrong fasteners. In order to clarify the proper usage and for
exact replacement parts, all standard fasteners have been identified by part number, size and
description. This will enable a customer to obtain fasteners locally rather than ordering from
the factory. These parts are identified in tables that will be found at the rear of the parts
illustrations. Any fastener that has not been identified by both part number and size is a
specially engineered part that must be ordered by part number to obtain the exact replacement
part.
Markings and Decals
NOTICE
Do not paint over safety warnings or instructional decals. If safety
warning decals become illegible, immediately order replacements from
the factory.
Part numbers for original individual decals and their mounting locations
are shown within Parts List Section. These are available as long as a
particular model is in production.
Afterwards, service sets of exterior decals and current production safety warning decals are
available. Contact the Product Support Group at Mocksville for your particular needs and
availability.
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Operation & Maintenance Manual
Parts Ordering
How to Use Parts List
a. Locate the area or system of the compressor in which the desired part is used
and find illustration page number.
b. Locate the desired part on the illustration by visual identification and make note
of part number and description.
How to Order
The satisfactory ordering of parts by a purchaser is greatly dependent upon the proper use of
all available information.
In order that all avoidable errors may be eliminated, the following instructions are offered as a
guide to the purchaser when ordering replacement parts:
a. Always specify the model number of the unit as shown on the general data
decal attached to the unit.
b. Always specify the serial number of the unit.
c. Always specify the number of the parts list publication.
d. Always specify the quantity of parts required.
e. Always specify the part number, as well as the description of the part, or parts,
exactly as it is given on the parts list illustration.
In the event parts are being returned to your nearest sales office, autonomous company or
authorized distributor, for inspection or repair, it is important to include the serial number of the
unit from which the parts were removed.
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Parts Ordering
Operation & Maintenance Manual
Airend Exchange Program
Ingersoll–Rand offers an airend exchange program to benefit portable compressor users.
Consult the Ingersoll–Rand representative for details.
For parts, service or information regarding your local U.S, Latin America or Asia Pacific
distributor, please contact:
Facility:
Telephone:
Fax:
Ingersoll–Rand Company
501 Sanford Avenue
P.O. Box 868
Mocksville, N.C. 27028
800–633–5206 (US & Canada)
305–222–0835 (Latin America)
65–860–6863 (Asia Pacific)
336–751–1579 (US & Canada)
336–751–4325 (Latin America)
336–751–4325 (Asia Pacific)
Office hours: Monday - Friday 8:00 a.m. to 5:30 p.m. (EST)
For information on how to order parts or information regarding your local distributor (Europe,
Middle East, Africa) please contact:
Facility:
Portable Power Aftermarket ESA
Ingersoll–Rand European Sales Ltd
Swan Lane, Hindley Green
Wigan WN2 4 EZ
United Kingdom
Telephone: +44 (0) 1942 257 171
Emergency order telephone # +44 (0) 777 617 0921
Fax: +44 (0) 1942 523 417
Office hours: Monday - Friday 8:00 a.m. to 4:30 p.m. (GMT)
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**Always use Ingersoll-Rand Replacement parts!**
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©2004 Ingersoll-Rand Company, Printed in the USA
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