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Operation & Maintenance Manual XHP700WCU CODE: HP915WCU XP1000WCU VHP750WCU MHP825WCU CODE: A CODE: D CODE: B 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 22560858 (1/05) 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Ingersoll-Rand Portable Compressor Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 General Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Complete Machine Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine Registration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Noise Emission Control Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. Compressed Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. Safety and Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C. Acoustic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D. Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F. Air Intake and Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 G. Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 H. Isolation Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 I. Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 J. Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SAFETY SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Engine Starting Fluid (Ether). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 General Information - MSA (SRG/HRG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Sound Level Data (’W’ Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Site Running Gear (SRG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 High Speed Running Gear (HSRG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Prior to Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Operating Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Wedge Diagnostic Display Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Cummins Engine Model QSL-9s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Starting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Inlet heater/Wait to start light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Emergency Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Re-Starting After an Emergency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Monitoring During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Maintenance Interval Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Protective Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Low engine fuel level switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Compressor Oil Cooler & Engine Radiator Air Charge Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Air Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Fuel Filter Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Charge Cooler Pipework:-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Running Gear/Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Engine Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Engine Lubricating Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Engine Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Compressor Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Running Gear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Speed & Pressure Regulation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Speed & Pressure Regulation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 MACHINE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Control System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 FAULT FINDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 IQ System Operating Instructions - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 IQ System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 IQ System Operating Instructions - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Low Ambient Option Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Daily Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Weekly Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Yearly Maintenance:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 5 TABLE OF CONTENTS Operation & Maintenance Manual TITLE 6 PAGE Foreword 22560858 7 Operation & Maintenance Manual Foreword Foreword The contents of this manual are considered to be proprietary and confidential to IngersollRand 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 authorised 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. 8 22560858 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. 22560858 9 **Always use Ingersoll-Rand Replacement parts!** 10 22560858 Warranty 22560858 11 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. 12 22560858 Warranty Operation & Maintenance Manual General Warranty Information Comments Portable Compressor 2.5kVA - 8kVA Generators Package 12 Months/ 2,000 Hours Covers controls, switches, sheet metal, radiator, oil cooler, receiver, pipework, electrical circuit etc. Airend 24 Months/ 4,000 Hours 60 months/10,000 hours. extended limited warranty available on major components. Refer to operator’s manual. Engine See below Package 12 Months/ 2,000 Hours Contact IR network for warranty (parts only no labour). Alternator 12 Months/ 2,000 Hours Contact IR network for warranty (parts only no labour). Engine 9kVA - 550kVA Generators See below Package 12 Months/ 2,000 Hours Covers controls, switches, sheet metal, electrical circuit etc. Alternator 24 Months/ 4,000 Hours Contact IR network for warranty. Engine Light Tower See below Package 12 Months/ 2,000 Hours Covers controls, switches, sheet metal, electrical circuit etc. Alternator 12 Months/ 2,000 Hours 2 years/4000 hours, for Lightsource introduced 8/16/99. Engine See below Engines Comments Months Hours Caterpillar 12 Unlimited Extended warranty provided via engine supplier’s own approved network at time of purchase. Cummins 24 2,000 Extended warranty provided via engine supplier’s own approved network at time of purchase. Perkins 12 Unlimited 24 1,000 22560858 If under 500 hours in first year then below applies. All components covered excluding injectors. 13 Operation & Maintenance Manual Warranty John Deere (in Compressors) 24 2,000 5 yrs/5,000 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. 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. (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 Deutz Parts Ingersoll-Rand Comments Months Hours 6 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 Comments 12 N/A 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. 14 22560858 Warranty Operation & Maintenance Manual 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. 22560858 15 Operation & Maintenance Manual Warranty 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 16 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. 22560858 Warranty 22560858 Operation & Maintenance Manual 17 **Always use Ingersoll-Rand Replacement parts!** 18 22560858 Noise Emission 22560858 19 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 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). 20 22560858 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 the 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. 22560858 21 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 seating between gasket or acoustic material and the mating frame. F. Air Intake and Engine Exhaust Engine and compressor air intake and engine exhaust systems should be inspected after each 100 hours of operation for loose, damaged, or deteriorated components. Repairs or replacements should be made before the next period of use. G. Cooling Systems All components of the cooling system for engine water and compressor oil should be inspected every 250 hours of use. Any discrepancies found should be corrected before placing the unit back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at all times during operation. H. Isolation Mounts Engine/airend isolation mounts should be inspected after each 250 hours of operation. Those mounts with cracks or splits in the molded rubber, or with bent or broken bolts due to operation or storage in severe environments, all should be replaced with equivalent parts. I. Engine Operation Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer. J. Fuels and Lubricants Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand Company and Engine Manufacturer’s Operator and Maintenance Manuals. 22 22560858 Noise Emission Operation & Maintenance Manual Table 1: MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. 22560858 DESCRIPTION OF WORK OR COMMENTS HOURMETER READING MAINT/ INSPECT DATE LOCATION CITY/STATE WORK DONE BY (NAME) 23 **Always use Ingersoll-Rand Replacement parts!** 24 22560858 Safety Symbols 22560858 25 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 Indicates important set-up, operating or maintenance information. (Blue Background) 26 22560858 Safety Symbols 22560858 Operation & Maintenance Manual 27 Operation & Maintenance Manual 28 Safety Symbols 22560858 Safety Symbols 22560858 Operation & Maintenance Manual 29 **Always use Ingersoll-Rand Replacement parts!** 30 22560858 Safety 22560858 31 Operation & Maintenance Manual Safety 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. 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 pressurised/over pressurised by another. Compressed air must not be used for a direct 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. 32 22560858 Safety Operation & Maintenance Manual 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 AVOID INHALATION Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times. The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: • anti-freeze • compressor lubricant • engine lubricant • preservative grease • rust preventative • diesel fuel • battery electrolyte 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. 22560858 33 Operation & Maintenance Manual Safety 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 and that connections are secure. DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY SINCE THIS MAY CAUSE IT TO EXPLODE. Radiator 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. 34 22560858 General Information 22560858 35 Operation & Maintenance Manual General Information General Information - MSA (SRG/HRG) 36 22560858 General Information 22560858 Operation & Maintenance Manual 37 Operation & Maintenance Manual General Information MODEL MHP825 XP1000 XHP700 VHP750 HP915 cfm (m3/min) 825 (23,3) 1000 (28,2) 700 (20,1) 750 (21,5) 915 (25,9) Normal operating discharge pressure. psi (bar) 175 (12) 125 (9) 300 (21) 200 (14) 150 (10) Safety valve setting psi (bar) 217 (15) 217 (15) 362 (25) 250 (17) 200 (14) Whisperized (W) operating ambient temperature range °F (°C) 14/115 (-10/+46) 14/115 (-10/+46) 14/115 (-10/+46) 14/115 (-10/+46) 14/115 (-10/+46) High Ambient (HA) operating ambient temperature range °F (°C) 14/122 (-10/+50) 14/122 (-10/+50) 14/122 (-10/+50) 14/122 (-10/+50) 14/122 (-10/+50) Maximum discharge temperature °F (°C) 248 (120) 248 (120) 248 (120) 248 (120) 248 (120) COMPRESSOR Actual free air delivery. COMPRESSOR Cooling system. Oil Injection Gallons/ Litres 18.5 (70) 18.5 (70) 19.8 (75) 18.5 (70) 18.5 (70) Maximum oil system temperature °°F (°C) 248 (120) 248 (120) 248 (120) 248 (120) 248 (120) Maximum oil system pressure psi (bar) 217 (15) 217 (15) 362 (25) 250 (17) 200 (14) SEE NOTE -1 Protec Protec Protec Protec Protec MHP825 XP1060 XHP750 VHP750 HP950 Oil capacity. LUBRICATING OIL SPECIFICATION (for the specified ambient temperatures). ENGINE MODEL Whisperized (W) Engine Type Displacement /litre CU QSL - 9 (8.9) CU QSL - 9 (8.9) CU QSL - 9 (8.9) CU QSL - 9 (8.9) CU QSL - 9 (8.9) Type/. Displacement (HA) /litre NA NA NA NA NA 6 6 6 6 6 Number of cylinders Oil capacity. gal (litre) 6.3 (24) 6.3 (24) 6.3 (24) 6.3 (24) 6.3 (24) Speed at full load. RPM 1800 1800 1800 1800 1800 Speed at idle. RPM 1200 1200 1300 1200 1200 Electrical system. V DC 24 24 24 24 24 Power available at rated speed hp (KW) 299 (223) 299 (223) 299 (233) 299 (223) 299 (223) Fuel tank capacity. gal (litre) 145 (550) 145 (550) 145 (550) 145 (550) 145 (550) Coolant capacity gal (litre) 12.7 (48) 12.7 (48) 12.7 (48) 12.7 (48) 12.7 (48) Max. gross weight lb 10,560 10,560 10,560 10,560 10,560 Shipping weight lb 9460 9460 9460 9460 9460 NOTE: Refer to Compressor Lubrication Chart. NA = not available 38 22560858 General Information Operation & Maintenance Manual 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. 22560858 39 **Always use Ingersoll-Rand Replacement parts!** 40 22560858 Operating Instructions 22560858 41 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). 42 22560858 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. 22560858 43 Operation & Maintenance Manual Operating Instructions 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%. ! 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). 44 22560858 Operating Instructions Operation & Maintenance Manual ! 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. 22560858 45 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. 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. 46 22560858 Operating Instructions Operation & Maintenance Manual 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 22560858 47 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. 48 22560858 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 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 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. 22560858 49 Operation & Maintenance Manual Operating Instructions ALERT CODE LIGHT BLINKS Disch. Temp (RT2) Sensor Fault Sep. Tank Pressure (PT1) Sensor Fault 33 SHUTDOWN CODE LIGHT STEADY DELAY (sec) 32 CPRSR Malfunction. 10 CPRSR Malfunction. CPRSR Malfunction. Separator Tank Pressure >20 PSI During Start Attempt (Engine Will Not Crank) 34 CPRSR Malfunction. 0 Machine Over Pressure 35 CPRSR Malfunction. 1 Safety Valve Open 36 CPRSR Malfunction. 2 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 *CAN derived data Reg. System Pressure (PT2) Sensor Fault 54 CPRSR Malfunction. Estop Button Pushed 55 CPRSR Malfunction. Minimum Pressure Not Met 56 CPRSR Malfunction. Serial Comm. Problem 70 CPRSR Malfunction. CAN Bus Problem 71 CPRSR Malfunction. Communication With Autostart Module Lost 73 CPRSR Malfunction. Dedicated Lights: Low Fuel Level Air Filter Restriction Soiled Filter Low Battery Voltage 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 50 Fuel Level 3 High Engine Temp. 22560858 Operating Instructions Operation & Maintenance Manual ALERT CODE *Engine Coolant Temperature>=220 deg. F IQ Filter Restriction High Discharge Temp. (RT2>247 deg. F) LIGHT BLINKS SHUTDOWN CODE LIGHT STEADY DELAY (sec) High Engine Temp. 10 IQ Filt. Rest 3 High Comp Temp. 3 *CAN derived data 22560858 51 Operation & Maintenance Manual Operating Instructions Cummins Engine Model QSL-9s Displayed Code 52 Definition 111 Engine Control Module - Critical internal failure 115 Engine Speed/Position Sensor Circuit - lost both of two signals from the magnetic pickup sensor 121 Engine Speed/Position Sensor Circuit - lost one of two signals from the magnetic pickup sensor 122 Intake Manifold Pressure Sensor #1 Circuit - shorted high 123 Intake Manifold Pressure Sensor #1 Circuit - shorted low 131 Accelerator Pedal Position Sensor Circuit - shorted high 132 Accelerator Pedal Position Sensor Circuit - shorted low 133 Remote Accelerator Pedal Position Sensor Circuit - shorted high 134 Remote Accelerator Pedal Position Sensor Circuit - shorted high 135 Engine Oil Pressure Sensor Circuit - shorted high 141 Engine Oil Pressure Sensor Circuit - shorted low 143 Engine Oil Pressure Low - Warning 144 Engine Coolant Temperature Sensor Circuit - shorted high 145 Engine Coolant Temperature Sensor Circuit - shorted low 146 Engine Coolant Temperature High - Warning 147 Accelerator Pedal Position Sensor Circuit - low frequency 148 Accelerator Pedal Position Sensor Circuit - high frequency 151 Engine Coolant Temperature High - Critical 153 Intake Manifold Temperature Sensor #1 Circuit - shorted high 154 Intake Manifold Temperature Sensor #1 Circuit - shorted low 155 Intake Manifold Temperature #1 High - Critical 184 Engine Control Module Identification Input State Error 211 Additional OEM/Vehicle Diagnostic Codes have been logged. Check other ECM’s for DTC’s. 221 Ambient Air Pressure Sensor Circuit - shorted high 222 Ambient Air Pressure Sensor Circuit - shorted low 22560858 Operating Instructions Displayed Code 22560858 Operation & Maintenance Manual Definition 234 Engine Speed High v Critical 235 Engine Coolant Level Low - Critical 241 Vehicle Speed Sensor Circuit - data incorrect 242 Vehicle Speed Sensor Circuit - tampering has been detected 243 Engine Brake Driver #1 Circuit - shorted low 245 Fan Clutch Circuit - shorted low 263 Fuel Temperature Sensor Circuit - shorted high 265 Fuel Temperature Sensor Circuit - shorted low 268 Fuel Pressure Sensor Circuit - data incorrect 271 High Fuel Pressure Solenoid Valve #1 Circuit - shorted low 272 High Fuel Pressure Solenoid Valve #1 Circuit - shorted high 273 High Fuel Pressure Solenoid Valve #2 Circuit - shorted low 274 High Fuel Pressure Solenoid Valve #2 Circuit - shorted high 275 Fuel Pumping Element #1 (Front) - mechanically stuck 276 Fuel Injection Control Valve Circuit - shorted high 277 Fuel Injection Control Valve - mechanically stuck 278 Fuel Priming Pump Control Circuit - shorted high/low 279 Fuel Injection Control Valve Circuit - shorted low 281 High Fuel Pressure Solenoid Valve #1 - mechanically stuck 282 High Fuel Pressure Solenoid Valve #2 - mechanically stuck 283 Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted high 284 Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted low 285 SAE J1939 Multiplexing PGN Timeout Error 286 SAE J1939 Multiplexing Configuration Error 287 SAE J1939 Multiplexing Accelerator Pedal Sensor System Error 288 SAE J1939 Multiplexing Remote Throttle Data Error 296 Auxiliary Pressure Sensor Input # 2 Engine Protection - Critical 297 Auxiliary Pressure Sensor Input # 2Circuit - shorted high 298 Auxiliary Pressure Sensor Input # 2 Circuit - shorted low 319 Real Time Clock - Power Interrupt 328 Fuel Pumping Element #2 (Rear) - mechanically stuck 329 Fuel System Leakage error 53 Operation & Maintenance Manual Displayed Code 54 Operating Instructions Definition 349 Transmission Output Shaft (Tailshaft) Speed High - Warning 352 Sensor Supply Voltage #1 Circuit - shorted low 381 Intake Air Heater (Relay Enable) #1 Circuit - data incorrect 382 Intake Air Heater (Relay Enable) #2 Circuit - data incorrect 385 OEM Sensor Supply Voltage Circuit - shorted high 386 Sensor Supply Voltage #1 Circuit - shorted high 387 Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high 415 Engine Oil Pressure Low - Critical 418 Water in Fuel Indicator High - Maintenance 422 Engine Coolant Level Sensor Circuit - data incorrect 429 Water in Fuel Sensor Circuit - shorted low 431 Accelerator Pedal Idle Validation Circuit - data incorrect 432 Accelerator Pedal Idle Validation Circuit - out of calibration 433 Intake Manifold Pressure Sensor Circuit - data incorrect 434 Power Lost without Ignition Off 441 Battery #1 Voltage Low - Warning 442 Battery #1 Voltage High - Warning 443 Accelerator Pedal Position Sensor Supply Voltage Circuit v shorted low 444 OEM Sensor Supply Voltage Low - Warning 449 Fuel Pressure High - Warning 451 Injector Metering Rail #1 Pressure Sensor Circuit - shorted high 452 Injector Metering Rail #1 Pressure Sensor Circuit - shorted low 488 Intake Manifold Temperature High - Warning 489 Transmission Output Shaft (Tailshaft) Speed Low - Warning 493 Fuel Pump Calibration Trim Circuit Error 497 Multiple Unit Synchronization Switch Circuit - data incorrect 515 Accelerator Pedal Frequency Position Sensor Supply Circuit - shorted high 516 Accelerator Pedal Frequency Position Sensor Supply Circuit - shorted low 524 OEM Alternate Droop Switch Validation - data incorrect 527 Auxiliary Input/Output #2 Circuit - shorted high 528 OEM Alternate torque validation switch - data incorrect 529 Auxiliary Input/Output #3 Circuit - shorted high 22560858 Operating Instructions Displayed Code 22560858 Operation & Maintenance Manual Definition 539 Injector Control Valve Electronic Filter (Transorb) Error 551 Accelerator Pedal Idle Validation Circuit - shorted low 599 OEM Commanded Dual Output Shutdown 611 Engine Hot Shutdown 55 Operation & Maintenance Manual Operating Instructions 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 56 • 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. 22560858 Operating Instructions Operation & Maintenance Manual 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 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. 22560858 57 Operation & Maintenance Manual ! Operating Instructions 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. 58 22560858 Operating Instructions Operation & Maintenance Manual 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:- 22560858 • 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. 59 **Always use Ingersoll-Rand Replacement parts!** 60 22560858 Maintenance 22560858 61 Operation & Maintenance Manual Maintenance Maintenance Maintenance Interval Chart Maintenance Interval Chart Initial 500 miles /850 km 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 C Fan/Alternator Belts C Battery Connections/Electrolyte C Tire Pressure and Surface C *Wheel Lug Nuts C Hoses (Oil, Air, Intake, etc.) C Automatic Shutdown System C Air Cleaner System C Compressor heat exchanger exterior C * Engine heat exchanger exterior C Air Cleaner Elements 3 Monthly. 500 hrs. 6 Monthly. 1000 hrs 12 Monthly. 2000 hrs D Air Cleaner Precleaner Dumps Fasteners, Guards 62 Daily C R/WI 22560858 Maintenance Operation & Maintenance Manual *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. 22560858 63 Operation & Maintenance Manual Initial 500 miles/ 850 km Daily Weekly Maintenance 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 CU Engine Oil Filter R CU R *Water Pump Grease. *Wheels (Bearings, Seals, etc.) C C *Engine Coolant Fuel Filter Element (Service interval varies with fuel quality) R R CU C *Injection Nozzle Check 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 64 12 Monthly. 2000 hrs C T Fasteners C Running gear linkage G Running gear bolts(1) C 22560858 Maintenance Operation & Maintenance Manual *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. 22560858 65 Operation & Maintenance Manual Initial 500 miles /850 km Maintenance Daily Weekly Monthly 3 Monthly. 500 hrs. 6 Monthly. 1000 hrs 12 Monthly. 2000 hrs CR Separator tank (2) exterior C Lubricator (Fill) * 2 Yrs Safety valve 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. 66 22560858 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. • 22560858 Disconnect batteries. 67 Operation & Maintenance Manual Maintenance 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. 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:- 68 • 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. 22560858 Maintenance Operation & Maintenance Manual 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. ! 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. 22560858 69 Operation & Maintenance Manual Maintenance 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. 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. 70 22560858 Maintenance Operation & Maintenance Manual 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. 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). 22560858 71 Operation & Maintenance Manual ! Maintenance 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 & 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. ! 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. 72 22560858 Maintenance Operation & Maintenance Manual 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. 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. 22560858 73 Operation & Maintenance Manual Maintenance 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). 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). 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. 74 22560858 Maintenance Operation & Maintenance Manual 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. 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. 22560858 75 Operation & Maintenance Manual Maintenance 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. 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. 76 22560858 Maintenance Operation & Maintenance Manual 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. ! 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. 22560858 77 Operation & Maintenance Manual Maintenance 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. XP1000, XP950, HP915, MHP825, VHP750 Key 78 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 D Unloader solenoid H K Unloader Panel pressure gauge 22560858 Maintenance Operation & Maintenance Manual Speed & 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 maximum allowable pressure (refer to GENERAL INFORMATION). 22560858 79 Operation & Maintenance Manual Maintenance XHP700 Key 80 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 22560858 Maintenance Operation & Maintenance Manual Speed & 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 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’. ! CAUTION 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 anticlocwise to reduce pressure. RATED OPERATING PRESSURE: XHP650 350psig XHP750 300psig SHP825 250psig 22560858 81 Operation & Maintenance Manual Maintenance Torque Values 82 22560858 Maintenance Operation & Maintenance Manual Table 1: Wheel Torque Chart - Inch Wheel Torque Chart - Metric 1/2” lug nuts Torque (Ft-Lbs) Torque (N-m) Torque (ft-Lbs) 13” Wheel 80-90 15” Wheel 105-115 M12 Bolts 85-95 62-70 16” Wheel 105-115 M14 Bolts 145-155 107-115 16.5” Wheel 105-115 M16 Bolts 175-185 129-137 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 22560858 105-115 83 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. NOTE: Compressor oil carryover (oil consumption) may be greater with the use of alternative fluids. Design Operating Pressure Ambient Temperature Specification 100 psi to 300 psi -10°F to 125°F (-23°C to 52°C) Preferred: IR Pro-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) 84 Preferred: XHP605, IR XHP1001 22560858 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) 5 gal. (208.2 Litre) 220 gal. (836 litre) 36899698 36899706 36899714 36899722 IR XHP605 -- 22252076 22252050 22252068 IR XHP1001 -- 35612738 35300516 -- XHP405 -- 22252126 22252100 22252118 54480918 36875938 36866903 -- Preferred: IR Pro-TecTM Engine Oil 22560858 85 **Always use Ingersoll-Rand Replacement parts!** 86 22560858 Machine Systems 22560858 87 Operation & Maintenance Manual Machine Systems Control System Schematic 88 22560858 Machine Systems Operation & Maintenance Manual Key BAT Battery PM Plug, machine ID BDS Battery disconnect switch RS Relay-spst CO RS232C comms RT1 Thermistor, separator tank temperature -30 - 255°F ECON Engine controller RT2 Thermistor, airend discharge temperature -30 - 255°F ES Engine speed ESTOP Emergency stop FT Frequency throttle. Range = 150Hz(1200 RPM) to 375Hz(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 batery disconnect 0–225 PSIG - HP935, VHP750, MHP825, XP1060 TE Transducer excitation 0–500 PSIG - XHP750, XHP650, SHP825 WCON Wedge controller PT2 22560858 Pressure transducer, regulation system 0-100 PSIG 89 Operation & Maintenance Manual 90 Machine Systems 22560858 Machine Systems Operation & Maintenance Manual CUMMINS QSL-9 LOW PRESSURE ELECTRICAL PARTS MHP825, XP1000, VHP750, HP915 PART NUMBERS 22560858 DESCRIPTION QTY PER MACHINE 22162572 IQ HARNESS OPTION 1 36899599 IQ FILTER SWITCH 1 36899615 IQ FILTER SWITCH 1 54474572 COOLANT LEVEL SWITCH 1 36896975 SW MASTER DISCONNECT 1 36920825 0-100 PRESSURE TRANS 1 54496773 0-225 PRESSURE TRANS 1 36892362 24V SEALED RELAY 2 36785319 MAG SPEED SENSOR 1 36898922 THERMISTOR PROBE 1 36840481 SOLENOID VALVE 1 36847838 AIR FILTER RESTRICTION INDICATOR SWITCH 2 36870608 ENGIINE OIL PRESSURE SENDER 1 36841138 COMPRESSOR AND ENGIINE TEMPERATURE SENDER 2 36757581 COMPRESSOR OIL PRESSURE SWITCH 1 36850691 COMPRESSOR MOTOR 1 35577873 RELAY, MAGNETIC 24V K1 1 36841526 CONTROL HEATER 2 26854677 REGULATOR HEATER 1 54658323 NEGATIVE BATTERY CABLE 1 54658331 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 22173579 WEDGE CONTROLLER 1 22110779 W1 CHASSIS HARNESS 1 22094650 HARNESS DIAGRAM 22101968 INLET HEATER, 120 AMPS 1 36853521 INLET HEATER RELAY 1 89303127 EMERGENCY STOP OPERATOR 1 89303135 NC E-STOP CONTACT BLOCK 2 N/A 91 Operation & Maintenance Manual Machine Systems CUMMINS QSL-9 HIGH PRESSURE ELECTRICAL PARTS XHP700 PART NUMBERS 92 DESCRIPTION QTY PER MACHINE 22162572 IQ HARNESS OPTION 1 36899599 IQ FILTER SWITCH 1 36899615 IQ FILTER SWITCH 1 54474572 COOLANT LEVEL SWITCH 1 36896975 SW MASTER DISCONNECT 1 36920825 0-100 PRESSURE TRANS 1 54765946 0-500 PRESSURE TRANS 1 36892362 24V SEALED RELAY 2 36785319 MAG SPEED SENSOR 1 36898922 THERMISTOR PROBE 1 36842300 START/RUN SOLENOID VALVE 1 36840481 SOLENOID VALVE 1 36847838 AIR FILTER RESTRICTION INDICATOR SWITCH 2 36870608 ENGIINE OIL PRESSURE SENDER 1 36841138 COMPRESSOR AND ENGIINE TEMPERATURE SENDER 2 36757581 COMPRESSOR OIL PRESSURE SWITCH 1 36850691 COMPRESSOR MOTOR 1 35577873 RELAY, MAGNETIC 24V K1 1 36841526 CONTROL HEATER 2 54658323 NEGATIVE BATTERY CABLE 1 54658331 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 22173579 WEDGE CONTROLLER 1 22110779 W1 CHASSIS HARNESS 1 22094650 HARNESS DIAGRAM 22101968 INLET HEATER, 120 AMPS 1 36853521 INLET HEATER RELAY 1 89303127 EMERGENCY STOP OPERATOR 1 89303135 NC E-STOP CONTACT BLOCK 2 N/A 22560858 Fault Finding 22560858 93 Operation & Maintenance Manual Fault Finding Fault Finding FAULT No reaction from instrument panel when key turned to (I) position. Engine fails to start. Engine stops while in service or is reluctant to start. Engine starts but stalls when the switch returns to position 94 CAUSE REMEDY Emergency stop actuated. Reset emergency stop button. Batteries not connected. Connect batteries. Fuse at starter motor ‘blown’. Replace fuse. 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. 22560858 Fault Finding FAULT Engine starts but will not run or engine shuts down prematurely. Operation & Maintenance Manual CAUSE REMEDY 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. Refer also to the Engine Manufacturer’s Manual. 22560858 95 Operation & Maintenance Manual FAULT Air discharge capacity too low. Compressor overheats. Excessive oil present in the discharge air. 96 Fault Finding CAUSE REMEDY 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. 22560858 Fault Finding FAULT Safety valve operates. 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. 22560858 Operation & Maintenance Manual CAUSE REMEDY Operating pressure too high. Check the setting and operation of the regulator valve piping. Incorrect setting of the regulator. Adjust the regulator. Faulty regulator. Replace the regulator. Inlet valve set incorrectly. Refer to SPEED AND PRESSURE REGULATION ADJUSTMENT in the MAINTENANCE section of this manual. Loose pipe/hose connections. Check all pipe/hose connections. Faulty safety valve. Check the relieving pressure. Replace the safety valve if faulty. DO NOT ATTEMPT A REPAIR. 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. 97 **Always use Ingersoll-Rand Replacement parts!** 98 22560858 Options 22560858 99 Operation & Maintenance Manual Options Options IQ System Operating Instructions - 1 Key 100 1 Three way valve 5 Filters 2 Ball valve1¼” 6 Aftercooler 3 Ball valve2” 7 Minimum pressure valve 4 Safety valve 8 Separator tank 22560858 Options 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, high-efficiency filtration, and a patented condensate disposal system to provide the cool, clean air. The condensate disposal system injects all liquid condensed from the moisture separator and filters into the engine exhaust system where it is vaporized by heat. This eliminates the need for collecting the condensate, and the added cost of disposing of the condensate, which is often regulated by local, state, and/or federal regulations. When equipped with the low ambient feature, the IQ System automatically adjusts movable louvers to control airflow through the aftercooler, ensuring that the compressed air temperature always remains above freezing temperatures (typically 45°F (7°C)) at any ambient temperature down to -10°F (-23°C). This prevents the need for 120V AC heat tracing systems, or any manual adjustment to prevent freezing of the compressed air system. All drain points for the condensate handling system are heated with 24VDC heaters, which are integral to the compressor heater system. Standard Non-Louvered configuration not to be operated below freezing. IQ System Operating Instructions - 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. 22560858 101 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 102 • 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. 22560858 Options Operation & Maintenance Manual • Remove and replace the filter element, being careful not to damage outer wrap. Verify the part number of new element vs. old element, as the two IQ filters are of different media. 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. 22560858 103 **Always use Ingersoll-Rand Replacement parts!** 104 22560858 ©2004 Ingersoll-Rand Company, Printed in the USA ">

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