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OPERATION and MAINTENANCE MANUAL COMPRESSOR MODELS P105WJD P130WJD P160WJD P175WJD CODE: CODE: D This manual contains important safety information. Do not destroy this manual. This manual must be available to the personnel who operate and maintain this machine. 501 Sanford Ave Mocksville, N.C. 27028 Book 22478325 (2/05) Revised (10-12) Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Doosan Company or the products of either. 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 TITLE PAGE FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 DRAWBAR NOTICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Drawbar Notice - This machine may have been shipped from the factory with the drawbar positioned upright. To convert from Shipping Position to Towing Position. . . . . . . . . . 2-2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 General Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 WARRANTY REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Complete Machine Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 This section pertains only to machines distributed within the United States. . . . . . . . . . . . . . . . . . . 3-30 Noise Emission Control Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 General Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 ENGINE (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 UNITS MEASUREMENTS WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 EXPENDABLE SERVICE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 SECTION 5 - OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 BEFORE TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 1-1 TABLE OF CONTENTS TITLE PAGE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Compressor Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Receiver-Separator Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Exterior Finish Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58 Action Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58 Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59 1-2 Foreword 1 Foreword Foreword Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll-Rand products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such products, which are available upon request. This manual contains instructions and technical data to cover all routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be referred to an authorized Ingersoll-Rand service department. All components, accessories, pipes and connectors added to the compressed air system should be: • of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Ingersoll-Rand. • clearly rated for a pressure at least equal to the machine maximum allowable working pressure. • compatible with the compressor lubricant/coolant. • accompanied with instructions for safe installation, operation and maintenance. Details of approved equipment are available from Ingersoll-Rand Service departments. The use of repair parts other than those included within the Ingersoll-Rand approved parts list may create hazardous conditions over which Ingersoll-Rand has no control. Therefore, Ingersoll-Rand cannot be held responsible for equipment in which non-approved repair parts are installed. Ingersoll-Rand reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. The intended uses of this machine are outlined below and examples of unapproved usage are also given. However, Ingersoll-Rand cannot anticipate every application or work situation that may arise. If in doubt, consult supervision. This machine has been designed and supplied for above ground operation to be used for compression of normal ambient air containing no additional gases, vapors or particles within the ambient temperature range specified in the general data section of this manual. This machine should not be used: A. For direct or indirect human consumption of the compressed air. B. Outside the ambient temperature range of minus 20°F to 115°F. C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists. D. With other than Ingersoll-Rand approved components. E. With guards, or controls or switches missing or disabled. F. For storage or transportation of materials inside or on the enclosure. This company accepts no responsibility for errors in translation of this manual from the original English version. 2 Foreword 3 Foreword 4 Drawbar Notice 1 Drawbar Notice Drawbar Notice - This machine may have been shipped from the factory with the drawbar positioned upright. To convert from Shipping Position to Towing Position. The following tools are required: Ratchet and 13mm socket to fit ratchet Torque wrench set to 68 foot pounds (9.4 kg-meters) 16mm socket to fit torque wrench 5 inch extension for torque wrench Hardware included: (4) 12mm bolts with pre-applied thread lock, (2) 8mm Taptite bolts, (2) Washers, (2) Safety Chains 1. Remove hardware box from compressor toolbox. 2. Open box and remove the bag containing hardware, safety chains and assembly instructions. 3. Using the jack, raise the front of the unit so that the legs are approximately 1 inch above the ground. 4. Remove the temporary retaining bolts from both sides of the frame at the drawbar connection (See Fig. 1). 5. Carefully lower drawbar to the Level Position. 6. Install the four bolts (with pre-applied thread lock) to the four points inside the enclosure and torque to 68 ft. lbs. (9.4kg-m) (See Fig.2). 7. Install safety chains by sliding the second link of one chain into the slot in drawbar plate. Fasten chain to plate using taptite and washer. Repeat for other chain. 2 Section 1 - Safety 3 Operating & Maintenance Manual Safety Safety Precautions General 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 manual holder if equipped, are not removed permanently from the machine. Compressed air must not be used for a feed to any form of breathing apparatus or mask. Ensure that maintenance personnel are adequately trained, competent and have read the manuals. The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible. Make sure that all protective covers are in place and that the canopy/doors are closed during operation. If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided. The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas. If such an application is required then all local regulations, codes of practice and site rules must be observed. To ensure that machine can operate in a safe and reliable manner, additional equipment such as gas detection, exhaust spark arrestors, and intake (shut-off) valves may be required, dependent on local regulations or the degree of risk involved. When using compressed air, always use appropriate personal protective equipment. Air discharged from this machine may contain carbon monoxide or other contaminants which will cause serious injury or death. Do not breathe this air. Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally. Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel. All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine safety valve rating. If more than one compressor is connected to 4 one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidentally be pressurized or over pressurized by another. 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. Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. Never operate the engine of this machine inside a building without adequate ventilation. Avoid breathing exhaust fumes when working on or near the machine. Do not alter or modify this machine. A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water. Exercise extreme caution when using booster battery. To jump battery, connect Safety ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After starting unit, always disconnect cables in reverse order. Operating & Maintenance Manual Ether is an extremely volatile, highly flammable gas. USE SPARINGLY! DO NOT use ETHER if unit has GLOW Plug starting aid. Engine damage will result. Never allow the unit to sit stopped with the pressure in receiver-separator system. As a precaution, open manual blowdown valve. High Pressure Air can cause serious injury or death. Relieve pressure before removing filler plugs/caps, fittings or covers. Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, blow gun tips, etc. well away from moving parts. Air pressure can remain trapped in air supply line which can result in serious injury or death. Always carefully vent air supply line at tool or vent valve before performing any service. Make sure wheels, tires and tow bar connectors are in safe operating condition and tow bar is properly connected before towing. This machine produces loud noise with doors open or service valve vented. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open or service valve is vented. Never inspect or service unit without first disconnecting battery cable(s) to prevent accidental starting. Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing pressure cap. Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent debris from injuring eye(s). Disconnected air hoses whip and can cause serious injury or death. Always attach a safety flow restrictor to each hose at the source of supply or branch line in accordance with OSHA Regulation 29CFR Section 1926.302(b). Whenever the machine is stopped, air will flow back into the compressor system from devices or systems downstream of the machine unless the service valve is closed. Install a check valve at the machine service valve to prevent reverse flow in the event of an unexpected shutdown when the service valve is open. Stop machine to add fuel. Hazardous Substance Precaution The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly. Avoid ingestion, skin contact and breathing fumes for the following substances: Antifreeze, Compressor Oil, Engine Lubricating Oil, Preservative Grease, Rust Preventative, Diesel Fuel and Battery Electrolyte. : Rotating fan blade can cause serious injury. Do not operate without guard in place. Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). 5 Operating & Maintenance Manual Safety Look for these signs on machines shipped to international markets outside North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor. 6 Safety Operating & Maintenance Manual 7 Operating & Maintenance Manual 8 Safety Safety Operating & Maintenance Manual Look for these signs on machines shipped to markets in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor. ! DANGER DANGER (Red Background) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. ! WARNING WARNING (Orange Background) indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. ! CAUTION CAUTION (Yellow Background) indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE NOTICE (Blue Background) indicates important set-up, operating or maintenance information. 9 Operating & Maintenance Manual 10 Safety Safety Operating & Maintenance Manual 11 Operating & Maintenance Manual Safety Table 1: FREE SAFETY DECALS Safety Decals are available free of charge. Safety Decals are identified by the decal heading: DANGER, WARNING, or CAUTION. Decal part numbers are on the bottom of each decal and are also listed in the compressor’s parts manual. Submit orders for Safety Decals to the Mocksville Parts Service Department. The no charge order should contain only Safety Decals. Help promote safety! Assure that decals are present on the machines. Replace decals that are not readable. 12 Section 2 - WARRANTY 13 Operating & Maintenance Manual WARRANTY WARRANTY Ingersoll-Rand, through its distributors, warrants to the initial user that each portable air compressor manufactured by it, will be free of defects in material and workmanship for a period of the earlier of twelve (12) months from shipment to or the accumulation of 2,000 hours of service by the initial user. Portable compressor airends will be free of defects in material and workmanship for a period of the earlier of twenty four months from shipment to or the accumulation of 4,000 hours of service by the initial user. The warranty against defects will include replacement of the complete airend, provided the original airend is returned assembled and unopened. Portable Compressor Airend Limited Optional Warranty - The earlier of sixty (60) months from shipment to or the accumulation of 10,000 hours of service. The optional warranty is limited to defects in rotors, housings, bearings and gears and is automatically available when meeting the following conditions: The original air end is returned assembled and unopened. Continued use of genuine Ingersoll-Rand parts, fluids, oil and filters. 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. 14 WARRANTY Operating & Maintenance Manual General Warranty Information GENERAL WARRANTY Portable Compressor Extended Coverage Package 1 year/2000 hours None Airend 2 years/4000 hours 5 years/10,000 hours Limited warranty Package 1 year/2000 hours None Generator 2 years/4000 hours None Portable Genset 2 KW Package 2 months PARTS ONLY None Portable Genset 3,5,7 KW Package 1 year/1000 hrs PARTS ONLY None Light Tower Package 1 year/2000 hours Generator 1 year/2000 hours Light Concrete Products (power buggy, screeds, mixers, saws, vibrators) Package 1 year PARTS ONLY None Light Compaction Equipment (plate and drum compactors and rammers) Package 1 year PARTS and LABOR None Backhoe, Loaders, Wheel Loaders Package 1 year None Portable Genset 8KW, 11KW, 20KVA thru 575KVA 2 years/4000 hours, for Lightsource ONLY. ENGINES Months Hours Extended Coverage Caterpillar 12 No Limit Available at dealer Cummins 24 2000 Major components 3 yrs/10,000 hours - available at dealer John Deere (IN COMPRESSORS) 24 2000 5 yrs/5000 hours using JD fluids & filters with $250 deductible. 5 yrs/5000 hours using IR fluids and filters with $0 deductible. (IN GENERATORS AS OF 1/1/01) 24 2000 2 yrs/4000 hours using IR fluids & filters Deutz (Model 2011) 24 2000 Major components 3 yrs/3000 hours Deutz (Model 2012) 24 2000 Major components 3 yrs/3000 hours Ingersoll-Rand 24 4000 5 years/10,000 hours requires IR Fluids and Filters. Kubota (North America Only) 24 2000 Major components 36 months/3000 hrs - PARTS ONLY THROUGH DEALERS ONLY. (Western Europe & Oceania) 24 2000 None (Central & South America, Asia, Middle East & Africa) 12 1000 None Mitsubishi 24 2000 2 years/4000 hours requires IR fluids and filters, through IR dealers only. Volvo 24 2000 2 years/4000 hours requires IR fluids and filters, through IR dealers only. Honda 12 None 15 Operating & Maintenance Manual WARRANTY PARTS Ingersoll-Rand 6 months Hours - No Limit Coverage - Parts Only AIREND EXCHANGE - Extended Coverage Airend 12 months 2000 hours 5 yrs/10,000 hrs requires IR oil and filters. Note: Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with each new product. 16 WARRANTY Operating & Maintenance Manual WARRANTY REGISTRATION Complete Machine Registration Machines shipped to locations within the United States do not require a warranty registration unless the machine status changes (i.e. change of ownership). Machines shipped outside the United States require notification be made to initiate the machine warranty. Fill out the Warranty Registration Form in this section, keep a copy for your records and mail form to: Ingersoll-Rand Company Portable Compressor Division P.O. Box 868 Mocksville, North Carolina 27028 Attn: Warranty Department NOTE: Completion of this form validates the warranty. 17 Operating & Maintenance Manual 18 WARRANTY WARRANTY Operating & Maintenance Manual Selling Distributor Servicing Distributor WARRANTY REGISTRATION Name _________________ Name _________________ Owner/User Name _________ Address ________________ Address ________________ Address _________________ City ___________________ City ___________________ City_____________________ County _________________ County _________________ County __________________ State _________________ State ___________________ State Zip Code _______________ Zip Code _______________ Zip Code_________________ Telephone ______________ Telephone ______________ Telephone _______________ __________________ Complete the Applicable Blocks Owner / User Type of Business (check one only) Construction-Heavy (highway, excavation, etc.) Asphalt Contractor Coal Mining Other Mining Construction-Light (carpentry, plumbing, pools, mason, etc.) Government (municipal, state, county, etc.) Quarry Shallow Oil & Gas Rental (rental center, Building Contractor Waterwell Utility Company Industrial (plant use) Other specify Exploration Utility Contractor rental fleet, etc.) Model Unit Hours Unit S/N Engine S/N Date Delivered Airend S/N Truck S/N Truck Engine S/N SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT 1. The Purchaser has been instructed and/or has read the manual and understands proper preventative maintenance, general operation and safety precautions. 2. The warranty and limitation of liability has been reviewed and understood by the owner/ user. 3. In the event that this unit is to be used within a nuclear facility, the owner/user shall notify Ingersoll-Rand of such use so that Ingersoll-Rand may arrange for appropriate nuclear liability protection from the owner-licensee of the facility. 4. Ingersoll-Rand reserves the right to make design changes or modifications of IngersollRand products at anytime without incurring any obligation to make similar changes or modifications on previously sold units. 19 Operating & Maintenance Manual 20 WARRANTY Section 3 - Noise Emission 29 Operating & Maintenance Manual Noise Emission Noise Emission This section pertains only to machines distributed within the United States. ! WARNING Tampering with Noise Control System Prohibited Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or 2. the use of the compressor after such device or element of design has been removed or rendered inoperative by any person. Among those acts included in the prohibition against tampering are these: 3. Removal or rendering inoperative any of the following: a.the engine exhaust system or parts thereof b.the air intake system or parts thereof c.enclosure or parts thereof 4. Removal of any of the following: a.fan shroud b.vibration mounts c.sound absorption material 5. Operation of the compressor with any of the enclosure doors open. Compressor Noise Emission Control Information A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of design incorporated into this compressor in compliance with noise control act; B. The use of this compressor after such device or element of design has been removed or rendered inoperative. NOTE: The above information applies only to units that are built in compliance with the U.S. Environmental Protection Agency. Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor. 30 Noise Emission Operating & Maintenance Manual Noise Emission Control Maintenance Log COMPRESSOR MODEL __________________________ SERIAL NO. ___________________________________ USER UNIT NO. ________________________________ UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Engine Make & Model: ________________ __________________________________ 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. Introduction The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air Compressors. The purpose of this book is to provide (1) the Maintenance Performance Schedule for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when. The Maintenance Schedule and detailed instructions on the maintenance items are given on following page. 31 Operating & Maintenance Manual Maintenance Schedule Item A. B. C. D. E. F. G. H. I. J. Area Period Compressed Air Leaks Safety and Control Systems Acoustic Materials Fasteners Enclosure Panels Air Intake & Engine Exhaust Cooling Systems Isolation Mounts Engine Operation Fuels & Lubricants As Detected As Detected Daily 100 hours 100 hours 100 hours 250 hours 250 hours See Operator’s Manual 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). Noise Emission 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 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. 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. C. Acoustic Materials H. Isolation Mounts 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. 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. B. Safety and Control Systems I. Engine Operation 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 32 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 IngersollRand Company and Engine Manufacturer’s Operator and Maintenance Manuals. Noise Emission Operating & Maintenance Manual Maintenance Record For Noise Emission Control And Extended Warranty Item No. Description Of Work Hourmeter Reading Maint/inspect Date Location City/state Work Done By (Name) 33 Operating & Maintenance Manual 34 Noise Emission Section 4 - General Data 35 Operating & Maintenance Manual General Data General Data Models: P105 P130 P160 P175 Air Delivery (cfm (litres/sec) 105 (50) 130 (61) 160 (76) 175 (83) Engine Speed - RPM (Full Load) 2000 2000 2250 2400 Engine Speed - RPM (No Load) 2000 2000 1700 1700 COMPRESSOR Rated Operating Pressure - psi (kPa).......................100 psi (689) Safety Valve Setting - psi (kPa) ................................150 psi (1034) Net Weight (less fuel) pounds...................................2070 ENGINE (DIESEL) Manufacturer.............................................................John Deere Model ........................................................................3029 Electrical System ......................................................12 VDC FLUID CAPACITIES Compressor Lubricant...............................................12 quarts (11.4 litres) Engine Crankcase Lubricant.....................................10.8 quarts (10.2 litres) Fuel Tank .................................................................27 U.S. gal. (103 litres) UNITS MEASUREMENTS WEIGHTS . . . . . . . . . . . . . . . Overall Length...........................................................11.5 (3.5 meters) Overall Height ...........................................................5.2 feet (1.46 meters) Overall Width ............................................................5.7 feet (1.74 meters) Track Width...............................................................4.9 feet (1.49 meters) Weight (with fuel) ......................................................2325 lbs (1054 kgf) Weight (less fuel) ......................................................2130 lbs (966 kgf) 36 General Data Operating & Maintenance Manual EXPENDABLE SERVICE PARTS Compressor Oil Filter Element..................................36897353 Compressor Oil Separator Element ..........................54625942 Air Cleaner Element Primary (Compressor) .............35393685 Optional Secondary (Compressor) ...........................35393651 Air Cleaner Element (Engine) ...................................35393685 Optional Secondary (Engine)....................................35393651 Engine Oil Filter Element .........................................35308030 Engine Fuel Filter Element........................................36534659 ! WARNING Modification or alteration of this machine. Can result in severe injury or death. Do not modify or alter without the express written consent of Ingersoll-Rand Co. 37 Operating & Maintenance Manual 38 General Data SECTION 5 - OPERATION 39 Operating & Maintenance Manual BEFORE TOWING ! SECTION 5 - OPERATION towing. SETTING UP (ALL UNITS) WARNING Failure to follow these instructions CAN cause severe injury or death. • Position as level as possible. The design of these units permits a 15 degree sidewise limit on out-of-level operation. • Assure tow vehicle has towing capacity for weight of this unit as stated on general data decal. • When the unit is to be operated outof-level, it is important: • Position the tow vehicle to align its hitch with the pintle eye or coupler of the compressor. 1. To keep the engine crankcase oil level near the high level mark (with the unit level). • Engage the parking brake and chock the tires of the tow vehicle. 2. To have the compressor oil level gauge show no more than mid-scale. Do not overfill either the engine crankcase or the compressor lubricating oil system. • Stand to the side and ensure pin is FULLY inserted (secure) in tube of jack. . • Crank jack to seat pintle eye or coupler onto hitch. Latch and lock hitch. Cross safety chain(s) under drawbar. Attach to vehicle • Crank jack to raise pad off the ground. Pull pin from tube of jack. • Fold jack handle down and forward. Swing up jack tube and FULLY insert pin in tube. • Remove tire chocks. 3. The side doors must be closed to maintain a cooling air path and to avoid recirculation hot air. TOWING ! WARNING Failure to follow these instructions CAN cause severe injury or death. • Ensure that tires, wheels and running gear are in good condition and secure. • Test brakes, if so equipped. • Ensure that tires are inflated to 35 psi. • Test lights (running, stop, and turn signals). ! WARNING Always raise (or remove) jack for maximum ground clearance before 40 • Do not tow this unit in excess of 65 mph. • Use a tow vehicle whose towing capacity is greater than the gross weight of this unit. SECTION 5 - OPERATION Operating & Maintenance Manual DISCONNECT • Engage tow vehicle parking brake. • Chock tires of compressor. • Set the vehicle parking brake. Chock wheels of unit. • Standing to the side, remove pin from tube of jack. • Disconnect safety chains. Crank jack to raise eye or coupler from hitch. Tow vehicle can be moved. UTILITY PACKAGE SET-UP (no running gear) This unit must be located on vehicle bed to allow access for normal servicing and maintenance. The air going into the inlet must be relatively free of oil, dirt, soot and other debris. It must be no more than 10 degrees F. (5 degrees C) over the ambient temperature. 41 Operating & Maintenance Manual CONTROL PANEL - Diagnostics/Auto Shutdown (Standard and Optional) SECTION 5 - OPERATION 11. Low Fuel Level - Must add fuel to operate. 12. Fuel Level Gauge - Indicates amount of fuel in tank. 13. Engine Speed Gauge - Indicates engine speed. 14. Discharge Air Temp. Gauge Indicates in °F (82°C) to 210°F (99°C). 15. Engine Oil Pressure Gauge Indicates engine oil pressure. 16. Engine Water Temp. Gauge Indicates coolant temperature, with normal operating range from 180°F (82°C) to 210°F (99°C). 17. Voltmeter - Indicates battery condition. Instruments & Controls (STANDARD) 1. Compressor Discharge Pressure Gauge - Indicates pressure in receiver tank, psi (kPa). 2. Hourmeter - Records running time for maintenance. 3. Power Switch - Rotate “ON” to activate system prior to starting. Rotate “OFF” to stop engine. Instruments & Controls (OPTIONAL) 4. High Engine Temperature - Coolant above 220°F (104°C). 5. Low Engine Oil Pressure - 12 psi or less. 6. High Compressor Temperature 248°F (120°C) 7. Air Filters Restricted - Needs servicing. 8. Spare 9. Spare 10. Alternator Not Charging - Needs attention. 42 18. Ether Inject Button - Injects a measured shot. USE SPARINGLY. 19. Service Air Button - After warm-up, PUSH. Provides full air pressure at the service outlet. Indicates engine speed. 20. Spare 21. Spare SECTION 5 - OPERATION Before Starting • Open service valve(s) to ensure pressure is relieved in receiver-separator system. Close valve(s) in order to build up full air pressure and ensure proper oil circulation. • Check battery for proper connections and condition. • Check battery for proper connections and condition. Operating & Maintenance Manual ! WARNING This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve (s) are open. • Close all doors to maintain a cooling air path and to avoid recirculation of hot air. This will maximize the life of the engine and compressor and protect the hearing of surrounding personnel. • Check engine coolant level. • Be sure no one is IN or ON the compressor unit. ! WARNING Do not remove pressure cap from a HOT radiator. Allow radiator to cool down before removing pressure cap. Use extreme care when removing a pressure cap from a liquid cooling system for the engine. The sudden release of pressure from a heated cooling system can result in a loss of coolant and possible severe personal injury. • Check the engine oil level. Maintain per marks on dipstick. • Check the fuel level. Add only CLEAN DIESEL fuel for maximum service from the engine. • Check the compressor lubricating fluid level between bottom and midway of the sight glass on the separator tank. ! WARNING Unrestricted air flow from a hose will result in a whipping motion of the hose which can cause severe injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure in case of hose failure or other sudden pressure release. Reference: OSHA regulation 29 CFR Section 1926.302 (b). Starting • Turn the POWER switch to “ON”. • Turn Power switch to “START” position to crank engine. Hold switch in “START” position for approximately 5 seconds after engine starts. 43 Operating & Maintenance Manual NOTICE Do not operate the starter motor for more than 10 seconds without allowing at least 30 seconds cooling time between start attempts. Release Power Switch (it will automatically move to the “ON” position) when the engine starts and sustains running. • Allow engine to warm up 5 to 10 minutes. • If so equipped, press the “Service Air Button”. Open air service valve(s). Cold Weather Starting a. Turn power switch to the glow plug position and hold 10 seconds. Then turn to start. NOTICE Engine is equipped with glow plugs for cold starting aid. Do not use ETHER/ starting fluid. Engine damage can occur. NOTICE Exercise extreme caution when using a booster battery to start. To jump start: Connect the ends of one booster cable to the positive (+) terminals of each battery. Then connect one end of the other cable 44 SECTION 5 - OPERATION to the negative (-) terminal of the booster battery and the other end to the engine block. NOT TO THE NEGATIVE (-) TERMINAL OF THE WEAK BATTERY. Units With Optional Diagnostics Lamps NOTICE None of the panel lamps should be glowing when machine is operating. If they are, shut unit down and refer to Trouble Shooting Section. Stopping NOTICE Whenever the machine is stopped, air will flow back into the compressor system from devices or systems downstream of the machine unless the service valve is closed. Install a check valve at the machine service valve to prevent reverse flow in the event of an unexpected shutdown when the service valve is open. SECTION 5 - OPERATION Close air service valves. • Allow the unit to run at idle for 3 to 5 minutes to reduce the engine temperatures. • Turn Power Switch to “OFF” position. • When the engine stops, automatic blowdown valve should relieve system air pressure. If automatic blow-down valve malfunction is suspected, open manual blowdown valve. Operating & Maintenance Manual the engine. Compressor Air/Oil Temperature: • At the airend outlet. • In separator tank. UNITS WITH DIAGNOSTIC LAMPS In a shutdown situation, the function of the panel lamps is to indicate what specific failure caused the unit to shut down. These lamps will remain illuminated until the Power Switch is turned “OFF”. • Never allow unit to sit under pressure when engine is not running. ! WARNING Since the service valve is closed, air downstream of the valve may be trapped. A vent hole in the service valve will slowly bleed air from the hose. Do not disconnect hoses until all pressure has been vented. NOTICE Do NOT wire around or bypass a shutdown sensor or switch. Machine has shutdown and sensors as follows: • Low Engine oil pressure, in the engine. • High engine coolant temperature, in 45 Operating & Maintenance Manual SECTION 5 - OPERATION Speed and Pressure Regulator Adjusting Instructions The engine idle and full speed settings are set and sealed at the factory, and should not be adjusted. Serious injury may result if the full speed is increased. Removal of the seals without authorization could affect the warranty. If speed settings are lost due to engine fuel pump service or other repairs, the speed settings can be reset as follows: Before Starting 1. At the Pressure Regulator (on service pipe near receiver tank), remove the cover to expose the adjusting screw. Loosen the jam nut and turn screw counterclockwise until tension is no longer felt at the screw. Then, turn screw clockwise one full turn. 2. Close service valve(s). 3. Inspect throttle arm (G) on engine governor to see the arm is resting against the governor stop. Loosen jam nut on air actuating cylinder (A) and then turn cylinder rod (D) until throttle arm (G) is forced against the governor stop. After Starting Unit 4. If equipped, push the SERVICE AIR button on the control panel, making certain the button does not pop back out. The unit should speed up and then unload (and drop back to IDLE). With the unit unloaded, turn the adjusting screw on the pressure regulator clockwise until the discharge pressure gauge indicates 125-130 psi. Tighten the pressure regulator jam nut. Replace cover. 5. With the service valve closed, adjust IDLE speed (*). Adjust speed using adjusting rod (D). Tighten jam nut (H). 6. Open the service valve and adjust the discharge pressure to 100 psi (700 kPa). Now turn adjusting rod (C) until the proper engine FULL speed setting (*) is reached. Tighten jam nuts (B & J). 7. To obtain maximum CFM at any pressure between 80 psi (550kPa) and maximum pressure rating (*), make adjustment at the pressure regulator to obtain desired discharge pressure at FULL engine speed. Lock adjusting screw and replace cover. * See General Data Specifications. 46 SECTION 5 - OPERATION Operating & Maintenance Manual 47 Operating & Maintenance Manual 48 SECTION 5 - OPERATION Section 6 - MAINTENANCE 47 Operating & Maintenance Manual MAINTENANCE Maintenance ! CAUTION Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty. If performing more than visual inspections, disconnect battery cables and open manual blowdown valve. Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). Scheduled Maintenance The maintenance schedule is based on normal operation of the unit. This page can be reproduced and used as a checklist by the service personnel. In the event unusual environmental operating conditions exist, the schedule should be adjusted accordingly. Compressor Oil Level Never operate this machine with any guards removed. Check the compressor fluid level when the machine is not operating. Maintain the fluid level between bottom and midway of the sight glass on the separator tank. Inch and metric hardware was used in the design and assembly of this unit. Consult the parts manual for clarification of usage. Air Cleaner NOTICE Disregard any maintenance pertaining to components not provided on your machine. General In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and post-operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need 48 for repair. Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining your unit and keeping it clean at all times will facilitate servicing. If this unit is equipped with the Optional Diagnostic Panel, it has an AIR FILTERS RESTRICTED lamp on the instrument panel, covering both the engine and the compressor. This should be checked daily during operation. If the lamp glows (red) with the unit operating at full speed, servicing of the cleaner element is necessary. Also weekly squeeze the rubber valve (precleaner dirt dump) on each air cleaner housing to ensure that they are not clogged. The air filters restricted sensor will automatically reset after the main power switch is turned to “OFF.” To service the air cleaners on all units proceed as follows: 1. Loosen outer wing nut and remove with MAINTENANCE cover. Remove Element. 2. Inspect air cleaner housing for any condition that might cause a leak and correct as necessary. 3. Wipe inside of air cleaner housing with a clean, damp cloth to remove any dirt accumulation, especially in the area where the element seals against the housing. 4. Install new elements in the reverse order to the above. Tighten wing nut firmly. 5. Inspect to ensure that end cap seals tightly 360° around air cleaner body. In addition, the air cleaner system (housing and piping) should be inspected every month for any leakage paths or inlet obstructions. Make sure the air cleaner mounting bolts and clamps are tight. Check the air cleaner housing for dents or damage which could lead to a leak. Inspect the air transfer tubing from the air cleaner to the compressor and the engine for leaks. Make sure that all clamps and flange joints are tight. Operating & Maintenance Manual Battery Keep the battery posts-to-cable connections clean, tight and lightly coated with a grease. Also the electrolyte level in each cell should cover the top of the plates. If necessary, topup with clean distilled water. Tires A weekly inspection is recommended. Tires that have cuts or cracks or little tread should be repaired or replaced. Monthly check the wheel lug nuts for tightness. Fasteners Visually check entire unit in regard to bolts, nuts and screws being properly secured. Spot check several capscrews and nuts for proper torque. If any are found loose, a more thorough inspection must be made. Take corrective action. Table 1: Wheel Torque Chart M12 bolts Torque (ft-Lbs) Gauges 13” wheel 60-70 The instruments or gauges are essential for safety, maximum productivity and long service life of the machine. Inspect the gauges and test any diagnostic lamps prior to start-up. During operation observe the gauges and any lamps for proper functioning. Refer to Operating Controls, for the normal readings. 1/2” lug nuts 13” wheel 80-90 15” wheel 105-115 16” wheel 105-115 16.5” wheel 105-115 5/8” lug nuts Fuel Tank 16” wheel 190-210 CLEAN fuel in the fuel tanks is vitally important and every precaution should be taken to ensure that only clean fuel is poured or pumped into the tank. 17.5” wheel 190-210 When filling the fuel tank on this unit, by methods other than a pump and hose, use a CLEAN non-metallic funnel. 49 Operating & Maintenance Manual Radiator design. Features are as follows: NOTICE The use of water alone in this engine can result in major engine failure. Refer to engine section for coolant recommendation. Hoses Each month it is recommended that all of the intake lines to and from the air cleaners, the engine cooling system hoses and all of the flexible hoses used for air, oil, and fuel be inspected. Pulling on the tubing will cause the inner sleeve to withdraw and compress, thus tightening the connection. The tubing can be withdrawn only while holding the sleeve against the fitting. The tubing can be removed and replaced numerous times without losing its sealing ability. To install the nylon tubing, make a mark (with tape or grease pencil) approximately 7/8 inch from the end of the tubing. Insert the tubing into the sleeve and “push-in” past the first resistance to the bottom. The mark should be approximately 1/16 inch from the sleeve, for the 3/8 inch O.D. tubing; 1/8 inch for the 0.25 inch O.D. tubing. This will ensure that tubing is fully engaged in the sealing mechanism. To ensure freedom from air leaks, all rubber hose joints and the screw-type hose clamps must be absolutely tight. Regular inspection of these connections for wear or deterioration is necessary. Compressor Oil Filters Premature wear of both the engine and compressor is ASSURED whenever dustladen air is permitted to enter the engine’s combustion chamber or compressor intake. To service oil filters it will first be necessary to shut the unit down. Wipe off any external dirt and oil from the exterior of the filter to minimize any contamination from entering the lubrication system. Proceed as follows: The flexible hoses used in the fuel, oil and air lines on these units are primarily used for their ability to accommodate relative movement between components. It is important they be periodically inspected for wear and deterioration. It is also important the operator does not use the hoses as convenient hand hold or steps. Such use can cause early cover wear and hose failure. NOTICE Some of the airlines are nylon tubing. The associated fittings are “push-in” 50 MAINTENANCE The oil filter must be replaced every 500 hours of operation or six (6) months, whichever comes first. ! WARNING High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. 1. Open the service air valve(s) to ensure that system is relieved of all pressure. Close the valve(s). 2. Turn the spin-on filter element counterclockwise to remove it from the filter housing. Inspect the filter. MAINTENANCE 3. Inspect the oil filter head to be sure the gasket was removed with the oil filter element. Clean the gasket seal area on the oil filter head. NOTICE Installing a new oil filter element when the old gasket remains on the filter head, will cause an oil leak and can cause property damage. 4. Lubricate the new filter gasket with the same oil being used in the machine. 5. Install new filter by turning the element clockwise until gasket makes initial contact. Tighten an additional 1/2 to 3/ 4 turn. 6. Start unit and allow to build up to rated pressure. Check for leaks before placing unit back into service. Compressor Oil Cooler The compressor lubricating and cooling oil is cooled by means of the fin and tube-type oil cooler, located beside the radiator. The lubricating and cooling oil, flowing internally through the core section, is cooled by the air stream from the cooling fan flowing past the core section. When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler, its efficiency is impaired. Each month it is recommended that the oil cooler be cleaned by directing compressed air which contains a nonflammable, noncaustic safety solvent through the core of the oil cooler. This should remove the accumulation of grease, oil and dirt from the exterior surfaces of the oil cooler core so that the entire cooling area can transmit the heat of the lubricating and cooling oil to air stream. Operating & Maintenance Manual In the event foreign deposits, such as sludge and lacquer, accumulate in the oil cooler to the extent that its cooling efficiency is impaired, a resulting high discharge air temperature is likely to occur, causing shut down of the unit. To correct this situation it will be necessary to clean it using a cleaning compound in accordance with the manufacturer’s recommendations. Compressor Oil The lubricating and cooling oil must be replaced every 500 hours of operation or six (6) months, whichever comes first. Refer to warranty section about extended warranty. Receiver-Separator Systems ! WARNING High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. • Open service valve at end of machine. • Ensure pressure is relieved, with BOTH: — Discharge air pressure gauge reads zero (0). — No air discharging from service valve. Remove plug in bottom of separator tank to drain compressor oil. When adding oil, remove and replace (make tight) plug on side of separator tank. In the compressor lubricating and cooling system, separation of the oil from the compressed air takes place in the receiverseparator tank. As the compressed air enters the tank, the change in velocity and direction drop out most of the oil from the air. 51 Operating & Maintenance Manual Additional separation takes place in the oil separator element which is located in the top of the tank. 4. Run unit at rated operating pressure for 30 to 40 minutes to permit element to clear itself. Any oil accumulation in this separator element is continuously drained off by means of a scavenge tube which returns the accumulated oil to the system. Exterior Finish Care The life of the oil separator element is dependent upon the operating environment (soot, dust, etc.) and should be replaced every twelve months or 1000 hours. Scavenge Line ! WARNING High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. The scavenge line originates at the receiverseparator tank cover and terminates at the compressor air-end near the oil filter element. An orifice check valve is located on the scavenge tube. Once a year or every 1000 hours of operation, whichever comes first, replace the separator element and clean the scavenge orifice/check valve. NOTE: Excessive oil carry-over may be caused by an oil-logged separator element. Do not replace element without first performing the following maintenance procedure: 1. Check oil level. Maintain as indicated earlier in this section. 2. Thoroughly clean scavenge line, any orifice and check valve. 3. Assure minimum pressure valve/orifice is operational. 52 MAINTENANCE This unit was painted and heat cured at the factory with a high quality, thermoset polyester powder coating. The following care will ensure the longest possible life from this finish. 1. If necessary to remove dust, pollen, etc. from housing, wash with water and soap or dish washing liquid detergent. Do not scrub with a rough cloth, pad, etc. 2. If grease removal is needed, a fast evaporating alcohol or chlorinated solvent can be used. Note: This may cause some dulling of the paint finish. 3. If the paint has faded or chalked, the use of a commercial grade, non-abrasive car wax may partially restore the color and gloss. Field Repair of Texture Paint 1. The sheet metal should be washed and clean of foreign material and then thoroughly dried. 2. Clean and remove all grease and wax from the area to be painted using Duponts 3900S Cleaner prior to sanding. 3. Use 320 grit sanding paper to repair any scratches or defects necessary. 4. Scuff sand the entire area to be painted with a red scotch brite pad. 5. Wipe the area clean using Duponts 3900S. 6. Blow and tack the area to be painted. 7. Apply a smooth coat of Duponts 1854S Tuffcoat Primer to all bare metal areas and allow to dry. MAINTENANCE 8. Apply 2 medium - wet coats of Duponts 222S Adhesion Promoter over the entire area to be painted, with a 5 minute flash in between coats. 9. To apply the texture coat, use Duponts 1854S Tuffcoat Primer. The proper technique to do this is to spray the Tuffcoat Primer using a pressure pot and use about 2-5 pounds of air pressure. This will allow the primer to splatter causing the textured look. Operating & Maintenance Manual NOTE: You must be careful not to put too much primer on at one time, this will effect the amount of texture that you are trying to achieve. Allow the texture coat to flash for 20 minutes or until dry to touch. 10. Apply any of Duponts Topcoat Finishes such as Imron™ or Centari™ according to the label instructions. NOTE: To re-topcoat the textured surfaces when sheet metal repairs are not necessary, follow steps 1, 2, 4, 5, 6, 8 and 10. 53 Operating & Maintenance Manual MAINTENANCE MAINTENANCE SCHEDULE Daily Compressor Oil Level Engine Oil Level Radiator Coolant Level Gauges/Lamps Air Cleaner Service Indicators Fuel Tank (fill at end of day) Fuel Water Separator (Drain) Oil Leaks Fuel Leaks Drain Water From Fuel Filters Coolant Leaks Radiator Filler Cap Air Cleaner PreCleaner Dumps Fan/Alternator Belts Battery Connections/Electrolyte Tire Pressure and Surface Wheel Lug Nuts Hoses (oil, air, intake, etc) Automatic Shutdown System Test Air Cleaner System Visual Compressor Oil Cooler Exterior Engine Radiator Exterior Fasteners, Guards Air Cleaner Elements Fuel/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change (initial change @ 50 hrs) 3 MOS. 250 hours 6 MOS. 500 hours 12 MOS. 1000 hours DRAIN C C C C C C C C C C CLEAN CLEAN C R -non IR fluids R - non IR fluids R R R R R* R* C C R R C CLEAN R CBT CBT R=replace, C=check (adjust if necessary) CBT = check before towing. * Applies only when using IR Protec™ Engine Fluid 54 Monthly C C C C C C C C C DRAIN C C Engine Oil Filter (initial change @ 50 hrs) Wheels (bearings, seals, etc) Engine Coolant Test Fuel Filter Element Shutdown Switch Settings Test Scavenge Orifice & related parts Oil Separator Element Lights (running, brake, & turn) Pintle Eye Bolts Weekly Section 7 - LUBRICATION 55 Operating & Maintenance Manual LUBRICATION Lubrication Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change. NOTE: Fluids listed as “preferred” are required for extended warranty. Compressor oil carryover (oil consumption) may be greater with the use of alternative fluids. Design Ambient Operating Temperature Pressure Specification 100 psi to -100F to 1250F Preferred: 300 psi IR Pro•Tec™ (-230C to 520C) Alternate: ISO Viscosity Grade 46 with rust and oxidation inhibitors, designed for air compressor service. 350 psi (-230C to 520C) Preferred: IR XHP 605 -100F to 1250F Alternate: IR XHP405 ISO Viscosity Grade 68 Group 3 or 5 with rust and oxidation inhibitors designed for air compressor service. Preferred Ingersoll-Rand Fluids - Use of these fluids with original I-R filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your IR representative. 650F to 1250F Preferred: (-18°C to 52°C) XHP605 IR XHP1001 Ingersoll-Rand Preferred Fluids 1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Litre) 36899698 36899706 36899714 36899722 - 22252076 22252050 22252068 Preferred: IR Pro-Tec™ IR XHP605 IR XHP1001 - 35612738 35300516 - XHP405 - 22252126 22252100 22252118 54480918 36875938 36866903 Engine Oil 56 LUBRICATION Operating & Maintenance Manual 57 Operating & Maintenance Manual 58 LUBRICATION Section 1 - Trouble Shooting 57 Operating & Maintenance Manual Trouble Shooting Trouble Shooting B. Do The Simplest Things First Introduction Most troubles are simple and easily corrected. For example, most complaints are “low capacity” which may be caused by too low an engine speed or “compressor overheats” which may be caused by low oil level. Trouble shooting for a portable air compressor is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The trouble shooting chart that follows includes some of the problems that an operator may encounter during the operation of a portable compressor. The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the answers for correction of the problems. The chart does give those problems that are most apt to occur. To use the trouble shooting chart: A. Find the “complaint” depicted as a bold heading. B. Follow down that column to find the potential cause or causes. The causes are listed in order (1,2,3 etc.) to suggest an order to follow in trouble shooting. Always check the easiest and most obvious things first; following this simple rule will save time and trouble. NOTE: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in Parts List Section. C. Double Check Before Disassembly The source of most compressor troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a compressor can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly. Check again to be sure an easy solution to the problem has not been overlooked. D. Find And Correct Basic Cause Action Plan A. Think Before Acting Study the problem thoroughly and ask yourself these questions: 1. What were the warning signals that preceded the trouble? 2. Has a similar trouble occurred before? 3. What previous maintenance work has been done? 4. If the compressor will still operate, is it safe to continue operating it to make further checks? 58 After a mechanical failure has been corrected, be sure to locate and correct the cause of the trouble so the same failure will not be repeated. A complaint of “premature breakdown” may be corrected by repairing any improper wiring connections, but something caused the defective wiring. The cause may be excessive vibration. Trouble Shooting Operating & Maintenance Manual Trouble Shooting Chart Bold Headings depict the COMPLAINT - Subheadings indicate CAUSES NOTE: Subheadings suggest sequence to follow troubleshooting. Table 1: Unit Shutdown Cause Out of Fuel Compressor Oil Level Too Low Compressor Oil Temp. Too High Engine Water Temp. Too High Loose Wire Connection Low Fuel Level Shutdown Switch Defective Discharge Air Temp. Switch Defective Engine Oil Pressure Switch Broken Engine Fan Belt Engine Oil Pressure Too Low Defective Shutdown Solenoid Malfunctioning Relay Blown Fuse * < 10 Volts at Shutdown Solenoid Engine Malfunctioning Airend Malfunctioning Corrective Action Add CLEAN diesel Fuel Add correct oil See Table 10 Check coolant level. If necessary, Add. Wiggle wires at switches & connector blocks. Make repairs. Replace switch. Replace switch. Replace switch. Replace fan belt. See Table 3 and Table 4. Replace solenoid. Replace relay. Replace fuse/Check for Short. Check battery and alternator. Make repairs. See Trouble Shooting in Engine Section. See Table 10. Table 2: Won’t Start/Run: Cause Out of Fuel Clogged Fuel Filters Compressor Oil Level Too Low Loose Wire Connection Low Battery Voltage * <10 Volts at Shutdown Solenoid Defective Alternator Out of Fuel Engine Water Temp. Too High Malfunctioning Start Switch Defective D2 Diode Blown Fuse Engine Oil Pressure Too Low Compressor Oil Temp. Too High Defective Discharge Air Temp. Switch Defective Engine Oil Pressure Switch Corrective Action Add CLEAN diesel Fuel Service filters. Add corrected oil Repair or replace connection. Check electrolyte level. Check connections. Charge battery and alternator. Make repairs. Replace/Repair Alternator Add CLEAN fuel. Check fluid level. If necessary, Add. Replace switch. Replace D2 Diode. Replace fuse/Check for Short. See Table 3 and Table 4. See Table 10. Replace switch. Replace switch. 59 Operating & Maintenance Manual Defective Shutdown Solenoid Defective Engine Temp. Switch Defective Separator Tank Temp Switch Defective Low Fuel Shutdown Switch Malfunctioning Relay Engine Malfunctioning Airend Malfunctioning Trouble Shooting Replace solenoid. Replace Switch Replace Switch Replace Switch Replace relay. See Trouble Shooting in Engine Section. See Table 10. Table 3: Engine Temperature Lamps Stays On: Complaint Dirty Cooler Operating Pressure Too High Recirculation of Cooling Air Dirty Operating Conditions * Out of Level >15 degrees * Ambient Temp. >125×F (52×C) Loose Wire Connection Broken Engine Fan Belt Malfunctioning Circuit Board Corrective Action Clean exterior of cooler. Reduce pressure to spec. Close side doors. Move unit to cleaner environment. Relocate or reposition unit. Above spec limit. Repair or replace. Replace fan belt set. Replace circuit board. Table 4: Engine Oil Pressure Lamp Stays On: Complaint Low Oil Level Clogged Oil Filter Element(s) Out of Level >15 degrees Loose Wire Connection. Wrong Lube Oil Malfunctioning circuit board Engine Malfunctioning Corrective Action Add oil. Replace element(s). Relocate or reposition. Repair or replace. See Engine Oil Spec. Change oil. Replace circuit. See Trouble Shooting in Engine Section. Table 5: Engine Temperature Lamps Stays Off: Complaint Bulb Burned Out Shorted Wire (Hot) Malfunctioning circuit board Corrective Action Replace circuit board. Repair short. Replace circuit board. Table 6: Engine Oil Pressure Lamp Stays Off: Complaint Bulb Burned Out Shorted Wire (Hot) Malfunctioning circuit board 60 Corrective Action Replace circuit board. Repair short. Replace circuit board. Trouble Shooting Operating & Maintenance Manual Table 7: Alternator Lamp Stays On: Complaint Low Battery Voltage Loose or Broken Belts Corrective Action Check electrolyte level. Add if necessary. Tighten or replace belt set. Check connectors. Clean & tighten. Recharge battery. Repair or replace alternator. Repair short. Malfunctioning Alternator Shorted wire (ground) Table 8: Alternator Lamp Stays Off: Complaint Bulb Burned Out Loose Wire Connection Malfunctioning circuit board Corrective Action Replace circuit board. Repair or replace connector. Replace circuit board. Table 9: Unit Fails To Shutdown: Complaint Defective Low Fuel Shutdown Switch Defective Discharge Air Temperature Switch Defective Sep. Temp. Switch Defective Engine Temp. Switch Defective Engine Oil Pressure Switch Defective Shutdown Solenoid Malfunctioning Relay Defective Start Switch Wire Shorted Hot Corrective Action Pull wire off shutdown solenoid. Replace switch. Pull wire off. Replace switch. Replace switch. Replace switch. Pull wire off. Replace switch. Carefully block air inlet to stop engine. Replace relay. Pull wire off shutdown solenoid. Replace defective item. Repair short. Table 10: Excessive Compressor Oil Temperature: Complaint Dirty Cooler Low Oil Level Clogged Oil Filter Elements Operating Pressure Too High Dirty Operating Conditions Ambient Temp. > 125°F (52°C) Out of Level > 15 degrees Wrong Lube Oil Recirculation Of Cooling Air Malfunctioning Thermostat Loose or Broken Belts Defective Oil Cooler Relief Valve Corrective Action Clean exterior surfaces. Add oil. Look for any leaks. Replace elements. Change oil. Reduce pressure to spec. Move unit to cleaner environment. Above spec limit. Relocate or reposition unit. Check spec in this manual. Close side doors. Replace belly pan. Replace thermostat in bypass valve. Tighten or replace belt set. Replace valve. 61 Operating & Maintenance Manual Defective Minimum Pressure Valve Malfunctioning Fan Blocked or Restricted Oil Lines Airend Malfunctioning Trouble Shooting Repair or replace valve. Check fan belt tension. Tighten or replace belt set. Clean by flushing or replace. See Tables 11, 12, 13, 15, 16 or 18. Table 11: Engine RPM Down Complaint Clogged Fuel Filter Dirty Air Filter Operating Pressure Too High Incorrect Pressure Regulator Adjustment Incorrect Linkage Adjustment Wrong Air Filter Element Malfunctioning Pressure Regulator Malfunctioning Air Cylinder Defective Separator Element Engine Malfunctioning Airend Malfunctioning Corrective Action Clean primary filter. Replace final filter. Drain tanks. Add CLEAN fuel. Clean or replace elements. Reduce pressure to spec limit. Adjust regulator. Adjust linkage. Install correct element. Replace regulator. Replace air cylinder and adjust. Install new element. See Trouble Shooting in Engine Section. Consult Dealer. Table 12: Excessive Vibration Complaint Dirty Fuel/Filters Engine idle speed too low. Rubber Mounts, Loose or Damaged Anti-rumble valve not working. Drive Coupling Defective Defective Fan Engine Malfunctioning Airend Malfunctioning Corrective Action Replace filters/fuel. Raise “No Load” speed. Tighten or replace. Repair or Replace. Replace coupling. Replace fan. See Trouble Shooting in Engine Section. See Table 15 and 17. Table 13: Low CFM Complaint Engine RPM too Low Malfunctioning Air Cylinder Incorrect Linkage Adjustment Malfunctioning Inlet Unloader Dirty Air Filter Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Wrong Air Filter Element Defective Separator Element Defective Minimum Pressure Valve 62 Corrective Action Adjust RPM Replace air cylinder. Adjust linkage. Inspect valve. Clean or replace elements. Adjust linkage. Replace regulator. Install correct element. Install new element. Repair or replace valve. Trouble Shooting Operating & Maintenance Manual Table 14: Short Air Cleaner Life Complaint Inadequate Element Cleaning Dirty Operating Conditions Incorrect Stopping Procedure Wrong Air Filter Element Corrective Action Install new element. Move unit to cleaner environment. Read procedure in this manual. Install proper element. Table 15: Excessive Oil In Air Complaint High Oil Level Clogged Scavenge Orifice Incorrect Oil Defective Scavenge Check Valve Out of Level > 15 degrees Defective Separator Element Scavenge Tube Blocked Sep. Tank Blow Down Too Quickly Defective Minimum Pressure Valve Corrective Action Read procedure in this manual. Remove scavenge orifice. Clean and Replace. Replace by spec. in this manual. Remove check valve. Replace with new valve. Relocate or reposition unit. Remove element. Install new. Remove scavenge tube. Clean and Replace. Allow unit to blow down automatically. Remove valve. Repair valve and replace. Table 16: Oil Seal Leak Complaint Contaminated Lube Oil Corrective Action Drain and flush system. Add new CLEAN oil. Replace seal. Remove, clean and replace line(s). Replace seal. Consult dealer. Replace seal. See instructions in new seal kit. Blocked or Restricted Oil Line(s) Malfunctioning Seal Scored Shaft Table 17: Will Not Unload Complaint Incorrect Pressure Regulator Adjustment Leak in Regulator Piping Malfunctioning Pressure Regulator Malfunctioning Inlet Valve Unloader Defective Separator Element Ice in Regulation Lines/Orifice Corrective Action Adjust regulator. Find and repair leak(s). Replace regulator. Inspect valve. Repair/Replace. Remove element. Install new. Apply heat to line(s) and or orifice. Table 18: Oil In Air Cleaner Complaint Incorrect Stopping Procedure Malfunctioning Unloader Corrective Action Read Procedure in this manual. Repair/Replace. 63 Operating & Maintenance Manual Trouble Shooting Table 19: Safety Valve Relieves Complaint Operating Pressure Too High Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Leak In Regulator Piping Malfunctioning Inlet Unloader Defective Separator Element Defective Safety Valve Ice in Regulation Lines/Orifice 64 Corrective Action Reduce pressure to spec limit. Refer to Section 6 in this manual. Replace regulator. Repair leak(s). Inspect valve. Repair/Replace. Remove element. Install new. Replace safety valve. Remove ice. WORD INDEX A Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 B Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 BEFORE TOWING . . . . . . . . . . . . . . . . . . . . . . . 5-40 C Compressor Oil Filters . . . . . . . . . . . . . . . . . . . . 6-50 Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . 6-48 CONTROL PANE . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . 6-48 SETTING UP (ALL UNITS) . . . . . . . . . . . . . . . . . 5-40 Speed and Pressure Regulator Adjusting Instructions 5-46 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 T Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . 8-58 Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . 8-59 U D DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 E Exterior Finish Care . . . . . . . . . . . . . . . . . . . . . . 6-52 F UNITS WITH DIAGNOSTIC LAMPS . . . . . . . . . . 5-45 Units With Optional Diagnostics Lamps . . . . . . . 5-44 W WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 WARRANTY REGISTRATION . . . . . . . . . . . . . . 1-17 WATER COOLED ENGINE . . . . . . . . . . . . . . . . 5-41 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 G Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 H Hazardous Substance Precaution . . . . . . . . . . . . 1-5 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 I Ingersoll-Rand Preferred Fluids . . . . . . . . . . . . . 7-56 L Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 M Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . 6-54 P Portable Compressor Airend Limited Optional Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Portable compressor airends . . . . . . . . . . . . . . . 1-14 Portable Compressor Fluid Chart . . . . . . . . . . . . 7-56 R Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Receiver-Separator Systems . . . . . . . . . . . . . . . 6-51 S Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Manual-Name 9-1 WORD INDEX 9-2 Manual-Name Portable Power Division Ingersoll-Rand Company P.O.Box 868 - 501 Sanford Ave. Mocksville, N.C. 27028 ©2003 Ingersoll-Rand Company, Printed in the USA ">

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