Ingersoll-Rand XHP1070WCAT Operating & Maintenance Manual
Ingersoll-Rand XHP1070WCAT is a powerful air compressor designed for various applications. Built for durability and efficiency, it features a robust design with a reliable engine and a high-capacity air receiver. The XHP1070WCAT delivers consistent compressed air output, making it ideal for powering a wide range of tools and equipment.
PDF
Download
Document
Advertisement
Advertisement
Operating & Maintenance Manual Compressor Models XHP1070WCAT XHP1170WCAT Code: C Code: A 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. 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. Utility Equipment P.O. Box 868 - 501 Sanford Ave Mocksville, N.C. 27028 Book: 22742944 (3-17-06) Rev. A Revised (10-12) 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 Operating & Maintenance Manual TITLE PAGE FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Safety chains/connections and their adjustment where fitted: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Compressor Noise Emission Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 A. Compressed Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 B. Safety and Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 C. Acoustic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 D. Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 E. Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F. Air Intake and Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 G. Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 H. Isolation Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 I. Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 J. Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Operating Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Lifting Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Before Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Wagon Style Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 High Speed Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Wheel Chock - HSRG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Setting Up (All Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Compressor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 IQ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 3 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE Daily Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Weekly Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Yearly Maintenance:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Before Starting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 After Starting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Prior to attempting any maintenance work, ensure that:- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Prior to opening or removing panels or covers to work inside a machine, ensure that:- . . . . . . . . . 51 Prior to attempting any maintenance work on a running machine, ensure that:- . . . . . . . . . . . . . . . 51 Protective Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Low engine fuel level switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Compressor Oil Cooler and Engine Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Air Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fuel Filter Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Charge Air Cooler Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Running Gear/wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Engine Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Compressor Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Running Gear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Compressor Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 4 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Action Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 A. Think Before Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 B. Do the Simplest Things First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 C. Double Check Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 D. Find and Correct Basic Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Wedge Diagnostic Display Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 General Information and Operational Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 WEDGE Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Sensors and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Digital Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Controller Outputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Electronic Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Trouble Shooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ELECTRICAL SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 5 **Always use Ingersoll-Rand Replacement parts!** 6 Foreword Book: 22742944 (3-17-06) Rev. A 7 Operating & Maintenance Manual Foreword Foreword Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European common market countries requires that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE certification and marking being rendered invalid. A declaration of that conformity follows: 8 Book: 22742944 (3-17-06) Rev. A Foreword Operating & Maintenance Manual Machine models represented in this manual may be used in various locations world-wide. Machines sold and shipped into European Union Territories require that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid. A declaration of that conformity follows: DECLARATION OF CONFORMITY WITH EC DIRECTIVES 98/37/EC, 93/68/EEC, 89/336/EEC We Ingersoll Rand Company Utility Equipment Division P.O. Box 868 501 Sanford Ave Mocksville, N.C. 27028 Represented in EC by: Ingersoll-Rand Company LTD Standard Products Division Swan Lane, Hindley Green Wigan WN2 4EZ United Kingdom Declare that under our sole responsibility for manufacture and supply, the product(s) NHP1500, XHP1070WCAT, XHP1170WCAT, HP1300WCU, HP1600WCU, XHP1070WCU, XHP1170WCU, 10/370, 10/455, 25/300, 25/330, 10/425 to which this declaration relates, is (are) in conformity with the provisions of the above directives using the following principal standards EN29001 : EN292, EN60204-1, EN1012-1, PN8NTC2, EN50081, EN50082 Issued at Mocksville on 1-1-2003 Ric Lunsford Manager of Quality Control EC Noise Directive 2000/14/EC We declare that this product has been assessed according to EC Noise Directive 2000/14EC and, in accordance with the terms of this directive, has been excluded from the scope of this directive. It may carry “CE” marking in compliance with other applicable EC Directives. EC Pressure Equipment Directive and Related Regulations We declare that this product has been assessed according to Pressure Equipment Directive (97/23/EC) and, in accordance with the terms of this Directive, has been excluded from the scope of this Directive. It may carry “CE” marking in compliance with other applicable EC Directives. Book: 22742944 (3-17-06) Rev. A 9 Operating & Maintenance Manual Foreword Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll-Rand products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such products, which are available upon request. This manual contains instructions and technical data to cover all routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be referred to an authorized Ingersoll-Rand service department. All components, accessories, pipes and connectors added to the compressed air system should be: • of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Ingersoll-Rand. • clearly rated for a pressure at least equal to the machine maximum allowable working pressure. • compatible with the compressor lubricant/coolant. • accompanied with instructions for safe installation, operation and maintenance. Details of approved equipment are available from Ingersoll-Rand Service departments. The use of repair parts other than those included within the Ingersoll-Rand approved parts list may create hazardous conditions over which Ingersoll-Rand has no control. Therefore, IngersollRand cannot be held responsible for equipment in which non-approved repair parts are installed. Ingersoll-Rand reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. The intended uses of this machine are outlined below and examples of unapproved usage are also given. However, Ingersoll-Rand cannot anticipate every application or work situation that may arise. If in doubt, consult supervision. This machine has been designed and supplied for above ground operation to be used for compression of normal ambient air containing no additional gases, vapors or particles within the ambient temperature range specified in the general data section of this manual. This machine should not be used: A. For direct or indirect human consumption of the compressed air. B. Outside the ambient temperature range specified in the general data section of this manual. C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists. D. With other than Ingersoll-Rand approved components. E. With guards, or controls or switches missing or disabled. F. For storage or transportation of materials inside or on the enclosure. 10 Book: 22742944 (3-17-06) Rev. A Foreword Operating & Maintenance Manual This company accepts no responsibility for errors in translation of this manual from the original English version. You as the customer are expected to provide certain service and maintenance items. Your Ingersoll-Rand dealer will provide all other more detailed service and maintenance items on a special preventive maintenance schedule for each machine. It is very important that the minimum service and maintenance requirements explained in this manual be performed at the required intervals. Exceeding these intervals may reduce the reliability of the machine. The purpose of this manual is to train the operator with functions, operation, and basic service and maintenance requirements of the compressor. During the preparation of this manual, every effort was made to ensure the adequacy and accuracy of the contents. Your Ingersoll-Rand dealer will assist with setup and initial startup of the compressor. He will also provide brief operating and service instructions and will insure that a copy of this manual is included with the machine. Before starting the compressor, this manual and instructions should be carefully read to obtain a thorough knowledge of the duties to be performed. Please take pride in the compressor, keep it clean, and in good mechanical condition. To enable proper maintenance records, Ingersoll-Rand provides a Noise Emission Control Maintenance Log Book (PCD Form 685) with each compressor shipped from the factory. This Log Book contains a recommended schedule and space so that the serviceman can note what service and maintenance was done, by whom, where, and when. Book: 22742944 (3-17-06) Rev. A 11 **Always use Ingersoll-Rand Replacement parts!** 12 Book: 22742944 (3-17-06) Rev. A Safety Book: 22742944 (3-17-06) Rev. A 13 Operating & Maintenance Manual Safety Safety Safety Precautions General Information Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenancce 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. Air discharged from this machine may contain carbon monoxide or other contaminants which will cause serious injury or death. Do not breathe this air. This machine produces loud noise with the doors open or service valve vented. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open or service valve is vented. Never inspect or service unit without first disconnecting batter cable(s) to prevent accidental starting. 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). Rotating fan blade can cause serious injury. Do not operate without guard in place. Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). Ether is an extremely volatile, highly inflammable gas. When it is specified as a starting aid, use sparingly. DO NOT USE ETHER IF THE MACHINE HAS GLOW PLUGS OR INLET HEATER STARTING AIDS OR ENGINE DAMAGE WILL RESULT. 14 Book: 22742944 (3-17-06) Rev. A Safety Operating & Maintenance Manual Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, blow gun tips, etc. well away from moving parts. 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 safety valve setting. If more than one compressor is connected to one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidentally be pressurized or over pressurized by another. Compressed air must not be used for a direct feed to any form of breathing apparatus or mask. High Pressure Air can cause serious injury or death. Relieve pressure before removing filler plugs/caps, fittings or covers. Air pressure can remain trapped in air supply line which can result in serious injury or death. Always carefully vent air supply line at tool or vent valve before performing any service. The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible. If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided. When using compressed air, always use appropriate personal protective equipment. All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions. Avoid bodily contact with compressed air. The safety valve located in the separator tank must be checked periodically for correct operation. 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 vent of an unexpected shutdown when the service valve is open. 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). Never allow the unit to sit stopped with pressure in the receiver-separator system. Book: 22742944 (3-17-06) Rev. A 15 Operating & Maintenance Manual Safety Materials The following substances may be produced during the operation of this machine: • brake lining dust • engine exhaust fumes ! WARNING 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 ! WARNING 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. Do NOT start or operate this machine in a confined area. Avoid breathing exhaust fumes when working on or near the machine. 16 Book: 22742944 (3-17-06) Rev. A Safety Operating & Maintenance Manual This machine may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authorities for proper disposal of these materials. Battery 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. ! WARNING Do not attempt to slave start a frozen battery since this may cause it to explode. Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After starting unit, always disconnect cables in reverse order. Radiator Hot engine coolant and steam can cause injury. Ensure that the radiator filler cap is removed with due care and attention. Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing pressure cap. Book: 22742944 (3-17-06) Rev. A 17 Operating & Maintenance Manual Safety 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. Do not exceed gross vehicle weight rating. Before towing the machine, ensure that:• the tires and towing hitch are in a serviceable condition. • the canopy is secure. • all ancillary equipment is stored in a safe and secure manner. • the brakes and lights are functioning correctly and meet necessary road traffic requirements. • break-away cables/safety chains are connected to the towing vehicle. The machine must be towed in a level attitude in order to maintain correct handling, braking and lighting functions. This can be achieved by correct selection and adjustment of the vehicle towing hitch and, on variable height running gear, adjustment of the drawbar. 1. Make sure wheels, tires and tow bar connectors are in safe operating condition and tow bar is properly connected before towing. 2. When parking always use the handbrake and, if necessary, suitable wheel chocks. Safety chains/connections and their adjustment where fitted: Ensure that the breakaway cable is securely coupled to the trailer and also to a substantial point on the towing vehicle. Ensure that the cable length is as short as possible, while still allowing enough slackness for the trailer to articulate without the handbrake being applied. Loop the chains onto the towing vehicle using the towing vehicle hitch as an anchorage point, or any other point of similar strength. Ensure that the effective chain length is as short as possible while still allowing normal articulation of the trailer and effective operation of the breakaway cable. 18 Book: 22742944 (3-17-06) Rev. A Safety Operating & Maintenance Manual Decals Decals are located on the machine to point out potential safety hazards. Read and follow these instructions. If you do not understand the instructions, inform your supervisor. Note that there are different decal headings: DANGER ! (Red Background) Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored. ! WARNING (Orange Background) Indicates the presence of a hazard which CAN cause serious injury, death or property damage, if ignored. ! CAUTION (Yellow Background) Indicates the presence of a hazard which WILL or can cause injury or property damage, if ignored. NOTICE (Blue Background) Indicates important set-up, operating or maintenance information. Book: 22742944 (3-17-06) Rev. A 19 Operating & Maintenance Manual Safety FREE SAFETY DECALS To promote communication of Safety Warnings on products manufactured by the Portable Compressor Division in Mocksville, N.C. Safety Decals are available free of charge. Safety decals are identified by the decal heading: DANGER, WARNING or CAUTION. Decal part numbers are on the bottom of each decal and are also listed in the compressor’s parts manual. Submit orders for Safety Decals to the Mocksville Parts Service Department. The no charge order should contain only Safety Decals. Help promote product safety! Replace decals that are not readable. 20 Book: 22742944 (3-17-06) Rev. A Noise Emission Book: 22742944 (3-17-06) Rev. A 21 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: 1. Removal or rendering inoperative any of the following: a. the engine exhaust system or parts thereof b. the air intake system or parts thereof c. enclosure or parts thereof 2. Removal of any of the following: a. fan shroud b. vibration mounts c. sound absorption material 3. Operation of the compressor with any of the enclosure doors open. Compressor Noise Emission Control Information A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of design incorporated into this compressor in compliance with the noise control act; B. The use of this compressor after such device or element of design has been removed or rendered inoperative. NOTE: the above information applies only to units that are built in compliance with the U.S. Environmental Protection Agency. Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor. 22 Book: 22742944 (3-17-06) Rev. A Noise Emission Operating & Maintenance Manual 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. Book: 22742944 (3-17-06) Rev. A 23 Operating & Maintenance Manual Noise Emission Introduction The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air Compressors. The purpose of this book is to provide (1) the Maintenance Performance Schedule for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when. The Maintenance Schedule and detailed instructions on the maintenance items are given on following page. Maintenance Schedule Item Area Period A. Compressed Air Leaks As Detected B. Safety and Control Systems As Detected C. Acoustic Materials Daily D. Fasteners 100 hours E. Enclosure Panels 100 hours F. Air Intake & Engine Exhaust 100 hours G. Cooling Systems 250 hours H. Isolation Mounts 250 hours I. Engine Operation See Operator’s Manual J. Fuels & Lubricants See Operator’s Manual A. Compressed Air Leaks Correct all compressed air leaks during the first shutdown period after discovery. If severe enough to cause serious noise problems and efficiency loss, shut down immediately and correct the leak(s). B. Safety and Control Systems Repair or replace all safety and control systems or circuits as malfunction occurs. No compressor should be operated with either system bypassed, disabled, or nonfunctional. C. Acoustic Materials In daily inspections, observe these materials.Maintain all acoustic material as nearly as possible in its original condition. Repair or replace all sections that have: 1) sustained damage, 2) have partially separated from panels to which they were attached, 3) are missing, or have otherwise deteriorated due to severe operating or storage conditions. 24 Book: 22742944 (3-17-06) Rev. A Noise Emission Operating & Maintenance Manual D. Fasteners All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be inspected for looseness after each 100 hours of operation. They should be retightened, repaired, or if missing, replaced immediately to prevent subsequent damage and noise emission increase. E. Enclosure Panels Enclosure panels should also be inspected at 100 hour operational intervals. All panels that are warped, punctured, torn, or otherwise deformed, such that their noise containment function is reduced, should be repaired or replaced before the next operation interval. Doors, access panels, and hatch closures especially, should be checked and adjusted at this time to insure continuous seating between gasket or acoustic material and the mating frame. F. Air Intake and Engine Exhaust Engine and compressor air intake and engine exhaust systems should be inspected after each 100 hours of operation for loose, damaged, or deteriorated components. Repairs or replacements should be made before the next period of use. G. Cooling Systems All components of the cooling system for engine water and compressor oil should be inspected every 250 hours of use. Any discrepancies found should be corrected before placing the unit back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at all times during operation. H. Isolation Mounts Engine/airend isolation mounts should be inspected after each 250 hours of operation. Those mounts with cracks or splits in the molded rubber, or with bent or broken bolts due to operation or storage in severe environments, all should be replaced with equivalent parts. I. Engine Operation Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer. J. Fuels and Lubricants Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand Company and Engine Manufacturer’s Operator and Maintenance Manuals. Book: 22742944 (3-17-06) Rev. A 25 Operating & Maintenance Manual Noise Emission MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. 26 DESCRIPTION OF WORK HOURMETER MAINT/ INSPECT LOCATION READING DATE CITY/ STATE WORK DONE BY (NAME) Book: 22742944 (3-17-06) Rev. A General Data Book: 22742944 (3-17-06) Rev. A 27 Operating & Maintenance Manual General Data General Data MODELS Air Delivery - cfm (litres/sec) XHP1070CWCAT XHP1170AWCAT 1070 (505) 1170 (553) 150-350 (10342412) 150-350 (10342412) Manufacturer Caterpillar Caterpillar Model C15 C15 Rated Horsepower at 1800 rpm 475 540 Electrical System 24VDC 24VDC Full Load Speed - rpm 1800 1800 No Load Speed - rpm 1350 1350 COMPRESSOR Rated Operating Pressure - psi (kPa) ENGINE (Diesel) FLUID CAPACITIES - U.S. Gallons (litres) Compressor Lubricant 55 (208) 55 (208) Engine Lube (including filter) 10.5 (40) 10.5 (40) Engine Coolant (radiator) 15.2 (57.5) 15.2 (57.5) Fuel Tank (Clean DIESEL fuel) 230 (870) 230 (870) UNITS MEASUREMENTS/WEIGHTS Feet (Meters) HSRG WAGON RG LRG Overall Length 24.3 (7.4) 19.2 (5.85) 19.2 (5.85) Overall Height 8.33 (2.54) 8.33 (2.54) 7.25 (2.21) Overall Width 7.5 (2.29) 7.5 (2.29) 7.5 (2.29) Gross Weight - pounds (kg) 16,700 (7590) 16,000 (7258) 15, 300 (6940) est est (including fluids - no fuel) 28 Book: 22742944 (3-17-06) Rev. A General Data Operating & Maintenance Manual RUNNING GEAR Tire Size 215/ 75R17.5H 215/ 75R17.5H NA Towing Speed (maximum) mph 65 20 NA Inflation Pressure 125 psig 125 psig NA EXPENDABLE SERVICE PARTS Part Number Description Where Used Quantity 36860336 ....................... Filter, Oil .................................... Airend ............................... 2 36762250 ........................ Separator, Oil HP ....................... Airend ............................... 1 36864361 ....................... Filter, Inlet Primary ..................... Engine & AE inlet .............. 2 36864379 ....................... Filter, Inlet Secondary ................ Engine & AE inlet .............. 2 35362235 ....................... Filter Oil, Engine ........................ C15 .................................... 1 55362268 ....................... Filter Coolant, Engine ................ C15 .................................... 1 22730014 ....................... Filter Fuel Eng-primary w/seals .. C15 .................................... 1 22090526 ....................... Filter Fuel Engine -secondary..... C15 .................................... 1 22730022 ....................... Filter Bowl, Fuel - primary........... C15 .................................... 1 ! CAUTION Any departure from the specifications may make this equipment unsafe. Book: 22742944 (3-17-06) Rev. A 29 **Always use Ingersoll-Rand Replacement parts!** 30 Operating Instructions Book: 22742944 (3-17-06) Rev. A 31 Operating & Maintenance Manual Operating Instructions Operating Instructions Operating Controls and Instruments The operating controls and instruments are arranged on the control panel as shown above. A description of each panel device is as follows: 1. Panel Light: Illuminates instrument and control panel. Controlled by Switch 14. 2. High Compressor Temp: Fault indicator lamp. Indicates shutdown due to high compressor temperature. 3. Low Radiator Coolant Level: Alarm indicator lamp. Indicates engine coolant needs service. 4. Low Engine Oil Pressure: Fault indicator lamp. Indicates shutdown due to low engine oil pressure. 5. Restricted Air Filter: Alarm indicator lamp. Indicates engine/compressor air inlet filters need service. 6. High Engine Coolant Temp: Fault indicator lamp. Indicates shutdown due to high engine water temperature. 32 Book: 22742944 (3-17-06) Rev. A Operating Instructions Operating & Maintenance Manual 7. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to dirty IQ air filters (if equipped). 8. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to low fuel level. Lamp blinks at low fuel warning. 9. Compressor Malfunction: Fault indicator lamp. Indicates shutdown due to compressor system fault. Refer to Fault Code List. 10. Low Battery Voltage: Alarm indicator lamp. Indicates battery or charging system requires service. 11. Engine Malfunction: Engine Fault code. Refer to service card or engine manual for codes and service requirements. 12. Malfunction Code (4 Digit): Compressor or engine fault. Refer to manual for list of codes and service requirements. 13. Ether Inject: Injects a measured shot of ether for aid in cold weather starting of engine. ! CAUTION Use Sparingly. 14. Panel Light Switch: Controls panel lamp # 1. 15. Pressure Control: Momentary contact switch. Allows engine to warm up at low compressor pressure. 16. Main Power Control Switch: ON/OFF Start Switch. 17. Heaters: ON/OFF Power Switch for regulation and IQ heaters. Prevents freeze up in cold weather. 18. Hourmeter: Indicates machine operating hours. 19. E-STOP: Emergency Stop Push Button (ESA units only). Push to stop, turn to release. 20. Discharge Air Pressure Gage: Indicates pressure in receiver tank, normally from 0 psi(kPa) to the rated pressure of the machine. 21. Engine Tachometer: Indicates engine speed in RPM from 0 when stopped to full speed. 22. Engine Water Temp 23. Fuel Level Gauge: Not used on “S” Models. 24. Compressor Oil Temp 25. Engine Oil Pressure 26. Battery Voltage Book: 22742944 (3-17-06) Rev. A 33 Operating & Maintenance Manual Operating Instructions Lifting Unit The central lifting bail can be reached through the roof door only from inside the machine. Use hoist or crane capable of lifting machine gross weight (see General Data). Before Towing Ensure that the tires, wheels and running gear are in good condition and secure. Wagon Style Running Gear • Do not tow this unit in excess of 20 mph (32km/hr). • Use a tow vehicle whose towing capacity is greater than the gross weight of this unit. (see general data). • Machine is not designed to be Highway Towable. • Set parking brake or chock wheels before disconnecting from towing vehicle. • Optional Parking Brake - located beside towbar on front of unit, if equipped. • Push lever down to apply brake. High Speed Running Gear • Use jack to raise or lower lunette eye. • Use tow vehicle whose towing capacity is greater than the gross weight of this unit (see general data). • Do not tow this unit in excess of 65 mph. • Place wheel chocks under tires before disconnecting from towing vehicle. • When raising or lowering lunette eye, always stand to one side. Wheel Chock - HSRG — Located inside of front towbar — Secure unit with chocks before disconnecting drawbar from tow vehicle. Setting Up (All Units) Place the unit in an open, well-ventilated area. Position as level as possible. The design of these units permits a maximum 10 degree limit on out-of-level operation. When the unit is to be operated out-of-level, it is important: (1) to keep the engine crankcase oil level near the high level mark (with the unit level), and (2) to have the compressor oil level gauge show no more than mid-scale (with the unit running at full load). Do not overfill either the engine crankcase or the compressor lubricating oil system. Chock wheels or set parking brake. 34 Book: 22742944 (3-17-06) Rev. A Operating Instructions Operating & Maintenance Manual This unit is equipped with on-board fuel tanks with a total capacity of 230 gallons which provides 10 hours of full load operation. Compressor Mounting Portable compressors, which are modified to remove the running gear and mount the machine direct to trailers, truck beds or frames, etc. may experience failure of the enclosure, frame, and/or other components. It is necessary to isolate the compressor package from the carrier base with a flexible mounting system. Such a system must also prevent detachment of the package from the carrier base in the event the isolators fail. Contact Ingersoll-Rand representative for flexible mounting kits. Warranty does not cover failures attributable to mounting of the compressor package to the carrier base unless it is an Ingersoll-Rand provided system. ! WARNING Do not connect the air discharge on this unit onto a common header with any other unit of any description, or any other source of compressed air, without first making sure a check-valve is used between the header and the unit. If this unit is connected in parallel with another unit of higher discharge pressure and capacity, a safety hazard could occur in a backflow condition. ! WARNING Unrestricted air flow from a hose will result in a whipping motion of the hose which can cause serious injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure in case of hose failure or other sudden pressure release. Reference: OSHA regulation 29 CFR Section 1926.302 (b). Air hose restraining cable installation: Secure hose restraining cable at each end to prevent accidental hose whipping. At the machine-side of the air hose, install and secure one end of the hose restraining cable on the 3” nipple on the inlet side of the 3” service valve. Install the other end of the hose restraining cable over the main hose connector. Install suitable 3” air hose between service valve on unit and point of air use. The air hose must be rated for outdoor use and for pressurized air service. Minimum rating is 250°F (121°C) and 200 psig (HP) or 425 psig (XHP). Book: 22742944 (3-17-06) Rev. A 35 Operating & Maintenance Manual Operating Instructions Before Starting Open manual blowdown valve to ensure the separator has been vented of all pressure. Close the valve before starting. Inspect the complete installation including remote fuel lines (if any) and air hose routing and connections. Check battery for proper connections and condition. ! WARNING Combustible gas can cause severe burns, blindness or death. Keep sparks and open flame away from battery. • Check the compressor fluid level. Maintain the fluid level between bottom and midway of the sight glass on the separator tank. • Check engine oil level. The proper level is labeled on the engine dipstick. Add oil when required. Do not overfill. • To jump-start, connect the positive booster/charger cable to the 24VDC positive (+) terminal of the battery. Then connect the negative booster/charger cable to the engine block...Not to the negative (-) terminal of the weak battery. After starting, disconnect the negative (-) cable from engine block; then from the booster battery/ charger. Disconnect positive (+) cable from both batteries. ! WARNING Do not remove the cap from a HOT engine radiator. The sudden release of pressure from a heated cooling system can result in a loss of coolant and possible severe personal injury. ! WARNING Hot pressurized fluid can cause serious burns. Do not open radiator while hot. Check coolant to assure coolant level is at minimum level when the unit is cold. Check engine coolant level on coolant recovery bottle on inside of rear door. Add coolant as required. Insure that radiator cap is installed properly and tightened. 36 Book: 22742944 (3-17-06) Rev. A Operating Instructions Operating & Maintenance Manual NOTE: This machine will not allow engine starting if engine coolant is low. NOTICE If the appropriate mixture of antifreeze is not used during freezing temperatures, failure to drain the engine may cause costly engine damage. Never use water only, as corrosion inhibitors are required in engine coolant fluid. ! CAUTION No smoking, sparks, or open flame near fuel. Check the fuel level. Add only CLEAN DIESEL fuel for maximum service from the engine. Refer to the Engine Operator’s Section for fuel specifications. NOTICE To minimize condensation (water) in the fuel tank, it is recommended to fill the tank at the end of each day. NOTE: This machine will not allow engine starting if the fuel level is below the minimum fuel shut off level. ! WARNING This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve(s) are open. • Close the side doors to maintain a cooling air path and to avoid recirculation of hot air. This will maximize the life of the engine and compressor and protect the hearing of surrounding personnel. • Make sure no one is IN or ON the compressor unit. Book: 22742944 (3-17-06) Rev. A 37 Operating & Maintenance Manual Operating Instructions Starting NOTICE This unit is equipped with a battery disconnect switch which removes power from the machine controller for long term storage. The switch is located on the side of the engine near the battery. This switch must be turned ON to provide power to the control panel for starting this unit. Close the air service valve to isolate the compressor from the compressed air tool until the engine is warmed up. 1. Turn the keyswitch to the “ON” position (first position). All diagnostic lamps and the LED display will light for two (2) seconds. All lamps should then go off and ALTERNATOR NOT CHARGING and LOW ENGINE OIL PRESSURE lamps will flash. 2. In freezing weather (below 32°F/0°C), flip HEATERS switch “ON” and wait sixty (60 seconds). This applies heat to the control system components for easier starting. Leave this switch “ON” while operating at these temperatures. 3. When the keyswitch is turned to “START” the engine starter will be engaged. Do not operate the engine starter motor for more than ten (10) seconds without allowing at least one minute cooling time between start attempts. Extended engine starter engagement will result in starter drop-out and generate a starter engagement time fault. ! CAUTION Ether is an extremely volatile, high flammable gas. Use Sparingly! If too much is injected, the uncontrolled explosion may result in costly damage to the engine. 4. In cold weather, as required, press the ETHER INJECT button once or twice only while the engine is cranking. This injects a measured amount of ETHER to the engine. 5. Following a successful start, the engine will accelerate to 1200 rpm initially, then 1500 rpm for warm-up. Compressor discharge pressure will be maintained at 60 psi during warm-up. After warm-up, rpm will maintain 1200 rpm idle. 6. Press the LOAD button. The engine will increase speed up to 1800 rpm until the pressure reaches the desired set point. After the engine has warmed up, open the service air valve to supply air to compressed air tool. 38 Book: 22742944 (3-17-06) Rev. A Operating Instructions Operating & Maintenance Manual Normal Operation The Operator may observe and monitor operating parameters using the gages on the panel. In the event the machine controller detects a parameter outside normal operating limits, the unit will shutdown. In the event the machine controller detects a parameter at a dangerously high or low level, the machine will be automatically be stopped with the cause of the SHUTDOWN shown on the diagnostic lights and display. Delivered air volume at set point pressure is accomplished by two methods: 1. The compressor is loaded (inlet valve fully open or modulated partially open) or unloaded (inlet valve fully closed). 2. Engine speed varies between 1200 RPM and 1800 RPM while compressor is loaded to match the required volume flow. Operation - Loaded Assume engine has been started and is running in the unload state at 1200 RPM. If there is air demand (pressure falls below the load point pressure), compressor will load at 1200 RPM by opening the inlet valve. As air demand rises and falls, engine speed is controlled between 1200 RPM and 1800 RPM to match the required flow while maintaining rated pressure. Operation - Unloaded If there is no air demand at 1200 RPM (pressure rises above the unload point pressure), the compressor will unload by closing the inlet valve. The unit then runs at 1200 RPM unloaded with no air delivery. If air demand increases (pressure falls below the load point pressure), the compressor reloads to meet the required air demand. Stopping • Close air service valve(s). • Allow the unit to run at “IDLE” for 3 to 5 minutes to reduce the engine temperatures. • Turn the keyswitch to the “OFF” position. NOTICE Failure to allow turbo cool down prior to stopping can cause turbocharger damage. Book: 22742944 (3-17-06) Rev. A 39 Operating & Maintenance Manual ! Operating Instructions CAUTION Machines with EMERGENCY STOP BUTTON - Use the Emergency Stop Button only for emergency conditions. Do not use for normal machine stopping. Button must be reset before starting can be accomplished. NOTICE Once the engine stops, the automatic blowdown valve will relieve pressure from the separator tank. ! WARNING Even after pressure is relieved from the piping system, any air supply line from the compressor to a tool or machine could remain under pressure and cause serious personal injury or death. After the compressor stops, carefully open a valve at any tool or machine to exhaust the pressure in any line prior to removal or servicing. ! CAUTION Never allow the unit to sit stopped with pressure in the receiverseparator system. As a precaution, open the service valve. 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 of the IQ System automatically adjusts movable louvers to control airflow through the aftercooler, ensuring that the compressed air temperature always remains above freezing temperatures (typically 45º F) at any ambient temperature down to -20º F. 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 24V DC heat tracing, which is integral to the compressor control orifice heater system. 40 Book: 22742944 (3-17-06) Rev. A Operating Instructions Operating & Maintenance Manual Theory of Operation The compressed air exits the separator tank through the top cover piping, and can then travel along one of two paths, selectable via manual valving. One path allows Standard Operation, which bypasses the IQ System, and delivers air quality equivalent to a standard oil-flooded portable compressor.If the IQ System is enabled by proper setting of the selector valve, the compressed air first enters the aftercooler. The aftercooler is cooled by the incoming compressor package air, which is controlled by movable louvers mounted on the aftercooler (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. Book: 22742944 (3-17-06) Rev. A 41 Operating & Maintenance Manual Operating Instructions If the IQ System is bypassed (Standard Operation selected), the delivered air pressure will be approximately equal to the separator tank pressure. If the IQ System operation is selected, the delivered air pressure will be slightly less, depending on the restriction of the filters. ! CAUTION The compressor regulation system is adjusted to maintain regulated pressure at the separator tank. DO NOT adjust regulation to provide full regulation pressure at the service valve when the IQ System is enabled. This will result in operation at excessive horsepower levels, causing overheating, reduced engine life, and reduced airend life. Low Ambient Option Operation When the ambient temperature falls to the point that the aftercooler outlet temperature is approaching 45° F, the Temperature Control Unit (TCU), mounted on the rear of the control panel, will automatically adjust the louvers to control the cooling airflow through the aftercooler. In the event that the unit is operating under abnormal conditions (i.e., an enclosure door open) which would cause excessive cooling of the aftercooler, a temperature sensor in the aftercooler outlet header will signal the TCU to further close the louvers if the compressed air temperature falls to approximately 36º F 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. 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. ! CAUTION Excessively restricted filter elements may cause an increase in the amount of aerosol water and oil carryover, which could result in damage to downstream equipment. Normal service intervals should not be exceeded. Weekly Maintenance: • • 42 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. Book: 22742944 (3-17-06) Rev. A Operating Instructions • Operating & Maintenance Manual Verify that the piping from the orifice purge points to the exhaust system is not clogged. ! CAUTION Blockage of the Y-strainers, orifices, or piping can result in flooding of the vessels with condensate. If flooding occurs, excessive condensate may enter the air stream and could result in damage to downstream equipment. Yearly Maintenance: The normal maintenance interval on the primary and secondary IQ System filters is one year, or earlier if pressure drop becomes excessive. Restriction indicators for the filters are mounted on the filter support inside the front door, and will shut down the compressor if restriction exceeds recommended values. ! CAUTION Excessively restricted filter elements may cause an increase in the amount of aerosol water and oil carryover, which could result in damage to downstream equipment. Normal service intervals should not be exceeded. Filter Replacement • With engine stopped, ensure pressure is relieved from air system. • Remove all wires and hoses connected to drains on bottom of each filter housing. Inspect fittings and hoses for any blockage. Clean if necessary. • Using a chain wrench or similar tool, loosen the housing. The housing should be removed by hand after loosening, taking care to prevent the housing from falling to the floor panel. • Lower the housing to floor panel and lean it against the airend. Remove and replace the filter element, being careful not to damage outer wrap. Verify the part number of new element vs. old element, as the two IQ filters are of different media. • Put a small amount of petroleum jelly or other non-synthetic grease on the element O-Ring to aid installation into the filter head. • Replace housing making sure to not overtighten. • Repeat the above procedure on the remaining filter element. • Reconnect all wires and hoses to drains on bottom of each filter housing. Book: 22742944 (3-17-06) Rev. A 43 Operating & Maintenance Manual Operating Instructions Pressure Regulation Normally, regulation requires no adjusting; but if proper adjustment is lost, proceed as follows: Adjustment Instructions The operating pressure of this unit was set at the factory to the maximum rating (at full speed). See General Data. However, this pressure may be reset down to 150 psi (1050 kPa). 1. WITH UNIT STOPPED, loosen nut (E) to relax spring (G). 2. Loosen nut (H). Turn rod (L) in Air Cylinder (AC) until approximately 3/4 inch (20 mm) between nut (H) and flat on rod (L). 3. Turn rod (L) one round into rod end bearing. Tight nut (H). Rotate butterfly shaft/lever (C), open and close, several times to assure that linkage is not binding. 4. With air cylinder rod (L) fully extended, take slack out of spring (G) by moving nuts (E) and (F). Tighten nuts. 5. Start unit and allow to warm up for 3 to 5 minutes. 6. Push “Service Air” button on control panel. 7. With service air valve closed, adjust pressure regulator (PR) to rated pressure (350 psi) plus 10 psi (70 kPa) as follows: 8. Loosen locknut (M) counterclockwise. Turn adjustment cap (N) clockwise to increase pressure, counterclockwise to decrease pressure. 9. Open service air valve and observe full load engine speed (*). Adjust regulator to give rated operating pressure (*). Tighten locknut (M). 10. Close and slowly open service air valve. If engine speed surges, increase tension on spring (G) by moving nuts (E) and (F). 11. To regulate to any pressure between 150 psi (1050 kPa) and maximum rating (350 psi), make adjustments at the pressure regulator. 44 Book: 22742944 (3-17-06) Rev. A **Always use Ingersoll-Rand Replacement parts!** 45 Book: 22742944 (3-17-06) Rev. A Operating & Maintenance Manual 46 Operating Instructions Book: 22742944 (3-17-06) Rev. A Maintenance Book: 22742944 (3-17-06) Rev. A 47 Operating & Maintenance Manual Maintenance Maintenance Initial 500 miles /850 km Daily Compressor Oil Level C Engine Oil Level C *Radiator Coolant Level C Gauges/Lamps C *Air Cleaner Service Indicators C Fuel Tank (Fill at end of day) C *Fuel/Water Separator Drain C Oil Leaks C Fuel Leaks C Drain Water From Fuel Filters D Coolant Leaks C Radiator Filler Cap C Weekly Monthly 3 Months 6 Months 500 hrs. 1000 hrs. 12 Months 2000 hrs. D Air Cleaner Precleaner Dumps C Fan/Alternator Belts C Battery Connections/Electrolyte C Tire Pressure and Surface C *Wheel Lug Nuts C Hoses (Oil, Air, Intake, etc.) C Automatic Shutdown System C Air Cleaner System C Compressor Oil Cooler Exterior C *Engine Rad/Oil Cooler Exterior C Fasteners, Guards C Air Cleaner Elements R/WI *Disregard if not appropriate for this particular machine. D = Drain (1) or 3000 miles/5000km whichever is the sooner G = Grease C = Check (adjust, clean or replace as necessary) R = Replace CBT = Check before towing. T = Test CR = Check and report W I = or when indicated if earlier. Refer to specific sections of the operator's manual for more information. 48 Book: 22742944 (3-17-06) Rev. A Maintenance Operating & Maintenance Manual Initial 500 miles /850 km Daily Weekly Monthly 3 Months 6 Months 500 hrs. 1000 hrs *Fue/Water Separator Element R Compressor Oil Filter Element R Compressor Oil 18 12 Months Months 2000 hrs 3000 hrs R Engine Oil Change R Engine Oil Filter R *Water Pump Grease. R *Wheels (Bearings, Seals, etc.) C G *Engine Coolant C R Fuel Filter Element R *Injection Nozzle Check C Shutdown Switch Settings T Scavenger Orifice & Related Parts C Oil Separator Element R *Feed Pump Strainer Cleaning. C *Valve Clearance Check C Lights (running, brake, & turn) CBT Pintle Eye Bolts CBT * Brakes C * Brake linkage C * Emergency stop C T Running gear linkage G Safety valve C Running gear bolts(1) C *Disregard if not appropriate for this particular machine. D = Drain (1) or 3000 miles/5000km whichever is the sooner G = Grease (2) or as defined by local or national legislation R = Replace C = Check (adjust, clean or replace as necessary) T = Test CBT = Check before towing. W I = or when indicated if earlier. CR = Check and report Refer to specific sections of the operator's manual for more information. Book: 22742944 (3-17-06) Rev. A 49 Operating & Maintenance Manual Maintenance Initial 500 miles /850 km Daily Weekly Monthly 3 Months 6 Months 500 hrs. 1000 hrs 12 Months 2000 hrs Scavenge line C * Engine breather element C Separator tank (2) exterior CR *Lubricator (Fill) C 2 Yrs Safety valve 4 Yrs 6 Yrs C Hoses Separator tank (2) interior R C *Disregard if not appropriate for this particular machine. D = Drain (1) or 3000 miles/5000km whichever is the sooner G = Grease (2) or as defined by local or national legislation R = Replace C = Check (adjust, clean or replace as necessary) T = Test CBT = Check before towing. W I = or when indicated if earlier. CR = Check and report Refer to specific sections of the operator's manual for more information. Routine Maintenance This section refers to the various components which require periodic maintenance and replacement. The MAINTENANCE CHART indicates the various components' descriptions and the intervals when maintenance has to take place. Oil capacities, etc., can be found in the GENERAL DATA SECTION of this manual. For any specification or specific requirement on service or preventative maintenance for the engine, refer to the Engine Section. 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. 50 Book: 22742944 (3-17-06) Rev. A Maintenance Operating & Maintenance Manual 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. • the discharge pipe / manifold area is depressurised by opening the discharge valve, while keeping clear of any airflow from it. ! WARNING Pressure will remain in the system between the minimum pressure valve and the service valve after shutdown and operation of the auto blowdown valve. This pressure must be relieved by : (a) Disconnecting any downstream equipment. (b) Opening the discharge valve to atmosphere. • the machine cannot be started. Post warning signs and/or fit anti-start devices. • Disconnect battery cables. 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. 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, jewelry, long hair etc. is made safe. Book: 22742944 (3-17-06) Rev. A 51 Operating & Maintenance Manual • Maintenance warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen. Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:• the machine is suitably tested. • all guards and safety protection devices are refitted. • all panels are replaced, canopy and doors closed. • hazardous materials are effectively contained and disposed of. Protective Shutdown System Refer to the diagnostic display codes table for a listing of shutdown conditions. Low engine fuel level switch. 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. Test the low engine fuel level switch by removing and operating the float manually. ! WARNING 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. 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. 52 Book: 22742944 (3-17-06) Rev. A Maintenance Operating & Maintenance Manual Compressor Oil Filter Refer to the MAINTENANCE 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 MACHINE in the OPERATING INSTRUCTIONS section of this manual) Clean the exterior of the filter housing and remove the spin-on element. lnspection 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. ! 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. 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. Book: 22742944 (3-17-06) Rev. A 53 Operating & Maintenance Manual Maintenance Reassembly Clean the filter gasket contact area and install the new element.Tighten until the gasket makes contact with the filter housing. Tighten an additional 1/2 to 3/4 of a revolution. ! CAUTION Start the machine (refer to PRIOR TO STARTING and STARTING THE MACHINE in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the machine is put back into service. Compressor Oil Separator Element Refer to the MAINTENANCE CHART in this section for the recommended servicing intervals. If, however, the element has to be replaced, then proceed as follows: 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 MACHINE 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. lnspection Examine the filter element. Examine all hoses and tubes, and replace if necessary. 54 Book: 22742944 (3-17-06) Rev. A Maintenance Operating & Maintenance Manual 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). Reconnect all hoses and tubes to the separator tank cover plate. Replace the compressor oil (refer to LUBRICATION later in this section). ! CAUTION Start the machine (refer to PRIOR TO STARTING and STARTING THE MACHINE in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the machine is put back into service. Compressor Oil Cooler and Engine Radiator 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. Book: 22742944 (3-17-06) Rev. A 55 Operating & Maintenance Manual ! Maintenance WARNING Follow the instructions provided by the antifreeze supplier when adding or draining the antifreeze solution. It is advisable to wear personal protective equipment to prevent skin and eye contact with the antifreeze solution. Air Filter Elements The air filter element should be replaced regularly (refer to the MAINTENANCE CHART) or when the restriction indicator shows red, whichever comes first. The aircleaner precleaner dumps should be cleaned as indicated in the MAINTENANCE CHART (more frequently in dusty operating conditions). 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. Reassembly Assemble the new element into the filter housing ensuring that the seal seats properly. Secure element by tightening nut. Before restarting the machine, check that all clamps are tight. Ventilation Always check that the air inlets and outlets are clear of debris etc. Cooling Fan Drive Periodically check that the fan mounting bolts in the fan hub have not loosened. If, for any reason, it becomes necessary to remove the fan or re-tighten the fan mounting bolts, 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. 56 Book: 22742944 (3-17-06) Rev. A Maintenance Operating & Maintenance Manual 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. Drain any sediment or condensate that may have accumulated in the tank(s). Refer to MAINTENANCE CHART. 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 Air Cooler Pipework Inspect all hoses and clamps 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 MAINTENANCE CHART), inspect all of the intake lines to the air filter, and all flexible hoses used for air lines, oil lines and fuel lines. Periodically inspect all pipework for cracks, leaks, etc. and replace immediately if damaged. Electrical System ! WARNING Disconnect the battery cables before performing any maintenance or service. 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 Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion. Book: 22742944 (3-17-06) Rev. A 57 Operating & Maintenance Manual Maintenance The battery restraint should be kept tight enough to prevent the battery from moving. Pressure System Regularly, 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 DATA SECTION of this manual. Running Gear/wheels Check the wheel nut torque 20 miles (30 kilometres) after refitting the wheels. Refer to the TORQUE SETTING TABLE later in this section. Lifting jacks should only be used under the axle The bolts securing the running gear to the chassis should be checked periodically for tightness (refer to the MAINTENANCE CHART for frequency) and re-tighten where necessary. Refer to the TORQUE SETTING TABLE later in this section. Lubrication ! 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 and oil filter element should be changed at the engine manufacturer's recommended intervals. Refer to the Engine operator manual/section. Refer to the Engine operators' manual/section for engine oil specifications. 58 Book: 22742944 (3-17-06) Rev. A Maintenance Operating & Maintenance Manual Compressor Lubricating Oil Refer to the 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 MACHINE 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. Refer to Portable Compressor Fluid Chart. Running Gear Wheel Bearings Wheel bearings should be packed with grease every 12 months. The type of grease used should conform to specification MIL-G-10924. Book: 22742944 (3-17-06) Rev. A 59 **Always use Ingersoll-Rand Replacement parts!** 60 Book: 22742944 (3-17-06) Rev. A Lubrication Book: 22742944 (3-17-06) Rev. A 61 Operating & Maintenance Manual Lubrication Lubrication General Information Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit require more frequent lubrication than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures. The Preventive Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed. A regular service program should be developed to include all items and fluids. These intervals are based on average operating conditions. In the event of extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than specified may be necessary. Details concerning lubrication of the running gear are in Maintenance Section. All filters and filter elements for air and compressor lubricant must be obtained through Ingersoll-Rand to assure the proper size and filtration for the compressor. Compressor Oil Change These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit for approximately 6 months or 1000 hours, whichever comes first. If a unit has been completely drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to specifications in Lubrication Table. NOTICE Some oil types are incompatible when mixed and result in the formation of varnishes, shellacs, or lacquers which may be insoluble. Such deposits can cause serious troubles including clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different brands. A type or brand change is best made at the time of a complete oil drain and refill. If the unit has been operated for the time/hours mentioned above, it should be completely drained of oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier change period may be necessary as oil deteriorates with time as well as by operating conditions. 62 Book: 22742944 (3-17-06) Rev. A Lubrication Operating & Maintenance Manual ! WARNING High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. Ensure the following conditions are met: — Discharge air pressure gauge reads zero (0). — No air discharging from an “open” manual blowdown valve. An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products. Completely drain the reservoir, piping, and cooler. If the oil is drained immediately after the unit has been run for some time, most of the sediment will be in suspension and, therefore, will drain more readily. However, the fluid will be hot and care must be taken to avoid contact with the skin or eyes. After the unit has been completely drained of all old fluid, close the drain valve, install new oil filter elements. Add oil in the specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil. Check the oil level. DO NOT OVERFILL. NOTICE Ingersoll-Rand provides compressor oil specifically formulated for Portable Compressors and requires the use of these fluids in order to obtain extended limited airend warranty. Book: 22742944 (3-17-06) Rev. A 63 Operating & Maintenance Manual Lubrication Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change. NOTE: Fluids listed as “preferred” are required for extended warranty. Compressor oil carryover (oil consumption) may be greater with the use of alternative fluids. Design Operating Ambient Pressure Temperature Specification 100 psi to 300 psi -10°F to 125°F Preferred: (-23°C to 52°C) IR Pro-Tec™ Alternate: ISO Viscosity Grade 46 with rust and oxidation inhibitors, designed for air compressor service. 350 psi -10°Fto 125°F Preferred: (-23°C to 52°C) IR XHP 605 Alternate: IR XHP405 ISO Viscosity Grade 68 Group 3 or 5 with rust and oxidation inhibitors 65°Fto125°F designed for air (18°C to 52°C) compressor service. Preferred: XHP605 IR XHP1001 Preferred Ingersoll-Rand Fluids - Use of these fluids with original I-R filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your I-R representative. Ingersoll-Rand 1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Llitre) Preferred Fluids IR Pro-Tec™ 64 36899698 36899706 36899714 36899722 IR XHP605 - 22252076 22252050 22252068 IR XHP1001 - 35612738 35300516 - XHP405 - 22252126 22252100 22252118 Book: 22742944 (3-17-06) Rev. A Trouble Shooting Book: 22742944 (3-17-06) Rev. A 65 Operating & Maintenance Manual Trouble Shooting Trouble Shooting Introduction Trouble shooting for a portable air compressor is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The trouble shooting chart that follows includes some of the problems that an operator may encounter during the operation of a portable compressor. The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the answers for correction of the problems. The chart does give those problems that are most apt to occur. To use the trouble shooting chart: A. Find the “complaint” depicted as a bold heading. B. Follow down that column to find the potential cause or causes. The causes are listed in order (1, 2, 3 etc.) to suggest an order to follow in trouble shooting. A. Think Before Acting Study the problem thoroughly and ask yourself these questions: 1. What were the warning signals that preceded the trouble? 2. Has a similar trouble occurred before? 3. What previous maintenance work has been done? 4. If the compressor will still operate, is it safe to continue operating it to make further checks? B. Do The Simplest Things First Most troubles are simple and easily corrected. For example, most complaints are “low capacity” which may be caused by too low an engine speed or “compressor over- heats” which may be caused by low oil level. Always check the easiest and most obvious things first; following this simple rule will save time and trouble. NOTE: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in Parts List Section. 66 Book: 22742944 (3-17-06) Rev. A Trouble Shooting Operating & Maintenance Manual NOTE: General Information The WEDGE controller records and displays diagnostic fault codes for the compressor system and the electronic engine. These codes are displayed on the 4-digit LED display on the machine control panel. Two of the ten LED diagnostic lamps on the control panel are used with fault codes display. One lamp is designated “Engine Fault” and the other “Compressor Fault”. When the engine fault lamp is on, all codes displayed are engine faults. When the compressor fault lamp is on, all codes displayed are compressor or package related faults. A list of compressor and engine faults is attached with the placards inside the machine control panel and provided in this section. The table of Alert/Shutdown conditions in this section also lists the compressor fault codes and a list of the engine fault codes is provided. The engine diagnostic fault codes can also be read with the manufacturer's service tool. A service tool connector is mounted on the engine. This connector provides a connection to the J1939 CAN network. For advanced engine troubleshooting, it is recommended that the manufacturer's service tools be used with accompanying service literature. Fault Code 13 Caterpillar Model C15 Engine Diagnotic Codes Fuel Temperature open/short to + battery 5 Volt Sensor DC power supply short to + battery 5 Volt Sensor DC power supply short to ground 21 8 Volt DC supply short to + battery 8 Volt DC supply short to ground Engine Oil Pressure open/short to + battery 24 Engine Oil Pressure short to ground Engine Oil Pressure abnormal rate of change Boost Pressure Sensor abnormal rate of change 25 Boost Pressure Sensor open/short to + battery Boost Pressure Sensor short to ground Atmospheric Pressure open/short + battery 26 Atmospheric Pressure short to ground Engine Coolant Temperature open/short to + battery 27 Engine Coolant Temperature short to ground 28 Throttle position calibration required 32 Throttle position signal abnormal Book: 22742944 (3-17-06) Rev. A 67 Operating & Maintenance Manual Fault Code Trouble Shooting Caterpillar Model C15 Engine Diagnotic Codes Engine Speed Signal abnormal 34 Secondary Engine Speed Signal abnormal Engine Overspeed Warning 35 Engine Overspeed Shutdown Fuel Pressure open/short + battery 37 Fuel Pressure short to ground Intake Manifold Air Temperature open/short + battery 38 Intake Manifold Air Temperature short to ground Injector Actuation Pressure Signal Erratic Injector Actuation Pressure Voltage High 39 Injector Actuation Pressure Voltage Low Injector Actuation Pressure System Fault 42 Engine Timing Calibration Required Low Engine Oil Pressure Warning 46 Low Engine Oil Pressure Derate Low Engine Oil Pressure Shutdown Air Inlet Heater Relay Open/Current Below Normal 49 Air Inleter Heater Relay Grounded/Current Above Normal 51 System Voltage Intermittent/Erratic/High/Low 56 Check Programmable Parameters 58 J1939 Data Link Communication High Engine Coolant Temperature Warning 61 High Engine Coolant Temperature Derate High Engine Coolant Temperature Shutdown Low Engine Coolant Level Warning 62 Low Engine Coolant Level Derate Low Engine Coolant Level Shutdown 63 68 High Fuel Pressure Warning Book: 22742944 (3-17-06) Rev. A Trouble Shooting Fault Code 64 Operating & Maintenance Manual Caterpillar Model C15 Engine Diagnotic Codes High Inlet Air Temperature Warning High Inlet Air Temperature Shutdown High Fuel Temperature Warning 65 High Fuel Temperture Derate High Fuel Temperature Shutdown 71 Injector Cylinder #1 Fault 72 Injector Cylinder #2 Fault 73 Injector Cylinder #3 Fault 74 Injector Cylinder #4 Fault 75 Injector Cylinder #5 Fault 76 Injector Cylinder #6 Fault Book: 22742944 (3-17-06) Rev. A 69 Operating & Maintenance Manual Trouble Shooting Wedge Diagnostic Display Codes If the If the ? ? fault indicator lamp is illuminated, refer to the ?? fault indicator lamp is illuminated, refer to the ? Alert/Shutdown List Engine Diagnostic List ALERT/SHUTDOWN CONDITIONS Alert Dedicated Lights Code LIght (Steady) Delay (sec). Engine Speed <min rpm 1 CPRSR Malf. 30 Engine Speed >max rpm 2 CPRSR Malf. 30 Engine Crank Time Exceeded 3 CPRSR Malf. 0 Light (Blinks) Too many start attempts during Autostart 11 CPRSR Malf. 0 Engine shuts itself down, reason unknown 29 CPRSR Malf. 0 Low AE Oil Pressure 31 CPRSR Malf. 20 Disch. Temp (RT2) Sensor Fault 32 CPRSR Malf. 10 Sep. Tank Press >20 psi during start attempt (engine will not crank) 34 CPRSR Malf. 0 Machine Over Pressure 35 CPRSR Malf. 1 Safety Valve Open 36 CPRSR Malf. 2 Sep. Tank Temp >247°F 50 CPRSR Malf. 3 Machine ID not valid 51 CPRSR Malf. 0 Sep. Tank Temp. (RT1) Sensor Fault 53 CPRSR Malf. 10 55 CPRSR Malf. 3 High Engine Oil Temperature 5 CPRSR Malf. High Intake Manifold Temp 6 CPRSR Malf. Water in Fuel 8 CPRSR Malf. Engine not responding to throttle command 10 CPRSR Malf. Sep. Tank Pressure (PT1) Sensor Fault 70 Code Shutdown 33 CPRSR Malf. Reg. Sys. Pressure (PT2) Sensor Fault 54 CPRSR Malf. ESTOP Button Pushed 55 CPRSR Malf. Minimum Pressure not met 56 CPRSR Malf. Book: 22742944 (3-17-06) Rev. A Trouble Shooting Operating & Maintenance Manual ALERT/SHUTDOWN CONDITIONS Dedicated Lights Code Light (Blinks) Serial Comm. Problem 70 CPRSR Malf. CAN Bus Problem 71 CPRSR Malf. Auto Start/Stop Module Failure - no comm for 17 sec. 73 CPRSR Malf. LIght (Steady) Delay (sec). fuel level 3 high engine temp. 10 IQ Filter Restriction IQ filter restriction 3 High Disch. Temp (RT2>247°F) high comp. temp. 3 Low Fuel Level fuel level Air Filter Restriction soiled filter Low Battery Voltage battery charging cond. Low Engine Oil Pressure low engine oil press Low Coolant Level engine coolant level High Engine Coolant Temp. high engine temp. Book: 22742944 (3-17-06) Rev. A Code 71 Operating & Maintenance Manual Trouble Shooting Trouble Shooting Chart Bold Headings depict the COMPLAINT - Subheadings suggest the CAUSE NOTE: Subheadings suggest sequence to follow troubleshooting. 1. Unit Shutdown: Out of Fuel Compressor Oil Temp. too High Engine Water Temp. too High Engine Oil Pressure too Low Broken Engine Fan Belt Low Fuel Level Shutdown Defective Sensor Malfunctioning Relay Blown Fuse Engine Malfunctioning Airend Malfunctioning Corrective Action Add CLEAN diesel Fuel See Complaint 6 Check coolant level. If necessary, Add. See Complaint 3 and Complaint 4. Replace fan belt. Wiggle wires at switches & connector blocks. Make repairs. Replace fuel sender. Replace sensor. Replace relay. Replace fuse. See Trouble Shooting in Engine Manual. See Complaint 6. 2. Won’t Start/Run: Low Battery Voltage Blown Fuse Malfunctioning Start Switch Clogged Fuel Filters Out of Fuel Compressor Oil Temp. too High Engine Water Temp. too High Engine Oil Pressure too Low Loose Wire Connection Defective Sensor Malfunctioning Relay Engine Malfunctioning Airend Malfunctioning Check electrolyte level. Check connections. Replace fuse. Replace switch. Service filters. See Engine Operator’s Manual. Add CLEAN fuel. See Complaint 6. Check fluid level. If necessary, Add. See Complaint 3 and Complaint 4. Repair or replace connection. Replace sensor. Replace relay. See Trouble Shooting in Engine Manual. See Complaint 10, 11. 3. High Engine Temperature Broken Engine Fan Belt *Ambient Temp. > 115° F Dirty Operating Conditions Dirty Cooler *Out of Level > 15 degrees Operating Pressure too High Recirculation of Cooling Air Loose Wire Connection Replace fan belt set. Above spec limit. Move unit to cleaner environment. Clean exterior of cooler. Relocate or reposition unit. Reduce pressure to spec. Close side doors. Repair or replace. Loose Wire Connection * : > = greater than, < = less than 72 Book: 22742944 (3-17-06) Rev. A Trouble Shooting 4. Low Engine Oil Pressure Low Oil Level Out of Level > 15 degrees Wrong Lube Oil Clogged Oil Filter Element(s) Engine Malfunctioning Loose Wire Connection. 5. Alternator Low Voltage Loose or Broken Belts Loose Wire Connection Low Battery Voltage Malfunctioning Alternator Operating & Maintenance Manual Corrective Action Add oil. Relocate or reposition. See Engine Oil Spec. Change oil. Replace element(s). See Trouble Shooting in Engine Manual. Repair or replace. Tighten or replace belt set. Repair or replace connection. Check electrolyte level. Add if necessary. Check connectors. Clean & tighten. Recharge battery. Repair or replace alternator. 6. High Compressor Discharge Temperature: Ambient Temp. > 115° F Above spec limit. Out of Level > 15 degrees Relocate or reposition unit. Low Oil Level Add oil. Look for any leaks. Wrong Lube Oil Check spec. in this manual. Dirty Cooler Clean exterior surfaces. Dirty Operating Conditions Move unit to cleaner environment. Clogged Oil Filter Elements Replace elements. Change oil. Loose or Broken Belts Tighten or replace belt set. Operating Pressure too High Reduce pressure to spec. Recirculation of Cooling Air Close side doors. Replace belly pan. Malfunctioning Thermostat Replace thermostat in bypass valve. Check fan belt tension. Tighten or replace belt Malfunctioning Fan set. Defective Oil Cooler Relief Valve Replace valve. Defective Minimum Pressure Valve Repair or replace valve. Blocked or Restricted Oil Lines Clean by flushing or replace. Airend Malfunctioning See Complaint 11, 12 7. Engine RPM Down: Clogged Fuel Filter (primary) Operating Pressure too High Dirty Air Filter Wrong Air Filter Element Engine Malfunctioning Airend Malfunctioning Book: 22742944 (3-17-06) Rev. A Replace primary filter. Replace final filter. Drain tanks. Add CLEAN fuel. Reduce pressure to spec limit. Clean or replace elements. Install correct element. See Trouble Shooting in Engine Manual. Refer to Factory. 73 Operating & Maintenance Manual 8. Excessive Vibration: Rubber Mounts, Loose or Damaged Defective Fan Drive Coupling Defective Engine Malfunctioning Airend Malfunctioning Engine idle speed too low. Trouble Shooting Tighten or replace. Replace fan. Replace coupling. See Trouble Shooting in Engine Manual. See Complaint 7, 11, 12 See Engine Manual. 9. Low CFM: Dirty Air Filter Clean or replace elements. Incorrect Linkage Adjustment Make adjustment per Section 6. Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve. Make adjustment per Section 6. Wrong Air Filter Element Install correct element. 10. Short Air Cleaner Life: Dirty Operating Conditions Inadequate Element Cleaning Incorrect Stopping Procedure Wrong Air Filter Element Move unit to cleaner environment. Install new element. Read procedure in this manual. Install proper element. 11. Will Not Unload: Malfunctioning Inlet Butterfly Valve Ice in Regulation Lines/Orifice Load Solenoid Leak Plugged Vent Leak Inspect valve fit. Re-adjust per Section 6. Apply heat to line(s) and or orifice. Replace load solenoid. Clean and/or replace. 12. Safety Valve Relieves: Operating Pressure too High Reduce pressure to spec limit. Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve fit. Readjust per Section 6. Defective Safety Valve Replace safety valve. Unit will not Unload Fast Enough Apply heat to lines and/or orifice. 74 Book: 22742944 (3-17-06) Rev. A **Always use Ingersoll-Rand Replacement parts!** 75 Book: 22742944 (3-17-06) Rev. A Operating & Maintenance Manual 76 Trouble Shooting Book: 22742944 (3-17-06) Rev. A Electrical Book: 22742944 (3-17-06) Rev. A 77 Operating & Maintenance Manual Electrical Electrical General Information and Operational Theory General The XHP1070/1170 machine has an electronic monitor and control system to provide discharge air pressure control and engine and package monitor functions. The system uses the WEDGE controller to perform these functions. The electrical system connects all the necessary switches, sensors and transducers to the WEDGE controller in order for it to perform the monitor and control functions. WEDGE Controller The WEDGE controller is the heart of the machine monitor and control system. It provides data collection, alarming and control functions for compressor operations. It is a micro controller based unit with analog and digital inputs and outputs. The WEDGE controller is attached to the back of the control panel. The LED annunciators are part of the front panel of the WEDGE. They can be seen through the laminate on the front of the control panel. The WEDGE is attached to the control panel with four #10 size nuts. The first function of the WEDGE is to scan all analog and digital inputs at a fixed interval. These inputs are scanned every 50 milliseconds. The analog values are then compared against minimum and maximum values and an ALERT or SHUTDOWN is issued, if a value is out of range. The various ALERTS and SHUTDOWNS are listed in section. The second function of the WEDGE controller is machine discharge pressure control. The WEDGE monitors the regulation system air pressure and varies the engine throttle to maintain the setpoint discharge airpressure. The setpoint pressure is set using the regulator on the separator tank. The third function of the WEDGE controller is to communicate with the diesel engine via the J1939 CAN network. The WEDGE controller provides the engine throttle setting to the engine controller and retrieves diagnostic information from the engine. A frequency throttle is used to communicate with the engine. A square wave frequency signal from 150 Hz to 375 Hz is sent from the WEDGE controller to the engine controller. The signal is linear from 150 Hz at engine idle (1200 RPM) to 375 Hz at maximum run speed (1800 RPM). Figure 8-2 shows the signals between the engine controller and the WEDGE controller. 78 Book: 22742944 (3-17-06) Rev. A Electrical Operating & Maintenance Manual Sensors and Transducers The electronics system contains sensors and transducers that are used to collect process data from the compressor. The temperature is measured by a thermistor. This device exhibits a change in resistance as the temperature changes. The resistance causes an input voltage change to the WEDGE controller input and is interpreted as a temperature change. The electronics system also uses pressure transducers to measure process pressure changes. These devices have an output signal of .45V DC to 4.5V DC, corresponding to 0 psi and the maximum measured psi for a particular device. The maximum pressure transducer ranges are 100 or 225 psi. The 100 and 225 psi devices are gauge pressure devices. These transducers are provided with 5V DC excitation to power the device. These are three wire devices: excitation, signal and ground (return) connections. Digital Inputs and Outputs The WEDGE controller scans digital inputs such as switch contacts. These are either “ON” (24V DC) or “OFF” (0V DC). These digital inputs are connected to switches within the package such as the key start switch, air filter switches and IQ filter switches. The WEDGE controller provides 24V DC digital outputs to control solenoids, start compressor and DC heaters. These are 24V DC “ON” and 0V DC “OFF”. They are current limited and short circuit protected. Controller Outputs: The WEDGE controller has three different types of outputs: frequency, pulse width modulated (PWM) and 24V DC digital (ON/OFF). The frequency output is used as a throttle signal for the engine. The WEDGE controller varies the frequency from 150 Hz to 375 Hz, corresponding to 1200 to 1800 rpm. The frequency signal is a 50% duty cycle, 24V DC, square wave. This throttle signal is used with the Cummins engine. The PWM signal is used as a throttle signal for the Caterpillar engine. It has a base frequency of 500 Hz and the duty cycle varies from 10% to 90%. Pressure Control The discharge pressure is controlled by manipulating the engine speed and compressor inlet valve position. The inlet valve position is controlled pneumatically and the engine speed is determined by the WEDGE controller. The WEDGE measures the pneumatic system regulation pressure and computes an engine throttle setting. This throttle setting is sent to the engine via the frequency throttle, PWM or J1939 throttle, depending on which technique is used. The engine controller will control engine speed to this throttle setting. Book: 22742944 (3-17-06) Rev. A 79 Operating & Maintenance Manual Electrical Electronic Engine The HP1600/1300 machine contains an emissions certified diesel engine. In order to meet the emissions requirements, the engine has an electronic control system. The control system handles all the monitor, alarm and control functions for the engine. The WEDGE controller communicates with the engine controller over the J1939 CAN network. The WEDGE controller receives diagnostic and run time data from the engine over the J1939 CAN network. A frequency throttle interface with the engine is used. Figure 8-2 shows the connections between the WEDGE controller and the engine controller. J1939 Data Link - The CAN network is a single pair shielded cable within the W1 main harness. Figure 8-3 shows a layout of the CAN harness or “backbone” as it is referred to. The termination resistors (Terminator) are important to prevent reflections on the transmission line and must be in place for the network to function properly. The shield from the cable is connected to the machine metal at the WEDGE controller end. The connection must be properly made with good metal to metal contact between the wire terminal and the machine metal. The engine diagnostics connector is located on the left side of the engine. This is used to connect the engine manufacturers service tools to the CAN network. This connector also provides 24V DC power to these service tools. Electrical System The electrical system consists of the wiring harnesses and associated electrical devices such as relays, switches, lights, solenoids and alarm horn. There are two wiring harnesses in the HP1600 machines. They are as follows: 22614416 W1 Chassis Main Wiring Harness 22060594 Control Panel Wiring Harness The schematic diagrams show the connections for these harnesses. Figure 8-1 is a system diagram showing harness connection with devices and controllers. The electrical circuits are protected using ATC style fuses. A fuse should only be replaced with one of the same rating. Replacing a fuse with one of a larger rating could lead to harness damage. If a fault occurs and the circuit does not have the appropriate size fuse, wires could be burned in the harness and damage other circuits. 80 Book: 22742944 (3-17-06) Rev. A Electrical Operating & Maintenance Manual Trouble Shooting Flow Chart Book: 22742944 (3-17-06) Rev. A 81 **Always use Ingersoll-Rand Replacement parts!** 82 Book: 22742944 (3-17-06) Rev. A Electrical Schematics Book: 22742944 (3-17-06) Rev. A 83 Operating & Maintenance Manual 84 Electrical Schematics Book: 22742944 (3-17-06) Rev. A Electrical Schematics Book: 22742944 (3-17-06) Rev. A Operating & Maintenance Manual 85 Operating & Maintenance Manual 86 Electrical Schematics Book: 22742944 (3-17-06) Rev. A Electrical Schematics Book: 22742944 (3-17-06) Rev. A Operating & Maintenance Manual 87 88 Book: 22742944 (3-17-06) Rev. A Electrical Schematics Operating & Maintenance Manual CPN 22840775 Book: 22742944 (3-17-06) Rev. A 89 Operating & Maintenance Manual 90 Electrical Schematics Book: 22742944 (3-17-06) Rev. A ©2004 Ingersoll-Rand Company, Printed in the USA ">

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- High-capacity air receiver
- Durable construction
- Reliable engine
- Consistent air output
- Wide range of applications
- Easy maintenance
- Safety features
- Quiet operation
- Compact design
- Heavy-duty components
Frequently asked questions
Always read and understand the safety warnings and instructions in the manual. Ensure all protective covers are in place, and never operate the unit with guards or controls removed.
Refer to the maintenance schedule in the manual for specific oil change intervals. Regular oil changes are crucial for maintaining optimal performance and extending the life of the compressor.
The manual provides information on the type of fuel recommended for this model. Ensure you use the correct fuel to avoid damage to the engine.