Ingersoll-Rand P185WIR Operating, Maintenance & Parts Manual

OPERATING, MAINTENANCE,
PARTS MANUAL
COMPRESSOR MODEL
P185WIR
XP185WIR
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.
Portable Air Compressor Division
P.O. Box 868 -- 501 Sanford Ave
Mocksville, N.C. 27028
Book: 22305593 (8/03) Revised (09-12)
(1)
QUALITY POLICY
We will supply products and services that consistently meet the requirements
of our customers and each other.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Book: 22305593 (8/03)
(2)
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:
Declaration of Conformity
WITH EC DIRECTIVE
98/37/EC
Ingersoll--Rand Company
P.O. Box 868
501 Sanford Avenue
Mocksville, North Carolina 27028
We
Represented In EC By:
Ingersoll--Rand Company Limited
Swan Lane, Hindley Green
Wigan WN2 4EZ
United Kingdom
Declare that, under our sole responsibility for manufacture and supply, the product(s)
HP1300WCU
XP1400WCU
P1600WCU
XP900WCU
VHP825WCU
HP935WCU
XP1050WCU
HP825WCU
XHP900WCAT
XHP650WCAT
XHP750WCAT
XHP825WCAT
VHP750WCAT
VHP850WCAT
HP900WCAT
XP1000WCAT
XHP1070CAT
NXP1300WCU
To which this declaration relates, is (are) in conformity with the provisions of the above
directives using the following principal standards
EN1012--1, EN29001, EN202, EN60204--1
PN8NTC2, EN 50081, EN50082
Issued at Mocksville on 1--1--95
Issued at Hindley Green on 1--1--95
________________________________
Ric Lunsford
Manager of Quality Control
________________________________
H. Seddon, Q.A. Manager
Book: 22305593 (8/03)
(3)
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:
S of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by
Ingersoll--Rand.
S clearly rated for a pressure at least equal to the machine maximum allowable working pressure.
S compatible with the compressor lubricant/coolant.
S accompanied with instructions for safe installation, operation and maintenance.
Details of approved equipment are available from Ingersoll--Rand Service departments.
The use of repair parts other than those included within the Ingersoll--Rand approved parts list may create
hazardous conditions over which Ingersoll--Rand has no control. Therefore, Ingersoll--Rand cannot be held
responsible for equipment in which non--approved repair parts are installed.
Ingersoll--Rand reserves the right to make changes and improvements to products without notice and without
incurring any obligation to make such changes or add such improvements to products sold previously.
The intended uses of this machine are outlined below and examples of unapproved usage are also given. However,
Ingersoll--Rand cannot anticipate every application or work situation that may arise. If in doubt, consult
supervision.
This machine has been designed and supplied for above ground operation to be used for compression of normal
ambient air containing no additional gases, vapors or particles within the ambient temperature range specified in
the general data section of this manual.
This machine should not be used:
A. For direct or indirect human consumption of the compressed air.
B. Outside the ambient temperature range 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.
This company accepts no responsibility for errors in translation of this manual from the original English version.
Book: 22305593 (8/03)
(4)
TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . SAFETY
SECTION 2 . . . . . . . . . . . . . . WARRANTY/REGISTRATION
SECTION 3 . . . . . . . . . . . . . . NOISE EMISSION
SECTION 4 . . . . . . . . . . . . . . GENERAL DATA
SECTION 5 . . . . . . . . . . . . . . OPERATION
SECTION 6 . . . . . . . . . . . . . . MAINTENANCE
SECTION 7 . . . . . . . . . . . . . . LUBRICATION
SECTION 8 . . . . . . . . . . . . . . TROUBLESHOOTING
SECTION 9 . . . . . . . . . . . . . . ENGINE (operation, maintenance,
lubrication, troubleshooting)
SECTION 10 . . . . . . . . . . . . . PARTS ORDERING
SECTION 11 . . . . . . . . . . . . . PARTS LIST
SECTION 12 . . . . . . . . . . . . . OPTIONS PARTS LIST
Book: 22305593 (8/03)
(5)
IMPORTANT
NOTICE
1.
2.
This machine may have been shipped from the factory
with the drawbar positioned upright.
To Convert From Shipping Position to Towing Position
The following tools are required:
Ratchet
13mm socket to fit ratchet
Torque wrench set to 68 foot pounds
(9.4 kg--meters)
16mm socket to fit torque wrench
5 inch extension for torque wrench
3.
4.
5.
6.
7.
Hardware Included:
(4) 12mm bolts with pre--applied thread lock
(2) 8mm Taptite Bolts
(2) Washers
(2) Safety Chains
Remove hardware box from compressor
toolbox.
Open box and remove the bag containing
hardware, safety chains and assembly
instructions.
Using the jack, raise the front of the unit so
that the legs are approximately 1” above
the ground.
Remove the temporary retaining bolts from
both sides of the frame at the drawbar
connection (See Figure 1).
Carefully lower drawbar to the Level
Position.
Install the four bolts (with pre--applied
thread lock) to the four points inside the
enclosure and torque to 68 ft. lbs.
(9.4 kg--m) (See Figure 2).
Install safety chains by sliding the second
link of one chain into the slot in drawbar
plate. Fasten chain to plate using taptite
and washer. Repeat for the other chain
(See Sketch).
#6
#4
Figure 2
Safety Chain Attachment
Figure 1
Drawbar Position
Book: 22305593 (8/03)
(6)
SECTION 1-- SAFETY
Compressed air must not be used for a feed to any
form of breathing apparatus or mask.
SAFETY PRECAUTIONS
General Information
Ensure that the operator reads and understands the
decals and consults the manuals before maintenance
or operation.
The discharged air contains a very small percentage
of compressor lubricating oil and care should be taken
to ensure that downstream equipment is compatible.
Ensure that the Operation and Maintenance manual,
and the manual holder if equipped, are not removed
permanently from the machine.
If the discharged air is to be ultimately released into a
confined space, adequate ventilation must be provided.
Ensure that maintenance personnel are adequately
trained, competent and have read the manuals.
When using compressed air, always use appropriate
personal protective equipment.
Make sure that all protective covers are in place and
that the canopy/doors are closed during operation.
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.
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.
Air discharged from this machine may contain carbon
monoxide or other contaminants which will cause serious injury or death. Do not breathe this air.
Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all
pressure is vented from the system and that the machine cannot be started accidentally.
Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel.
All air pressure equipment installed in or connected to
the machine must have safe working pressure ratings
of at least the machine safety valve rating.
If more than one compressor is connected to one common downstream plant, effective check valves and
isolation valves must be fitted and controlled by work
procedures, so that one machine cannot accidentally
be pressurized or over pressurized by another.
Book: 22305593 (8/03)
(7)
Avoid bodily contact with compressed air.
Never operate unit without first observing all safety
warnings and carefully reading the operation and
maintenance manual shipped from the factory with
this machine.
Never operate the engine of this machine inside a
building without adequate ventilation. Avoid breathing
exhaust fumes when working on or near the machine.
Do not alter or modify this machine.
A battery contains sulfuric acid and can give off gases
which are corrosive and potentially explosive. Avoid
contact with skin, eyes and clothing. In case of contact,
flush area immediately with water.
Exercise extreme caution when using booster battery.
To jump battery, connect 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.
Never operate unit without first observing all safety
warnings and carefully reading the operation and
maintenance manual shipped from the factory with
this machine.
This machine may include such materials as oil, diesel
fuel, antifreeze, brake fluid, oil/air filters and batteries
which may require proper disposal when performing
maintenance and service tasks. Contact local authorities for proper disposal of these materials.
High Pressure Air can cause serious injury or death.
Relieve pressure before removing filler plugs/caps, fittings or covers.
Air pressure can remain trapped in air supply line
which can result in serious injury or death. Always
carefully vent air supply line at tool or vent valve before
performing any service.
This machine produces loud noise with the doors open
or service valve vented. Extended exposure to loud
noise can cause hearing loss. Always wear hearing
protection when doors are open or service valve is
vented.
Never inspect or service unit without first disconnecting battery cable(s) to prevent accidental starting.
Do not remove the pressure cap from a HOT radiator.
Allow radiator to cool down before removing pressure
cap.
Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and
result in serious illness. wear eye protection while
cleaning unit with compressed air to prevent debris
from injuring eye(s).
Disconnected air hoses whip and can cause serious
injury or death. Always attach a safety flow restrictor
to each hose at the source of supply or branch line in
accordance with OSHA Regulation 29CFR Section
1926.302(b).
Hot pressurized fluid can cause serious burns. Do not
open radiator while hot.
Rotating fan blade can cause serious injury. Do not
operate without guard in place.
Use care to avoid contacting hot surfaces (engine
exhaust manifold and piping, air receiver and air
discharge piping, etc.).
Ether is an extremely volatile, highly flammable gas.
USE SPARINGLY! Do NOT use ETHER if unit has
GLOW Plug starting aid. Engine damage will result.
Never allow the unit to sit stopped with pressure in the
receiver--separator system. As a precaution, open the
manual blowdown valve.
Never operate unit with guards, covers or screens
removed. Keep hands, hair, clothing, tools, blow gun
tips, etc. well away from moving parts.
Make sure wheels, tires and tow bar connectors are in
safe operating condition and tow bar is properly
connected before towing.
Whenever the machine is stopped, air will flow back
into the compressor system from devices or systems
downstream of the machine unless the service valve
is closed. Install a check valve at the machine service
valve to prevent reverse flow in the event of an
unexpected shutdown when the service valve is open.
Hazardous Substance Precaution
The following substances are used in the manufacture
of this machine and may be hazardous to health if used
incorrectly.
Precaution: Avoid ingestion, skin contact and
breathing fumes for the following substances:
Antifreeze, Compressor Oil, Engine Lubricating Oil,
Preservative Grease, Rust Preventative, Diesel Fuel
and Battery Electrolyte.
The following substances may be produced during the
operation of this machine and may be hazardous to
health:
Avoid build--up of Engine Exhaust Fumes in confined
spaces.
Avoid breathing Exhaust Fumes.
Avoid breathing Brake Lining Dust during maintenance.
Book: 22305593 (8/03)
(8)
SAFETY LABELS
Look for these signs on machines shipped to international markets outside North America, which point
out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings
and follow instructions. If you do not understand, inform you supervisor.
Hot Surface
Corrosion risk
WARNING: Electrical shock risk.
Parking Brake
No open flame
Do not operate the machine
without guard being fitted.
Lifting point
Diesel Fuel.
No open flame.
WARNING -- Flammable liquid.
When parking use prop stand,
handbrake and wheel chocks.
WARNING -- Hot and harmful exhaust gas.
Book: 22305593 (8/03)
Lifting point
Tie down point
(9)
Air/gas flow or Air discharge.
Do not breathe the compressed
air from this machine.
Read the Operation and Maintenance
manual before operation or maintenance
of this machine is undertaken.
BAR
WARNING -- Maintain correct tire pressure.
(Refer to the GENERAL INFORMATION section
of this manual).
WARNING: Consult the operation
and maintenance manual before
performing any maintenance.
Rough Service Designation
Wet Location Operation
Do not stack
Do not use fork lift truck from this side
Replace any cracked
protective shield.
On (power).
Off (power).
Do not operate with the doors or enclosure
open.
WARNING -- Before connecting the tow bar or
when preparing to tow, consult the operation
and maintenance manual.
Book: 22305593 (8/03)
Emergency stop.
(10)
Oil Drain
XX
km/h
WARNING -- Do not undertake any
maintenance on this machine until the
electrical supply is disconnected and the air
pressure is totally relieved.
Do not exceed the speed limit.
Read the Operation and Maintenance manual
before operation or maintenance of this
machine is undertaken
0_C
WARNING -- For operating temperature below
0_C, consult the operation and maintenance
manual.
Pressurized vessel.
Book: 22305593 (8/03)
Do not remove the Operating and Maintenance
manual and manual holder from this machine.
Use fork lift truck from this side only.
(11)
Pressurized component or system.
Look for these signs on machines shipped to markets in North America, which point out potential
hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow
instructions. If you do not understand, inform you supervisor.
Indicates the presence of a hazard which WILL cause
serious injury, death or property damage, if ignored.
!
(Red Background)
Indicates the presence of a hazard which CAN
cause serious injury, death or property damage,
if ignored.
!
(Orange Background)
Indicates the presence of a hazard which WILL or
can cause injury or property damage, if ignored.
(Yellow Background)
Indicates important set--up, operating or maintenance
information.
(Blue Background)
WARNING
DANGER
Trapped air pressure.
Can cause serious
injury or death.
Close service valve and
operate tool to vent
trapped air before
performing any service.
Discharged air can contain carbon
monoxide or other contaminants.
Will cause serious injury or death.
Do not breathe this air.
WARNING
WARNING
High pressure air.
Can cause serious
injury or death.
Hot pressurized fluid.
Can cause serious
burns.
Relieve pressure before
removing filler plugs/caps,
fittings or covers.
Do not open radiator
while hot.
Book: 22305593 (8/03)
(12)
105
km/h
WARNING
WARNING
Improper operation of this equipment.
Can cause serious injury or death.
Read Operator’s Manual supplied with
this machine before operation or
servicing.
Collapsing jackstand.
Can cause serious injury.
Insert locking pin completely.
Excessive towing speed.
Can cause serious injury
or death.
Do NOT exceed 65 mph
(105 km/hr.)
Modification or alteration of this machine.
Can cause serious injury or death.
Do not alter or modify this machine
without the express written consent of
the manufacturer.
WARNING
WARNING
Falling off machine.
Rotating fan blade.
Can cause serious
injury.
Can cause serious injury
or death.
Do not operate without
guard in place.
Access lifting bail from
inside machine.
WARNING
WARNING
Door under pressure.
Can cause serious injury.
Disconnected air hoses whip.
Can cause serious
injury or death.
Use both hands to open door
when machine is running.
When using air tools
attach safety device
(OSHA Valve) at source of
air supply for each tool.
WARNING
WARNING
CAUTION
DO NOT WELD.
ELECTRONIC DAMAGE
WILL OCCUR.
This engine is equipped with an
electronic engine controller and
other electronic components.
Book: 22305593 (8/03)
Combustible gas.
Can cause serious burns,
blindness or death.
Keep sparks and open
flames away from batteries.
(13)
+
CAUTION
WARNING
DO NOT USE ETHER.
High pressure air.
Can cause serious
injury or death.
ENGINE DAMAGE WILL OCCUR.
This engine is equipped with an
electric heater starting aid.
Relieve pressure before
removing filler plugs/caps,
fittings or covers.
NOTICE
COOLANT FILL INSTRUCTIONS
Adding:
Do NOT remove radiator cap. Top off at overflow
reservoir. Use same anti--freeze mixture as in
radiator.
Replacing:
With system cool, removeradiator cap. Drain
coolant and close drain. At radiator, refill system.
Replace radiator cap. At reservior, fill to ”Hot”
level. Run for 30 minutes. Stop and allow to cool.
At reservoir, add coolant as necessary to reach
”Cold” level.
USE DIESEL
FUEL ONLY
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! Assure that
decals are present on the machines. Replace decals that
are not readable.
Book: 22305593 (8/03)
(14)
SECTION 2 -- Warranty
Ingersoll--Rand, through its distributor, warrants that each item of equipment manufactured by it and delivered
hereunder to the initial user will be free of defects in material and workmanship for a period of three (3) months from
initial operation or six (6) months from the date of shipment to the initial user, whichever occurs first.
With respect to the following types of equipment, the warranty period enumerated below will apply in lieu of the
foregoing warranty period.
A.
Aftercoolers -- The earlier of nine (9) months from date of shipment to or six (6) months from start up by
initial user.
B.
Portable Compressors, Portable Generator Sets (GENSET) 8KW, 11KW, 20KVA thru 575KVA, Portable
Light Towers and Air Dryers -- The earlier of twelve (12) months from shipment to or the accumulation of
2,000 hours of service by the initial user.
3.5KW thru 7.0KW and 10KW– The earlier of twelve (12) months from shipment to or the accumulation of
2,000 hours of service by the initial user, whichever occurs first. Ingersoll--Rand will provide a new part or repaired part, at it’s election, in place of any part which is found to be defective in material or workmanship during
the period described above. Labor cost to replace the part is the responsibility of the user.
C. Portable Compressor Air Ends -- The earlier of twenty--four (24) months from shipment to or the accumulation
of 4,000 hours of service by the initial user. For Air Ends, the warranty against defects will include replacement
of the complete Air End, provided the original Air End is returned assembled and unopened.
C.1 Portable Compressor Airend Limited Optional Warranty -- The earlier of sixty (60) months from shipment
to or the accumulation of 10,000 hours of service. The optional warranty is limited to defects in rotors, housings, bearings and gears and provided all the following conditions are met:
1. The original air end is returned assembled and unopened.
2. Continued use of genuine Ingersoll--Rand parts, fluids, oil and filters.
3. Maintenance is performed at prescribed intervals.
Oil--Free airends are fee--based and may require a maintenance agreement. Formal enrollment is
required.
D.
Genset Generators 8KW, 11KW, 20KVA thru 575KVA -- The earlier of twenty--four (24) months from shipment to or the accumulation of 4,000 hours of service by the initial user.
3.5KW thru 7.0KW and 10KW -- The earlier of twelve (12) months from shipment to or the accumulation of 2,000 hours of service.
E.
Portable Light Tower Generators-- The earlier of twelve (12) months from shipment to or the accumulation
of 2,000 hours of service by the initial user. Light Source model only, the earlier of twenty--four (24) months
from shipment to or the accumulation of 4,000 hours of service.
F.
Ingersoll--Rand Engines -- The earlier of twenty--four (24) months from shipment to or the accumulation of
4,000 hours of service.
Book: 22305593 (8/03)
(15)
G.
Ingersoll--Rand Platinum Drive Train Warranty (Optional) – Platinum drive train pertains to the Ingersoll-Rand Engine and Airend combination. The earlier of sixty (60) months from shipment to, or the accumulation
of 10,000 hours of service. The starter, alternator, fuel injection system and all electrical components are excluded from the extended warranty. The airend seal and drive coupling are included in the warranty (airend
drive belts are not included). The optional warranty is automatically available when meeting the following conditions:
1. The original airend is returned assembled and unopened.
2. Continued use of genuine Ingersoll--Rand parts, fluids, oil and filters.
3. Maintenance is performed at prescribed intervals.
It is the obligation of the user to provide verification that these conditions have been satisfied when submitting
warranty claims.
F.
Spare Parts– Six (6) months from date of shipment.
Ingersoll--Rand will provide a new part or repaired part, at its election, in place of any part which is found upon
its inspection to be defective in material and workmanship during the period prescribed above. Such part will
be repaired or replaced without charge to the initial user during normal working hours at the place of business
of an Ingersoll--Rand distributor authorized to sell the type of equipment involved or other establishment authorized by Ingersoll--Rand. User must present proof of purchase at the time of exercising warranty.
The above warrantees do not apply to failures occurring as a result of abuse; misuse, negligent repairs, corrosion,
erosion and normal wear and tear, alterations or modifications made to the product without express written consent
of Ingersoll--Rand; or failure to follow the recommended operating practices and maintenance procedures as provided in the product’s operating and maintenance publications.
Accessories or equipment furnished by Ingersoll--Rand, but manufactured by others, including, but not limited to,
engines, tires, batteries, engine electrical equipment, hydraulic transmissions, carriers, shall carry whatever warranty the manufacturers have conveyed to Ingersoll--Rand and which can be passed on to the initial user.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT OF
TITLE),AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.
Book: 22305593 (8/03)
(16)
GENERAL WARRANTY INFORMATION
GENERAL WARRANTY
Portable Compressor
Extended Coverage
Package
1 year/2000 hours
Airend
2 years/4000 hours
Portable Genset 8KW, 11KW, 20KVA
thru 575KVA
Portable Genset 3.5KW thru 7.0KW
and 10KW
Light Tower
5 years/10,000 hours Limited warranty, major components
(refer to operator’s manual).
Package
1 year/2000 hours
None
Generator
2 years/4000 hours
None
Package
1 year/2000 hours PARTS ONLY
None
Generator
1 year/2000 hours PARTS ONLY
None
Package
1 year/2000 hours
Generator
1 year/2000 hours
Months
Hours
Extended Coverage
12
No Limit
Available at dealer
24
2000
Major components 3 yrs/10,000 hours -- available at dealer
24
2000
5 yrs/5000 hours using OEM fluids & filters with $250 deductible.
2 years/4000 hours, for Lightsource
introduced 8/16/99.
ENGINES
Caterpillar
Cummins
John Deere
(IN COMPRESSORS)
2 yrs/4000 hours using IR fluids & filters
(IN GENERATORS AS OF 1/1/01)
24
2000
Deutz
24
2000
Available at dealer
Ingersoll--Rand
24
4000
5 years/10,000 hours when using genuine Ingersoll--Rand fluids
and parts. Refer to operator’s manual.
Kubota (North America Only)
24
2000
Major components 36 months/3000 hrs -- parts only
(Western Europe & Oceania)
24
2000
None
(Central & South America, Asia,
Middle East & Africa)
12
1000
None
Mitsubishi
24
2000
2 years/4000 hours using IR fluids and filters
Volvo
24
2000
2 years/4000 hours using IR fluids and filters
Honda
12
unlimited
None
Vanguard
24
unlimited
None
PARTS
Ingersoll--Rand
Months
Hours
Coverage
6
No Limit
Parts Only
Months
Hours
Extended Coverage
12
2000 hours
2 years/4000 hours -- available
from IR.
AIREND EXCHANGE
Airend
Note:
Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with each new product.
Book: 22305593 (8/03)
(17)
Extended Limited Airend Warranty
Ingersoll--Rand Portable Compressor Division is pleased to announce the availability of extended limited airend
warranty. Announcement of the extended warranty coincides with the introduction of PROSTECt Compressor
Fluid. PROSTECt Compressor Fluid is an amber colored fluid specially formulated for Portable Compressors and
is being provided as the factory filled fluid for all machines except ! XHP650/900/1070 models.
All machines have the standard airend warranty -- The earlier of 24 months from shipment to, or the accumulation
of 4000 hours of service.
The warranty against defects will include replacement of the complete airend, provided the original airend is returned assembled and unopened.
The optional limited warranty is the earlier of 60 months from shipment to, or the accumulation of 10,000 hours
of service. The optional warranty is limited to defects in major components (rotors, housings, gears, bearings), and
is automatically available when the following three conditions are met:
1. The original airend is returned assembled and unopened.
2. Submissions of proof that Ingersoll--Rand fluid, filters and separators have been used.
Refer to the Operation and Parts manual for the correct fluids, filters and separator elements required.
3. Submission of proof that maintenance intervals have been followed.
WARRANTY
TIME
*BARE AIREND
STANDARD
2 yrs/4000 hrs
100% parts and labor
OPTIONAL
5 yrs/10,000 hrs
100% parts and labor
* * AIREND COMPONENTS
100% parts and labor
0%
* Bare Airend -- pertains to major airend parts (rotors, housings, gears and bearings).
** Airend Components -- pertains to auxiliary attachments to the bare airend (drive coupling, seals, pumps, valves,
tubes, hoses, fittings and filter housing).
PROSTECt and XHP505 Compressor Fluids are available from the Mocksville
Product Support department by calling 1--800--633--5206.
! XHP650/900/1070 will continue to use XHP505 and will have the extended warranty when above conditions are
met.
Book: 22305593 (8/03)
(18)
WARRANTY REGISTRATION
Complete Machine Registration
Machines shipped to locations within the United States do not require a warranty registration
unless the machine status changes (i.e. change of ownership).
Machines shipped outside the United States require notification be made to initiate the machine
warranty.
Fill out the Warranty Registration Form in this section, keep a copy for your records and
mail form to:
Ingersoll--Rand Company
Portable Compressor Division
P.O. Box 868
Mocksville, North Carolina 27028
Attn: Warranty Department
Note: Completion of this form validates the warranty.
Book: 22305593 (8/03)
(19)
WARRANTY REGISTRATION
Selling Distributor
Servicing Distributor
Name
Name
Owner/User Name
Address
Address
Address
City
City
City
County
County
County
State
State
State
Zip Code
Zip Code
Zip Code
Telephone
Telephone
Telephone
Complete the Applicable Blocks
Owner/User Type of Business (check one only)
Construction--Heavy
(highway, excavation, etc.)
Asphalt Contractor
Coal Mining
Other Mining
Government
(municipal, state,
county, etc.)
Quarry
Shallow Oil & Gas
Rental
(rental center, rental fleet, etc.)
Building Contractor
Waterwell
Utility Company
(gas, electric, water, etc.)
Industrial (plant use)
Other
specify __________
Exploration
Utility Contractor
Construction--Light
(carpentry,
plumbing,
mason, etc.)
pools,
Model
Unit S/N
Engine S/N
Date Delivered
Unit--Hours
Airend S/N
Truck S/N
Truck Engine S/N
SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT
1.
2.
3.
4.
The Purchaser has been instructed and/or has read the manual and understands proper preventative
maintenance, general operation and safety precautions.
The warranty and limitation of liability has been reviewed and understood by the owner/user.
In the event that this unit is to be used within a nuclear facility, the owner/user shall notify Ingersoll--Rand of such
use so that Ingersoll--Rand may arrange for appropriate nuclear liability protection from the owner--licensee of the
facility.
Ingersoll--Rand reserves the right to make design changes or modifications of Ingersoll--Rand products at anytime
without incurring any obligation to make similar changes or modifications on previously sold units.
Book: 22305593 (8/03)
(20)
Attention: Warranty Department
Ingersoll- Rand Company
Portable Compressor Division
P.O. Box 868
Mocksville, North Carolina 27028
Book: 22305593 (8/03)
fold
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
(21)
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
CALIFORNIA EMISSION CONTROL WARRANTY
STATEMENT
EMISSION RELATED SYSTEM DEFECT WARRANTY
Ingersoll--Rand Company warrants to the initial owner
and subsequent owner of a certified non--road diesel
engine (powering non--road machines and equipment), that the engine is:
1. Designed, built, and equipped so as to conform, at
the time of sale, with all applicable regulations
adopted by the United States Environmental
Protection Agency (EPA) and the California Air
Resource Board.
2. Free from defects in materials and workmanship
in specific emission related parts for a period of
five (5) years or 3,000 hours of operation whichever occurs first, after date of delivery to the initial
owner.
If an emission related part fails during the warranty period, it will be repaired or replaced. Any such part repaired or replaced under warranty is warranted for the
remainder of the warranty period.
During the term of this warranty, Ingersoll--Rand Company will provide repair or replacement of any warranted part at no charge to the non--road engine owner.
In an emergency, repairs may be performed at any service establishment, or by the owner, using any replacement part.
Ingersoll--Rand Company will reimburse the owner for
their expenses, including diagnostic charges for such
emergency repair. These expenses shall not exceed
Ingersoll--Rand Company suggested retail price for all
warranted parts replaced, and labor charges based on
Ingersoll--Rand Company recommended time allowance for the warranty repair and the geographically
appropriate hourly labor rate.
•
•
•
If failure of one of these components results in failure
of another part, both will be covered by this warranty.
Any Replacement part may be used for maintenance
or repairs. The owner should ensure that such parts
are equivalent in design and durability to genuine INGERSOLL--RAND parts.
Use of non--genuine INGERSOLL--RAND parts does
not invalidate the warranty.
However, Ingersoll--Rand Company is not liable for
parts which are not genuine INGERSOLL--RAND
parts.
LIMITATIONS AND RESPONSIBILITIES
These warranties are subject to the following:
INGERSOLL--RAND COMPANY RESPONSIBILITIES
During the emission warranty period, if a defect in material or workmanship of a warranted part or component is found, Ingersoll--Rand Company will provide:
•
This warranty covers the following emission related
parts and components.
• Charge Air Cooling System (If Equipped)
• Fuel Injection System
• Intake Manifold
Book: 22305593 (8/03)
(22)
New, Remanufactured, or repaired parts and/or
components required to correct the defect.
Note: Items replaced under this warranty become the
property of Ingersoll--Rand Company
•
Labor, during normal working hours, required to
make the warranty repair. This includes diagnosis and labor to remove and install the engine, if
necessary.
OWNER RESPONSIBILITIES
During the emission warranty period, the owner is responsible for:
•
The performance of all required maintenance. A
warranty claim will not be denied because the
scheduled maintenance was not performed.
However, if the lack of required maintenance was
the reason for the repair, then the claim will be denied.
•
Premium of overtime labor costs.
•
Costs to investigate complaints which are not
caused by a defect in Ingersoll--Rand Company
material or workmanship.
•
Providing timely notice of a warrantable failure
and promptly making the product available for repair.
A part not being available within 30 days constitutes an
emergency.
As a condition of reimbursement, replaced parts and
receipted invoices must be presented at a place of
business of Ingersoll--Rand Company or other establishment authorized by Ingersoll--Rand Company.
Exhaust Manifold
Turbocharger System
Miscellaneous hoses, clamps, connectors and
sealing devices used in the above systems.
LIMITATIONS
Your emission control system may include parts such
as the fuel injection system, air induction system.
Also included may be hoses, belts, connectors and
other emission--related assemblies.
Ingersoll--Rand Company is not responsible for resultant damages to an emission related part or component resulting from:
Where a warrantable condition exists, an authorized
INGERSOLL--RAND Dealer will repair the heavy-duty off--road engine at no cost to the owner including
diagnosis, parts and labor.
MANUFACTURER’S WARRANTY COVERAGE:
•
Any application or installation Ingersoll--Rand
Company deems improper as explained in the Instruction Manual.
•
Attachments, accessory items, or parts not authorized for use by Ingersoll--Rand Company
•
Improper off--road engine maintenance, repair, or
abuse.
•
Owner’s unreasonable delay in making the product available after being notified of a potential
product problem.
This warranty is in addition to Ingersoll--Rand Company standard warranty, applicable to the off--road engine product involved.
Remedies under this warranty are limited to the provision of material and services as specified herein. Ingersoll--Rand Company is not responsible for incidental or consequential damages such as downtime or
loss--use of engine powered equipment.
CALIFORNIA EMiSSION CONTROL WARRANTY
STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Ingersoll--Rand Company are please to explain the
emission control system warranty on your 1996 and
later certified heavy duty off--road engine. In California, new heavy--duty off--road engines must be designed, built and equipped to meet the state’s stringent anti--smog standards. Ingersoll--Rand Company
must warrant the emission control system on your engine for the periods of time listed below provided there
has been no abuse, neglect, or improper maintenance of your engine.
Book: 22305593 (8/03)
(23)
The 1996 and later heavy--duty off--road engines are
warranted for a period of five (5) years, or 3000 hours
of operation which ever occurs first. If any emission-related part on your engine is defective, the part will be
repaired or replaced by an authorized INGERSOLL-RAND Dealer.
OWNER’S WARRANTY RESPONSIBILITIES:
•
As the heavy--duty off--road engine owner, you
are responsible for the performance of the required maintenance listed in owner’s manual (Instruction Manual). Ingersoll--Rand Company recommends that you retain all receipts and records
covering the maintenance on your engine, but Ingersoll--Rand Company cannot deny warranty
solely for the lack of receipts and records or for
your failure to ensure the performance of all
scheduled maintenance.
•
As the heavy--duty off--road engine owner, you
should however be aware that Ingersoll--Rand
Company may deny you warranty coverage if
your heavy--duty off--road engine, or part has
failed due to abuse, neglect, improper maintenance, or unapproved modifications.
•
Your engine is designed to operate on commercial diesel fuel only. Use of any other fuel may result in our engine no longer operation in compliance with California’s emission requirements.
•
You are responsible for initiating the warranty process. The CARB suggests that you present your
heavy--duty off--road engine to an authorized INGERSOLL--RAND Dealer as soon as a problem
exists. The warranty repairs should be completed
by the dealer as expeditiously as possible.
If you have any questions regarding your warranty
rights and responsibilities, you should contact Ingersoll--Rand Company, at P.O. Box 868, Mocksville, NC
27028 or the State of California Air Resources Board,
Mobile source Operation Division, P.O. Box 8001, at
El Monte, CA 91731--2990.
MAINTENANCE RECOMMENDATION:
Some Ingersoll--Rand Company non--road engines
are certified by the United States Environmental
Protection Agency and California Air Resource Board
to comply with smoke and gaseous emission standards prescribed by Federal laws at the time of
manufacture.
The engine is certified if it has a special certification
label. An INGERSOLL--RAND Dealer can also inform
you if the engine is certified.
Efficiency of emission control and engine performance depends on adherence to proper operation
and maintenance recommendations and use of recommended fuels and lubrication oils. It is recommended that major adjustments and repair be made
by your authorized INGERSOLL--RAND Dealer.
Various chemical fuel additives, which claim to reduce
visible smoke, are available commercially. Although
additives have been used by individuals to solve
some isolated smoke problems in the field, they are
not recommended for general use.
Federal smoke regulations require that engines be
certified without smoke depressants.
The corrective steps taken immediately on discovery
of worn parts, which may affect emission levels, will
help assure proper operation of emission control systems. The use of genuine INGERSOLL--RAND parts
is recommended. Suppliers of non--INGERSOLL-RAND parts must assure the owner that the use of
such parts will not adversely affect emission levels.
Regular maintenance intervals, along with special
emphasis on the following items, are necessary to
keep exhaust emissions within acceptable limits for
the useful life of the engine. Refer to the Maintenance
Section of this manual. If the engine is operating under severe conditions, adjust the maintenance schedule accordingly. See your authorized INGERSOLL-RAND Dealer to help analyze your specific application, operating environment and maintenance schedule adjustments.
The following is an explanation of maintenance for
emission--related components.
See the Maintenance Schedule for the specific interval for the following items.
Book: 22305593 (8/03)
(24)
FUEL INJECTION PUMPS OR NOZZLES – Fuel injection pumps or nozzles are subject to tip wear as a
result to fuel contamination. This damage can cause
an increase in fuel consumption, the engine to emit
black smoke, misfire or run rough. Inspect, test and
replace if necessary. Fuel injection pumps can be
tested by an authorized INGERSOLL--RAND Dealer.
TURBOCHARGER – Check for any unusual sound or
vibration in the turbocharger. Inspect inlet and exhaust piping and connections. Check bearing condition and perform maintenance as described in the
Maintenance Schedule.
Slow engine response and low power may indicate a
need for adjustment or repair. Your INGERSOLL-RAND Dealer is equipped with the necessary tools,
personnel, and procedures to perform this service.
Owner is encouraged to keep adequate maintenance
records, but the absence of such, in and of itself, will
not invalidate the warranty.
The machine or equipment owner may perform routine maintenance, repairs and other non--warranty
work or have it done at any repair facility. Such non-warranty work need not e performed at a designated
warranty station in order for the warranty to remain in
force.
CUSTOMER ASSISTANCE – EMISSION CONTROL
SYSTEM WARRANTY:
Ingersoll--Rand Company aims to ensure that the
Emission Control Systems Warranty is properly
administered. In the event that you do not receive the
warranty service to which you believe you are entitled
under the Emission Control Systems Warranty, call or
write:
Ingersoll--Rand Company
P.O. Box 868
Mocksville, NC 27028
Tel.: 336--751--3561
Authorized Dealers are recommended for major
maintenance and repair work as they are staffed with
trained personnel, proper tools and are aware of the
latest maintenance methods and procedures. Owners and others who desire to perform their own work
should purchase a Service Manual and obtain current
service information from their INGERSOLL--RAND
Dealer.
SECTION 3 -- 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:
4.
5.
6.
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
Removal of any of the following:
a.
fan shroud
b.
vibration mounts
c.
sound absorption material
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.
Book: 22305593 (8/03)
(25)
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.
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.
Book: 22305593 (8/03)
(26)
MAINTENANCE SCHEDULE
ITEM
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
AREA
PERIOD
Compressed Air Leaks
Safety and Control Systems
Acoustic Materials
Fasteners
Enclosure Panels
Air Intake & Engine Exhaust
Cooling Systems
Isolation Mounts
Engine Operation
Fuels & Lubricants
As Detected
As Detected
Daily
100 hours
100 hours
100 hours
250 hours
250 hours
See Operator’s Manual
See Operator’s Manual
F. Air Intake and Engine Exhaust
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).
G. Cooling Systems
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.
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.
Book: 22305593 (8/03)
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.
(27)
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.
MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY
ITEM NO.
DESCRIPTION OF WORK
Book: 22305593 (8/03)
HOURMETER
READING
(28)
MAINT/
INSPECT DATE
LOCATION CITY/
STATE
WORK DONE BY
(NAME)
SECTION 4 -- GENERAL DATA
UNIT MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P185WIR . . . . . XP185WIR
Air Delivery -- cfm (litres/sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 (87) . . . . . . 185 (87)
Engine Speed -- RPM (Full Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 . . . . . . . . . 2500
-- RPM (No Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1700 . . . . . . . . . 1700
COMPRESSOR
Rated Operating Pressure -- psi (kPa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 (689) . . . . . 125 (861)
Safety Valve Setting -- psi (kPa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 (1034) . . . . 150 (1034)
Net Weight (less fuel) pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2130 . . . . . . . . 2130
ENGINE (Diesel)
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ingersoll--Rand
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4IRI8N . . . . . . . 4IR18T
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC . . . . . . 12 VDC
FLUID CAPACITIES (P/XP185WIR)
Compressor Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 quarts (11.4 litres)
Engine Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 quarts ( 10.2 litres)
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 U.S. gal. (103 litres)
UNITS MEASUREMENTS/WEIGHTS (P/XP185WIR)
Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 feet (3.5 meters)
Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 feet (1.46 meters)
Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 feet (1.74 meters)
Track Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 feet (1.49 meters)
RUNNING GEAR (P/XP185WIR)
Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST205/75D15
Inflation Pressure (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 psi
Towing Speed (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 mph (105 km/hr)
CAUTION: Any departure from the specifications may make this equipment unsafe.
EXPENDABLE SERVICE PARTS (P/XP185WIR)
Compressor Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36897353
Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54625942
Air Cleaner Element (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35393685
Air Cleaner Element (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35393685
Engine Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22226351
Engine Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22226369
Fuel Water Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54525530
Book: 22305593 (8/03)
(29)
SECTION 5 -- OPERATION
SETTING -- UP (ALL UNITS)
BEFORE TOWING
WARNING
Failure to follow these instructions CAN cause
severe injury or death.
S
Assure tow vehicle has towing capacity for weight
of this unit as stated on general data decal.
S
Position the tow vehicle to align its hitch with the
pintle eye or coupler of the compressor.
S
Engage the parking brake and chock the tires of
the tow vehicle.
S
Stand to the side and ensure pin is FULLY
inserted (secure) in tube of jack. Crank jack to
seat pintle eye or coupler onto hitch. Latch and
lock hitch. Cross safety chain(s) under drawbar.
Attach to vehicle.
S
Crank jack to raise pad off the ground. Pull pin
from tube of jack. Fold jack handle down and
forward. Swing up jack tube and FULLY insert pin
in tube.
S Remove tire chocks.
S Test brakes, if so equipped.
S Test lights (running, stop, and turn signals).
•
Place the unit in an open, well--ventilated area.
Position as level as possible. The design of these
units permits a 15 degree sidewise 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 run
ning at full load). Do not overfill either the engine
crankcase or the compressor lubricating oil
system.
TOWING
WARNING
Failure to follow these instructions CAN cause
severe injury or death.
--
Ensure that tires, wheels and running gear are
in good condition and secure.
--
Ensure that tires are inflated to 35 psi.
--
Do not tow this unit in excess of 50 mph
(80 km/hr).
--
Use a tow vehicle whose towing capacity is
greater than the gross weight of this unit.
WARNING
Always raise (or remove) jack for maximum
ground clearance before towing.
Book: 22305593 (8/03)
(30)
DISCONNECT
S
Engage tow vehicle parking brake.
S
Chock tires of compressor.
S
Set the vehicle parking brake. Chock wheels of
unit.
S
Standing to the side, remove pin from tube of
jack.
S
Disconnect safety chains. Crank jack to raise eye
or coupler from hitch. Tow vehicle can be moved.
COMPRESSOR OIL LEVEL
Check the compressor oil level in the sight glass
located on the separator tank.
WARNING
NO SMOKING, SPARKS or OPEN FLAME near fuel.
WARNING
Always raise (or remove) jack for maximum
ground clearance before towing.
UTILITY PACKAGE SET--UP
(no running gear)
This unit must be located on vehicle bed to allow access for normal servicing and maintenance.
The air going into the inlet grille must be relatively free
of oil, dirt, soot and other debris. It must be no more
than 10 degrees F. (5 degrees C) over the ambient
temperature.
WATER COOLED ENGINE
CAUTION
Do not remove pressure cap from a HOT radiator.
Allow radiator to cool down before removing
pressure cap. Use extreme care when removing a
pressure cap from a liquid cooling system for the
engine. The sudden release of pressure from a
heated cooling system can result in a loss of
coolant and possible severe personal injury.
Book: 22305593 (8/03)
(31)
CONTROL PANEL
10
13
3
5
2
4
6
15
16
17
Controls (Standard)
12. Power Switch -Rotate “ON” to activate systems prior to Starting.
Rotate “Off” to stop engine.
8
7
1
14
9
19. Service Air Button -- After warm--up, PUSH.
Provides full air pressure at the service outlet.
11
12
18
19
Optional Controls
20
13. Engine Speed Gauge -Indicates engine speed.
21
14. Discharge Air Temp. Gauge -Indicates in _F and _C. Normal operating range:
185_F/85_ to 248_F/120_C.
Diagnostic/Auto Shutdown (Optional)
1.
High Engine Temperature --
15. Engine Oil Pressure Gauge --
Coolant above 220_F (104_C) or more.
2.
Low Engine Oil Pressure -- 12 psi or less
3.
High Compressor Temperature --
Indicates engine oil pressure (psi (kPa).
16. Engine Water Temp. Gauge -Indicates coolant temperature, with normal
operating range from 180_F (82_C) to
210_F(99_C).
248_F (120_C)
4.
Air Filters Restricted -- Needs Servicing.
5.
Spare
6.
Spare
17. Voltmeter -- Indicates battery condition.
18. Ether Inject Button -- Injects a measured shot.
USE SPARINGLY. (Not on WIR Models).
Diagnostic/Auto Shutdown (Standard)
7.
Alternator Not Charging -- needs attention.
8.
Low Fuel Level -- Must add fuel to operate.
9.
Hourmeter -- Records running time for
maintenance.
20. Spare
21. Spare
10. Compressor Discharge Pressure Gauge -Indicates pressure in receiver tank, psi (kPa).
11. Fuel Level Gauge -- Indicates amount of fuel in
tank.
Book: 22305593 (8/03)
(32)
BEFORE STARTING
CAUTION
Whenever the machine is stopped, air will flow back
into the compressor system from devices or systems
downstream of the machine unless the service valve
is closed. Install a check valve at the machine service
valve to prevent reverse flow in the event of an
unexpected shutdown when the service valve is open.
Exercise extreme caution when using a booster
battery to start. To jump start: Connect the ends of one
booster cable to the positive (+) terminals of each
battery. Then connect one end of the other cable to the
negative (--) terminal of the booster battery and the
other end to the engine block. NOT TO THE
NEGATIVE (--) TERMINAL OF THE WEAK BATTERY.
After Starting:
a.
b.
c.
Reduce engine speed to IDLE.
Disconnect the negative (--) cable from the
engine block first, then from the booster battery.
Disconnect positive (+) cable from both batteries.
STARTING
WARNING
Unrestricted air flow from a hose will result in a
whipping motion of the hose which can cause severe
injury or death. A safety device must be attached to the
hose at the source of supply to reduce pressure in
case of hose failure or other sudden pressure release.
Reference: OSHA regulation 29 CFR Section
1926.302 (b).
1.
Turn the POWER switch to “ON”.
2.
Turn power switch to “START” position to crank
engine.
Note: Do not operate the starter motor for more than
10 seconds without allowing at least 30 seconds cooling time between start attempts.
Before Starting:
•
Open service valve (s) to ensure pressure is
relieved in receiver--separator system. Close
valve (s) in order to build up full air pressure and
ensure proper oil circulation.
•
Check battery for proper connections and
condition.
•
Check the engine oil level. Maintain per marks
on dipstick.
•
Check the fuel level. Add only CLEAN DIESEL
fuel for maximum service from the engine.
•
Check the compressor lubricating oil level in the
sight glass located on the separator tank.
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.
Be sure no one is IN or ON the compressor unit.
CAUTION
Book: 22305593 (8/03)
Intake Heaters. Leave “ON” 15 seconds before
starting.
Open manual blowdown valve and service valve, if
nothing is connected until engine is running.
WARNING
•
Cold Weather Starting:
(33)
CAUTION
Engine is equipped with glow plugs for cold starting
aid.
Do not use Ether/starting fluid. Engine damage can
occur.
3.
Release POWER SWITCH when the engine
starts and sustains running.
4.
Allow engine to warm up 5 to 10 minutes
5.
If so equipped, press Service Air Button. Open air
service valve(s).
UNITS WITH OPTIONAL DIAGNOSTICS LAMPS
NOTICE
NOTICE
Do NOT wire around or bypass a shutdown sensor or
switch.
None of the panel lamps should be glowing when machine is operating. If they are, shut unit down and refer
to Trouble Shooting Section.
All units in this family of machines are protected by
sensors or switches at the following locations:
(1) Low engine oil pressure, in the engine.
STOPPING
(2) High engine coolant temperature, in the engine.
1.
Close air service valve.
High Discharge AIR Temperature
2.
Allow the unit to run at idle for 3 to 5 minutes to
reduce the engine temperatures.
3.
Turn Power Switch to “OFF” position.
4.
When the engine stops, automatic blowdown
valve should relieve system air pressure. If
automatic blowdown valve malfunction is
suspected, open manual blowdown valve.
5.
(4) In separator tank.
Units with Diagnostic Lamps:
In a shutdown situation, the function of the panel lamps
is to indicate what specific failure caused the unit to
shut down.These lamps will remain illuminated until
the Power Switch is turned “OFF”.
Never allow unit to sit under pressure when
engine is not running.
WARNING
Since the service valve is closed, air downstream of
the valve may be trapped. A vent hole in the service
valve will slowly bleed air from the hose. Do not disconnect hoses until all pressure has been vented.
Book: 22305593 (8/03)
(3) At the airend outlet.
(34)
P185WIR Speed and Pressure Regulator Adjusting Instructions
H
FULL
J
The engine idle and full speed settings are set and
sealed at the factory, and should not be adjusted.
Serious injury may result if the full speed is
increased. Removal of the seals without
authorization could affect the warranty. If speed
settings are lost due to engine fuel pump service
or other repairs, the speed settings can be reset as
follows:
Before Starting
1.
At the Pressure Regulator (on service pipe
near receiver tank), remove the cover to
expose the adjusting screw. Loosen the
jam nut and turn screw counterclockwise
until tension is no longer felt at the screw.
Then, turn screw clockwise one full turn.
2.
Close service valve(s).
3.
Inspect throttle arm (G) on engine governor to see the arm is resetting against
FULL stop (L) on governor. Loosen jam
nut on air actuating cylinder (A) and then
turn cylinder rod (D) until throttle arm (G)
is forced against stop (L).
After Starting Unit
4.
If equipped, push the SERVICE AIR button on the control panel, making certain
the button does not pop back out. The unit
should speed up and then unload (and
drop back to IDLE). With the unit unloaded, turn the adjusting screw on the
pressure regulator clockwise until the discharge pressure gauge indicates
125--130 psi. Tighten the pressure regulator jam nut. Replace cover.
5.
With the service valve closed, adjust IDLE
speed (*). Adjust speed using adjusting
rod (D). Tighten jam nut (H).
6.
Open the service valve and adjust the discharge pressure to 100 psi (700 kPa).
Now turn adjusting rod (C) until the proper
engine FULL speed setting (*) is reached.
Tighten jam nuts (B & J)
7.
To obtain maximum cfm at any pressure
between 80 psi (550 kPa) and maximum
pressure rating (*), make adjustment at
the pressure regulator to obtain desired
discharge pressure at FULL engine
speed. Lock adjusting screw and replace
cover.
* See General Data Specifications.
Book: 22305593 (8/03)
(35)
SECTION 6 -- MAINTENANCE
CAUTION
Any unauthorized modification or failure to maintain
this equipment may make it unsafe and out of factory
warranty.
COMPRESSOR OIL LEVEL
Check the compressor oil level in the sight glass
located on the separator tank.
If performing more than visual inspections, disconnect
battery cables and open manual blowdown valve.
Use extreme care to avoid contacting hot surfaces
(engine exhaust manifold and piping, air receiver and
air discharge piping, etc.).
Never operate this machine with any guards removed.
Inch and metric hardware was used in the design and
assembly of this unit. Consult the parts manual for
clarification of usage.
AIR CLEANER
If this unit is equipped with the Optional Diagnostic
Panel, it has an AIR FILTERS RESTRICTED lamp on
the instrument panel, covering both the engine and
the compressor.
Notice: Disregard any maintenance pertaining to
components not provided on your machine.
This should be checked daily during operation. If the
lamp glows (red) with the unit operating at full speed,
servicing of the cleaner element is necessary.
GENERAL
Also weekly squeeze the rubber valve (precleaner dirt
dump) on each air cleaner housing to ensure that they
are not clogged.
In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing
may consist of pre--operation and post--operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive
maintenance is to prevent failure, and consequently,
the need for repair. Preventive maintenance is the
easiest and the least expensive type of maintenance.
Maintaining your unit and keeping it clean at all times
will facilitate servicing.
SCHEDULED MAINTENANCE
The maintenance schedule is based on normal
operation of the unit. This page can be reproduced
and used as a checklist by the service personnel. In
the event unusual environmental operating conditions
exist, the schedule should be adjusted accordingly.
Book: 22305593 (8/03)
(36)
The air filters restricted sensor will automatically reset
after the main power switch is turned to “OFF.”
To service the air cleaners on all units proceed as
follows:
1.
Release cover latches, and remove cover.
2.
3.
4.
Inspect air cleaner housing for any condition
that might cause a leak and correct as
necessary.
Wipe inside of air cleaner housing with a clean,
damp cloth to remove any dirt accumulation,
especially in the area where the element seals
against the housing.
Inspect element by placing a bright light inside
and rotating slowly. If any holes or tears are
found in the paper, discard this element. If no
ruptures are found, the element can be
cleaned.
In the event the element is contaminated with dry dirt,
oil or greasy dirt deposits, and a new element is not
available, cleaning can be accomplished by washing,
using the air cleaner element manufacturer’s
recommendations.
NOTE: It is recommended that replacement elements
be installed in the unit. The elements just removed for
cleaning can be washed and stored as future
replacement elements.
In addition, the air cleaner system (housing and
piping) should be inspected every month for any
leakage paths or inlet obstructions. Make sure the air
cleaner mounting bolts and clamps are tight. Check
the air cleaner housing for dents or damage which
could lead to a leak. Inspect the air transfer tubing from
the air cleaner to the compressor and the engine for
leaks.
Make sure that all clamps and flange joints are tight.
5.
If a new air filter element is to be used check it
closely for shipping damage.
6.
Install cleaned or new elements in the reverse
order to the above.
7.
Install cover and fasten latches.
In the event that the filter element must be reused
immediately, compressed air cleaning (as follows) is
recommended since the element must be thoroughly
dry. Direct compressed air through the element in the
direction opposite to the normal air flow through the
element.
GAUGES
The instruments or gauges are essential for safety,
maximum productivity and long service life of the
machine. Inspect the gauges and test any diagnostic
lamps prior to start--up. During operation observe the
gauges and any lamps for proper functioning. Refer
to Operating Controls, for the normal readings.
FUEL TANK
CLEAN fuel in the fuel tanks is vitally important and
every precaution should be taken to ensure that only
clean fuel is poured or pumped into the tank.
When filling the fuel tank on this unit, by methods other
than a pump and hose, use a CLEAN non--metallic
funnel.
BATTERY
Move the nozzle up and down while rotating the
element. Be sure to keep the nozzle at least one inch
(25.4 mm) from the pleated paper.
Keep the battery posts--to--cable connections clean,
tight and lightly coated with a grease. Also the
electrolyte level in each cell should cover the top of the
plates. If necessary, top--up with clean distilled water.
TIRES
NOTE: To prevent damage to the element, never
exceed a maximum air pressure of 100 psi (700
kPa).
A weekly inspection is recommended. Tires that have
cuts or cracks or little tread should be repaired or
replaced. Monthly check the wheel lug nuts for
tightness.
Book: 22305593 (8/03)
(37)
COMPRESSOR OIL COOLER
The compressor lubricating and cooling oil is cooled
by means of the fin and tube--type oil cooler, located
below the radiator. The lubricating and cooling oil,
flowing internally through the core section, is cooled by
the air stream from the cooling fan flowing past the
core section. When grease, oil and dirt accumulate on
the exterior surfaces of the oil cooler, its efficiency is
impaired.
Each month it is recommended that the oil cooler be
cleaned by directing compressed air which contains a
nonflammable, non--caustic safety solvent through the
core of the oil cooler. This should remove the
accumulation of grease, oil and dirt from the exterior
surfaces of the oil cooler core so that the entire cooling
area can transmit the heat of the lubricating and
cooling oil to the air stream.
In the event foreign deposits, such as sludge and lacquer, accumulate in the oil cooler to the extent that its
cooling efficiency is impaired, a resulting high discharge air temperature is likely to occur, causing shut
down of the unit. To correct this situation it will be necessary to clean it using a cleaning compound in accordance with the manufacturer’s recommendations.
Pulling on the tubing will cause the inner sleeve to withdraw and compress, thus tightening the connection.
The tubing can be withdrawn only while holding the
sleeve against the fitting. The tubing can be removed
and replaced numerous times without losing its sealing ability.
To install the nylon tubing, make a mark (with tape or
grease pencil) approximately 7/8 inch from the end of
the tubing. Insert the tubing into the sleeve and “push-in” past the first resistance to the bottom. The mark
should be approximately 1/16 inch from the sleeve, for
the 3/8 inch O.D. tubing; 1/8 inch for the 0.25 inch O.D.
tubing. This will ensure that the tubing is fully engaged
in the sealing mechanism.
COMPRESSOR OIL FILTER
The oil filter must be replaced every 500 hours of
operation or six (6) months, whichever comes first.
To service the oil filters it will first be necessary to shut
the unit down. Wipe off any external dirt and oil from
the exterior of the filter to minimize any contamination
from entering the lubrication system. Proceed as
follows:
WARNING
HOSES
Each month it is recommended that all of the intake
lines to and from the air cleaners, the engine cooling
system hoses and all of the flexible hoses used for alr,
oil, and fuel be inspected.
To ensure freedom from air leaks, all rubber hose
joints and the screw--type hose clamps must be
absolutely tight.
Regular inspection of these
connections for wear or deterioration is necessary.
Premature wear of both the engine and compressor is
ASSURED whenever dust--laden air is permitted to
enter the engine’s combustion chamber or the
compressor intake.
The flexible hoses used in the fuel, oil and air lines on
these units are primarily used for their ability to accommodate relative movement between components. It is
important they be periodically inspected for wear and
deterioration. It is also important the operator does
not use the hoses as convenient hand hold or steps.
Such use can cause early cover wear and hose failure.
Piping systems operating at less than 150 psi (1050
kPa) may use a special nylon tubing. The associated
fittings are also of a special “push--in” design. If so,
features are as follows:
High pressure air can cause severe injury or death
from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other
parts from pressurized air system.
1.
Open the service air valve(s) to ensure that
system is relieved of all pressure. Close the
valve(s).
2.
Turn the spin--on filter element counterclockwise
to remove it from the filter housing. Inspect the
filter.
NOTICE
If there is any indication of formation of varnishes,
shellacs or lacquers on the oil filter element, it is a
warning the compressor lubricating oil has improper
characteristics and should be immediately changed.
3. Inspect the oil filter head to be sure the gasket was
removed with the oil filter element. Clean the gasket
seal area on the oil filter head.
NOTICE
Installing a new oil filter element when the old gasket
remains on the filter head, will cause an oil leak and
can cause property damage.
Book: 22305593 (8/03)
(38)
4. Lubricate the new filter gasket with the same oil
being used in the machine.
5. Install new filter by turning element clockwise until
gasket makes initial contact. Tighten an additional 1/2
to 3/4 turn.
6. Start unit and allow to build up to rated pressure.
Check for leaks before placing unit back into service.
FASTENERS
Visually check entire unit in regard to bolts, nuts and
screws being properly secured. Spot check several
capscrews and nuts for proper torque. If any are found
loose, a more thorough inspection must be made.
Take corrective action.
COMPRESSOR OIL
The lubricating and cooling oil must be replaced every
500 hours of operation or six (6) months, whichever
comes first.
Excessive grease in the hub or grease cap serves no
purpose due to the fact that there is no way to force the
grease into the bearing. The manufacturer’s standard
procedure is to thoroughly pack the inner and outer
bearing with grease and then to apply only a very small
amount of grease into the grease cap.
If bearing adjustment is required or the hub has been
removed for any reason, the following procedure must
be followed to ensure a correct bearing adjustment of
0.001 to .012 free play.
1.
tighten spindle nut to approximately 15 lbs.--ft.
Grasp the tire at the top and bottom and rock, in
and out.
Every month or 500 miles, tighten the wheel lug nuts to
85 -- 95 lbs.--ft. Every six months the wheel bearings,
grease seals and axle spindles should be inspected
for damage (corrosion, etc.) or excessive wear.
Replace any damaged or worn parts. Repack wheel
bearings. Use a wheel bearing grease conforming to
specification MIL--G--10924 and suitable for all
ambient temperatures.
Grease can be replaced in a wheel bearing using a
special fixture or by hand as follows.
Before installing bearing, place a light coat of grease
on the bearing cups which are pressed in the hub.
Place a spoonful of grease in the palm of one hand and
take the bearing in the other hand. Push a segment of
the wider end of the bearing down into the outer edge
of the grease pile closest to the thumb. Keep lifting and
pushing the bearing down into the edge of the grease
pile until grease oozes out both from the top and from
between the rollers. Then rotate the bearing to repeat
this operation on the next segment. Keep doing this
until you have the entire bearing completely filled with
grease.
There should be no evidence of
looseness (free play) at the bearing.
2.
Loosen nut to remove preload torque. Do not
rotate hub.
3.
RUNNING GEAR
While rotating hub slowly to seat the bearings,
Finger tighten nut until just snug. Loosen nut
until the first nut castellation lines up with cotter
pin hole in spindle. Insert cotter pin.
4.
Ensure a definite but minimal amount of free
play by rocking the tire.
6.
Nut should be free to move with only restraint
being the cotter pin.
RECEIVER--SEPARATOR SYSTEMS
WARNING
High pressure air can cause severe injury or death
from hot oil and flying parts. Always relieve
pressure before removing caps, plugs, covers or
other parts from pressurized air system.
S Open service valve at end of machine.
S Ensure pressure is relieved, with BOTH:
-- Discharge air pressure gauge reads zero (0).
-- No air discharging from service valve.
S When draining oil, remove plug from bottom of
separator tank.
S When adding oil, remove and replace (make tight)
plug on side of separator tank.
Book: 22305593 (8/03)
(39)
S In the compressor lubricating and cooling system,
separation of the oil from the compressed air takes
place in the receiver--separator tank.
As the
compressed air enters the tank, the change in velocity
and direction drop out most of the oil from the air.
Additional separation takes place in the oil separator
element which is located in the top of the tank. Any oil
accumulation in this separator element is continuously
drained off by means of a scavenge tube which returns
the accumulated oil to the system.
The life of the oil separator element is dependent upon
the operating environment (soot, dust, etc.) and
should be replaced every twelve months or 2000
hours. To replace the element proceed as follows:
S
Ensure the tank pressure is zero.
S
Disconnect the hose from the scavenge tube.
S
Remove scavenge tube from tank cover.
S
Disconnect service line from cover.
S
Remove cover mounting screws.
S
Remove cover and element.
S
Remove any gasket material left on cover or tank.
S
Install new element.
Book: 22305593 (8/03)
(40)
SCAVENGE LINE
The scavenge line runs from the combined orifice/drop
tube in the separator tank, to the orifice fitting located
in the airend.
Examine the orifice, check valve and hoses at every
service or in the event of oil carryover into the
discharge air.
It is good preventative maintenance to check that the
scavenge line and tube are clear of any obstruction
each time the compressor lubricant is changed as any
blockage will result in oil carryover into the discharge
air.
SCAVENGE LINE
3.
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.
If the paint has faded or chalked, the use of a
commercial grade, non--abrasive car wax may
partially restore the color and gloss.
Field Repair of Texture Paint
1.
The sheet metal should be washed and clean of
foreign material and then thoroughly dried.
2.
The scavenge line originates at the receiver--separator tank cover and terminates at the compressor airend near the oil filter element. An orifice check valve
is located on the scavenge tube.
Clean and remove all grease and wax from the
area to be painted using Duponts 3900S
Cleaner prior to sanding.
3.
Once a year or every 1000 hours of operation,
whichever comes first, replace the separator element
and clean the scavenge orifice/check valve.
Use 320 grit sanding paper to repair any
scratches or defects necessary.
4.
Scuff sand the entire area to be painted with a
red scotch brite pad.
5.
Wipe the area clean using Duponts 3900S.
6.
Blow and tack the area to be painted.
7.
Apply a smooth coat of Duponts 1854S
Tuffcoat Primer to all bare metal areas and
allow to dry.
8.
Apply 2 medium -- wet coats of Duponts 222S
Adhesion Promoter over the entire area to be
painted, with a 5 minute flash in between coats.
9.
To apply the texture coat, use Duponts 1854S
Tuffcoat Primer. The proper technique to do this
is to spray the Tuffcoat Primer using a pressure
pot and use about 2--5 pounds of air pressure.
This will allow the primer to splatter causing the
textured look. Note: you must be careful not to
put too much primer on at one time, this will
effect the amount of texture that you are trying
to achieve. Allow the texture coat to flash for 20
minutes or until dry to touch.
10.
Apply any of Duponts Topcoat Finishes such as
Imront or Centarit according to the label
instructions.
Excessive oil carry--over may be caused by an oil-logged separator element. Do not replace element
without first performing the following maintenance procedure:
1.
Check oil level. Maintain as indicated
earlier in this section.
2.
Thoroughly clean scavenge line, any
orifice and check valve.
3.
Assure minimum pressure valve/orifice is
operational.
4.
Run unit at rated operating pressure for 30
to 40 minutes to permit element to clear
itself.
EXTERIOR FINISH CARE
This unit was painted and heat cured at the factory with
a high quality, thermoset polyester powder coating.
The following care will ensure the longest possible life
from this finish.
1.
2.
If necessary to remove dust, pollen, etc. from
housing, wash with water and soap or dish
washing liquid detergent. Do not scrub with a
rough cloth, pad, etc.
If grease removal is needed, a fast evaporating
alcohol or chlorinated solvent can be used.
Note: This may cause some dulling of the paint
finish.
Book: 22305593 (8/03)
(41)
Note: To re--top coat the textured surfaces when sheet
metal repairs are not necessary, follow steps 1,
2, 4, 5, 6, 8 and 10.
MAINTENANCE SCHEDULE
These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty or wet).
Daily
3 MOS .
6 MOS.
12 MOS.
SMALL UNITS (P100--P600)
250 hours
500 hours
1000 hours
LARGE UNITS (HP600--P1600)
500 hours
1000 hours
2000 hours
**Hydraulic Oil Level
Monthly
C
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)
**Fuel/Water Separator
Weekly
R
C
DRAIN
DRAIN
C
Air Cleaner Precleaner Dumps
C
Fan/Alternator Belts
C
Battery Connections/Electrolyte
C
**Tire Pressure and Surface
C
**Wheel Lug Nuts
C
Hoses (oil, air, intake, etc.)
C
Automatic Shutdown System
Test
C
Air Cleaner System
Visual
C
Compressor Oil Cooler
Exterior
C
CLEAN
**Engine Radiator
Exterior
C
CLEAN
Fasteners, Guards
C
Air Cleaner Elements
WI
** Fuel/Water Separator Element
R
*Compressor Oil Filter Element
B
*Compressor Oil
A
R
**Wheels (bearings, seals, etc)
Engine Coolant
Test
Shutdown Switch Settings
Test
C
C
C
R
C
Scavenge Orifice & related parts
CLEAN
Oil Separator Element
R
**Lights (running, brake, & turn)
CBT
**Pintle Eye Bolts
CBT
Engine (oil changes, oil & fuel filters, etc)
R
**Disregard if not appropriate for this particular machine.
*NXP Units -- consult manual
R=replace, C=check (adjust if necessary), WI=OR when indicated, CBT = check before towing.
A = Small Units
B = Large Units
Refer to specific sections of the operator’s manual for more information.
Book: 22305593 (8/03)
(42)
SECTION 7 -- 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.
RATED OPERATING PRESSURE
100 -- 300 PSI
50_C
Note: Fluids listed as “preferred” are required for
extended warranty.
Compressor oil carryover (oil consumption) may be
greater with the use of alternative fluids.
IR
PRO--TECt
Design Operating
Pressure
Ambient
Temperature
100 psi to 300 psi
--10_F to 125_F
(--23_C to 52_C)
Specification
Preferred:
IR Pro--Tect
Alternate:
ISO Viscosity Grade 46
with rust and oxidation
inhibitors, designed for
air compressor service.
(--23_C to 52_C)
--10_F to 125_F
350 psi
Ingersoll--Rand
Preferred Fluids
104_F
30_C
86_F
20_C
65_F
10_C
50_F
0_C
32_F
--10_C
14_F
IR
XHP605
IR
XHP405
IR
XHP 1001
10_F
--10_F
Preferred:
IR XHP 605
--30_C
--22_F
--40_C
--40_F
Consult Factory
Consult Factory
Alternate:
IR XHP405
ISO Viscosity Grade 68
Group 3 or 5 with rust
and oxidation inhibitors
designed for air compressor service.
65_F to 125_F
(--18_C to 52_C)
40_C
--20_C
350 PSI
125_F
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.
Preferred:
XHP605
IR XHP1001
1 gal. (3.8 Litre)
5 gal. (19.0 Litre)
55 gal.
(208.2Litre)
220 gal. (836 litre)
IR Pro--Tect
36899698
36899706
36899714
36899722
IR XHP605
--
22252076
22252050
22252068
IR XHP1001
--
35612738
35300516
--
XHP405
--
22252126
22252100
22252118
Engine Oil
54480918
36875938
36866903
Preferred:
Book: 22305593 (8/03)
(43)
Section 8 -- 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 to suggest an order to follow in trouble shooting.
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.
C. Double Check Before Disassembly
The source of most compressor troubles can be traced
not to one component alone, but to the relationship of one
component with another. Too often, a compressor can be
partially disassembled in search of the cause of a certain
trouble and all evidence is destroyed during disassembly.
Check again to be sure an easy solution to the problem
has not been overlooked.
D. Find And Correct Basic Cause
ACTION PLAN
A. Think Before Acting
After a mechanical failure has been corrected, be sure to
locate and correct the cause of the trouble so the same
failure will not be repeated. A complaint of “premature
breakdown” may be corrected by repairing any improper
wiring connections, but something caused the defective
wiring. The cause may be excessive vibration.
Study the problem thoroughly and ask yourself
these questions:
(1)
(2)
(3)
(4)
What were the warning signals that preceded
the trouble?
Has a similar trouble occurred before?
What previous maintenance work has been
done?
If the compressor will still operate, is it safe to
continue operating it to make further checks?
Book: 22305593 (8/03)
(44)
TROUBLE SHOOTING CHART
Bold Headings depict the COMPLAINT -- Subheadings depict the CAUSE
Note: Subheadings suggest order to follow in cause of troubleshooting.
Excessive Compressor Oil Temperature:
Ambient Temperature Too High
Out of Level > 15 degrees
Low Oil Level
Dirty Cooler
Dirty Operating Conditions
Loose or Broken Belts
Operating Pressure Too High
Malfunctioning Thermostat
Defective Minimum Pressure Valve
Blocked or Restricted Oil Lines
Airend Malfunctioning
Short Air Cleaner Life:
Dirty Operating Conditions
Inadequate Element Cleaning
Defective Service Indicator
Incorrect Stopping Procedure
Wrong Air Filter Element
Excessive Oil In Air:
High Oil Level
Out of Level > 15 degrees
Clogged Scavenge Orifice
Scavenge Tube Blocked
Defective Scavenge Check Valve
Sep. Tank Blown Down Too Quickly
Defective Minimum Pressure Valve
Defective Separator Element
Will Not Unload:
Leaks in Regulator Piping
Incorrect Pressure Regulator Adjustment
Malfunctioning Pressure Regulator
Malfunctioning Inlet Unloader/Butterfly Valve
Ice in Regulation Lines/Orifice
Oil In Air Cleaner:
Incorrect Stopping Procedure
Safety Valve Relieves:
Leaks In Regulator Piping
Incorrect Pressure Regulator Adjustment
Malfunctioning Pressure Regulator
Malfunctioning Inlet Unloader/Butterfly Valve
Defective Separator Element
Ice in Regulation Lines/Orifice
Defective Safety Valve
Book: 22305593 (8/03)
(45)
Engine RPM Low:
Clogged Fuel Filter
Operating Pressure Too High
Incorrect Pressure Regulator Adjustment
Dirty Air Filter
Malfunctioning Speed Control Cylinder
Defective Separator Element
Ice In Regulation Lines/Orifice
Engine Malfunctioning
Airend Malfunctioning
Excessive Vibration:
Low Engine RPM
Rubber Mounts Damaged
Out of Balance Fan
Engine Malfunctioning
Airend Malfunctioning
Low CFM:
Low Engine RPM
Dirty Air Filter
Incorrect Linkage Adjustment
Incorrect Pressure Regulator Adjustment
Malfunctioning Inlet Unloader/Butterfly Valve
Malfunctioning Speed Control Cylinder
Defective Minimum Pressure Valve
Defective Separator Element
Unit Shutdown:
Out of Fuel
Compressor Oil Temp. Too High
Engine Oil Pressure Too Low
Broken Engine Fan Belt
Loose Wire Connection
Defective Switches
Defective Shutdown Solenoid
Malfunctioning Relay
Blown Fuse
Engine Malfunctioning
Airend Malfunctioning
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 Switches
Malfunctioning Relay
Engine Malfunctioning
Airend Malfunctioning
Unit Fails To Shutdown:
Defective Switches
Defective Shutdown Solenoid
Malfunctioning Relay
Defective Start Switch
Engine Temperature Lamps Stays On:
Broken Engine Fan Belt
Malfunctioning Circuit Board
Defective Engine Belt Break Switch
Ambient Temperature Too High
Dirty Operating Conditions
Dirty Cooler
Out of Level >15 degrees
Operating Pressure Too High
Alternator Lamp Stays On:
Loose or Broken Belts
Loose Wire Connection
Defective Battery
Malfunctioning Alternator
Malfunctioning Circuit Board
Engine Oil Pressure Lamp Stays On:
Low Oil Level
Out of Level >15 degrees
Wrong Lube Oil
Engine Malfunctioning
Alternator Lamp Stays Off:
Loose Wire Connection
Malfunctioning Circuit Board
Engine Temperature Lamps Stays Off:
Bulb Burned Out
Loose Wire Connection
Malfunctioning Circuit Board
Defective Engine Belt Break Switch
Engine Oil Pressure Lamp Stays Off:
Bulb Burned Out
Malfunctioning Circuit Board
Defective Engine Oil Pressure Switch
Engine Malfunctioning
Book: 22305593 (8/03)
(46)
SECTION 9
4IRI8N ENGINE
CONTENTS
FOREWORD
EXTERNAL VIEW : 4IRI8N
GENERAL INFORMATION: 4IRI8N
Main data and specifications
Engine identification
Ingersoll--Rand engine after sales support
EMISSION CONTROL LABEL
FUEL, LUBRICANT, AND COOLANT
Fuel
Lubricant
Coolant
OPERATION
Check before operation
Check and operation after start-- up
Operation and care of a new engine
PERIODICAL INSPECTION
AND MAINTENANCE
Lubricating system
Cooling system
Fuel system
Air intake system
Routine maintenance
MAINTENANCE SCHEDULE
TROUBLESHOOTING
FORWORD
The INGERSOLL-- RAND industrial diesel engines are a product of long years of experience, advanced technology, and up-- to date production
facilities. INGERSOLL-- RAND takes great pride in the superior durability and operating economy of these engines.
In order to get the fullest use and benefit from your engine, it is important that you operate and maintain it correctly. This Manual is designed to help
you do this.
Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of trouble-- free and
economical engine operation.
Should your engine require servicing, please contact your nearest INGERSOLL-- RAND branch or distributor.
All information, illustrations, and specifications contained in this Manual are based on the latest product information available at the time of
publication.
INGERSOLL-- RAND reserves the right to make changes in this Manual at any time without prior notice.
EXTERNAL VIEWS
DIESEL ENGINE Engine External View -- Model
1. Lifting eye
25.Rocker arm cover
2. Cooling water pump
26.Filler port (engine oil)
3. Cooling fan
4. Crank shaft V--pulley
5. V--belt
6. Filler port (engine oil)
7. Drain plug (engine oil)
8. Fuel injection pump
9. Engine oil cooler (4IRH8N)
10.Engine oil filter
11. Dipstick (engine oil)
12.Governor lever
13.Intake manifold
14.Fuel filter
15.Fuel oil inlet
16.Fuel filter mounting with fuel priming pump
17.Fuel priming pump
18.Engine name plate
19.Air intake port
20.Flywheel
21.Flywheel housing 3IRH8N, 4IRH8N & 4IRI8N
22.Starter motor
23.Exhaust manifold
24.Alternator
EPA CERTIFIED ENGINE DATA and SPECIFICATIONS GENERAL INFORMATION
Model: 4IRI8N
Engine model name
4IRI8N
Engine type
Vertical inline water cooled diesel engine
Combustion type
Direct injection
No. of cylinders -- bore x stroke. mm
4--98x110
Engine displacement L
3.319
Compression ratio
18.1:1
Firing order
1 -- 3 -- 4 -- 2
Exhaust emission control system
Fuel injection nozzles, fuel injector pump
Governor
Mechanical type
Injection nozzles
Hole type
Specified fuel
Diesel fuel (ISO 8217 DMA, BS2869 A1/A2)
Starter
(V--kW)
12--2.3
Alternator
(V--A)
12--40
Specified engine oil (API grade) (SAE grade)
(CD,CF) (10W--30 or 15W--40)
Coolant volume (Engine only) L
4.2
Engine dry weight kg
220
Engine dimensions
Overall length mm
719
Overall width mm
508
Overall height mm
717
Valve clearance (cold) mm
Nozzle injection pressure MPa
Injection timing B.T.D.C. at 2.5mm cam lift
ENGINE IDENTIFICATION
Serial No Location
The engine serial number is stamped on engine name plate on top of
rocker cover. See illustration on page NO TAG
Confirmation of Engine Number
It is advisable to quote the engine serial number together with the
machine serial number, as it is required when you contact the
Ingersoll--Rand branch or distributor for repair, service or parts
ordering.
CAUTION: Conduct confirmation of engine serial number with the
engine stopped. To avoid being injured, do not check it, while the engine
is still hot.
INGERSOLL--RAND ENGINE AFTER SERVICE
Please feel free to contact your Ingersoll--Rand dealer for periodical
inspection and maintenance.
Ingersoll-- Rand Genuine Parts
Genuine Ingersoll--Rand parts are identical with those used in the
engine production, and accordingly, they are warranted by
Ingersoll--Rand.
Genuine Ingersoll--Rand parts are supplied by your Ingersoll--Rand
branch or distributor.
Please ensure that only genuine Ingersoll--Rand parts, lubricants and
fluids are used for service and/or repair.
0.2 ± 0.05
21.6
15.3_ +/-- 1
ENGINE LABEL (FOR EPA)
EMISSION CONTROL LABEL
Emission control label is attached on the “top of rocker arm cover.”
The location of emission control label attached on the engine may vary depending on the engine specification
The following is the sample of a label required for engine emission control information, along with location.
*
Engine family name as assigned by EPA and ARB identifying engine family group 3YDXL1.33M3N and this identifies
3 YDX L 1.33 M 3 N
Method of air aspiration
Number of cylinders
Engine speed specifications3*:2003
Displacement (liter)4:2004
Non road / Off--road engine5:2005
Yanmar Diesel
*2003 Model year
S
Label location:
A. Emission control information label (4IRH8N, 4IRI8N)
FUEL, LUBRICANTS, and COOLANT
FUEL
Fuel Selection
The following properties are required of the diesel fuel.
Must be free from minute dust particles.
If refueling is done from an oil drum directly, ensure that it has been
kept stationary to allow any dust, sediment or water to settle at the
bottom. Do not draw fuel direct from the bottom of the drum to prevent
pickup of any settled foreign material.
Always fully fill the fuel tank. Drain the sedimented particles in the
fuel tank frequently.
Must have adequate viscosity.
Must have high cetane value.
Water in Fuel
Must have high cetane value., (45 or greater)
During refueling, it is possible for water (and other contaminants) to be
pumped into your fuel tank along with the diesel fuel. This can happen
if a fuel provider does not regularly inspect and clean its fuel tanks, or
receives contaminated fuel from its supplier(s). To protect your engine
from contaminated fuel, there is a fuel filter system on the engine which
allows you to drain excess water.
Must have high fluidity at low temperature.
Must have low sulphur content.
Must have little residual carbon.
It is strongly advisable to use ASTM D975 No. 2D (the general
automotive diesel engine purpose fuel oil) or equivalent which fully
meets the above requirements.
Applicable Standard
Recommendation
JIS (Japanese Industrial Standard)
K22O4 -- 2
DIN (DEUTSCHE INDUSTRIE NORMEN)
DIN 51601
SAE (Society of Automotive Engineers) Based
on SAE--J--313C
NO. 2--D
BS (BRITISH
BS/2869--1970
Class A--1 or A--2
STANDARD)
Based
on
ISO 8217
DMA
FUEL REQUIREMENTS
Notice: the fuel injection pump, injector or other parts of the fuel system
and engine can be damaged if you use any fuel or fuel additive other
than those specifically recommended by Ingersoll--Rand.
NOTE: If any fuel other than the one specified is used, engine operation
will be impaired. Engine failure or malfunction resulting from use of such
improper fuel will not be warranted by Ingersoll-- Rand.
To help avoid fuel system or engine damage, please read the following:
Do not use diesel fuel which has been contaminated with engine oil.
Besides causing engine damage, such fuel can also affect emission
control. Before using any diesel fuel, check with the fuel supplier to see
if the fuel has been mixed with engine oil.
Your engine is designed to use either Number 1--D or Number 2--D
diesel fuel. However, for better fuel economy, use Number 2--D diesel
fuel whenever possible. At temperatures less than --7_C, (20_F),
Number 2--D fuel may pose operating problems (see “Cold Weather
Operation” which follows). At colder temperatures, use Number 1--D
fuel (if available) or use a “winterized” Number 2--D (a blend of Number
1--D and Number 2--D). This blended fuel is usually called Number 2--D
also, but can be used in colder temperatures than Number 2--D fuel
which has not been “winterized.”
Check with the fuel supplier to be sure you get the properly blended
fuel.
NOTICE: Do not use home heating oil or gasoline in your diesel
engine; either may cause engine damage.
Handling of the Fuel.
Any fuel containing dust particles or water might cause engine
failure .
Therefore, the following must be observed.
Take care to protect the fuel from ingress of dust particles or water
when filling the fuel tank.
CAUTION: The water/diesel fuel mixture is flammable, and could be
hot. To avoid personal injury and/or property damage, do not touch the
fuel coming from the drain valve, and do not expose the fuel to open
flames or sparks.
Be sure you do not overfill the fuel tank. Heat (such as from the engine)
can cause the fuel to expand. If the tank is too full, fuel could be forced
out. This could lead to a fire and the risk of personal injury and/or
equipment damage.
Biocides
In warm or humid weather, fungus and/or bacteria may form in diesel
fuel if there is water in the fuel.
NOTICE: Fungus or bacteria can cause fuel system damage by
plugging the fuel lines, fuel filters or injector. They can also cause fuel
system corrosion.
If fungus or bacteria has caused fuel system problems, you should
have your authorized dealer correct these problems. Then, use a diesel
fuel biocide to sterilize the fuel system (follow the biocide
manufacturer‘s instructions). Biocides are available from your dealer,
service stations, parts stores and other automotive places. See your
authorized dealer for advice on using biocides in your area and for
recommendations on which biocides you should use.
Smoke Suppressants
The use of a smoke suppressant additive is not allowed because of the
greater possibility of stuck rings and valve failure, resulting from
excessive ash deposits.
LUBRICANT.
NOTE
The quality of engine oil can affect engine performance, startability
and engine life.
Using a mixture of different brands or quality of oils will adversely affect
the original oil quality; therefore, never mix different brand or different
type oils.
Use of unsuitable engine oil will result in piston ring, piston and
cylinder seizure and accelerate surface wear causing increased oil
consumption, lowered output and, finally engine failure. To avoid this,
use the specified engine oil.
Do not use API, CA, CB grade and reconstituted engine oil
Engine damage due to improper maintenance, or using oil of the
improper quality and/or viscosity, is not covered by the warranty.
1) Engine Oil Selection
Pro Tec t
2) Oil Viscosity
Engine oil viscosity affects engine startability, performance, oil
consumption, wear and the potential for seizure, etc. Always ensure
that lubricants with the correct viscosity for the operating temperature
are used. Refer to fig 12.
Fig. 12
A. (Single -- grade)
B. Ambient Temperature
C. (Multi -- grade)
COOLANT
All Ingersoll--Rand portable compressor engines are factory filled
with a 50/50 Ethylene glycol base antifreeze/water mix. which provides
protection to --33_C (--27_F)
IMPORTANT:
• Be sure to add Long Life Coolant Antifreeze (LLC) to soft water. In
cold season, the LLC is especially important. Without LLC, cooling
performance will decrease due to scale and rust in the cooling water
line. Without LLC, cooling water will freeze and expand to break the
cooling line.
• Be sure to use the mixing ratios specified by the LLC manufacturer
for your temperature range.
• Do not mix different types (brand) of LLC, chemical reactions may
make the LLC useless and engine trouble could result
• Replace the cooling water every once a year
CAUTION:
When handling Long Life Coolant Antifreeze, wear protective
rubber gloves not to contact with it. If contact with the eyes or skin
should occur, wash with clean water
ENGINE OPERATION
Engine Exhaust Gas Caution (Carbon Monoxide)
WARNING
Do not breathe exhaust gas because it contains carbon monoxide,
which by itself has no color or odor. Carbon monoxide is a dangerous
gas. It can cause unconsciousness and can be lethal.
Do not run the engine in confined areas (such as garages or next to a
building). Keep the exhaust tailpipe area clear of snow and other
material to help reduce the buildup of exhaust gases under the
equipment. This is particularly important when parked in blizzard
conditions.
CHECK BEFORE OPERATION
CAUTION: For safety reasons, conduct the inspection with the engine
stopped.
Engine Oil Level.
Place the engine or the machine on a level surface
Remove the dipstick, wipe it with a cloth. Insert it fully and take it out
gently again.
Check the oil level against the marks on the dipstick. The oil level
must be between the upper level mark and the lower level mark as
illustrated.
Remove filler cap (yellow coloured) on the rocker arm cover side of
engine.
Fill with engine oil up to the upper limit on the dipstick.
Manually tighten the filler cap. Do not use a tool such as pliers to tighten
it.
Table of oil pan capacities.
Engine oil pan capacity (oil pan) (L)
4IRI8N
10.2
A certain period of time is required before the engine oil completely
flows down from the oil filler to the crankcase. Wait at least ten minutes
before checking the oil level.
NOTE: Take care to avoid engine oil being splashed on the fan drive
belt because it causes belt slippage or slackness.
CAUTION: When adding oil, take care not to spill it. If you spill oil on the
engine or equipment, wipe it properly, to prevent the risk of fire and
personal injury and/or equipment damage.
Fan Belt Check
Check the fan belt for tension and abnormalities.
When the belt is depressed 7 -- 10 mm with the thumb (about 100
N [10 kg] pressure) midway between the fan pulley and alternator
pulley, the belt tension is correct.
If the belt tension is too high, it will result in alternator failure.
A loose belt will cause belt slippage which may result in a damaged
belt, abnormal noise, poor battery charging and engine overheating.
Fig. 16
Coolant Level Check
The coolant level must be between “MAX COLD” and “MIN” marks on
the reserve tank depending on the temperature of the engine. Check
and ensure that the level is correct.
A. Filler cap
B. Filler port (engine oil)
C. Dipstick
D. Upper limit
E. Lower limit
F. Dipstick
CAUTION: When removing the radiator filler cap, while the engine is
still hot, cover the cap with cloth, then turn it slowly to gradually release
the internal steam pressure. this will prevent anyone from being
scalded by hot steam spurting out from the filler neck.
Add coolant mixed to the correct ratio: 50/50 ethylene glycol/water.
Radiator Cap Condition
After the replenishment of the coolant, install the radiator filler cap.
Make sure the cap is securely installed.
Battery Cable Connection
CHECKS AND OPERATION AFTER START-- UP
Check the battery cable connections for looseness or corrosion. A
loosened cable connection will result in hard engine starting or
insufficient battery charge. The battery cables must be tightened
securely. Never reverse “+” and “--” terminals when reconnecting
cables after disconnection. Even a short period of reverse connection
will damage the electrical parts.
Check after the Engine Start-- up
Check the following items in the engine warming--up operation.
Engine noise and exhaust smoke color -Listen to the engine and, if any abnormal noise is heard, check to
determine the cause.
Check the fuel combustion condition by observing the exhaust
smoke color. The exhaust smoke color after engine warm--up and at
no--load condition should be colorless or light blue.
Black or white smoke indicates incorrect combustion.
Note: After start-- up from cold the engine might be noisier and the
exhaust smoke color darker than when it has warmed up. However this
condition will disappear after warm up.
Leakage in the systems Check the following items:
Fig. 17
A Battery cable
B Connections
Lubrication oil leakage -Check the engine for oil leaks, paying particular attention to oil filter
and oil pipe joints.
Fuel leakage --
Battery Electrolyte level
The amount of electrolyte in the batteries will be reduced after repeated
discharge and recharge. Check the electrolyte level in the batteries,
replenish with a commercially available electrolyte such as distilled
water, if necessary. The battery electrolyte level checking procedure
will vary with battery type. NOTICE: Do not replenish with dilute sulfuric
acid in the daily service.
Check the fuel injection pump, fuel lines and fuel filter for leakage.
Coolant leakage -- Check the radiator and water pump hose
connections and the water drain cock on the cylinder block for leakage.
Exhaust smoke or gas leakage
Checking coolant level
CAUTION:
The coolant level could drop because any mixed air is expelled in about
5 minutes after the engine started.
When inspecting the batteries, be sure to stop the engine first.
Stop the engine, remove radiator cap, and add coolant.
As dilute sulphuric acid is used as electrolyte, be careful not to
contaminate your eyes, hands, clothes, and metals with the electrolyte.
If it gets in your eye, wash with a large amount of water at once, then
seek medical advice.
CAUTION: Hot steam can rush out and you could get burnt if the
radiator cap is removed when the engine is hot. Cover the radiator cap
with a thick cloth and loosen the cap slowly to reduce the pressure, then
remove the cap.
As highly flammable hydrogen gas is released from the batteries, do not
create a spark or allow any naked flame near the batteries.
When handling such metallic articles as tools near the batteries, be
sure not to contact the “+” terminal because the compressor body is “--”
and a dangerous short circuit might result.
When disconnecting the terminals, start with “--” terminal. When
connecting them, connect the “--” terminal last.
Fuel level
Check the remaining fuel oil level in the fuel tank and re--fuel if
necessary.
OPERATION AND CARE OF A NEW ENGINE.
Your Ingersoll--Rand engine is carefully tested and adjusted in the
factory, however, further run--in is necessary. Avoid any harsh engine
operation within the initial 100 operating hours.
Do not operate the unit at full load until the engine is warmed--up.
Do not allow the engine to run unloaded for extended periods so as to
minimise the risk of cylinder bore glazing.
During operation, pay attention to the following points if the engine
shows any sign of abnormalities.
(1) Engine Oil Pressure -- The engine oil pressure is monitored by a
switch that will stop the engine if the pressure falls below a pre--set
value.
(2) Coolant Temperature -- The engine performance will be adversely
affected if engine coolant temperature is too hot or too cold. The normal
coolant temperature is 75 to 85_C (167 to 185_F).
Overheating
CAUTION:
If you see or hear escaping steam or have other reason to suspect
there is a serious overheat condition, stop the engine immediately.
If the Engine Coolant Temperature gage (where fitted) shows an
overheat condition, or you have reason to suspect the engine may be
overheating, take the following step:
S
Close the service valve to reduce the load.
S Let the engine run at normal idle speed for two or three minutes. If
the engine coolant temperature does not start to drop, turn off the
engine and proceed as follows:
CAUTION: To help avoid being burned -S Do not open the canopy or door if you see or hear steam or engine
coolant escaping. Wait until no steam or engine coolant can be seen or
heard before opening the engine canopy or door.
S Do not remove the radiator filler cap if the engine coolant in the
reserve tank is boiling. Also do not remove the radiator filler cap while
the engine and radiator are still hot. Scalding fluid and steam can be
blown out under pressure if either cap is taken off too soon.
If no steam or engine coolant can be seen or heard, open the canopy
or door. If the engine coolant is boiling, wait until it stops before
proceeding. The engine coolant level should be between the “MAX
COLD” and “MIN” marks on the reserve tank.
Make sure the fan belt is not broken, or off the pulley, and that the fan
turns when the engine is started. If the engine coolant level in the
reserve tank is low, look for leaks at the radiator hoses and
connections, radiator, and water pump. If you find major leaks, do not
run the engine until these problems have been corrected. If you do not
find a leak or other problem, WAIT UNTIL THE ENGINE HAS COOLED
DOWN then carefully add engine coolant to the reserve tank.
(Engine coolant is a mixture of ethylene glycol antifreeze and water.
See “Engine Care in cold season” for the proper antifreeze and
mixture.)
CAUTION: To avoid being burned, do not spill antifreeze or engine
coolant on the exhaust system or hot engine parts. Under some
conditions the ethylene glycol in engine coolant is combustible.
If the engine coolant level in the reserve tank is at the correct level but
there is still an indication of an overheat condition and no cause was
found, please consult your local Ingersoll--Rand branch or dealer.
Overcooling
Operating the engine at low coolant temperature will not only increase
the oil and fuel consumption but also will lead to premature parts wear
which may result in engine failure. Ensure that the engine reaches
normal operating temperature 75 to 85_C (167 to 185_F) within ten
minutes of starting.
(3) Hourmeter
This meter indicates the machine operation hours. Make sure that the
meter is always working during engine operation. Periodical machine
maintenance is scheduled on the operation hours indicated on the
hourmeter.
(4) Liquid and Exhaust Smoke Leakage
Make regular checks for lubricant, fuel, coolant and exhaust smoke
leakage.
(5) Abnormal Engine Noise
In the event of any abnormal engine noise, please consult your local
Ingersoll--Rand branch or dealer.
(6) State of the Exhaust Smoke
Check for any abnormal exhaust smoke color.
ENGINE STOPPING
(1) Close service valves.
(2) Before stopping the engine, cool down the engine by operating it at
reduced load about three minutes. In this period, check the engine
noise for abnormalities.
LONG TERM STORAGE
If the equipment is to be out of operation for an extended period, it
should be started at least once per week and run on load for about 15
minutes after it has reached normal operating temperature.
If this is not possible,
S
Do not drain the cooling water
S
Clean dust or oil from the engine extension
S
Either fill completely or drain the fuel tank
S
Grease accelerator joints and electrical connections
S
Disconnect the negative battery terminal
When performing the following items, the daily inspection items should also be carried out.
ENGINE MAINTENANCE SCHEDULE
IMPORTANT:
Establish a periodic check plan according to the operating conditions and make sure to conduct checks at specified intervals. Otherwise,
malfunctioning may occur to shorten the engine life.
As special knowledge and skill are required for items marked with F, consult your local Ingersoll-- Rand branch or distributor.
f: Check
Z: Replace
F: Contact your dealer
Periodic inspection interval
System
Fuel oil
Check item
Every 50
hours
Daily
Fuel tank oil level check and refill
Every 250
hours
Every
1000
hours
Draining from fuel tank
f
Draining from oil / water separator
f
f
Fuel filter replacement
Z
Engine oil level
f
Engine oil replacement
Z
1st time
Engine oil filter replacement
Check & addition cooling
Z
2nd &
after
f
Radiator fin checking & cleaning
f
Cooling fan V--belt checking & adjusting
f
1st time
Cooling
g water
f
2nd &
after
Cooling water replacement
Z
or every 1
yr
Cooling water path flushing & maintenance
Rubber hoses
Governor lever & accelerator check & adjust
Intake and
exhaust
Air cleaner element cleaning & replacement
Electrical
equipment
Battery electrolyte check and recharging
Fuel valve
pump *
F
Fuel & cooling water pipe replacement
Operating
system
Cylinder head
Every
2000
hours
f
Cleaning oil / water separator
Engine
g
oil
Every 500
hours
F
or every 2
yrs
f
f
f
Z
f
Adjust intake I exhaust valve clearance
F
Lapping intake I exhaust valve seats
F
Check fuel injection valve pressure & adjust
F
Check & adjust fuel injection pump
F
* The specific emissions related parts for the EPA/ARB regulations
EPA allows to apply Maintenance schedule for Emission related parts as follows.
-kW ≦ 130
Check Fuel Valve Nozzle and clean
Adjust, cleaning and repair of fuel injection Pump
and fuel valve nozzle
1500 hours of use and at 1500--hour intervals 3000 hours of use and at 3000--hour intervals
thereafter
thereafter
PERIODICAL INSPECTION AND MAINTENANCE
Inspection after initial 50 hours operation
(1) Replacing the engine oil and engine oil filter (1st time)
When the engine oil is still hot, be careful with a splash of engine oil
which may cause burns. Cool the engine to replace engine oil until the
engine oil becomes warm. It is most effective to drain the engine oil
while the engine is still warm.
In early period of use, the engine oil gets dirty rapidly because of the
initial wear of internal parts. Replace the engine oil earlier.
Engine oil filter should also, be replaced when the engine oil is replaced.
Engine oil and engine oil filter replacing procedures are as follows.
Remove the oil filler cap to drain easily while draining the engine oil.
1) Prepare a waste oil container collecting waste oil.
2) Loosen the drain plug using a wrench (customer procured) to drain
the engine oil.
3) Securely tighten the drain plug after draining the engine oil.
4) Turn the engine oil filter counter--clockwise using a filter wrench
(customer procured) to remove It.
5) Clean the engine oil filter mounting face.
6) Moisten the new engine oil filter gasket with the engine oil and install
the new engine oil filter manually turning it clockwise until it comes into
contact with the mounting surface, and tighten it further to 3/4 of a turn
with the filter wrench.
Tightening torque: 19.6µ23.5NSm (2.0µ2.4kgfSm)
The location depends on the engine installed on the machine unit
A. Dipstick
B. Oil pan
C. Drain plug
Applicable engine oil filter Part No 22226351.
7) Fill with the new engine oil until it reaches the specified level as
explained in OPERATION section.
IMPORTANT:
Do not overfill the oil pan with engine oil. Be sure to keep the specified
level between upper and lower limit on the dipstick.
8) Warm up the engine by running for 5 minutes while checking any oil
leakage.
9) Stop the engine after warming up and leave it stopping for about 10
minute to recheck the engine oil level with dipstick and replenish the
engine oil. If any oil is spilled, wipe it away with a clean cloth.
A. Engine oil filter
B. Loosen
C. Tighten
(2) Checking and adjusting cooling fan V-- belt
When there is not enough tension in the V--belt, the V--belt will slip
making it impossible for the alternator to generate power and cooling
water pump and cooling fan will not work causing the engine to
overheat. Check and adjust the V--belt tension (deflection) in the
following manner.
S ”Used V--belt” refers to a V--belt which has been used on a running
engine for 5 minutes or more.
Install the new V--belt adjusting the deflection to the value in the table
below according to the above manner. After adjusting. run the engine
for 5 minutes end readjust the deflection to the value in the table above.
1) Press the V--belt down with your thumb [approx. 98N(10kgf)]. at the
middle of the V--belt span to check the tension (deflection).
Available positions to check and adjust the V--belt tension (deflection)
are at the A, B and C showing with the arrow direction as shown
illustration right.
A
B
C
8µ12mm
5µ8mm
7µ11mm
You may choose a position whichever you can most easily carry out the
check and adjustment on the machine unit.
The specified deflection to be measured at each position should be as
follows.
A
B
C
10µ14mm
7µ10mm
9µ13mm
(Adjusting the V--belt tension)
D. Radiator fan
E. Set bolt
F. Alternator
G. Deflection
A. Adjust the V--belt tension by prying with a wooden bar
B. Alternator
C. Adjusting bracket
H. Press with thumb
I. Crankshaft V--pulley
J. V--belt
2) If necessary, adjust the V--belt tension (deflection). To adjust the
V--belt tension, loosen the set bolt and move the alternator to tighten the
V--belt.
3) Visually check the V--belt for cracks, oiliness or wear. If any , replace
the V--belt with new one.
S “New, V--belt” refers to a V--belt which has been used less than 5
minutes on a running engine.
Use of genuine Ingersoll-- Rand fan belt
Always use genuine Ingersoll--Rand fan belts as they provide high
driving ability and long operating durability. Use of non--Ingersoll--Rand
fan belts could result in premature belt wear or belt elongation leading
to engine overheating or excessive belt noise.
CAUTION:
To help avoid being injured, check and adjust the fan belt tension with
engine stopped.
Inspection every 50 hours operation
Governor Control Seals
(1) Draining of the fuel tank (NOT 7/26)
As the governor is precisely adjusted, most of the controls are sealed,
please do not break them. Should any adjustment be necessary,
contact your local Ingersoll--Rand branch or distributor.
1) Prepare a waste oil container.
2) Remove the drain plug of the fuel tank to drain (water, dust ,etc.)
from the fuel tank bottom.
3) Drain until fuel with no water and dust flow out. Then tighten the
drain plug firmly.
(2) Draining of the oil/water separator
NOTE: Ingersoll- Rand will not accept any warranty claim on an
engine with broken governor seals.
(3) Inspection of battery
Fire due to electric short-- circuit
Draining Water from Fuel Filter/separator.
S Make sure to turn off the battery switch or
disconnect the negative cable (--) before
inspecting the electrical system. Failure to do so
could cause short--circuiting and fires.
The fuel filter/separator is provided to allow water to be drained from the
fuel system. Water is heavier than fuel so any water contained in the
system will collect in the bottom of the bowl.
The clear bowl ‘D’ should be checked on a daily basis and if water is
present, it should be drained from the separator.
S Always disconnect the (--) Negative battery
cable first before disconnecting the battery cables
from battery. An accidental “Short circuit” may
cause damage, fire and or personnel injury.
Place a suitable container under the separator to prevent any spillage
inside the machine.
Slacken the drain valve ‘E’ until water drains from the vent tube.
When all the water has been evacuated, tighten the drain valve ‘E’ and
follow the “fuel system air bleeding” procedure below.
And remember to connect the (--) Negative battery cable (back onto the
battery) LAST.
Proper ventilation of the battery area
Keep the area around the battery Well ventilated,
paying attention to keep away any fire source.
During operation or charging, hydrogen gas is
generated from the battery and can be easily
ignited.
Do not come in contact with battery electrolyte
Pay sufficient attention to avoid your eyes. or skin
from being in contact with the fluid. The battery
electrolyte is dilute sulfuric acid and causes burns.
Wash it off immediately with a large amount of
fresh water if you get any on you.
S
Fuel System Air Bleeding
The entry of air into the fuel system will cause difficult engine starting
or engine malfunction.
When carrying out service procedures such as emptying the fuel tank,
draining the filter/separator, and changing the fuel filter element be sure
to bleed air from the fuel system.
To activate the “automatic air--bleeding system”, turn the key switch to
the “ON” position and energize the electromagnetic pump” to bleed the
air.
Air bleeding method:
When the “starter switch” is set to the “ON” position to activate the
electromagnetic pump, fuel is forced to the fuel valve of each injection
pump and then to the leak--off pipe of each injector nozzle, so that any
air in the fuel system bleeds off automatically to the fuel tank.
NOTE:
Although the fuel system can bleed air automatically when the key
switch is in the “ON” position, air can also be manually bled by use of
the primer pump facility in the filter/separator assembly.
By unscrewing the plastic primer pump head ‘A’ and stroking it up and
down, any air bubbles in the system will be purged back to the fuel tank.
When this has been completed, the pump head must be screwed back
into the filter/separator assembly.
Start the engine and visually check the fuel system for leaks.
Clean the battery terminals
S Check the level of fluid in the battery.
When the amount of fluid nears the lower limit, fill with battery fluid
(available in the market) to the upper limit. If operation continues with
insufficient battery fluid, the battery life is shortened, and the battery
may overheat and explode.
S Battery fluid tends to evaporate more quickly in the summer, and the
fluid level should be checked earlier than the specified limes.
S If the engine cranking speed is so slow that the engine does not start
up, recharge the battery.
S
If the engine still will not start after charging, replace the battery.
S Remove the battery from the battery mounting of the machine unit
after daily use if letting the machine unit leave in the place that the
ambient temperature could drop at --15_C or less. And store the battery
in a warm place until the next use the unit to start the engine easily at
low ambient temperature.
Inspection every 250 hours operation
(1) Replacing the engine oil and engine oil filter (2nd time and
after)
Replace the engine oil every 250 hours operation from 2nd time and on.
Replace the engine oil filter at the same time. Refer to 50 hour
inspection, section (1).
(2) Checking and cleaning radiator fins.
Beware of dirt from air blowing
Wear--protective equipment such as goggles to
protect your eyes when blowing compressed air.
Dust or flying debris can hurt eyes.
Dirt and dust adhering on the radiator fins reduce the cooling
performance, causing overheating. Make it a rule to check the radiator
fins daily and clean as needed.
S Blow off dirt and dust from fins and periphery with compressed air
[0.19MPa (2kgf/cm2) or less] not to damage the fins with compressed
air.
OPTION
S If contaminated heavily, apply detergent, thoroughly clean and rinse
with tap water shower.
Follow the instructions an precautions in the manual from the battery
maker.
A. Battery fluid
B. Lower limit
C. Upper limit
A. Dust, dirt.
B. Radiator fins
C. Air blow
IMPORTANT:
Never use high pressure water or air from close by fins or never attempt
to clean using a wire brush. Radiator fins can be damaged.
(3) Checking the governor lever and accelerating device.
Screw the new element onto the head firmly by hand.
The governor lever and accelerating devices (accelerating lever, pedal.
etc.) of the machine unit are connected by a fixed linkage to a
pneumatic actuator. If the linkage becomes loose, the deviation in the
position may result and make operation unsafe. Check the linkage
connections for excess play. For adjustment of linkage see
compressor operation section.
Follow the “fuel system air bleeding” procedure. see “inspection after
every 50 hours operation” section 2.
(6) Air cleaner element inspection
Governor Control Seals
As the governor is precisely adjusted, most of the controls are sealed,
please do not break them. Should any adjustment be necessary,
contact your local Ingersoll--Rand branch or distributor.
AIR INTAKE SYSTEM
Air cleaner
Engine performance and life vary with the air intake conditions.
NOTE: Ingersoll- Rand will not accept any warranty claim on an
engine with broken governor seals.
A dirty air cleaner element reduces the amount of intake air, causing
reduced engine output and possible engine damage.
(4) Replacing fuel filter
Also, a damaged element leads to abrasion of cylinders and valves,
resulting in increased oil consumption, reduced output and shortened
engine life.
Replace the fuel filter at specified intervals before it is clogged with dust
to adversely affect the fuel flow. Also, replace the fuel filter after the
engine has fully been cooled.
1) Remove the fuel filter using a filter wrench(customer procured).
When removing the fuel filter, hold the bottom of the fuel filter with a
piece of rag to prevent the fuel oil from dropping. If you spill fuel, wipe
such spillage carefully.
INSPECT THE CONDITION OF THE ELEMENT.
2) Clean the filter mounting surface and slightly apply fuel oil to the
gasket of the new fuel filter.
3) Install the: new fuel filter manually turning until it comes into contact
with the mounting surface, and tighten it further to 1/2 at a turn, using
a filter wrench. Tightening torque: 11.8µ15.6NSm(1.2µ1.6kgfSm)
Applicable fuel filter Part No: 22226369.
4) Bleed the fuel system. Refer to section 2 of inspection at 50 hours
IMPORTANT:
Be sure to use genuine IR part (super fine mesh filter). Otherwise, it
results in engine damage, uneven engine performance and shorter
engine life.
Fig. 32
(5) Changing oil/water separator element.
NOTE:
The cartridge and bowl contain fuel. Take care not to spill it during
disassembly and reassembly.
A Normal
B Clogged
C Indicator
D Red signal
The fuel filter/separator also provides primary filtration and the element
‘C’ should be changed every 500 operating hours or 6 months,
whichever comes first.
Change procedure:
Unscrew the element ‘C’ from the head taking care not to spill fuel inside
the machine. Drain any fuel within into a suitable container, then
unscrew the clear bowl ‘D’ from the element.
Discard the old element into a suitable container.
Remove the old ‘O’ ring from the bowl ‘D’ and install the new one
supplied with the element. Apply a light coat of clean engine oil to the
‘O’ ring and screw the bowl ‘D’ onto the new element ‘C’.
Using a clean cloth, wipe the sealing face of the filter/separator head
to ensure correct seating of the sealing ring.
Fill the element/bowl assembly with clean fuel oil then apply a light coat
of clean engine oil to the new element seal ring.
Air cleaner with dust indicator
This indicator is attached to the air cleaner. When the air cleaner
element is clogged, air intake resistance becomes greater and the dust
indicator signal turns to red indicating the element needs to be
changed.
When the signal turns to red, replace the element. Then press the dust
indicator button to reset the indication.
(1) Checking and adjusting cooling fan V-- belt (2nd time and after)
Check and adjust the cooling fan V--belt tension every 250 hours
operation from 2nd time and on.
See “inspection after initial 50 hours” section (2)
Inspection every 500 hours operation
(1) Replacing the air cleaner element
Replace the air cleaner element periodically even if it is not damaged
or dirty. When replacing the element, clean the inside air cleaner case
at the time. If having the air cleaner with double elements, do not
remove the inner element. If the engine output is still not recover (or the
dust indicator still actuates if having the air cleaner with a dust indicator)
even though the outer element has replaced with new one, replace the
inner element with new one.
Inspection every 1000 hours operation
(1) Replacing cooling water
Cooling water contaminated with rust or water scale - reduces the
cooling effect. Even when antifreeze agent (LLC) is mixed, the cooling
water gets contaminated due to deteriorated ingredients. Replace the
cooling water at least Once a year.
1) Remove the header tank cap.
2) Remove the bottom radiator hose of the radiator and drain the
cooling water.
3) After draining the cooling water, reconnect the hose.
4) Fill radiator and engine with cooling water via the header tank.
Beware of scalding by hot water
Wait until the temperature goes down before draining the Cooling water.
Otherwise, hot water may splash to cause scalding.
(2) Checking and adjusting the fuel injection valve
As the adjustment requires specialized knowledge and skill, .consult
your Ingersoll--Rand dealer. This adjustment is needed to obtain the
optimum injection pattern for full engine performance.
(3) Adjusting intake / exhaust valve clearance
As this adjustment requires specialized knowledge and skill, consult
your Ingersoll--Rand dealer. The adjustment is necessary to maintain
the correct timing for the opening and closing of valves. Neglecting the
adjustment will cause the engine to run noisily and result in poor engine
performance and other damage.
Inspection every 2000 hours operation
(1) Flushing the cooling system and checking the
cooling system parts
As this maintenance requires specialized knowledge and skill, consult
your Ingersoll--Rand dealer. Rust and water scale will accumulate in the
cooling system through many hours of operation. This lowers the
engine cooling effect.
And for the engine oil cooler (4TNV98T), they quickly deteriorate the
engine oil.
Cooling system parts: radiator, cooling water pump, thermostat,
cylinder block, cylinder head, oil cooler (4TNV98T).
(2) Checking and replacing fuel hoses and cooling water hoses
As this maintenance requires specialized knowledge and skill, consult
your Ingersoll--Rand dealer. Regularly check the rubber hoses of the
fuel system and cooling water system. If cracked or degraded, replace
them with new one. Replace the rubber hoses at least every 2 years.
(3) Lapping the intake and exhaust valves
As this maintenance requires specialized knowledge and skill, consult
your Ingersoll--Rand dealer. The adjustment is necessary to maintain
proper contact of the valves and seats.
(4) Checking and adjusting the fuel injection timing
As this maintenance requires specialized knowledge and skill, consult
your Ingersoll--Rand dealer.
Checking and adjusting the EPA emission related parts.
The inspection and servicing require specialized knowledge and
techniques. Consult your Ingersoll--Rand dealer or distributor.
EPA allows to apply maintenance schedule for emission related parts
as follow.
--
Check Fuel Valve Adjust, cleaning and
Nozzle and clean
repair of Fuel injection
Pump and Fuel Valve
Nozzle.
kW ≦ 130
1500 hours of use 3000 hours of use
and at 1500--hour and at 3000--hour
intervals thereafter
intervals thereafter
Note:
L This is a recommended maintenance. The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior
to the completion engine useful life. Ingersoll--Rand, however, urges that recommended maintenance service is performed at the indicated intervals.
EXPLANATION OF MAINTENANCE SCHEDULE
The following is a brief explanation of the services listed in the preceding Engine Maintenance schedule.
1.
Oil level.
Check that the oil level is between the max. and the min. level marks.
Add oil to the max. level mark if it is below the min. level.
If it is above the max. level mark, drain oil until the max. level is reached.
2.
Engine oil replacement
Change at 500 hours or 6 months, whichever comes first.
3.
Oil filter element
replacement
Change at 500 hours or 6 months, whichever comes first.
4.
Fuel leakage
Replace any damaged or malfunctioning parts which could cause leakage.
5.
Draining water in fuel
filter/separator.
Drain off water in the fuel filter/separator bowl.
6.
Fuel filter element
replacement
Replace both primary (filter/separator) and secondary elements at 500 hours or 6 months whichever come first.
7.
Injection nozzle check
Check injection opening pressure and spray condition. (This is a recommended maintenance item L). Consult
your local Ingersoll--Rand branch or distributor.
8.
Coolant level.
Check coolant level and add coolant if necessary.
9.
Coolant leakage check
Replace any damaged or malfunctioning parts which could cause leakage.
10.
Radiator filler cap fitting
condition
The radiator cap must be installed tightly and sealing correctly.
11.
Fan belt tension check
Check and adjust fan belt deflection. Look for cracks, fraying and wear. Replace if necessary.
12.
Coolant temperature
Normal running temperature is 75 to 85_C (167 to 185_F). Check and repair the cooling system if temperature
is abnormal.
13.
Coolant replacement
Change coolant at intervals of 1000 hours or 12 months, whichever comes first.
14.
Radiator external face
cleaning
Check monthly. Clean at intervals of 250 hours or 3 months, whichever comes first. In very dusty environments,
more frequent cleaning might be necessary.
15.
Cooling system circuit
cleaning
Clean at intervals of 1000 hours or 12 months, whichever comes first.
16.
Radiator filling cap
function check
Check radiator pressure cap periodically for proper operation. Consult your local Ingersoll--Rand branch or
distributor.
17.
Battery electrolyte level
check
Replenish with distilled water if necessary.
18.
Battery cleaning
Clean the terminals
19.
Battery charge condition
If cranking speed is too slow to start the engine, charge the battery.
20.
Air filter element
replacement
Change element at 500 hrs or sooner if the restriction indicator shows red.
21.
Cylinder compression
pressure
Consult your Ingersoll--Rand dealer or distributor
22.
Valve clearance check
Check and adjust every 1000 hours. Consult your Ingersoll--Rand dealer or distributor
This item contains a simple troubleshooting. When a failure takes place on your Ingersoll--Rand engine, diagnose the cause referring this
troubleshooting. Should the cause of failure not be detected or you are unable to manage the failure, consult your machine supply source or nearest
Ingersoll--Rand engine service outlet.
Battery discharged
Engine does not start
Starter does not turn.
Bad cable connections.
Starter or starter switch failure.
Safety relay failure.
Engine stop solenoid malfunction.
No fuel in the fuel tank.
No fuel injection.
Clogged fuel filter element.
Air in the fuel system.
Starter turns but engine does not
fire.
Control rack is stuck at no fuel
position.
Incorrect preheating operation.
Faulty air heater.
Fuel is injected but engine does not Incorrect injection timing.
fire.
Low
cylinder
pressure.
compression
Engine stop solenoid not fully
returned.
Engine fires but stalls immediately.
Air in the fuel system.
Incorrect low idle speed adjustment.
Crack in injection pipe.
Unstable engine running
Injection nozzle failure.
Unstable low idling
Engine stop solenoid return failure.
Uneven compression pressure between cylinders.
Incorrect high idle speed
adjustment.
Incorrect control lever adjustment.
Governor internal malfunction.
Engine hunting in medium speed
range.
Governor spring deteriorated.
Air in the fuel system
Insufficient fuel supply.
Clogged fuel filter element
Piping failure (squeezed/restricted
etc.)
Engine malfunction in high speed
range.
Uneven fuel injection amount between cylinders.
Deteriorated governor spring.
Incorrect valve clearance adjustment.
Deteriorated valve spring.
Engine speed stuck at high idle.
Engine control restriction or seizure.
Insufficient coolant volume.
Engine overheat.
Fan belt slippage.
Cooling system defect
Thermostat malfunction.
Radiator filler cap malfunction.
Cooling system interior fouled.
Radiator clogged.
Engine over--loaded.
Improper servicing
Air cleaner element clogged.
Insufficient airflow/restriction.
Restricted coolant flow (high concentration of antifreeze, etc.)
Low oil pressure
Lack of oil
Oil leakage
High oil consumption
Wrong oil
Wrong type and viscosity.
High coolant temperature.
Over heat.
Clogged filter and strainer.
Worn bearings and oil pump.
Faulty relief valve.
Incorrect injection timing
Low engine output
Too far advanced.
Too far retarded.
Injection nozzle malfunction
Incorrect injection pressure.
Incorrect spray condition.
Incorrect injection pump adjustment
Lack of fuel in tank.
Insufficient fuel supply
injection pump
to the Air in injection pump.
Fuel filter clogged.
Overflow valve malfunction.
Governor malfunction
Incorrect
adjustment.
engine
control
Deteriorated governor spring.
Incorrect
adjustment.
Cylinder compression leakage
Low cylinder compression pressure
valve
Injector nozzle misalignment.
Cylinder bore wear.
Insufficient air intake volume.
Air cleaner clogged.
Restricted air flow.
Excessive oil consumption
Incorrect oil
Wrong selection of type and viscosity.
Too much oil quantity.
Engine burning oil
Faulty piston rings/damaged cylinder bores.
Faulty valve stem seal.
Damaged seal / Damaged turbocharger seal
Oil leakage
Loose joints/gaskets.
Improper installation of filter and piping.
Fuel leakage
Damaged seals.
Improper component installation or tightening.
Excessive fuel consumption
Excessive injection volume.
Excessive mechanical loads
Injection pump defective.
clearance
Clogged air cleaner.
Improper exhaust
Damaged injector nozzle.
Excessive black smoke
Wrong injector nozzle.
Injection timing incorrect.
Excessive injection volume.
Incorrect fuel.
Water mixing in fuel
Excessive white smoke
Low compression pressure.
Injection timing incorrect.
Low coolant temperature
Faulty turbocharger
Battery over discharge
Low electrolyte level
Crack in battery body.
Natural consumption.
Charging failure
Loose or damaged belt.
Faulty alternator.
Damaged wiring or contact failure.
Excessive electrical loads
Insufficient battery capacity for the application.
SECTION 11 -- PARTS LIST
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