(OF?) Ingersoll Rand OPERATION and MAINTENANCE MANUAL COMPRESSOR MODELS P185WJD XP185WJD CODE: E This manual contains important safety information, Do not destroy this manual. This manual must be available to the personnel who operate and maintain this maching SCS aPD Ingersoll Rand tility Equipment Mocksvila, N.C. 27028 Bok 22CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.TABLE OF CONTENTS Manual-Name TITLE PAGE FOREWORD... 2.20.00 02000 e eee eee cece eect e tee ee eet eee eeeeee 11 DRAWBAR NOTICE. . Drawbar Notice - This machine may have been shipped from the factory with the drawbar positioned upright. To convert from Shipping Position to Towing Position. . = 22 Safety Precautions. General WARRANTY .. General Warranty Information . : WARRANTY REGISTRATION «00. ..e.0sccceeeeeeuseceeeeeeeraeseeeneeeeeeeses BAT Complete Machine Registration 247 NOISE EMISSION. . Noise Emission ... “ This section pertains only to machines distributed within the United States. 3:30 Noise Emission Control Maintenance Log . . * Noise Emission Warranty Introduction GENERAL DATA .. General Data. . . Models: COMPRESSOR ENGINE (DIESEL) FLUID CAPACITIES... UNITS MEASUREMENTS WEIGHTS: Tire Size . EXPENDABLE SERVICE PARTS: SECTION 6 OPERATION cos sco we sins wen co can new ene van eerie ree eee BBD) BEFORE TOWING . 5-40TABLE OF CONTENTS Manual-Name TITLE PAGE MAINTENANCE . . 6-47 Maintenance.........6.s6ccseeesese secu eee eseeesesee ess ses esse eseesee ees 6odB General 6-48 ‘Scheduled Maintenance 6-48 Compressor Oil Level 6-48 Air Cleaner 6-48 Gauges 6-49 Fuel Tank 6-49 Battery. : . 6-49 Fasteners co . 6-49 Radiator. : co : : 6-50 Hoses . co : 6-50 Compressor Oil Cooler : . : : 651 Compressor Oil . : : : 651 Receiver-Separator Systems : we : 651 Scavenge Line : : . : 6-52 Exterior Finish Care 6-52 MAINTENANCE SCHEDULE 6-54 LUBRICATION... 7-55 Lubrication .. 7-56 Portable Compressor Fluid Chart 7-56 TROUBLE SHOOTING. 8-57 Trouble Shooting. . = 8-58 Introduction : : 8-58 Action Plan . .. : : 8-58 Trouble Shooting Chart... 8-59ForewordForeword Foreword Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll-Rand products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such products, which are available upon request. This manual contains instructions and technical data to cover all routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this ‘manual and should be referred to an authorized Ingersoll-Rand service department. All components, accessories, pipes and connectors added to the compressed air system should be: + of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Ingersoll-Rand, + clearly rated for a pressure at least equal to the machine maximum allowable working pressure + compatible with the compressor lubricant/coolant. + accompanied with instructions for safe installation, operation and maintenance. Detalls 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 changas 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 inditect human consumption of the compressed air B. Outside the ambient temperature range of minus 20°F to 115°F. C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists D. With other than Ingersoll-Rand approved components. E. With guards, or controls or switches missing or disabled. F.. For storage or transportation of materials inside or on the enclosure. This company accepts no responsibilty for errors in transtation of this manual from the original English version.ForewordDrawbar NoticeDrawbar Notice Drawbar Notice - This machine may have been shipped from the factory with the drawbar positioned upright. To convert from Shipping Position to Towing Position. The following tools are required: Ratchet and 13mm socket to fit ratchet Torque wrench set to 68 foot pounds (9.4 kg-meters) 16mm socket to fit torque wrench 5 inch extension for torque wrench Hardware included: (4) 12mm bolts with pre-applied thread lock, (2) 8mm Taptite bolts, (2) Washers, (2) Safety Chains 1. Remove hardware box from compressor toolbox. 2. Open box and remove the bag containing hardware, safety chains and assembly instructions. 3. Using the jack, raise the front of the unit so that the legs are approximately 1 inch above the ground. 4. Remove the temporary retaining bolts from both sides of the frame at the drawbar connection (See Fig. 1) 5. Carefully lower drawbar to the Level Position. 6. Install the four bolts (with pre-applied thread lock) to the four points inside the enclosure and torque to 68 ft. Ibs. (9.4kg-m) (See Fig.2). 7. Install safety chains by sliding the second link of one chain into the slot in drawbar plate. Fasten chain to plate using taptite and washer. Repeat for other chain. ‘Satety Chain AttachmentSection 1 - SafetyOperating & Maintenance Manual Safety Precautions General Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the Operation and Maintenance manual, and manual holder if equipped, are not removed permanently from the machine. Ensure that maintenance personnel are adequately trained, competent and have read the manuals, Make sure that all protective covers are in place and that the canopy/doors are closed during operation. The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas. If such an application is required then all local regulations, codes of practice and site rules must be observed. To ensure that 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 Safety ‘one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidentally be pressurized or over pressurized by another. Compressed air must not be used for a feed to any form of breathing apparatus or mask. The discharged air contains a very small percentage of compressor lubricating oil and ‘care should be taken to ensure that downstream equipment is compatible. Ifthe discharged air is to be ultimately released into a confined space, adequate ventilation must be provided When using compressed air, always use ‘appropriate personal protective equipment. All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions. Avoid bodily contact with compressed air. The safety valve located in the separator tank must be checked periodically for correct operation. Never operate unit without first observing all safety warnings and carefully reading the ‘operation and maintenance manual shipped from the factory with this machine. Never operate the engine of this machine inside a building without adequate ventilation. Avoid breathing exhaust fumes when working on or near the machine. Do not alter or modify this machine. ‘A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive, Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water. Exercise extreme caution when using booster battery. To jump battery, connectSafety ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After starting unit, always disconnect cables in reverse order. 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 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). 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.) Operating & Maintenance Manual Ether is an extremely volatile, highly flammable gas. USE SPARINGLY! DO NOT use ETHER if unit has GLOW Plug starting aid. Engine damage will result. Never allow the unit to sit stopped with the pressure in receiver-separator system. As a Precaution, open manual blowdown valve. Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, blow gun tips, ete, well away from moving parts. Make sure wheels, tires and tow bar connectors are in safe operating condition and tow bar is properiy 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. Stop machine to add fuel, Hazardous Substance Precaution The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly. Avoid ingestion, skin contact and breathing fumes for the following substances: Antifreeze, Compressor Oil, Engine Lubricating Oil, Preservative Grease, Rust Preventative, Diesel Fuel and Battery Electrolyte.Operating & Maintenance Manual Safety Look for these signs on machines shipped to international markets outside North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor rein ok — rey (@) (S) 4) \AENG Efe Sock ek. Paring ine a Gna Fot © cele Os nt ptt mctne Le pone Sache warvmse-Pumnetie hq, Wepre pop ne ewerarenen ‘enn Wetondbomtt tet gen, Todeenpaet Do nt neo meee rom thie machine.Safety Operating & Maintenance Manual THooe tt GENEL Hace con Sra 1.5m. § Tipss > Ay Rough Service Designation ‘Wet Lozation Operation SsOperating & Maintenance Manual Safety ‘obra J WARING D9, not undertake any Do nt exceed the speed int ebntonrce” on ti machin ae presereie persion or maintenance’ ot tis Wapnna 5 For opening emery bl ‘anal a ance’ helen om ie machine: OYE coneat Be Speratn and maintenanceSafety Operating & Maintenance Manual Look for these signs on machines shipped to markets in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed ‘warnings and follow instructions. if you do not understand, inform your supervisor. DANGER (Red Background) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING (Orange Background) indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. A CAUTION CAUTION (Yellow Background) indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE (Blue Background) indicates important set-up, operating or maintenance information.Operating & Maintenance Manual | WARNING | SafetySafety Operating & Maintenance Manual | &@ | _AWARNING __ WARNING | Fang ot machine. fe AWARNING | | AWARNING. | — faery GE| cae ogee rene soraus ry 1 esaea 6 meh fret on mmr a ‘ayo ot12 Operating & Maintenance Manual Table 1: Safety FREE SAFETY DECALS Satety Decals are available free of charge. Safety Decals are identified by the decal heading: DANGER, WARNING, or CAUTION. Decal part numbers are on the bottom of each decal and are also listed in the compressor's parts manual. Submit orders for Safety Decals to the Mocksville Parts Service Department. The no charge order should contain only Safety Decals. Help promote safety! Assure that decals are present on the machines. Replace decals that are not readable.Section 2 - WARRANTY14 Operating & Maintenance Manual WARRANTY WARRANTY Ingersoll-Rand, through its distributors, warrants to the initial user that each portable air compressor manufactured by it, will be free of defects in material and workmanship for a period of the earlier of twelve (12) months from shipment to or the accumulation of 2,000 hours of service by the initial user. Portable compressor airends will be free of defects in material and workmanship for a period of the earlier of twenty four months from shipment to or the accumulation of 4,000 hours of service by the initial user. The warranty against defects will include replacement of the complete airend, provided the original airend is returned assembled and unopened. Portable Compressor Airend Limited Optional Warranty - The earlier of sixty (60) months from shipment to or the accumulation of 10,000 hours of service. The optional warranty is limited to defects in rotors, housings, bearings and gears and is automatically available when meeting the following conditions The original air end is returned assembled and unopened, Continued use of genuine Ingersoll-Rand parts, fluids, oil and filters. Maintenance is performed at prescribed intervals. Oil-Free airends are fee-based and may require a maintenance agreement. Formal enrollment is required. Ingersoll-Rand will provide a new part or repaired part, at its election, in place of any part, which is found upon its inspection to be defective in material and workmanship during the period prescribed above. Such part will be repaired or replaced without charge to the initial user during normal working hours at the place of business of an IngersolRand distributor authorized to sell the type of equipment involved or other establishment authorized by Ingersoll-Rand. User must present proof of purchase at the time of exercising warranty. The above warranty does not apply to failures occurring as a result of abuse; misuse, negligent repairs, corrosion, erosion and normal wear and tear, alterations or modifications made to the product without express written consent of Ingersoll-Rand; or failure to follow the recommended operating practices and maintenance procedures as provided in the product's operating and maintenance publications. Accessories or equipment furnished by Ingersoll-Rand, but manufactured by others, including, but not limited to, engines, shall carry whatever warranty the manufacturers have conveyed to Ingersoll-Rand and which can be passed on to the initial user. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT OF TITLE),AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.WARRANTY Operating & Maintenance Manual General Warranty Information GENERAL WARRANTY Extended Coverage Portable Compressor Package [7 year'2000 nous None [Arend [2 years/4000 hours 3 years 10,000 hours Limited waranty [Portable Gansat KW, TIKW, | Package | 7 year2000 hours Wane 20KVA thru S75KVA (Generator |2years O00 nears Wome Forabie Genser 2 KW Package [2 montis PARTS ONLY [None Portable Genset 35,7 KW Package | tyoar1000 ns PARTS | None ONLY ght Tower Package [1 year?2000 hows Gensraior | Tyear2000 hows PZ years 4000 hours for LightsouTC= ONLY. Light Concrete Produc (power [Package [1 year PARTS ONLY None buggy, screeds, mies, saws, virators) [Hight Compaction Equipment (plata [Package 1 year PARTS and TABOR Nona and drum compactors and rammers) (Backhoe, Leaders Wheel Loaders [Package | T year Noe ENGINES: Months [Hours | Extended Coverage [caterpar 72 __[NoLimi_[ Avalable at dealer [Commins 24 [2000 | Mijor components 3 7s/10,000 hours - available at dealer John Deore (N COMPRESSORS) [24 2000 | 51s/5000 hours using JD fuids & fitars wih $250 deductible 5 ys/5000 hours using IR fus and fiters with $O deductible (IN GENERATORS AS OF 1/1101) [pq [2000 [2 yrs/4000 hours using TR Mus & ites Dautz (Wedel 2077) 24 [2000 [Major components 3 ys/4000 hours este (hiedel 2012) 24] 2000 | Major components 3 ys/2000 hours Tngersoi Rand 2a [A000 |S yearsi10 000 hours requres IR Fluds and Fiers [Kubota (Narin America Only) 28 2000 | Major components 36 months/2000 frs- PARTS ONLY THROUGH DEALERS ONLY [Wester Europe & Oceania) [24 [2000 | None (Central & South America, Asia | 12 [1000 | None Middia East & afica) bis 2a} 2000 |Z years/ 2000 hours requires IR furs and ters, froogh TR eaars ony Vow 2a] 7000 | 2 yaarsiaod haus requres IR fads and ites, Uwough eslers only Honda @ ‘None 15WARRANTY Operating & Maintenance Manual PARTS Ingersol-Rend fe months [Hours - No Limit ‘Coverage - Parts Oniy AIREND EXCHANGE - Extended Coverage "TZ months | 2000 Rous 3 ye T0 000 ns requires IR ol and fiers, Arend 16 Note: Actual warranty mes may change. Consult the manufacturer's warranty policy as shipped with each new productWARRANTY Operating & Maintenance Manual WARRANTY REGISTRATION Complete Machine Registra 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. 718 Operating & Maintenance Manual WARRANTYWARRANTY Operating & Maintenance Manual Selling Distributor ‘Servicing Distributor WARRANTY REGISTRATION Name Name ‘Owner/User Name Address Address Address: city city city County County County Sate 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 ‘Asphalt Contactor C1 Coal Mining EY Other Mining (highway, excavation, etc.) Construction-Light Government OD Quany 1 Shallow Oil & Gas (carpentry, plumbing, (municipal, state, Pools, mason, etc.) county, etc.) Rental (rental center, Building Contractor Waterwell 1 Utility Company rental fleet, etc.) Industrial (plant use) Other specify 1 Exploration Utility Contractor Model Unit SIN Engine S/N Date Delivered Unit Hours Airend SIN Truck SiN Truck Engine S/N ‘SERVICING DISTRIBU TORIUSER ACKNOWLEDGEMENT 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. 19Operating & Maintenance Manual WARRANTY qwauedeg Auewey, :vonuony 8Z0L2 BUIO.ED YLON ‘@IEASYOONY 998x098 ‘Od uossina sossaxdwiog ayqevod ‘fureduiog ped - 108,964)Section 3 - Noise EmissionOperating & Maintenance Manual Noise Emission Noise Emission This section pertains only to machines distributed within the United States. Noise Control System Prol Tampering 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 itis in use; or 2. the use of the compressor after such device or element of design has been removed or rendered inoperative by any person. ‘Among those acts included in the prohibition against tampering are these: 3. Removal or rendering inoperative any of the following: a.the engine exhaust system or parts thereof the air intake system or parts thereof c.enclosure or parts thereof 4, Removal of any of the following: a.fan shroud b.vibration mounts ¢.sound absorption material 5. Operation of the compressor with any of the enclosure doors open. Compressor Noise Emission Control Information ‘A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of design incorporated into this compressor in compliance with noise control act; B. The use of this compressor after such device or element of design has been removed or rendered inoperative. NOTE: The above information applies only to units that are built in compliance with the U.S. Environmental Protection Agency. Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. The Purchaser is urged to include the above provisions in any agreement for any resale of this, ‘compressor.Noise Emission Operating & Maintenance Manual Noise Emission Control Maintenance Log COMPRESSOR MODEL SERIAL NO. USER UNIT NO. UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Engine Make & Model: Serial No.: Purchaser or Owner: Address: Date Purchased: ‘The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations, specifically the following acts or the causing thereof: (1) the removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while itis 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. 34Operating & Maintenance Manual Maintenance Schedule tem ‘Area Pariod [x |Comipressea ar Cass — [as Detecter IB. |Sefety and Control Systems |As Detected Ic facouste matenals Day D. [Fasteners 100 hours IE [Enclosure Panels 100 hours IF |Air intake & Engine Exnaust | 100 hours G_—_ [Cooling Systems 250 hours IH. |isolaton Mounts 250 nours I. [Engine Operation See Operator's Manusl 3 [Fuels & Luoncants ‘See Operator's Manual A. Compressed Air Leaks Correct all compressed air leaks during the first shutdown period after discovery. If severe enough to cause serious noise problems and efficiency loss, shut down immediately and correct the leak(s). B. Safety and Control Systems Repair or replace all safety and control systems or circuits as malfunction occurs. No compressor should be operated with either system bypassed, disabled, or nonfunctional, C. Acoustic Materials In daily inspections, observe these materials. Maintain all acoustic material as nearly as possible in its original condition. Repair or replace all sections that have: 1) sustained damage, 2) have partially separated from panels to which they were attached, 3) are missing, or have otherwise deteriorated due to severe operating or storage conditions. 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, Tepaired, or if missing, replaced immediately to prevent subsequent damage and noise emission increase. E. Enclosure Panels Enolosure panels should also be inspected at 100 hour operational intervals. All panels that are warped, punctured, torn, or otherwise Noise Emission deformed, such that their noise containment function is reduced, should be repaired or replaced before the next operation interval. Doors, access panels, and hatch closures especially, should be checked and adjusted at this time to insure continuous seating between gasket or acoustic material and the mating frame. F. Air Intake and Engine Exhaust Engine and compressor air intake and engine exhaust systems should be inspected after each 100 hours of operation for loose, damaged, or deteriorated components. Repairs or replacements should be made before the next period of use. G Cooling Systems 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. |. 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,Noise Emission Operating & Maintenance Manual Maintenance Record For Noise Emission Control And Extended Warranty Kom’ No. Description Of Work Hourmeter Reading Maintiinspect Date Location ity/state: Work Bon By (Name) 33Operating & Maintenance Manual Noise EmissionSection 4 - General DataOperating & Maintenance Manual General Data Models: General Data Unit Model P185 XP185 Air Delivery (cfm (litres/sec) 185 (87) 185 (87) Engine Speed - RPM (Full Load) 2500 2500 Engine Speed - RPM (No Load) 1700 1700 COMPRESSOR Rated Operating Pressure - psi (kPa). Safety Valve Setting - psi (kPa) Net Weight (less fuel) pounds. ENGINE (DIESEL) Manufacturer....... Model Electrical System 0... FLUID CAPACITIES Compressor Lubricant. Engine Crankcase Lubricant Fuel Tank UNITS MEASUREMENTS WEIGHTS. Overall Length..cconee Overall Height Overall Width . Track Width, Weight (with fuel) Weight (less fuel)... 100 psi (689) 150 psi (1034) 2265 ..John Deere 4045D 12 VDC on 12 quarts (11.4 litres) 10.8 quarts (10.2 litres) 27 US. gal. (103 litres) 11.5 (3.5 meters) 5.2 feat (1.46 meters) 5.7 feet (1.74 meters) 4.9 feet (1.49 meters) 2325 Ibs (1054 kgf) +2130 Ibs (966 kgf)General Data Operating & Maintenance Manual Tire Size... eee eee eee Tire Size... P215/TSRX15 Inflation Pressure (cold)..... : +35 psi Towing Speed (maximum) 65 mph (105 km/hr) EXPENDABLE SERVICE PARTS. Compressor Oil Filter Element. 36897353, Compressor Oil Separator Element 54625942 Air Cleaner Element Primary (Compressor) 35393685 Optional Secondary (Compressor)... 35393651 Alt Cleaner Element (Engine) 35393685 Optional Secondary (Engine)... 35393651 Engine Oil Filter Element ... 35308030 Engine Fuel Filter Element. 36534659 Modification or alteration of this machine. Can result in severe injury or death. Do not modify or alter without the express written consent of Ingersoll-Rand Co. a7Operating & Maintenance Manual General DataSECTION 5 - OPERATIONOperating & Maintenance Manual SECTION 5 - OPERATION BEFORE TOWING towing. ‘SETTING UP (ALL UNITS) + Position as level as possible. The Failure to follow these instructions CAN cause severe injury or death. + Assure tow vehicle has towing capacity for weight of this unit as stated on general data decal. + Position the tow vehicle to align its hitch with the pintle eye or coupler of the compressor. + Engage the parking brake and chock the tires of the tow vehicle. + Stand to the side and ensure pin is FULLY inserted (secure) in tube of jack. + Crank jack to seat pintle eye or coupler onto hitch. Latch and lock hitch. Cross safety chain(s) under drawbar. Attach to vehicle + Crank jack to raise pad off the ground. Pull pin from tube of jack, + Fold jack handle down and forward. ‘Swing up jack tube and FULLY insert pin in tube. + Remove tire chocks. + Test brakes, if so equipped. + Test lights (running, stop, and turn signals). Always raise (or remove) jack for maximum ground clearance before design of these units permits a 15 degree sidewise limit on out-of-level operation. When the unit is to be operated out- oflevel, itis important: To keep the engine crankcase cil level near the high level mark (with the unit level). To have the compressor cil level gauge show no more than mid-scale. Do not overfill either the engine crankcase or the compressor lubricating oil system. 3. The side doors must be closed to ‘maintain a cooling air path and to avoid recirculation hot air TOWING 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 65 mph + Use a tow vehicle whose towing capacity is greater than the gross Weight of this unit.SECTION 5 - OPERATION Operating & Maintenance Manual DISCONNECT + Engage tow vehicle parking brake + Chock tires of compressor. + Set the vehicle parking brake. Chock wheels of unit. + Standing to the side, remove pin from tube of jack. + Disconnect safety chains. Crank jack to raise eye or coupler from hitch Tow vehicle can be moved. UTILITY PACKAGE SET-UP (no running gear) This unit must be located on vehicle bed to allow access for normal servicing and maintenance. The air going into the inlet must be relatively free of ol, dirt, soot and other debris. It must be no more than 10 degrees F. (5 degrees C) over the ambient temperature. 4a42 Operating & Maintenance Manual CONTROL PANEL - Diagnostics/Auto Shutdown (Standard and Optional) Instruments & Controls (Optional) 1. High Engine Temperature - Coolant above 20°F (104°C). 2. Low Engine Oil Pressure - 12 psi or less. 3, High Compressor Temperature - 248°F (120°C) 4, Air Filters Restricted - Needs servicing. 5. Spare 6. Spare 7. Alternator Not Charging - Needs attention. 8. Low Fuel Level - Must add fuel to operate. 9. Hourmeter - Records running time for maintenance. (Standard) 10. Compressor Discharge Pressure Gauge - Indicates pressure in receiver tank, psi (kPa). (Standard) 14. Fuel Level Gauge - Indicates amount of fuel in tank. 12, 13, 14, 15, 16. 17. 18, 19, 20. 24 SECTION 5 - OPERATION Power Switch - Rotate “ON” to activate system prior to starting. Rotate “OFF” to stop engine. (Standard) Engine Speed Gauge - Indicates engine speed. Discharge Air Temp. Gauge - Indicates in °F (82°C) to 210°F (99°C). Engine Oil Pressure Gauge - Indicates engine oil pressure. Engine Water Temp. Gauge - Indicates coolant temperature, with normal operating range from 160°F (82°C) to 210°F (99°C). Voltmeter - Indicates battery condition Ether Inject Button - Injects a measured shot, USE SPARINGLY. ‘Service Air Button - After warm-up, PUSH. Provides full air pressure at the service outlet, Indicates engine speed. Spare ‘Spare Note: 9, 10 and 12 are standard.SECTION 5 - OPERATION Operating & Maintenance Manual Refers Starting “AWARNING + Open service valve(s) to ensure pressure is relieved in receiver-separator system. This machine produces loud noise Close valve(s) in order to build up full air with doors open. Extended exposure pressure and ensure proper oil to loud noise can cause hearing loss. circulation. Wear hearing protection when doors or valve (s) are open. Check battery for proper connections and condition + Close all doors to maintain a cooling air path and to avoid recirculation of hot air. + Check battery for proper connections and This will maximize the life of the engine condition. and compressor and protect the hearing of surrounding personnel. + Check engine coolant level + Be sure no one is IN or ON the “AWARNING ‘= Do not remove pressure cap from a HOT radiator. Allow radiator to cool down before removing Unrestricted air flow from a hose will pressure cap. Use extreme care result In a whipping motion of the when removing a pressure cap hose which can cause severe injury or from a liquid cooling system for death. A safety device must be the engine. The sudden release of attached to the hose at the source of pressure from a heated cooling ‘supply to reduce pressure in case of system can result in a loss of hose failure or other sudden pressure coolant and possible severe release. Reference: OSHA regulation personal injury. 29 CER Section 1926.302 (b). + Check the engine oil level. Maintain per startin marks on dipstick 9 + Check the fuel level. Add only CLEAN = Tata NGTEONVER: ountenstor-ONI DIESEL fuel for maximum service from = tim Bowanswilth io TARE thprengine position to crank engine. Hold switch in “START” position for approximately 5 seconds afterengine stars. + Check the compressor lubricating fluid level between bottom and midway of the sight glass on the separator tank.Operating & Maintenance Manual SECTION 5 - OPERATION to the negative (-) terminal of the booster battery and NOTICE the other end to the engine block. NOT TO THE NEGATIVE (-) TERMINAL Do not operate the starter OF THE WEAK BATTERY. motor for more than 10 seconds without allowing Units With Optional Diagnostics at least 30 seconds cooling Lamps time between start attempts. Roloase Power Sth (til automaticaly NOTICE move to the “ON” position) when the engine starts and sustains running. None of the panel lamps should be glowing when + Allow engine to warm up § to 10 machine is operating. If minutes, they are, shut unit down and refer to Trouble + If so equipped, press the “Service Air Shooting Section. Button’. Open air service valve(s). Cold Weather Starting Stopping a. Tum power switch to the glow plug position and hold 10 seconds. Then turn to start NOTICE NOTICE Stopped at ow back into. the compressor Engine is equipped with system from devices or glow plugs for cold starting systems downstream of the aid. Do not use ETHER! machine unless the service starting fluid. Engine valve is closed. Install a damage can occur. check valve at the machine service valve to prevent reverse flow in the event of NOTICE 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SECTION 5 - OPERATION Close air service valves. + Allow the unit to run at idle for 3 to 5 minutes to reduce the engine temperatures. + Turn Power Switch to “OFF” position. + When the engine stops, automatic blowdown valve should relieve system air pressure. If automatic blow-down valve malfunction is suspected, open manual blowdown valve. + Never allow unit to sit under pressure when engine is not running 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. Do NOT wire around or bypass a shutdown sensor or switch. Machine has shutdown and sensors as follows: + Low Engine oil pressure, in the engine. + High engine coolant temperature, in Operating & Maintenance Manual the engine Compressor Air/Oil Temperature: + Atthe airend outlet. + In separator tank. UNITS WITH DIAGNOSTIC LAMPS. Ina 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 unti the Power ‘Switch is turned “OFF” 45Operating & Maintenance Manual SECTION 5 - OPERATION Speed and Pressure Regulator Adjusting Instructions The engine idle and full speed settings are set and sealed at the factory, and should not be adjusted, Serious injury may result if the full speed is increased. Removal of the seals without authorization could affect the warranty. If speed settings are lost due to engine fuel pump service or other repairs, the speed settings can be reset as follows: Before Starting 1, Atthe 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 tur. Close service valve(s). Inspect throttle arm (G) on engine governor to see the armis resting against the governor stop. Loosen jam nut on air actuating cylinder (A) and then tum cylinder rod (D) until throttle arm (G) is forced against the governor stop. MA After Starting Unit 4. 5. 6. 7. 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. With the service valve closed, adjust IDLE speed (°). Adjust speed using adjusting rod (D). Tighten jam nut (H) 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). To obtain maximum CFM at any pressure between 80 psi (550kPa) and maximum pressure rating (*), make adjustment at the pressure regulator to obtain desired discharge pressure at FULL engine speed. Lock adjusting screw and replace cover. * See General Data Specifications.SECTION 5 - OPERATION Operating & Maintenance Manual a7Operating & Maintenance Manual SECTION 5 - OPERATIONSection 6 - MAINTENANCEOperating & Maintenance Manual Maintenance A CAUTION Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty. If performing more than visual Inspections, disconnect _ battery cables and open manual blowdown valve. Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). 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. Disregard any maintenance pertaining to components not provided on your machine. General In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and post-operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need MAINTENANCE 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 asa checklist by the service personnel. In the event unusual environmental operating conditions exist, the schedule should be adjusted accordingly. Compressor Oil Level Check the compressor fluid level when the machine is not operating. Maintain the fluid level between bottom and midway of the sight glass on the separator tank 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. This should be checked daily during operation. If the lamp glows (red) with the unit operating at full speed, servicing of the cleaner element is necessary. ‘Also weekly squeeze the rubber valve (precleaner dirt dump) on each air cleaner housing to ensure that they are not clogged. The air filters restricted sensor will automatically reset after the main power switch is turned to “OFF.” To service the air cleaners on all units proceed as follows: 1. Loosen outer wing nut and remove withOperating & Maintenance Manual MAINTENANCE MAINTENANCE SCHEDULE [Daily | Weekly | Monthly | 3MOS. | MOS. | 72MOS. 250 hours | 800 hours | 1000 hours ‘Compressor Oil Level Engine Of Level Radiator Coolant Level GaugesiLamps Air Cleaner Service Indicators Fuel Tank (lat end of day) Fuel Water Separator (Drain) Ol Leaks Fuel Leaks Drain Water From Fuel Fifers Gootant Leaks. Radiator Filer Cap Air Cleaner PreCleaner Dumps FanvAllernator Belts Battery Connections/Electrohte Tire Pressure and Surlace. Wheel Lag Nuts Hoses (oil, air intake, elo) ‘Automatic Shutdown System Test ‘Ar Cleaner System Visual ‘Compressor Oil Cooler EWerIOr CLEAN Engine Radiator Exterior GLEAN Fasteners, Guards c Ar Cleaner Elements Fuel Water Separator Element ‘Compressor Oil Filter Element ‘Compressor Oi Engine Oi Change (nial charge @ 50 65) Rosen Engine OF FIter tina canoe @ 50105) Re nik RAIN RAIN alalg/afalalalalafal afl lala] a] alofalofafo| a ala)alalal Wheels (bearings, seals, ef) Engine Coolant Test Fuel Filer Element Shutdown Switch Setings Test e Soavenge Orifice & related paris CLEAN Oil Separator Element R Lights (running, brake, & turn) car Pintle Eye Bors car aol] al Rereplace, C=check (adjust if necessary) CBT = check before towing. * Applies only when using IR Protec™ Engine FluidMAINTENANCE cover. Remove Element. 2. Inspect air cleaner housing for any condition that might cause a leak and correct as necessary. 3. Wipe inside of air cleaner housing with a clean, damp cloth to remove any ditt accumulation. especially in the area where the element seals against the housing. 4, Install new elements in the reverse order to the above. Tighten wing nut firmly. 5. Inspect to ensure that end cap seals tightly 360° around air cleaner body. In addition, the air cleaner system (housing and piping) should be inspected every month for any leakage paths or inlet obstructions. Make sure the air cleaner mounting bolts and clamps are tight. Check the air cleaner housing for dents or damage which could lead to a leak. Inspect the air transfer tubing from the air cleaner to the compressor and the engine for leaks. Make sure that all clamps and flange joints are tight. 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 Operating & Maintenance Manual Battery Keep the battery posts-lo-cable connections clean, tight and lightly coated with a grease. A\so the electrolyte level in each cell should cover the top of the plates. If necessary, top- up with clean distilled water. Tires A weekly inspection is recommended. Tires that have cuts or cracks or little tread should be repaired or replaced. Monthly check the Wheel lug nuts for tightness, Fasteners Visually check entire unit in regard to bolts, nuts and screws being properly secured. Spot check several capscrews and nuts for proper torque. If any are found loose, a more thorough inspection must be made. Take corrective action. Table 1: Wheel Torque Chart M12 bolts | Torque (ft-Lbs) 13" wheel | 60-70 172” lug nuts 13" wheel | 80-80 18" wheel — | 105-115 16'wheel | 105-115 165° wheel | 105-115, 9/8” lug nuts 16" wheel —_| 190-210 17.5° wheel | 190-210Operating & Maintenance Manual Radiator The use of water alone in this engine can result in major engine failure. Refer to engine section for coolant recommendation. Hoses Each month it is recommended that all of the intake lines to and from the air cleaners, the engine cooling system hoses and all of the flexible hoses used for air, oll, 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 ofthese 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 compressor intake The flexible hoses used in the fuel, oll 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. ‘Some of the airlines are nylon tubin. The associated fittings are “push-i MAINTENANCE design. Features are as follows: 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 @ 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 .D. tubing. This will ensure that tubing is fully engaged in the sealing mechanism. Compressor Oil Filters The oil filter must be replaced every 500 hours of operation or six (6) months, whichever comes first. To service oil filters it will first be necessary to shut the unit down. Wipe off any external dirt and oil from the exterior of the filter to minimize any contamination from entering the lubrication system. Proceed as follows: 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 alr system. 1. Open the service air valve(s) to ensure that system is relieved of all pressure. Close the valve(s) 2 Tum the spin-on filter element counterclockwise to remove it from the filter housing. Inspect the filter.MAINTENANCE 3. Inspect the oil filter head to be sure the gasket was removed with the oil filter element. Clean the gasket seal area on the oil fiter head. NOTICE Installing a new oil filter element when the old gasket remains on the filter head, will cause an oil leak and can cause property damage. 4. Lubricate the new filter gasket with the same oil being used in the machine 5. Install new filter by turning the element — clockwise until gasket makes initial contact. Tighten an additional 1/2 to 3/ 4 tum. 6. Start unit and allow to build up to rated pressure. Check for leaks before placing unit back into service. Compressor Oil Cooler The compressor lubricating and cooling oil is cooled by means of the fin and tube-type oil cooler, located beside the radiator. The lubricating and cooling oil, flowing internally through the core section, is cooled by the air stream from the cooling fan flowing past the core section. When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler, its efficiency is impaired Each month it is recommended that the oil cooler be cleaned by directing compressed air which contains a nonflammable, 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 oll cooler core so that the entire cooling area can transmit the heat of the lubricating and cooling oil to air stream. Operating & Maintenance Manual In the event foreign deposits, such as sludge and lacquer, accumulate in the oil cooler to the extent that its cooling efficiency Is impaired, a resulting high discharge air temperature is likely to occur, causing shut down of the unit. To correct this situation it will be necessary to clean it using a cleaning compound in accordance with the manufacturer's recommendations. Compressor Oil The lubricating and cooling oil must be replaced every 500 hours of operation or six (6) months, whichever comes first. Refer to warranty section about extended warranty. Receiver-Separator Systems High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. + Open service valve at end of machine. + Ensure pressure is relieved, with BOTH: — Discharge air pressure gauge reads Zero (0). — Noair discharging from service valve. Remove plug in bottom of separator tank to drain compressor oil When adding oil, remove and replace (make tight) plug on side of separator tank. In the compressor lubricating and cooling system, separation of the oil from the compressed air takes place in the 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. 51Operating & Maintenance Manual Additional separation takes place in the oil separator element which is located in the top of the tank. Any oll accumulation in this separator elements continuously drained off by means of a scavenge tube which returns the accumulated oll 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 1000 hours. Scavenge High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. The scavenge line originates at the receiver- separator tank cover and terminates at the compressor air-end near the oil filter element. An orifice check valve is located on the scavenge tube. ‘Once a year or every 1000 hours of operation, whichever comes first, replace the separator element and clean the scavenge orifice/check valve. NOTE: Excessive oil carry-over may be caused by an oil-logged separator element. Do not replace element without first performing the following maintenance procedure: 1. Check oil level. Maintain as indicated earlier in this section. 2. Thoroughly clean scavenge line, any orifice and check valve. 3. Assure minimum pressure valvelorifice is operational MAINTENANCE 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, 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, ete. 2. If grease removal is needed, a fast evaporating alcohol or chlorinated solvent can be used. Note: This may cause some dulling of the paint finish. 3. If the paint has faded or chalked, the use of a. commercial grade, non-abrasive car wax may partially restore the color and gloss. Field Repair of Texture Paint 1. The sheet metal should be washed and clean of foreign material and then thoroughly dried. 2. Clean and remove all grease and wax from the area to be painted using Duponts 3900S Cleaner prior to sanding, 3. Use 320 grit sanding paper to repair any scratches or defects necessary. 4. Souff sand the entire area to be painted with a red scotch brite pad. 5. Wipe the area clean using Duponts 39008. Blow and tack the area to be painted Apply a smooth coat of Duponts 1854S Tuffcoat Primer to all bare metal areas and allow to dry.MAINTENANCE 8. Apply 2 medium - wet coats of Duponts 2228 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 Tuffooat Primer. The proper technique to do this is to spray the Tuffcoat Primer using a pressure pot and use about 2-5 pounds of air pressure. This will allow the primer to splatter causing the textured look. Operating & Maintenance Manual NOTE: You must be careful not to put too much primer on at one time, this will effect the amount of texture that you are trying to achieve. Allow the texture coat to flash for 20 minutes or until dry to touch. 10. Apply any of Duponts Topcoat Finishes such as Imron™ or Centari™ according to the label instructions. NOTE: To re-topcoat the textured surfaces when sheet metal repairs are not necessary, follow steps 1, 2, 4, 5, 6, 8 and 10. 53Section 7 - LUBRICATIONOperating & Maintenance Manual Lubrication Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change. NOTE: Fluids listed as “preferred” are Tequired for extended warranty. Compressor oil carryover (oil consumption) may be greater with the use of alternative fluids. LUBRICATION Deion no Ambient operat] ores specication | vert OO psito| AE Ise Preered | S00" | Sete geste fRProTee tomate [SO vscosty Grae 40 wih ust doxistarnhbtor, desis Preferred Ingersoll-Rand Fluids - Use of for aie compressor service these fluids with original I-R filters can extend Ops | (aii w so Prtared airend warranty. Refer to operator's manual 10°F 10 1250 [IR XH 605 warranty section for details or contact your IR emate WR XH 405 representative. |s0Viscosty Grade 08 Group 3 wh ust and oxidation Innit: detiones for a rmpresor sevice 65°F to 125"F |Preterrad: (18°C to 52°¢) PHPEOS IR xHP 001 ingersoitRand IngersoitRand 1 4 gaia tite) | Sgat.(12.0u8re) | $5 gat. (208.2 Litre) | 220 ga. (836 Litre) ed TRProsTec™ TBREDE SaRSTOE Sear TERT TRXHPOOS = 72282076 22252050 72352068 TRXAPI007 = SSTzTS 35300576 = HPO 5 POOLE 22262400 BERET Engine OF Baaa0oTe 36075008 36868003LUBRICATION Operating & Maintenance Manual 57Operating & Maintenance Manual LUBRICATIONSection 1 - Trouble ShootingOperating & Maintenance Manual Trouble Shooting Introduction Trouble shooting for a portable air compressor is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The trouble shooting chart that follows includes some of the problems that an operator may encounter during the operation of a portable compressor. The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the answers for correction of the problems. The chart does give those problems that are most apt to occur. To use the trouble shooting chart: ‘A. Find the “complaint” depicted as a bold heading. B. Follow down that column to find the potential cause or causes. The causes are listed in order (1,2,3 etc.) to suggest an order to follow in trouble shooting Action Plan A. Think Before Acting Study the problem thoroughly and ask yourself these questions: 1. What were the waming signals that preceded the trouble? Has a similar trouble occurred before? What previous maintenance work has been done? 4. If the compressor will still operate, is it safe to continue operating it to make further checks? 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 ol level Always check the easiest and most obvious things first; following this simple rule will save time and trouble. NOTE: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in Parts List Section. 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 After a mechanical failure has been corrected, be sure to locate and correct the cause of the trouble so the same failure will not be repeated. A complaint of “premature breakdown" may be corrected by repairing any improper wiring connections, but something caused the defective wiring. The cause may be excessive vibration,Trouble Shooting Trouble Shooting Chart Bold Headings depict the COMPLAINT - Subheadings indicate CAUSES NOTE: Subheadings suggest sequence to follow troubleshooting. Table 1: Unit Shutdown Operating & Maintenance Manual Cause Corrective Action Out of Fuel ‘Add CLEAN diesel Fue} ‘Compressor Oil Level Too Low ‘Add correct oft ‘Compressor Oil Temp. Too High ‘See Table 10 Engine Water Temp. Too High ‘Check coolant level. Irnecessary, Add. Loose Wire Connection Wiggle wires at switches & connector blocks. Make repairs. Low Fuel Level Shutdown Switch Replace switch Defective Discharge Air Temp. Switch Replace switch Defective Engine Oi Pressure Switch Replace switch Broken Engine Fan Belt Replace fan bait Engine Oil Pressure Too Low See Table Sand Table 4 | Detective Shutdown Solenoid Replace solenoid Malfunctioning Relay Replace relay. | Blown Fuse Replace fuse/Check for Short <0 Volis at Shutdown Solenoid Check baitery and alternator. Make repairs Engine Maifunctioning ‘See Trouble Shoating in Engine Section Airend Malfunctioning See Table 10 Table 2: Won't Start/Run: Cause Corrective Action | Out of Fuel \dd CLEAN diesel Fuel Clogged Fuel Filters Service Alters. Compressor Oil Leva Too Low ‘Add corrected alt Toose Wire Connaction Repair or replace connection, Low Battery Voltage ‘Check electrolyte level. Check connections: *<10 Volts at Shutdown Solenoid ‘Charge battery and alternator. Make repairs. Defective Alternator Replace/Repair Allernator ‘Out of Fuel ‘Add CLEAN fuel, Engine Water Temp. Too High Check fluid level, Iecessary, Add, Malfunctioning Start Switch Replace switch Detective D2 Diode Replace D2 Diode. Blown Fuse Replace fuse/Check for Short Engine Oil Pressure Too Low Soe Table 3 and Table 4, ‘Compressor Oil Temp. Too High s2@ Table 10. Defective Discharge Air Temp. Switch Replace switch Defective Engine Oil Pressure Switch Replace switch 59Operating & Maintenance Manual Trouble Shooting Defective Shutdown Solenoid Replace solenoid [Defective Engine Temp. Switch Replace Switch Defective Separator Tank Temp Switch Replace Switch Defective Low Fuel Shutdown Switch Replace Switch Malfunctioning Relay Replace relay. Engine Malfunctioning ‘See Trouble Shooting in Engine Section, Airend Maifunctioning ‘See Table 10. Table 3: Engine Temperature Lamps Stays On: ‘Complaint Corrective Action Dirty Cooler Clean exterior of cooler. ‘Operating Pressure Too High Reduce pressure fo spec. Recirculation of Cooling Air Close side doors. Dirty Operating Conditions Move unit fo cleaner environment * Oui of Level >15 degrees Relocate or reposition unit * Ambient Temp, >125xF (52xC) ‘Above spec limit Loose Wire Connection Repair or replace, Broken Engine Fan Belt Replace fan bell se, Malfunctioning Circuit Board Replace circuit board Table 4: Engine Oil Pressure Lamp Stays On: ‘Complaint [Corrective Action Low Oil Level ‘ad oi. Clogged Oil Filter Element(s) Replace element). Out of Level >15 degrees Relocate of reposition: Loose Wire Connection Repair or replace. ‘Wrong Lube Oi See Engine Oil Spec. Change ol Matfunctioning cireuit board Replace circuit Engine Malfunctioning See Trouble Shooting in Engine Section, Table 5: Engine ‘Temperature Lamps Stays Off: ‘Complaint Corrective Action Bulb Burned Out Replace circuit board Shorted Wire (Hot) Repair short Matfunetioning cireuit board Replace circuit board Table 6: Engine Oil Pressure Lamp Stays Off: ‘Complaint Corrective Action Bulb Burned Out Replace circuit board ‘Shorted Wire (Hot) Repair short. Malfunctioning creult board Replace circuit board.Trouble Shooting Table 7: Alternator Lamp Stays On: Operating & Maintenance Manual [Complaint Corrective Action Tow Battery Voltage Check slecirolyie level. Add i necessary. Loose or Broken Belts Tighten or replace belt set. Check connectors, Clean & fighten Recharge battery Malfunctioning Alternator Repair or replace alternator. ‘Shorted wire (ground) Repair short Table 8: Alternator Lamp Stays Off: [Complaint Corrective Action Bulb Bumed Out Replace circuit board Loose Wire Connection Repair of replace connector, Maffunctioning circuit board Replace circuit board Table : Unit Fails To Shutdown: Complaint Corrective Action [Defective Low Fuel Shutdown Switch Pull wire off shutdown solenoid. Replace switch. Defective Discharge Air Temperature Switch Pull wire off. Replace switch, [Defective Sep. Temp. Switch Replace switch Defective Engine Temp. Switch Replace switch, Defective Engine Oil Pressure Switch Pull wire off. Replace switch. Defective Shutdown Solenoid Carefully block air inlet to stop engine. Malfunctioning Relay Replace relay. Defective Start Switch Pull wire off shuldown solenoid, Replace defective item, Wire Shorted Hot Repair short Table 10: Excessive Compressor Oil Temperature: ‘Complaint Corrective Action Dirty Cooler Clean exterior surfaces. Tow Oil Level ‘Add oil. Look for any leaks, ‘Clogged Oil Filter Elamenis Replace elements. Change oil ‘Operating Pressure Too High Reduce pressure fo spec. Dirty Operating Conditions Move unitto cleaner environment, ‘Ambient Temp. > 125F (ZC) ‘Above Spec limit, Out of Level > 15 dagrees Relocate or reposition unit. Wrong Lube O7 ‘Check spec in this manual Recirculation Of Cooling Air Close side doors. Replace belly pan. Maffunctioning Thermostat Replace thermostat in bypass valve. Loose or Broken Belts Tighten or replace belt set Defective Oil Cooler Relief Valve Replace valve, etOperating & Maintenance Manual Trouble Shooting Defective Minimum Pressure Valve Ropair or replace vave. Matfunetioning Fan Check fan belt tension. Tighten or replace belt set Blocked or Restricted Oi Lines Clean by flushing or replace, ‘Airend Mafunctioning See Tables 11, 12, 13, 75, 16 or 18 Table 11: Engine RPM Down ‘Complaint Corrective Action fogged Fuel Fiter Clean primary fier: Replace final fiter. Drain tanks. Add CLEAN fuel Diy Ai Filter Clean or replace elements. ‘Operating Pressure Too High Reduce pressure to spec lit Tnoorrect Pressure Regulator Adjustment Adjust regulator. Tnoorrect Linkage Adjustment ‘Adjust linkage. Wrong Air Filler Element Tnstall correct element. Malfunctioning Pressure Regulator Replace regulator. Malfunctioning Air Cylinder Replace air oylindar and adjust. Defective Separator Element Install new element. Engine Malfunctioning ‘See Trouble Shooting in Engine Section: Airend Malfunctioning Consult Dealer. Table 12: Excessive Vibration ‘Complaint Corrective Action Dirty FuetFilters Replace fitersifuel. Engine idle speed too Tow. Raise "No Load’ speed. Rubber Mounts, Loose or Damaged Tighten or replace. ‘Anicrumble valve not working Repair or Replace: Drive Coupling Defective Replace coupling Defective Fan Replace fan. [Engine Malfanctioning 28 Trouble Shooting in Engine Section Airend Maifunctioning See Table 15 and 17. Table 13: Low CFM ‘Complaint Corrective Action Engine RPM too Low ‘Adjust RPM Maifunetioning Air Cylinder Replace air cylinder. Thoorrect Linkage Adjustment just inkage. Malfunetioning Inlet Untoader Tnspect valve. Dirty Air Fitter Clean of replace elements. Tnoorrect Pressure Regulator Adjustment __| Adjust linkage. Maffunetioning Pressure Regulator Replace regulator ‘Wrong Air Filter Element Tnstall correct element. Defective Separator Element Tastall new element Defective Minimum Pressure Valve Repair or replace valve,Trouble Shooting Operating & Maintenance Manual Table 14: Short Air Cleaner Life ‘Complaint Corrective Action Tnadequate Element Cleaning Tnstall new element. Dirty Operating Conditions Move unit to cleaner environment. Tneorrect Stopping Procedure Read procedure in this manual Wrong Air Filter Element Install proper element. Table 15: Excessive Oil In Air ‘Complaint Corrective Action High Oil Level Read procedure in this manual Clogged Seavenge Orifice Remove scavenge orifice. Clean and Replace. Incorrect Oi Replace by spec. in this manual Defective Scavenge Check Valve Remove check valve, Replace with new valve. ‘Out of Level > 15 degrees: Relocate or reposition unit. Defective Separator Element Remove element. Install new. ‘Scavenge Tube Blocked Remove scavenge tube. Clean and Replace. ‘Sep. Tank Blow Down Too Quickly ‘Allow unit to blow down automatically. Defective Minimum Pressure Valve Remove valve. Repair valve and replace, Table 16: : Oil Seal Leak ‘Complaint Corrective Action Contaminated Lube Oi Drain and flush system. Add new CLEAN ol Replace seal Blocked or Restricted Oil Line(s) Remove, clean and replace line(s). Replace seal Malfunctioning Seal Consul dealer. Replace seal. ‘Scored Shaft ‘See instructions in new seal kit Table 17: Will Not Unload ‘Complaint Corrective Action Tneorrect Pressure Regulator Adjusiment Agust reguiator. Leak in Regulator Piping Find and repair leak(s). Malfunctioning Pressure Regulator Replace regulator. Malfanctioning inlet Valve Unioader Tnspect valve. RepalvREplace. Defective Separator Element Remove element. Install new. Tee in Regulation Lines/Orifice poly heat fo ina(S) and or orifice. Table 18: Oil In Air Cleaner ‘Complaint Corrective Action Tneorrect Stopping Procedure Read Procedure in this manual. Malfanctioning Unloader Repair/Replace. 63Operating & Maintenance Manual Table 19: Safety Valve Relieves Trouble Shooting [Complaint Corrective Action Operating Pressure Too High Reduce pressure to spac limit. Thoorrect Pressure Regulator Adjustment | Refer to Section 6 in this manual Malfunctioning Pressure Regulator Replace regulator. Leak In Regulator Piping Repair Teak(s}. Malfunctioning Inlet Unioader Inspect valve. Repair/Replace. Defective Separator Element Remove element, Install new. Defective Safety Valve Replace safety vaive. Tee in Regulation Lines/Orifice Remove 108.A Air Cleaner B Battory ..... Bofore Starting BEFORE TOWING c Compressor Oil Filters Compressor Oil Level. CONTROL PANE D DISCONNECT E Exterior Finish Care F Fasteners Fuel Tank G Gauges H Hazardous Substance Precaution Hoses ceceeeeeee I Ingersoll-Rand Preferred Fluids L Lubrication ......00.ccee eee mM Maintenance ceeeeeee MAINTENANCE SCHEDULE . Pp Portable Compressor Airend Limited Optional Warranty Portable compressor airends Portable Compressor Fluid Chart R Radiator Receiver-Separator Systems s Safety Precautions ‘Scavenge Line WORD INDEX 6-48 6-52 6-49 6-49 6-49 7-56 7-58 6-48 6-54 244 244 7-56 6-50 6-51 1-4 6.52 Scheduled Maintenance 6-48 SETTING UP (ALL UNITS) 5-40 Speed and Pressure Regulator Adjusting Instructions 5-46 Starting 5.43 Stopping 5.44 T Tires... 6-49 TOWING ..... 5-40 Trouble Shooting .... 8-58 Trouble Shooting Chart 8-59 u UNITS WITH DIAGNOSTIC LAMPS ..........5-45 Units With Optional Diagnostics Lamps .......5-44 w WARRANTY 5 exons WARRANTY REGISTRATION 2247 WATER COOLED ENGINE . SAL Manual-Name 9-1WORD INDEX Manual-NamePortable Power Division Ingersoll-Rand Company P.O.Box 868 - 501 Sanford Ave. Mocksville, N.C. 27028 ©2003 Ingersoll-Rand Company, Printed in the USA