OPERATING, MAINTENANCE, PARTS MANUAL COMPRESSOR MODELS VHP750WCU HP935WCU XP1000WCU Code: This manual contains important safety information. Do not destroy this manu This manual must be available to the personnel who operate and m: GD igersounana Portable Power PotBoy 868 501 Sanford Ave fractile NC 27098 Book 54579040 (7/03) a)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 54579040 (7/03) (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 partis absolutely prohibited and would resultin 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 We Ingersoll-Rand Company Limited P.O, Box 868 py; Swan Lane Hindley Green 501 Sanford Avenue Represented InEC By: = wigan WN2 4EZ Mocksville, North Carolina 27028 United Kingdom, Declare that, under our sole responsibility for manufacture and supply, the product(s) HP1300WCU HP91SWCU = XP10SOWCU = XHPQOOWCAT ~—-VHP7S0WCAT. XP1400WCU VHP750WCU NXP1300WCU —-XHP6SOWCAT + VHP8S0WCAT P1600WCU —HP825WCU. XHP750WCAT — HP9OOWCAT XP 900WCU — VHP825WCU XHP825WCAT — XP1000WCAT XP1000WCU —HP935WCU XHP1070CAT ‘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 Z bo RicLansford H. Seddon, @.A. Manager Manager of Quality Control Book 54579040 (7/03) @)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 lubricanv/coolant. + accompanied with instructions for safe installation, operation and maintenance. Details of approved equipment are available from Ingersoll-Rand Service departments. The use of repair parts other than those included within the Ingersoll-Rand approved parts list may oreate 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 unapprovedusage 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: For direct or indirect human consumption of the compressed ait Outside the ambient temperature range specified in the general data section ofthis manual When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists. With other than Ingersoll-Rand approved components. With guards, or controls or switches missing or disabled. m™moo@ > For storage or transportation of materials inside or on the enclosure, This company accepts no responsibilty for errors in translation of this manual from the original English version. Book 54579040 (7/03) (4)TABLE OF CONTENTS SECTION 1 ............4- SAFETY SECTION 2 ..........-... WARRANTY/REGISTRATION SECTIONS .............. NOISE EMISSION SECTION 4 .............. GENERAL DATA SECTIONS . . OPERATION SECTIONG .............. MAINTENANCE SECTION 7 ...........045 LUBRICATION SECTIONS .............. TROUBLESHOOTING SECTION® .............. PARTS ORDERING SECTION 10 .. . PARTS LIST SECTION 11 ............. OPTIONS PARTS LIST SECTION 12 ............- ENGINE (operation, maintenance, lubrication, troubleshooting) Book 54579040 (7/03) (s)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 54579040 (7/03) (6)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 partis absolutely prohibited and would resultin the CE certification and marking being rendered invalid. A declaration of that conformity follows: Book 54579040 (7/03) a)Declaration of Conformity WITH EC DIRECTIVE 98/37/EC 89/336/EEC Ingersoll-Rand Company We Ingersoll-Rand Company Limited P.O. Box 868 I Swan Lane, Hindley Green 501 Sanford Avenue Wigan WN2 4EZ Mocksville, North Carolina 27028 Represented InEC By: United Kingdom Declare that, under our sole responsibility for manufacture and supply, the product(s) HP1300WCU — VHP825WCU = XHPSOOWCAT = VHP7S0OWCAT ~—XHP1170WCU XP1400WCU —- HP93SWCU = XHP6SOWCAT = VHP8S0WCAT ~—-XHP1070WCU. P160OWCU ——XP10S0WCU ——- XHP750WCAT == HPQOOWCAT_ = HP 1600WCU XxP900WCU HP825WCU —- XHP825WCAT ——-XP1000WCAT ~—-HP1300WCU NXP1300WCU NHP1S00WCU —XHP1070CAT —10/425 XHP1170SCAT ‘To which this declaration relates, is (are) in conformity with the provisions of the above directives using the following principal standards EN1012-1, EN29001, EN292, EN60204-1 PN8NTC2, EN 50081, EN50082 leeved at Mockavite on 11-98 eae Ge a cared FU Seco Ok on ‘Manager of Quality Control Book 54579040 (7/03) (8)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 atype approved by Ingersoll-Rand. + clearly rated for a pressure at least equal to the machine maximum allowable working pressure. + compatible with the compressor lubricant/coolant. + accompanied with instructions for safe installation, operation and maintenance. Details of approved equipment are available from Ingersoll-Rand Service departments. The use of repair parts other than those included within the Ingersoll-Rand approved parts list may create hazardous conditions over which Ingersoll-Rand has no control. Therefore, Ingersoll-Rand cannot be held responsible for equipment in which non-approved repair parts are installed. Ingersoll-Rand reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. ‘The intended uses of this machine are outlined below and examples of unapprovedusage 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. . 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 translation of this manual from the original English version. Youas the customer are expected to provide certain service and maintenance items. Your Ingersoll-Rand dealer will provide all other more detailed service and maintenance items on a special preventive maintenance schedule for each machine. Itis very important that the minimum service and maintenance requirements explained in this ‘manual be performed at the requiredintervals. Exceeding these intervals may reduce the reliability ofthe machine. The purpose of this manual is to train the operator with functions, operation, and basic service and maintenance requirements of the compressor. During the preparation of this manual, every effort was made to ensure the adequacy and accuracy of the contents. Book 54579040 (7/03) (9)Your Ingersoll-Rand dealer will assist with setup and initial startup of the compressor. He will also provide brief operating and service instructions and will insure that a copy of this manual is included with the machine, Before starting the compressor, this manual and instructions should be carefully read to obtain a thorough knowledge of the duties to be performed. Please take pride in the compressor, keep itclean, and in good mechanical condition. To enable proper maintenance records, Ingersoll-Rand provides a Noise Emission Control Maintenance Log Book (PCD Form 685) with each compressor shipped from the factory. This Log Book contains a recommended schedule and space so that the serviceman can note what service and maintenance was done, by whom, where, and when. Book 54579040 (7/03) (10)TABLE OF CONTENTS SECTION 1 ............-5 SAFETY SECTION 2 ...........--+ WARRANTY/REGISTRATION SECTIONS ...........-++ NOISE EMISSION SECTION 4 ............-+ GENERAL DATA SECTIONS ............-+ OPERATION SECTIONG ............-+ MAINTENANCE SECTION7 ...........065 LUBRICATION SECTION 8 ...........065 TROUBLESHOOTING SECTION ...........065 PARTS ORDERING SECTION 10 ..........065 PARTS LIST SECTION 11 ............- OPTIONS-PARTS LIST SECTION 12 ............- ENGINE O&M Book 54579040 (7/03) (uy)SECTION 1- SAFETY SAFETY PRECAUTIONS General Information Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the Operation and Maintenance manual, and the manual holder 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 ma- chine 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 asafe 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 seri- ous injury or death, Do not breathe this ai. Compressed air can be dangerous if incorrectly han- dled. Before doing any work onthe unit, ensure that all pressure is vented from the system and that the ma- chine cannot be started accidentally. Ensure that the machine is operating at the rated pres- ‘sure and that the rated pressure is known to all rele- vant personnel, Allair pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine safety valve rating |fmore than one compressoris connected to one com- mon 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 54579040 (7/03) (12) ‘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 oll 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 pro- vided. When using compressed air, always use appropriate personal protective equipment. Allpressure 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 ail. 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. Abattery contains sulfuric acid and can give off gases which are corrosive and potentially explosive, Avoid contactwith skin, eyes andclothing. Incase ofcontact, 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 fend 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 or- der. 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 oll, diesel fuel, antifreeze, brake fluid, oiVair filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authori- ties for proper disposal of these materials. High Pressure Air can cause serious injury or death, Relieve pressure before removing filler plugs/caps,fit- tings or covers. Air pressure can remain trapped in air supply line which can result in serious injury or death. Always carefully ventair 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 disconnect- ing 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) un- der 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 satety tlow restrictor to each hose at the source of supply or branch line in accordance with OSHA Regulation 29CFR Section 1926.202(b). Hot pressurized fluid can cause serious bums. Donot open radiator while hot. Rotating fan blade can cause serious injury. Do not operate without guard in place. Book 54579040 (7/03) (13) Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and 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 low 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 ofthis machine and may be hazardous to health fused 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 mainte- nance.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. & ° Corrosion risk Hot Surface ©) WARNING: Electrical shock risk. Parking Brake No open flame Lifting point | @ om ® Diesel Fuel. No open flame. i] ° Do not operate the machine Lifting point without guard being fitted. =O) WARNING - Flammable liquid. When parking use prop stand, handbrake and wheel chocks. Airlgas flow or Air discharge. WARNING - Hot and harmful exhaust gas. Tie down point Do not breathe the compressed air from this machine. Book 54579040 (7/03) (4)EFA) | Reve tne operation and Maintenance I] manual before operation or maintenance of this machine fs undertaken, X Bar| WARNING - Maintain correct tire pressure. (Reter to the GENERAL INFORMATION section of this manual), WARNING: Consult the operation and maintenance manual before Performing any maintenance. 1.5m. ¢T 1P54 > A Rough Service Designation Wet Location Operation Do not stack Replace any cracked Do not use fork lift truck from this side 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. Emergency stop. Book 54579040 (7/03) (as)Oil Drain Do not exceed the speed limit. WARNING - For operating temperature below 0°C, consult the operation and maintenance manual. Ay AN WARNING - Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved. O>e& Ee) Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken Donot remove the Operating and Maintenance ‘manual and manual holder from this machine. A © & Pressurized vessel. Book 54579040 (7/03) (19) Use fork lift truck from this side only. 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. FEN eaa (Red Background) AWARNING (Orange Background) ACAUTION (Yellow Background) NOTICE (Blue Background) 4. DANGER Discharged air can contain carbon ‘monoxide of other contaminants. Will cause serious injury or death. Do not breathe this ar. & DA A WARNING Hot pressurized fluid. Can cause serious 90. burns. Do not open radiato while hot Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored, Indicates the presence of a hazard which CAN cause serious injury, death or property damage, if ignored, Indicates the presence of a hazard which WILL or can cause injury or property damage, if ignored. Indicates important set-up, operating or maintenance information. 4, WARNING ‘Trapped air pressure. injury or death. Close sevice valve and ‘perate tool to vert trapped air before performing any service, La. 4 WARNING High pressure air. Can cause serious Injury or death. Relieve pressure before removing filer plugs/eaps, fitings of covers. Book 54579040 (7/03) (17)4 WARNING A, WARNING Improper operation of this Can eause serious injury or ead Operatgrs Manual auptied wih this machine betore operation oF servicing, use serious injury or death. Do not alter or modify this machine without the express writen consent of the manufacturer. Modification or alteration of this machine. ®) 4 WARNING Rotating fan blade. Can cause serious injury. Do not operate without Collapsing ‘Can cause ne Excessive towing speed. Can cause serious injury en —s| (105 kinvhe) 4. WARNING Falling off machine. Can cause serious iju or death. “ny i” ‘Access iting bal from inside machine. guard in place, 4 WARNING 4. WARNING Door under pressure. Can cause serious injury. Use both hands to open door when machine is running, Disconnected air hoses whip. Can cause sarous al injury or death. BE. hen sn a tol aah te (OSHA Vane) ‘at source of SSreupy tor each ®S CAUTION DO NOT WELD. ELECTRONIC DAMAGE WILL occur. This engine is equipped with an electronic engine controller and other electronic components. Book 54579040 (7/03) (18) A WARNING Combustible gas. Can cause serious burng, blindness or death. Keep sparks and open flames away from batteries.® CAUTION 4, WARNING DO NOT USE ETHER. ENGINE DAMAGE WILL OCCUR. This engine is equipped with an High pressure air. Can cause serious injury or death. Relieve pressure belo Femowing filer plugsicaps, i electric heater starting aid. NOTICE ‘COOLANT FILL INSTRUCTIONS ‘Adding: Remove radiator cap. Top off at radiator. Use same anti-freeze mixture as in radiator. eplacing: With system cool, remove radiator cap. Drain Coolant and clase drain. At radiator, refill system, Replace radiator cap. Run for 30 minutes. Stop and allow to cool, At radiator, add coolant as necessary to reach "Cold" level HG) 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 54579040 (7/03) (is)SECTION 2 - Warranty Ingersoll-Rand, through its distributor, warrants that each item of equipment manufactured by it and delivered hereunder to the initial user willbe free of defects in material and workmanship for a period of three (8) 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) BKW, 11KW, 20KVA thru575KVA, 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 anew part orre- palredpart, atit'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 partis the responsibilty of the user. C. Portable Compressor Air Ends - The earlier of twenty-four (24) months from shipmentto or the accumulation of 4,000 hours of service by the initial user. For Air Ends, the warranty against defects willinclude 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, hous- ings, 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, oll and filters. 3. Maintenance is performed at prescribed intervals. Oil-Free airends are fee-based and may require a maintenance agreement. Formal enrollment required. D. Genset Generators 8KW, 11KW, 20KVA thru 575KVA - The earller of twenty-four (24) months from ship ‘ment 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 accumula tion of 2,000 hours of service. E. Portable Light Tower Generators- The earlier of twelve (12) months from shipment o 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 54579040 (7/03) 20)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 ex- cluded from the extended warranty. The alrend seal and drive coupling are included in the warranty (airend drive belts are notincluded). The optional warranty is automatically available when meeting the following con- ditions: 1, The original airend is retuned assembled and unopened. 2. Continued use of genuine Ingersoll-Rand parts, fluid, oil and fiers. 3. Maintenance is performed at prescribed intervals, Itis the obligation of the user to provide verification that these conditions have been satisfied when submitting warranty claims. Spare Parts— Six (6) months from date of shipment. Ingersoll-Rand will provide a new part or repaired part, atts 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 tothe 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 au- thorized 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 pro- vided in the product's operating and maintenance publications. ‘Accessories or equipment fumished by Ingersoll-Rand, but manufactured by others, including, but not limited to, engines, tires, batteries, engine electrical equipment, hydraulic transmissions, carriers, shall carry whatever war- ranty 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 54579040 (7/03) (a)GENERAL WARRANTY INFORMATION [GENERAL WARRANTY Extended Coverage Portable Compressor Package T year B000 he irene DysHO00 hs SyTTO 000 Limited warranty, major components (eter to operator's manual), Portable Geneet kW, TTKW, Package Tyr R000 Ts None 2OKVA thru S75KVA [Generator 2yeO0O he None Portable Gonset 35KWihna [Package T 772000 hes (pats only) Tone /7.OKW and 10KW ‘Generater 772000 he (pats ony) Tone Tight Tower Package 7 yrRO00 Hs ‘Generator 7 yreO00 Ts Zyears/4000 hour, for LghIsouree introduced 816199, ENGINES CATERPILLAR Months [Hours Extended Cover 7% canted “Rraiable at dealer CONRINS Ey 2000 Major components 9 yraT0,000 fre ‘valle at dealer [JOHN DEERE (a comprossors) a 2000 5 yrv5000 ve using OEM fais and tors with 250 deductible ee) Fy Pont 2 yrs/4000 hs using IR fluids and fiters DEUTZ a 2000 ‘Available at dealer TNGERSOLL-FAND a 000 "5 yra/10,000 hrs when using genuine ngarsol- FRand fids and parts. Refer to operators man- a KUBOTA (Nomh Arneica ony) ae 2000 Talor components 36 ma/3000 Ws (parts ony) (Weston Europe & Oceania) 24 000 None (Central & South America, Asia, Middlo East & | 12 1000 None Aiea) TaTSUBIST a 2000 2 yrT4000 fs using Hide & fore VOWG a 2000 2 yPTHO00 Ws sing fds & are FONDA 7% canmed Tone VANGUARD a ied None PARTS onthe Hours Coverage Ingersoll-Rand z To Limi Parts Only TRIREND EXCHANGE Months Hours Extended Coverage Arend @ O00 hours ZyrT4000 fre ~avalable Fore ik Note: Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with each new product. Book 54579040 (7/03)Optional Warranty - The earlier of 60 months from shipment to, or the accumulation of 10,000 hours of service by the initial user. The optional warranty is limited to defects in major components (rotors, housings and bearings), and is automatically available to the original user when he meets the following two conditions: 1. 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, 2. Submission of proof that maintenance intervals: have been followed. Bare Airend - Pertains to major alrend parts (rotors, housings, and bearings). Arend Components - Pertains to auxiliary attachments to the bare airend (drive coupling, seals, pumps, valves, tubes, hoses, fittings and filter housing). ‘The compressor oil must be replaced every 1000 hours of operation or six (6) months, whichever comes first Refer to the fluids and lubricants chart for ambient temperature ranges and specifications, in the lubrication section of this manual. Refer to the fluids and lubricants chart for ambient temperature ranges and specifications in the lubrication section of this manual. WARRANTY TIME: “BARE AIREND ““AIREND COMPONENTS ‘STANDARD 2 yrs/4000 his 100% parts and labor 100% parts and labor OPTIONAL 5 yr5/10,000 hrs 100% parts and labor 0% Book 54579040 (7/03) (03)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 54579040 (7/03) (4)WARRANTY REGISTRATION! Name Owner/User Name Address ____ Address cly = ____ iy County =§___ county state state ZipCode ip Code Telephone ____ Telephone Complete the Applicable Blocks ‘Owner/User Type of Business (check one only) 1 Construction-Heavy DO Asphait Contractor == 1 Coat Mining other Mining (highway, excavation, ete) 1 Construction-Light 1D Government Clauary C0 shalow os. Gas (carpentry, plumbing, pools, ~_ (municipal, ‘state, mason, etc.) county, etc.) C7 Rental Buuling Contractor] Waterwel i (rental centr, rental feet, et.) I Suisina OMe OE ea er oe) industrial (plant use) ao on O Exploration 0 utility Contractor speci Mode! Unit SiN Engine S/N Date Delivered Unit-Hours Airend S/N Truck S/N ‘Truck Engine S/N SERVICING DISTRIBUTOR/USER 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 lability 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 se so that Ingersoll-Rand may arrange for appropriate nuclear liability protection from the owner-licensee of the | facllty. 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 54579040 (7/03) (3)SECTION 3 - NOISE EMISSION This section pertains only to machines distributed with- in the United States. ‘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 re- placement, 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 its in use; or (2) the use of the compressor after such device or element of design has been removed or rendered inoperative by any person. ‘Among those acts included in the prohibition against tampering are these: 1. Removal or rendering inoperative any of the following ‘a. the engine exhaust system or parts thereof b. the air intake system or parts thereof c. enclosure or parts thereof 2. Removal of any of the following: a. fan shroud b. Vibration mounts ©. sound absorption material 2. Operation of the compressor with any of the encloeure doore 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 improvement to products sold previously. ‘The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor. Book 54579040 (7/03) (26)NOISE EMISSION CONTROL MAINTENANCE LOG ‘® COMPRESSOR MODEL SERIAL NO. USER UNIT NO.. UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM Engine Make & Model: 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 removalor renderinginoperative by any persons, other than for purposes of maintenance, repair, orreplace- ‘ment, of any device or element of design incorporated into new compressor for the purpose of noise control prior toits sale or delivery tothe ultimate purchaser or while itisin use; or (2) the use ofthe compressor after such device or element of design has been removed or rendered inoperative by any person. NOISE EMISSION WARRANTY The manufacturer warrants tothe ultimate purchaser and each subsequent purchaser that this lr 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 alr compressor. Defects in the de- sign, 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, ap- plicable 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 54579040 (7/03) 7)MAINTENANCE SCHEDULE TEM AREA PERIOD a ‘Compressed Air Leaks As Detected B. Safety and Control Systems _| As Detected ic. ‘Acoustic Materials Daily D. Fasteners. 100 hours. E. Enclosure Panels 100 hours, F Air Intake & Engine Exhaust | 100 hours @ Cooling Systems 250 hours. H. Isolation Mounts 250 hours. I Engine Operation ‘See Operator's Manual v. Fuels & Lubricants ‘See Operator's Manual A. Compressed Air Leaks Correct all compressed air leaks during the first shut- down period after discovery. If severe enough tocause 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 cir- cuits as malfunction occurs. No compressor should be operated with either system bypassed, disabled, or nonfunctional. C. Acoustic Materials Indaily inspections, observe these materials. Maintain all acoustic material as nearly as possible nits 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 shouldbe retightened, repaired, orif missing, replaced immediately to preventsubsequent damage andnoise ‘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 heir noise containment function is reduced, should be re- paired 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 mate- rial and the mating frame. Book 54579040 (7/03) (8) 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 compo- nents. Repairs or replacements should be made be- fore the next period of use. G. Cooling Systems Allcomponents of the cooling system for engine water and compressor oil should be inspected every 250 hours of use. Any discrepancies found should be cor- rected before placing the unit back in operation. Unre- stricted 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 en- vironments, all should be replaced with equivalent parts. |. Engine Operation Inspect and maintain engine condition and operation las recommended in the manuals supplied by the en- gine 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 TTEM NO, DESCRIPTION OF WORK HOURMETER READING MAINT? INSPECT DATE LOCATION cIT¥ STATE ‘WORK DONE BY (Name) Book 54579040 (7/03) (29)SECTION 4 - GENERAL DATA Moder VHP750WCU HPSssWOU XPTOOOWCU Rated Delivery: fm 750 15 1000 litres/sec 354 432 472 Rated Pressure: = pal 200 150 725 ~kPa 1378 1034 862 Safety Valve Setting: = psi 250 200 200 = kPa 1723 1379 1378 Engine Model: Cummins Mi1-300 11-300 Mi1-300 AMBIENT OPERATING RANGE “10°F to 120°F (-12°C to 49°C) “Operation below 10°F (-12°C) requires optional equipment and lubricants ENGINE (Diesel) Full Load Speed - rpm 1850 No Load Speed - ppm vt ceteeeteteeeeees - eves 1200 Electrical System 24 VD0 FLUID CAPACITIES - gallons (litres) Compressor Lubricant ...........ceeeeee cot tteceeseeeeeee 26 (98.4) Engine Lube (including iter) ....... 0.5 £30000000005050000000000000 +. 6(22.7) Engine Coolant ...... cess ts tetseettieetseeteteesieeseetseeeereesses 15.8 (69.8) Fuel Tank (Clean DIESEL fuel)». vette te tteeeeeeteteneeees 142 (638) Notice: Above 15°F (-9°C) Use No. 2 Diesel Fuel with sulfur content not greater than 0.5% and minimum cetane number of 42. UNITS MEASUREMENTS/WEIGHTS - inch (mm) Overall Length (incl. drawbar) Tandem 205 (5207) Steerable eee eeeeeeeesseeseeetestesseesees 218 (5597) Overall Height 92 (2287) Overall Width... ces eevseestesteseeeateseesssaeessessssseseess 79.6 (2022) Gross Weight (al ids) pounds (kg) ss. ss. cs sses vcs vesseesuseseseuseseeseeesees +, 10,480 (4789)) RUNNING GEAR Track Width - inch (mm)... penne se eeceeseee ses ++ 65.6 (1667) Tire Size/Load Range ..... : coteeteeeeeeeeees LT215/85R16E Inflation Pressure (Cold) - psi (KPa) ssc... .csssssssssossssesssveesesseseveessss ++. 80 (551) Towing Speed (Maximum) Tandem = mph (knfit)........csssssesseerseseseeeeves+ es 65,105) Steerable ~ mph (km/hr) coceeetseeeeeeees 20 (32) CAUTION: Any departure from the specifications may make this equipment unsafe. Book 54579040 (7/03) (0)SECTION 5 - OPERATING INSTRUCTIONS PERATIN Control Panel INTROLS & INSTRUMENT: Operating Controls/Instruments (Standard) 1. Compressor Discharge Pressure Gauge - Indicates pressurein receivertank, normally from Ops! (kPa) to the rated pressure of the machine. 2. Discharge Air Temp. Gauge - Indicates in °F and °C. Normal operating range: 185°F/B5° to 248°F/120°C. 3. Engine Oil Pressure Gauge - Indicates engine oil pressure (psi (kPa). See engine for nonal range. 4. Engine Speed Gauge Indicates engine speed in RPM from zero when stopped to full speed. 5. Hourmeter - Records running time for maintenance purposes. 6. Fuel Level Gauge - Indicates amount of fuel in tank. 7. Engine Water Temp. Gauge ~ Indicates coolant temperature, with normal operating range from 180°F (82°C) to 210°F (99°C). 8 Voltmeter - Indicates battery condition, Book 54579040 (7/03) G1) DIAGNOSTICS/AUTO SHUTDOWN 9. High Compressor Temperature - 248°F (120°C) or more. 10. Low Engine Oil Pressure - 12 psi or less 11, High Engine Temperature - Coolant above 215°F (102°C). 12. Low Fuel Level - Comes on first as a warning and eventually trig- gers a shutdown. Must add fuel to operate. 13. Alternator Not Charging ~ needs attention 14, Low Coolant Level - Needs attention. Must add coolant. 15. Air Filters Restricted - Needs servicing. CONTROLS 16. Power Switch - Flip “ON” to activate systems prior to Starting. Flip “Off to stop engine. 17. Lights Switeh - Operates Lamps within Gauges. Hourmeter does not have a lamp. 18. Heaters Switch - Activates control system heaters for operation below 32°F (0°C). 19. Service Air Button - After warm up, PUSH. Provides full air pressure at the service outlet. 21. Start Button ~ Activates the Engine Starter. PRESS to crank engine. Release when engine sustains firing. 22. Bypass Button - PRESS while engine is starting. Bypasses automatic shutdown circuit. Release after 2-3 seconds. OPTIONAL CONTROLS: 20. Ether Inject Button - Injects a measured shot. USE SPARINGLY.Donot climb on top of unit. The lifting eye can be reached through the roof door ONLY from INSIDE of the unit. DISCONNECT and SET - UP + 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. to be operated out-of-level it is (1) Tokeep the engine crankcase cil levelnear the high level mark (with the unit level), (2) To have the compressor oil level gauge show no more than mid-scale. (COMPRESSOR MOUNTING Portable compressors, which are modified to remove the running gear and mount the machine direct to trallers, truck beds of frames, etc. may experience failure of the enclosure, frame, and/or other components. Itis necessary toisolate the compressor package from the carrier base with a flexible mounting system, Sucha system mustalso prevent detachment of the package from the carrier base in the event the isolators fall. Contact Ingersoll-Rand representative for flexible mounting kits. Warranty does not cover failures attributable to mounting of the compressor package to the carrier base unless itis an Ingersoll-Rand provided system, COMPRESSOR OIL LEVEL The cil level should be checked before the unit is started. Always check the oil level while the unit is level, the engine off, and there is zero pressure in the separator tank. The optimum oil level is with the pointer at the top of the green section on the level gage. Add oil if the pointer reaches the bottom of the green section, Note: The oil level gage will not read property while the engine is running Do not overfill compressor. the engine crankcase or the Book 54579040 (7/03) (2) forrmum om reve] YELLOW - TOO HIGH (EITHER SIDE) GREEN - 0K RED 100 LOW ADD OIL LEVEL (EITHER SIDE) DISCONNECT Engage parking brakes and chock wheels of both tow vehicle and compressor. Stand aside while: ‘+ Withdraw pin, swing jack down and fully insert pin to lock in down position. ‘+ Disconnect safety chains from tow vehicle. ‘= Disconnect brake actuator chain from tow vehicle. *Ifs0 equipped, disconnect running light plug from the tow vehicle. * Operate drawbar jack to raise pintle eye from hitch of tow vehicle. BEFORE TOWING Units equipped with hydraulic brakes: * Checkbrake fluid level. Top off as required with DOT 3 brake fluid, * Check condition of brake lines, hoses and cables. Repair or replace damaged parts. * Attach brake actuator breakaway chain above hitch on towing vehicle, CO)WIN Tandem Axle Units ‘These units are designed to be highway towable. Do NOT exceed 65 mph towing speed. Excessive towing speed can cause serious injury or death, Do NOT exeed 65 mph. Steerable Axle Units ‘These units are not designed to be highway towable, Do NOT tow on highway. Do NOT exceed 20 mph towing speed. Excessive towing speed can cause serious injury or death. Do NOT exeed 20 mph. Note: Use a tow vehicle whose towing capacity is greater than the gross weight of this machine. 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 the event of an unexpected shutdown when the service valve is open. Unrestricted air flow from a hose will result in a whipping motion of the hose which can cause serious injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure in case of hose failure or other sudden pressure release. Reference: OSHA regulation 29 CFR Section 1926.302 (b). Book 54579040 (7/03) (3) BEFORE STARTING - All checks should be made while unit is level. + 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. COMBUSTIBLE GAS CAN CAUSE SEVERE BURNS, BLINDNESS OR DEATH. KEEP SPARKS AND OPEN FLAME AWAY FROM BATTERY. * Check the compressor and engine lubricating oll levels. ‘The oll level should be checked before the unit is started. Always check the oil level while the unit is level, the engine off, and there is zero pressure in the separator tank. The optimum oil level is with the Pointer at the top of the green section on the level ‘gage. Add oll if the pointer reaches the bottom of the green section. Note: The oil level gage will not read properly while the engine is running, YELLOW - TOO HIGH GREEN - OK XY RED ‘Too Low ‘ADD OIL LEVEL, (EITHER SIDE) I necessary, Refer to Lubrication Section for recom- mended lubricant.Hot pressurized fluid can cause serious burns. Do not open radiator while hot. + Check engine coolant level by removing the radiator top cap and looking for coolant in the filer neck of the radiator. Add coolant as required. Insure that radiator cap Is installed properly and tightened, NOTICE: Ifthe appropriate mixture of antifreeze isnot used during freezing temperatures, failure to drain the engine may cause costly engine damage. Never use water only as corrosion inhibitors are required in engine coolant fluid. No smoking, sparks, or open flame near fuel. + Check the fuel level. Add only CLEAN DIESEL fuel for maximum service fromthe engine. Refertothe En- gine Section for fuel specifications. ‘A {uel level gauge reading can be obtained by turning the power switch to “ON”. NOTICE ] ‘To minimize condensation (water) in the fuel tank, fill the tank at the end of each day. WARNING ] This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve (s) are open. * Close the side doors to maintain a cooling air path and to avoid recirculation of hot alr. This will maximize the life of the engine and compressor and protect the hearing of surrounding personnel. ‘+ Make sure no one is IN or ON the compressor unit. Book 54579040 (7/03) G4) STARTING Exercise caution when using a booster battery charger to start. To jump-start, connect the positive booster/charger cable tothe 24VDC positive (+) terminal ofthe battery. Then connect the negative boostericharger cable to the engine block...Not to the negative (-) terminal of the weak battery. After starting, disconnect the negative (-) cable from engine biock; then from the boosterbattery/charger. Disconnect positive (+) cable {rom both batteries. ‘+ Flip the POWER switch to "ON". All diagnostics lamps will light (glow) for two (2) seconds. Then all lamps should go off except for ALTERNATOR NOT CHARGING and LOW ENGINE OIL PRESSURE. ‘In freezing weather, tip HEATERS switch “ON’ and wait sixty (60) seconds. This applies heatto the control system components for easier starting. Leave this switch "ON" while operating at these temperatures. If equipped with 24 volt compressor (Cold Start Option) + Press and hold the BYPASS button for ten (10) tofif- teen (15) seconds. This operates the 24 volt compres- ‘sor which pressurizes the inlet valve and holds it closed for easier starting. In cold weather: ‘+ Open manual blow down valve and, if so equipped, press the ETHER INJECT button once and release. ‘Then, while cranking, press and release button once ‘every five (5) seconds. This injects a measured amount of ETHER to the engine. * Press both the START and the BYPASS buttons to crank the engine. DO NOT OPERATE THE STARTER MOTOR FOR MORE THAN TEN (10) SECONDS WITHOUT ALLOWING AT LEAST ONE MINUTE COOLING TIME BETWEEN START ATTEMPTS.ETHER is an extremely volatile, highly flammable gas. Use sparingly! If too much is injected, the engine may be damaged. + Release the START button when the engine starts and sustains running. + Release BYPASS button when the engine speed reaches 1000 rpm. The engine oil pressure should be above 20 psi. Ifthe engine oil pressure does not rise within five (5) seconds, stop the unit and refer to Engine Operator's Manual. (Once running, All DIAGNOSTIC lamps should be off. If not, stop the machine and investigate. * Observe the gauges while the unit warms up for five (6) to ten (10) minutes or unti the coolant temperature reaches 140° F (60° C), * Push the SERVICE AIR button. The engine should 0 to full speed and the discharge pressure rise to slightly over rated pressure. If there is no air being consumed, the compressor will unload (intake should be throttled or closed) and the engine speed drop to the no load speed. + Compressor is now ready to furnish alr when the service valve is opened. AETERCOOLER OPTION 1. Do NOT operate when the ambient temperature is 32°F (0°C) or below. 2. BEFORE STARTING, insure ALL water is drained from aftercooler, water separator and iter (if 80 equipped) 3. f compressor is running, close service valve. 4, Locate aftercooler bypass valve at top inlet to af- tercooler, inside front door. Turn valve handle fully as follows. THRU Attercooler.... CLOCKWISE (To Right) BYPASS Aftercooler.. COUNTERCLOCKWISE 5. Open service valve. Book 54579040 (7/03) (3) 6. After use, insure ALL water is drained from after- cooler, water separator, and filter before or storing machine. leaving NOTICE: Dispose of condensate from aftercooler, water separator and fiter in accordance with local, state and federal regulations. STOPPING * Close air service valve (s). + Allow the unit to run at ‘no load” for 3 to 5 minutes to reduce the engine temperatures + Flip all toggle switches to “Off NOTICE ] Failure to allow turbo cool down prior to stopping can cause turbocharger damage. ‘Once the engine stops, the automatic blowdown valve will begin to relieve all pressure from the receiver-separator system. CauTiON]] Never allow the unitto sit stopped with pressure in the receiver-separator system. As a precaution, ‘open the manual blowdown valve. WARNING ] Even after pressure is relieved from the receiver-separator system, any air supply line from the compressor to a tool or machine could remain under pressure and cause very serious personal injury or death. After the compressor stops, carefully open avalve at any tool or machine to exhaust the pressure in any line prior to removal or serviEQUIPMENT PROTECTION Do NOT wire around or bypass a shutdown sensor or switch, Allunits in this family of machines are protected by five (5) sensors or switches at the following locations: (1) High engine COOLANT temperature in the engine, (2) Low engine oll pressure, in the engine. (9) Low Fuel Level. (Fits, the light on the control panel will come on as a warning). High Discharge AIR Temperature (4) Atthe airend outlet. (5) In the safety valve connection on the side of the separator tank. All sensors will automatically reset when the problem condition is corrected Automatic Shutdown/Diagnostics ‘Should any of these problem situations occur, the unit will automatically shutdown and stop. BEFORE restarting the unit or flipping the POWER switch to “Off, check the DIAGNOSTICS area on the instrument panel. Inashutdown situation, the function of the panellamps Is to indicate what specific failure caused the unit to shut down. These lamps will remain illuminated until the Power Switch is turned “OFF". Note: None of the panel lamps should be glowing when machine is operating. Ifthey are, shut unit down and investigate, ‘The upper four (4) lamps are electronically “latched to only respond to the first or primary signal for a shutdown. In other words, if the automatic shutdown is the result of one of these four problems, only that particular problem lamp will be lit. And the lamp will remain lit as long as the batteries provide power. Book 54579040 (7/03) (6) Refer 10 OPERATING CONTROLS AND INSTRUMENTS forthe various problem signal criteria (CF, psi, etc.). The indicated problem area should be inspected for a physical cause (low fluid, broken fan belt, evidence of excessive heat, etc.) and corrections made. Sensors (1) through (5) will automatically reset when the problem condition is corrected Other possible causes for an unexpected shutdown ate listed on the Trouble Shooting Chart. Adjustment Instructions ‘The operating pressure of this unitwas setatthe facto- ry to the maximum rating (at full speed). See General Data. However, this pressure may be reset down to 150 psi (1050 kPa). Normally, regulation requires no adjusting; butif prop- er adjustment is lost, proceed as follows: 1, WITH UNIT STOPPED, disconnect rod end bearing on governor cable (GC) at engine gov- emor lever, 2, Atbracket (A) near butterfly valve (BV) run nut (B) back on governor cable housing. Push gov- ernor cable housing toward lever (C). Tighten nut (0). 3. Loosen nut (E) to relax spring (@). 4, Loosennut (H). Tum rod (L) in Air Cylinder (AC) until approximately 3/4 inch (20 mm) between ‘nut (H) and flats on rod (L). 5. Tum rod (L) One round into rod end bearing. Tighten nut (H). Rotate butterfly shafviever (C), ‘open and close, several times to assure that linkage is not binding, 6. With engine governor lever in full speed posi- tion, reconnect rod end bearing 7. Take slack out of spring (G) by moving nuts (E) and (F). Tighten nuts.XHP 900 Units ONLY: Adjust spring so itis fully stretched, and nut (F) is at far end of rod, closest to ‘spring (G). Tighten nuts. 8 10. 1 12, 13, 14, 18. Start unit and allow to warm up for 3 to 5 min- utes. Push “Service Air” button on control panel. With service air valve closed, adjust pressure regulator (PR) to rated pressure (*) plus 10 psi (70 kPa) as follows: Loosen locknut (M) counterclockwise;. Tum adjustment cap (N) clockwise to increase pres- sure, counterclockwise to decrease pressure. Set no load speed (*) by adjusting position of rod end bearing on governor cable at engine. Tighten lock nut. Open service air valve and observetullloaden- gine speed (*). Adjust regulator to give rated ‘operating pressure (*). Tighten locknut (M). Close and slowly open service air valve. If en- gine speed surges, increase tension on spring (G) by moving nuts (E) and (F). XHP900 Units ONLY: Should not be adjusted by moving nuts (E) and (F). See Step 7. If set speeds are not correct, repeat steps 12, 1.and 14s required, To regulate to any pressure between 150 psi (1050 kPa) and maximum rating (*), make ad- just ments at the pressure regulator. Book 54579040 (7/03) 7)SECTION 6 - MAINTENANCE GENERAL In addition to periodic inspections, many of the componentsin these units require periodic servicingto 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, Refer to the engine Operator's Manual furnished in this manual for the specific requirements on preventive maintenance for the engine. 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 oxist, the schedule should be adjusted accordingly. COMPRESSOR OIL LEVEL Check the compressor and engine lubricating oil levels. The oil level should be checked before the unit is started. Always check the oil level while the unit is level, the engine off, and there is zero pressure in the separator tank. The optimum oil level is with the pointer at the top of the green section on the level ‘gage. Add oil if the pointer reaches the bottom of the {green section, Note: The oll level gage will not read property while the engine is running Book 54579040 (7/03) (8) [OPTIMUM OWL LEVEL OW- TOO HIGH | (EITHERSIDE) GREEN - OK. un eo 700 Low ‘ADD OIL LEVEL, (EITHER SIDE) Do not overfill either the engine crankcase or the compressor. It necessary, Refer to Lubrication Section for recom- mended lubricant. AIR CLEANER This unit is equipped with 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. NOTICE: Holes or cracks downstream of the air cleaner housing will cause the restriction indicators to be ineffective. ‘The air fiters restricted sensor will automatically reset after the main power switch is flipped to “OFF.” OQTo service the air cleaners on all u follows: proceed as 1. Loosen outer wing nut and remove with outer element. Remove loose inner wing nut and in- ner (safety) element. 2. Inspect air cleaner housing for any condition that might cause a leak and correct as neces- sary. ‘Wipe inside of air cleaner housing with a clean, damp cloth to remove any dirt accumulation, especially in the area where the element seals against the housing. 4. Inspect the primary element by placing a bright light inside and rotating slowly. I any holes or tears are found in the paper, discard this ele- ment. Ifno ruptures are found, the elementcan be cleaned by one of the following procedures. Donotclean the safety element. Replace itwith a new element, 5. Check new air fiter elements for any shipping damage. Install cleaned or new elements in the reverse order to the above. Tighten wing nuts firmly. 7. Inspect to ensure that the end cap seals tightly 360 degrees around the air cleaner body. 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. Move the nozzle up and down while rotating the ele- ment. Be sure to keep the nozzle at least one inch (25.4 mm) from the pleated paper. NOTICE To prevent damage to the element, never exceed a maximum air pressure of 100 psi (700 kPa). Book 54579040 (7/03) (9) ‘The air cleaner system (housing and piping) should be inspected every month for any leakage paths or inlet obstructions. Make sure the alr cleaner mounting bolts and clamps are tight. Check the aircleaner hous- ing for dents or damage which could lead to a leak. In- ‘spect the air transfer tubing from the air cleaner to the compressor and the engine for holes. Make sure that all clamps and flange joints are tight. COMPRESSOR OIL FILTER ELEMENTS ‘The compressor lubrication and cooling oil system includes dual spin-on, throw away type ol fiters, each with an internal bypass valve. With a clean, new filter ‘element, al of the oil flows through the full element atea, ftom the outside/inside. As each element becomes contaminated with dirt, a pressure differential is created in the filter housing between the oilinlet and outlet ports. As this dferential approaches 25 psi (175 kPa), the bypass valve starts to open, thus permitting a small quantity of ollto bypass the fiter. As the contaminants continue to build up, more and more of the oil bypasses the filter media itself. This does not provide any fitration but does allow a maximum flow of compressor lubricating and cooling «il to preclude any possible damage from loss of oil. {Also the design of the filter prevents any washing-off of any dirt during oil bypassing. NOTICE The oil filter must be replaced every 500 hours of ‘operation. On new or overhauled units, replace the element after the first 50 and 150 hours of opera- tion; thereafter, service the oil filter every 500 hours. Toservice the oil filters, it will frst be necessary to shut the unit down. Wipe off any external dirt and oll from the exterior of the filter to minimize any contamination from entering the lubrication system.High pressure air can cause serious 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. Openthe service air valve(s) and manual blow- down valve to ensure that system is relieved of all pressure. Close the valve(s). 2. Tum the spin-on filter element counterclock- wise to remove itfrom the filterhousing. Inspect the filter element and then discard, 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 fiter element. Clean the gasket seal area on the oil filter head. Installing a new oil fitter element when the old gasket remains on the oll filter head will cause an oll leak and can cause property damage. 4. Lubricate the new filter gasket with the eame oil being used in the machine. 5. Install new filter by turning element clockwise Until gasket makes initial contact. Tighten the filter one half turn 6. Start unit and allow to build up to rated pres- sure. Check for leaks before placing unit back into service, GAUGES The instruments or gauges are essential for safety, maximum productivity and long service life of the ma- chine. Inspect the gauges and test any diagnostic lamps priorto start-up. During operation observe the gauges and any lamps for proper functioning. Referto Operating Controls & Instruments for the normal read- ings. Book 54579040 (7/03) (40) FUEL TANK This unit is equipped with tank that can be filled from front of unit. Using clean fuel in the fuel tank is vitally important and every precaution should be taken to en- ‘sure that only clean fuel is either poured or pumped into the tank. Every six months the drain valve should be opened so that any sediment or accumulated condensate may be drained. When closing the valve, make sure itis fully closed and does not leak. BATTERY Keep the battery posts-to-cable connections clean, tight and lightly coated with a grease. Also the electro- lyte level in each cell should cover the top of the plates. Ifnecessary, top-up with clean distilled water. TIRES ‘Aweekly inspection is recommended. Tires that have ccuts or cracks or litle tread should be repaired or re- placed. Monthly check the wheel lug nuts for tight- ness. SWITCHES The discharge air temperature switches will require approximately 248°F (120°C) to actuate, The engine coolant temperature switch will require approximately 215° F (102°C) to actuate. Replace any defective ‘switch before continuing to operate the unit. Alow oil pressure switch may be tested by removing it land connecting it to a source of controlled pressure while monitoring an ohmmeter connectedtothe switch terminals. As pressure is applied slowly from the controlled source, the switch should close at 12 psi (.84 kgf per em 2) and show continuity through the contacts. As the pressure is slowly decreased to 8 psi (0.56 kgf per cm2) the contacts should open and the ‘ohmmeter should show lack of continuity (infinite ohms) through the contacts. Replace a defective ‘switch before continuing to operate the unit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 onflammable safety solvent through the core of the oll 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. Do not clean with caustic solutions. Aluminum Heat Exchangers will be damaged. In the event foreign deposits, such as sludge and lac- guer, accumulate in the oil cooler to the extent that its cooling efficiency is impaired, a resulting high dis- charge air temperature is likely to occur, causing shut down of the unit. To correct this situation it will be nec- essary to clean itusing a cleaning compound in accor- dance with the manufacturer's recommendations. Af- ter completing the cleaning procedure, the oil cooler must be flushed before returning to service. Donot remove the cap fromaHOT engine radiator. The sudden release of pressure from a heated cooling system can resultin serious personal inju- ry. RADIATOR Book 54579040 (7/03) (ai) The engine cooling systemis filed at the factory witha 50/50 mixture of water and ethylene glycol. This permanent type antifreeze contains rust inhibitors and provides protection to -35° F(-37°C). Theuse of such _amixtureis recommended for both summer andwinter ‘operation. When using water alone, be sure to add a reputable brand of rust inhibitor to prevent intemal corrosion Itis recommended o test the reezingprotection of the coolant every six months or prior to freezing temperatures. Replenish with a fresh mixture every twelve months. A drain forthe system is located in the bottom radiator tank. An alternate method would be to disconnect a bottom radiator hose. Each month, inspect the radiator exterior for obstruc- tions (dirt, bugs, ete.). If present, blow water or com- pressed air containing a nonflammable solvent be- tween the fins in a direction opposite the normal air flow. Should the radiator be clogged internally, stan- dard automotive practices should be followed. ENGINE CORROSION RESISTOR ELEMENT Replace as recommended in engine operation manual. HOSES Each month it is recommended that all of the intake lines to and from the air cleaners, the engine cooling ‘system hoses and allof the flexible hoses used for air, oil, and fuel be inspected. To ensure freedom from air leaks, all rubber hose joints and the screw-type hose clamps must be abso- lutely tight. Regular inspection of these connections for wear or deterioration is a definite “must if regulator servicing of the air cleaners is not to prove futile. Pre- mature wear of both the engine and compressoris AS- SURED whenever dust-laden air is permitted to enter the engine's combustion chamber or the compressor intake practically unfiltered,The flexible hoses used in the fuel, oil and airlines on these units are primarily used for their ability to accom- ‘modate relative movementbetween components. Itis extremely important they be periodically inspected for wear and deterioration. Clamps are used to prevent hose cover abrasion through vibration. This abrasion ‘may occur when two hose lines cross, or when a hose line rubs againsta fixed point; therefore, itisnecessary that all clamps be replaced if missing. Itis also impor- tant the operator does not use the hoses as conve- riient hand hold or steps. Such use can cause early cover wear and hose failure. NOTICE ing systems operating at less than 150 psi (1034 kPa) may use a special nylon tubing. The associated fittings are also of a special “push-in” design. If so, features are as follows: Pulling on the tubing will cause the inner sleeve to with- draw 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 seal- ing ability. To install the nylon tubing, make a mark (with tape or grease pencil) approximately 7/8 inch from the end of the tubing. Insertthe tubing into the sleeve and ‘push- in” past the first resistance to the bottom. The mark shouldbe approximately 1/16 inch from the sleeve, for the 8/8 inch O.D. tubing; 1/8 inch for the 0.25 inch 0.0. tubing. This wll ensure that the tubingis fully engaged inthe sealing mechanism. FASTENERS Visually check entire unit in regard to bolts, nuts and sctews being properly secured. Spot check several capscrews and nuts for proper torque. Ifany are found loose, a more thorough inspection must be made. Take corrective action, Note: For Nyloc Nuts, IF REMOVED, replace withnew ones. Book 54579040 (7/03) (a2) COMPRESSOR OIL ‘The lubricating and cooling oll must be replaced every +1000 hours of operation or six (6) months, whichever comes first. Check the compressor and engine lubricating oil levels. The oll level should be checked before the unit is started, Always check the oil level while the unit is level, the engine of, and there is zero pressure in the separator tank. The optimum oil level is with the Pointer at the top of the green section on the level ‘gage. Add oil if the pointer reaches the bottom of the ‘green section Note: The oil level gage will not read properly while the ‘engine is running. | ay OPHIMUM OM Levert] YELLOW - TOO HIGH (EITHER SIDE) GREEN - 0K RED O ‘ToOLow ADD OL LEVEL, (EITHER SIDE) Do not overfill either the engine crankcase or the compressor.RUNNING GEAR Every month or 500 miles, tighten the wheel lug nuts to 85 - 95 Ibs.-ft. Every six months the wheel bearings, grease seals and axle spindles should be inspected for damage (corrosion, etc.) or excessive wear. Re- place any damaged or worn parts. Repack wheel bearings. Use a wheel bearing grease conforming to specification MIL~G-10924 and suitable for all ambi- ent 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 ofone handand take the bearing in the other hand. Push a segmentof the wider end of the bearing down into the outer edge ofthe grease pile closestto the thumb. Keep litingand 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 filed with grease. NOTICE 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 manufactur- er'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. Book 54579040 (7/03) (3) It 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. While rotating hub slowly to seat the bearings, tighten spindle nut to approximately 15 Ibs.-ft Grasp the tire atthe top and bottom and rock, in andout. There shouldbe no evidence of loose- ness (free play) at the bearing. 2. Loosen nut to remove preload torque. Do not rotate hub. 3. Finger tighten nut until just snug. Loosen nut nti 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. 5. Bend over cotter pin legs to secure nut and clear grease cap. 6. Nut should be free to move with only restraint being the cotter pin. 7. __InspectLeaf Springs and Retaining Bolts/Nuts. RECEIVER-SEPARATOR SYSTEMS High pressure air can cause serious 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 and manual blowdown valve at end of machine. * Ensure pressure is relieved, with BOTH: = Discharge air pressure gauge reads zero (0). = No air discharging from service valve or manual blowdown valve. * When draining oil, use valve at bottom of separator tank, * 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 com- pressed air enters the tank, the change in velocity and direction drop out most of the oll from the all. ‘Additional separation takes place in the oil separator element which is located in the top of the tank. Any oll accumulation in this separator element is continuously drained off by means of a scavenge tube Which retums the accumulated oll to the system, ‘The life of the oil separator elementis 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: * Ensure the tank pressure is zero. * Disconnect the hose from the scavenge tube. * Remove scavenge tube from tank cover. * Disconnect service line from cover. Book 54579040 (7/03) (44) * Remove (20) cover mounting sorews. * Remove cover, element and inner shell * Remove any gasket material left on cover or tank. * Install new gasket, inner shell and new element. NOTICE Do not remove staples from the elementgasket. The staples provides continuity between the mat- ing components. “Place a straightedge across top of elementand mea- ‘sure from bottom of straightedge to bottom of ele- ment (See Fig. 4.1). “Replace scavenge tube in cover (cover is stil off of tank). *Measure from bottom of cover to end of scavenge tube (See Fig. 4.2). Measurement should be from 1/8" to 1/4" less than the element measurement. If not, cutto size, being sure tocut in an approximate 45° angle. “Remove scavenge tubs. “Reposition caver (usa cara not to damage gaskets). *Replace cover mounting screws: tighten in a crisscross patter to recommended torque value, “Reconnect service line. Replace scavenge tube. Re-connect hose. *Close service valve. Start unit and look for leaks. When replacing the element, the scavenge lines, orifice, filter, and check valve should be thoroughly cleaned and the oil changed| STRAIGHTEDGE cy a Le ELEMENT * Y ‘SHOULD BE 1/8" TO 1/4" SHORTER THAN ELEMENT MEASUREMENT ‘SEPARATOR TANK SCAVENGE LINE High pressure air can cause serious 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 fine originates. atthe receiver-separator tank cover and terminates at the compressor airend through an orifice. (Once a year or every 2000 hours of operation, which- ever comes first, remove this line and any orifice, thor- oughly clean, then reassemble. Book 54579040 (7/03) (43) TANK TOP a J i ~“<— SCAVENGE TUBE mk : — = cutlir ~~ ifecessary NOTICE Excessive oil carry-over may be caused by an oil logged separator element. Donot replace element without first performing the following mainte- nance procedure: 1. Check oll evel. Maintain as indicated earlier in this section, 2. Thoroughly clean scavenge line, any ontice and check valve. 3. Assure minimum pressure valve is holding 65-70 psi 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 liq- uid detergent, Do not scrub with a rough cloth, pad, ote. 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 partial- ly restore the color and gloss. Field Repair of Texture Paint 1. Thesheetmetal shouldbe washed andclean of foreign material and then thoroughly dried. 2. Clean and remove all grease and wax from the area to be painted using Duponts 3900S Cleaner prior to sanding, 3. Use 320 grit sanding paper to repair any scratches or defects necessary. 4. Scuff sand the entire area to be painted with a red scotch brite pad. 5. Wipe the area clean using Duponts 39008. Blow and tack the area to be painted. 7. Apply a smooth coat of Duponts 1854S Tuficoat Primer to all bare metal areas and allow to dry. Book 54579040 (7/03) (46) 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. Toapply the texture coat, use Duponts 18548 ‘Tuffcoat Primer. The proper technique todo this is to spray the Tutfcoat Primer using a pressure pot and use about 2-5 pounds of air pressure. This wil allow the primer to splatter causing the textured ook. 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 toachieve. 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, Band 10. COOLING FAN DRIVE ‘The heat exchanger or cooling fan is driven by a belt arrangement directly from the engine. Inspect the en- gine fan beltweekiy orat 50 hourintervals. Refertoen- gine section for proper belt adjustment procedures.BRAKE SYSTEMS (Hydraulic Only) This compressor is equipped with mechanical parking brakes and hydraulic surge brakes. The maintenance of these brake systems is required to ensure safe op- eration of this compressor. Every six months visually check the brake shoes for proper operation and deterioration. The common au- tomotive standards and procedures would apply in re- placing the brake shoes. When replacing brake cables itis necessary to adjust the brake shoes before adjusting the parking brake system. To adjust the shoes, remove the rubber hole plug in the brake backing plate and rotate the star ad- justing nut until you cannot rotate the wheel by hand, Then back off the adjustment ten to twelve (10-12) notches. Note: Always rotate wheel in direction of forward travel only. Replace hole plug and proceed tonext wheel and repeat procedure. ‘Adjust parking brakes after all brake shoes have been adjusted by: 41. Tuning knob on brake lever until leveris perpendic- ular to bracket when in “OFF” position, Wheels should tum freely. 2. With lever in “OFF” position, adjust brake cables un- til each has approximately the same tension. Wheels should tum freely. 3. Move lever to “ON' position. Check each wheel to see that twill not rotate. If all wheels will rotate, adjust knob on lever until brakes are fully applied. If one or two wheels will stil rotate, adjust the cables for those wheels and recheck. 4, After brakes are adjusted, move lever to “ON” posi- tion and apply grease to cable strands fromconduit six inches toward lever. This is to prevent dirt from getting into the conduit. NOTE: New cables will stretch and therefore should be readjusted after the first week of use. Every six months, apply a multi-purpose grease to the fitings on the brake actuator. Before servicing the hydraulic surgebrake system, the actuator, reservoir, wheels and underside of frame should be cleaned to prevent drt and other contami- nants from entering the hydraulic system. Book 54579040 (7/03) (7) Whenever abrake line hose, tube orfiting is removed! replaced, the hydraulic brake system must be bled of air to ensure proper brake operation. Bleed the brakes, at each wheel cylinder, in the following order: RH rear, LH rear; RH front; LH front (front i the hitch ‘end; instrument panelis on LH side), while maintaining brake fluid level in reservoir. Use brake fluid conform- ing to DOT 3 or DOT 4 specifications. BRAKE SYSTEMS - (Non Hydraulic) ‘This compressor may be equipped with mechanical parking brakes or electic brakes. The maintenance of these brake systems is required to ensure safe opera- tion of this compressor. Parking Brakes: Every six months visually check the brake shoes for proper operation and deterioration. The common au- tomotive standards and procedures would apply in re- placing the brake shoes, ‘When replacing brake cables itis necessary to adjust the brake shoes before adjusting the parking brake system. To adjust the shoes, remove the rubber hole plug in the brake backing plate and rotate the star ad- justing nut until you cannot rotate the wheel by hand. ‘Then back off the adjustment ten to twelve (10-12) notches. Note: always rotate wheel in direction of for- ward travel only. Replace hole plug and proceed to next wheel and repeat procedure, Adjust parking brakes after all brake shoes have been adjusted by: 1. Turing knob on brake lever until ever is perpendic- ular to bracket when in “OFF” position. Wheels should tum freely. 2.With leverin “OFF" position, adjust brake cables un- til each has approximately the same tension. Wheels should turn freely. ‘8, Move lever to “ON” position. Check each wheel to ‘see that twill nt rotate. Ifall wheels will rotate, adjust knob on lever until brakes are fully applied. If one or {two wheels will stil rotate, adjust the cables for those wheels and recheck. 4, After brakes are adjusted, move lever to "ON" posi- tion and apply grease to cable strands from conduit six inches toward lever. This is to prevent dirt from getting into the conduit.NOTE: New cables will stretch and therefore should be readjusted after the first week of use. Every six months, apply a multi-purpose grease to the fittings on the brake actuator. Electric Brake Adjustment: Brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have “seated”, (2) at 3000 mile intervals, (3) or as use and performance requires. The brakes should be adjusted in the following manner: 1. Jack up trailer and secure on adequate capacity jack stands. Check that the wheel and drum rotate freely. 2. Remove the adjusting hole cover from the adjust- ing slot on the bottom of the brake backing plate. 3. With a screwdriver or standard adjusting tool, ro- tate the starwheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to tur. 4, Then rotate the starwheel in the opposite direction until the wheel turns freely with a slight lining drag, 5. Replace the adjusting hole cover and lower the Wheel to the ground, 6. Repeat above procedures on all brakes. ‘Any unauthorized modification or failure to maintain this equipment may make itunsafe and out of factory warranty. If performing more than visual inspections, disconnect battery cables and open manual blowdown valve. Use 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. Noti Book 54579040 (7/03) (43) Disregard any maintenance pertaining to components not provided on your machine.MAINTENANCE SCHEDULE ‘These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty or wet) Daily Weekly Monthly 3MOS. 6 MOS. 72 MOS, TARGE UNITS) BOO ROE TOOO RENE 2000 FOUTS “Hydraulic Ol Level c F Compressor OT Level Engine OF Level “Radiator Coolant Level Gaugestamps Tir Gleaner Sence Indicators Foot Tank (ital ond of day) ‘DRAW “Fuel Water Separator DRAW apap] of of oy oF Thr Gleaner Precleaner Dumps FaniAterator Bae Battery Connectons/Elecroipe “Tie Pressure and Surace op apa | heel Log Nats Hoses (ol az take, fe) TRatomatc Shutdown Systers Test Tir Cleaner System Visual Compressor O1 Cooler Exaror CLEAN "Engine Fadiator Exon apo] of oP oy | CLEAN Fasteners, Guards Tir Cleaner Elements Wi Foal Water Separator Element "Compressor OW Fer Element Compressor Oi “Wheels (bearings, seal, 6) Engine Coolant Tet ‘Shutdown Switch Satinge Test ‘Scavenge Orca & ated pans [Oi Separator Element Tights running, rake, & tum) car Pino Eye Bats car Engine (ol changes, of & fool Mor, ote) a “Disregard if not appropriate for this particular machine. Rereplace, C=check (adjust if necessary), WI=OR when indicated, CBT heck before towing. Refer to specific sections of the operator's manual for more information, Book 54579040 (7/03) (49)SECTION 7 - LUBRICATION GENERAL INFORMATION Lubrication is an essential part of preventive mainte- nance, affecting to a great extent the useful fe of the unit, Differentlubricants are needed and some compo- rents in the unit require more frequent lubrication than others. Therefore, itis important that the instructions regarding types of lubricants and the frequency of their application be explicitly followed. Periodic lubrication ofthe moving parts reduces to a minimum the possibil- ity of mechanical failures. The Preventive Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed. A regular service program should be developed to include all items and fluids. These intervals are based on average operating conditions. In the event of extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than specified may be necessary. Details concerning lubrication of the running gear are in Maintenance Section. Allfiters and fiter elements for air and compressor lu- bricant must be obtained through Ingersoll-Rand to assure the proper size and filtration for the compres- sor. COMPRESSOR OIL CHANGE These units are normally furnished with an initial sup- ply of oil sufficient to allow operation of the unit for ap- proximately 6 months or 1000 hours, whichever comes first. Ifa unithas been completely drained of all oll, it must be refilled with new oll before itis placed in operation. Refer to specifications in Lubrication Table, NOTICE ‘Some oil types are incompatible when mixed and re~ sultin the formation of varnishes, shellacs, orlacquers which may be insoluble. Such deposits can cause se- rious troubles including clogging of the filters. Where possible, do NOT mix oils of diferent types and avoid mixing iferentbrands. A type orbrand change isbest made at the time of a complete oil drain and refill Book 54579040 (7/03) (50) If the unit has been operated for the time/ hours men- tioned above, it should be completely drained of ol. f the unit has been operated under adverse conditions, or after long periods in storage, an earlier change peri- ‘od may be necessary as oll deteriorates with time as well as by operating conditions. High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pres- sure before removing caps, plugs, covers or other parts from pressurized air system. Ensure the fol- lowing conditions are met: = Discharge air pressure gauge reads zero (0). = Noair discharging from an “open” manual blow- down valve. Anoilchangeis good insurance against the accumula- tion of dirt, sludge, or oxidized oil products. ‘Completely drain the receiver- separator, piping, and oil cooler. Ifthe ollis drained immediately after the unit has been run for some time, most of the sediment will bbe in suspension and, therefore, will drain more readi- ly. However, the fluid willbe hotand care mustbe taken to avold contact with the skin or eyes. After the unit has been completely drained of all old ol, close the drain valve. Add oil in the specified quantity atthe filer plug. Tighten the filer plug and run the ma- chine to circulate the oil. Check the oil level WHEN RUNNING AT FULL LOAD. If not near the middle of the sight tube, stop the unit and make corrections. DO NOT OVERFILL. NOTICE Ingersoll-Rand provides compressor oil specifically formulated or Portable Compressors and requires the use of these fluids in order to obtain extended limited airend warranty.Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note thattthe selection of fluidis dependenton the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oll change. Note: Fluids listed as “preferred” are required for ‘extended warranty. Compressor oil carryover (oll consumption) may be greater with the use of alternative fluids. ‘Ambient Temperature Design Operating Pressure ‘Specification Prefered t00psito 300psi | ~10°F 10 125°F, | IR Pro-Tec™ (Castcto52°0) Akemate: 180 Viscosity Grado 46, ‘wth rust and ‘oxidation inhibitors, do- Signed fr air compres SOT SETTES Protened: 1B XHP 605 Atomate TA XHPAOS 180 Viscosity Grade 68 Group 3 or 5 with rust, ‘and oxidation inhibitors Sesignad for ar com pressor sonic, as0psi | (-29°C 052°0) “10°F to 125°F Prefered: XHP60S IR xHP 1001 to 125°F (18°C 1052°0) RATED OPERATING PRESSURE —100 = 300 PSt_A) ya5¢¢ 350 PSI 50" aoc torr a sorcll]| ose mus ® zoel! este | sor sor 10 [| s0°F [| -10°F -20F 40°F. 7 Preferred Ingersoll-Rand Fluids - Use of these fluids with original |-R filters can extend airend warranty. Refer to operator's manual warranty section for details or contact your I-R representative. Ingersoll-Rand T gal (@B Litre) [5 gal. (19.0 Litre) [55 gal. [220 gal. (836 litre) Preferred Fluids (208.2Litre) Preferred: TRPro-Teo™ 36809608 36899706 36800714 36809722 TR XHPOOS 5 22OE2OTE 2E252050 P2DE2068 IR XHP1001 = 35612738 35300516 = XHPAOS 5 22OE2T26 [22252100 22OETS Engine Oil 54480918 36875938 36866903 Book 54579040 (7/03) (51)SECTION 8 - Trouble Shooting INTRODUCTION ‘Trouble shooting for a portable air compressor isan organized study of aparticular 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 ‘roubles that may occur, nor does it attempt to Give all of the answers for correction of the problems, The chartdoes give those problems that are most apt to occur. To use the trouble shooting chart: ‘A. Find the “complaint” depicted as a bold heading, Follow down that column to find the po- tential 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) Whatwere the warning signals that preceded the trouble? Has a similar trouble occurred before? What previous maintenance work has been done? Ifthe compressor will still operate, isit safe to continue operating it to make further checks? Book 54579040 (7/03) B. Do The Simplest Things First Most troubles are simple and easily corrected. For ‘example, most complaints are “low capacity" which may be caused by too low an engine speed or “compressor ‘over- heats” which may be caused by low oil level. ‘Always check the easiest and most obvious things first; following this simple rule will save time and trouble. Note: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in Parts List Section, 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 canbe partially disassembled in search of the cause of acertain 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 Atter 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 CHART Bold Headings depict the COMPLAINT - Subheadings suggest the CAUSE fe re 1, Unit Shutdown: Out of Fuel Compressor Oil Temp. Too High Engine Water Temp. Too High Engine Oil Pressure Too Low Broken Engine Fan Belt Loose Wire Connection Low Fuel Level Shutdown Switch Defective Discharge Air Temp. Switch Defective Engine Oil Pressure Switch Defective Shutdown Solenoid Malfunctioning Relay + < 16 Volts at Shutdown Solenoid Blown Fuse Engine Malfunctioning Arend Maifunctioning 2. Won't StarvRun: Low Battery Voltage * <16 Volts at Shutdown Solenoid Blown Fuse Malfunctioning Start Switch Defective Safety Bypass 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 Discharge Air Temp. Switch Defective Engine Oil Pressure Switch Defective Shutdown Solenoid Matfunctioning Relay Engine Matfunctioning Airend Maltunctioning 3. Engine Temperature Lamps Stays On: Broken Engine Fan Belt Malfunctioning Circuit Board + Ambient Temp. >125°F (52°C) Dirty Operating Conditions Dirty Cooler * Out of Level >15 degrees Operating Pressure Too High Recirculation of Cooling Air Loose Wire Connection Malfunctioning circuit board, greater than, <= less than Book 54579040 (7/03) ‘ubheadings suggest sequence to follow troubleshooting, ive Acti ‘Add CLEAN diesel Fuel ‘See Complaint 10 Check coolant level. It necessary, Add. ‘See Complaint 3 and Complaint 4. Replace fan belt. Wiggle wires at switches & connector blocks. Make repairs. Replace switch Replace switch Replace switch Replace solenoid, Replace relay. Check battery and altemator. Make repairs. Replace fuse, ‘See Trouble Shooting in Engine Manual. ‘See Complaint 10. Check electrolyte level. Check connections. Gharge battery and alternator. Make repairs. Replace fuse. Replace swith. Replace switch. Service fiters. See Engine Operator's Manual Add CLEAN fuel See Complaint 10. Check fluid level. It necessary, Add. See Complaint 3 and Complaint 4. Repair or replace connection. Replace switch. Heplace switch: Replace solen Replace relay. See Trouble Shooting in Engine Manual See Complaint 10. Replace fan belt set. Replace circuit board. ‘Above spec limit, Move unit to cleaner environment. Clean exterior of cooler. Relocate or reposition unit. Reduce pressure to spec. Close side doors. Repair or replace. Replace circuit board.4. Engine Oil Pressure Lamp Stays On: Low Oil Level Out of Level >15 degrees Wrong Lube Oil Clogged Oil Filter Element(s) Engine Malfunctioning Loose Wire Connection. Malfunctioning circuit board Engine Temperature Lamps Stays Off: Bulb Burned Out Malfunctioning circuit board Engine Oil Pr m1 Bulb Bumed Out Matfunctioning circuit board Alternator Lamp Stays On: Loose of Broken Belts Loose Wire Connection Low Battery Voltage Malfunctioning Alternator Malfunctioning circuit board Alternator Lamp Stays Off: Bulb Burned Out Loose Wire Connection Malfunctioning circuit board Unit Fails To Shutdown: Defective Low Fuel Shutdown Switch Defective Discharge Air Temperature Switch Defective Engine Oil Pressure Switch Defective Shutdown Solenoid Malfunctioning Relay Defective Safety Bypass Switch Book 54579040 (7/03) (54) Corrective Action ‘Add oll Relocate or reposition, See Engine Oil Spec. Change oil. Replace element(s). See Trouble Shooting in Engine Manual. Repair or replace. Replace circu. Replace circuit board, Replace circuit board, Replace circuit board. Replace circuit board. Tighten or replace belt set. Repair or replace connection. Check electrolyte level. Add if necessary. ‘Check connectors. Clean & tighten. Recharge battery. Repair or replace alternator. Replace circuit board, Replace circuit board, Repair or replace connector. Replace circuit board. Pull wire off shutdown solenoid. Replace switch. Pull wire off. Replace switch. Pull wire off. Replace switch. Carefully block air inlet to stop engine. Replace solenoid. Pull wire off shutdown solenoid. Replace relay. Pull wire off shutdown solenoid. Replace defective item,10, Excessive Compressor Oil Temperature ‘Ambient Temp. > 125°F (52°C) Out of Level > 15 degrees Low Oil Level Wrong Lube Oil Dirty Cooler Dirty Operating Conditions Clogged Oil Filter Elements Loose or Broken Belts Operating Pressure Too High Recirculation Of Cooling Air Malfunctioning Thermostat Malfunctioning Fan Detective Oil Cooler Relief Valve Defective Minimum Pressure Valve Blocked or Restricted Oil Lines Arend Maltunctioning 11. Engine RPM Down: Clogged Fuel Fitter Operating Pressure Too High Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Incorrect Linkage Adjustment Dirty Air Filter Malfunctioning Air Cylinder Wrong Air Filter Element Defective Separator Element Engine Malfunctioning Airend Malfunctioning Vibration: Rubber Mounts, Loose or Damaged Defective Fan Drive Coupling Defective Engine Malfunctioning Airend Malfunctioning ‘Anti-rumble valve not working. Engine idle speed too low. 12. Ex 13. Low CEM: Dirty Air Filter Incorrect Linkage Adjustment Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Malfunctioning Inlet Unloader/Butterlly Valve Malfunctioning Air Cylinder Defective Minimum Pressure Valve Defective Separator Element Wrong Air Filter Element Book 54579040 (7/03) (53) Corrective Action ‘Above spec limit, Relocate or reposition unit ‘Add oil. Look for any leaks ‘Check spec in this manual. Clean exterior surfaces. Move unit to cleaner environment. Replace elements. Change cil Tighten or replace belt set. Reduce pressure to spec. Close side doors. Replace belly pan. Replace thermostat in bypass valve. Check fan belt tension. Tighten or replace belt set. Replace valve. Repair or replace valve, Clean by flushing or replace. See Complaint 11, 12, 13, 15, 16 or 18. Clean primary filter. Replace final filter. Drain tanks. ‘Add CLEAN fuel, Reduce pressure to spec limit. See Section 6 in this manual. Replace regulator. See Section 6 in this manual Clean or replace elements. Replace alr cylinder and adjust per Section 6. Install correct element. Install new element per page 21. See Trouble Shooting in Engine Manual. Refer to Airend Rebuild Manual. Tighten or replace. Heplace tan. Replace coupling, ‘See Trouble Shooting in Engine Manual. ‘See Complaint 15 and 17. Repair or Replace. Raise “No Load” speed per Section 6. Clean or replace elements. ‘See Section 6 in this manual. ‘See Section 6 in this manual. Replace regulator. Inspect valve. Make adjustment per Section 6. Replace air cylinder. Repair or replace valve. Install new element per Page 21. Install correct element,14, short Air Cleaner Lite: Dirty Operating Conditions Inadequate Element Cleaning Incorrect Stopping Procedure Wrong Air Filter Element Oil Pump Drive Coupling 15, Excessive Oil in Ai High Oil Level Out of Level > 15 degrees Clogged Scavenge Orifice Scavenge Tube Blocked Defective Scavenge Check Valve Sep. Tank Blow Down Too Quickly Defective Minimum Pressure Valve 16. oil Seal Leak: Contaminated Lube Oil Blocked or Restricted Oil Line(s) Malfunctioning Seal Scored Shaft 17. Will Not Unload: Leak in Regulator Piping Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Malfunctioning Inlet Butterfly Valve Ice in Regulation Lines/Orifice 18, Ollin Air Cleaner: Incorrect Stopping Procedure Oil Pump Drive Coupling Discharge Check Valve Faulty 19. safety Valve Relieves: Operating Pressure Too High Leak In Regulator Piping Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Maifunctioning Inlet Unloader’Butterfty Valve Defective Safety Valve Defective Separator Element Ice in Regulation Lines/Oriice Book 54579040 (7/03) Corrective Action Move unit to cleaner environment. Install new element, Read procedure in this manual. Install proper element. Inspect coupling. If necessary, replace coupling. Read procedure in this manual. Relocate or reposition unit. Remove scavenge orifice. Clean and Replace. Remove scavenge tube, Clean and Replace. Remove check valve. Replace with new valve. Allow unit to blow down automatically. Remove valve. Repair valve and replace, Drain and flush system. Add new CLEAN oll Remove, clean and replace line(s). Refer to Airend Rebuild Manual See instructions in new seal Find and repair leak(s). Refer to Section 6 in this manual. Replace regulator. Inspect valve fit. Readjust per Section 6. Apply heat toline(s) and or orifice. Read Procedure in this manual. Inspect coupling. Replace if necessary. Replace. Reduce pressure to spec limit. Repair leak(s). Refer to Section 6 in this manual. Replace regulator. Inspect valve fit. Readjust per Section 6. Replace safety valve. Remove element. Install new. Apply heat to lines and/or orifice. (s6)SECTION 9 - PARTS ORDERING GENERAL This publication, which contains an illustrated parts breakdown, has been prepared as an aid in locating those parts which may be required in the maintenance of the unit. All of the compressor parts, listed in the Parts breakdown, are manufactured with the same precision as the original equipment. For the greatest protection always insist on genuine Ingersoll-Rand Company parts for your compressor. NOTICE Ingersoll-Rand Company can bear no responsibility for injury or damages resulting directly from the use of non-approved repair parts. Ingersoll-Rand Company service facilities and parts are available worldwide, There are Ingersoll- Rand ‘Company Construction Equipment Group Sales Ot- fices and authorized distributors located in the princi- Palcities of the United States. In Canada our custom- ers are serviced by the Canadian Ingersoll-Rand Company, Limited. There are also Ingersoll-Rand In- ternational autonomous companies and authorized distributors located in the principal cities throughout the free worl. ‘Special order parts may notbe included in this manual, Contact the Mocksville Parts Department with the unit serial number for assistance with these special parts. DESCRIPTION ‘Theillustratedparts breakdown illustrates and lists the various assemblies, subassemblies anddetailed parts which make up this particular machine. This covers the standard models and the more popular options that are available. series of illustrations show each part distinctly andin Book 54579040 (7/03) location relative to the otherpars inthe assembly. The part number, the description of the part and the quantity of parts required are shown on each illustration or on adjacent page. The quantities specified are the number of parts used per one assembly and are not necessarily the total number of parts used in the machine. Where no quantity is specified the quantity is assumed to be one, Each description of a part is based upon the “noun first’ method, ie., the identifying noun or item name is always the first partof the description. The noun name is generally followed by a single descriptive modifier. ‘The descriptive modifier may be followed by words or abbreviations such as upper, lower, inner, outer, front, rear, RH, LH, etc. when they are essential. In referring to the rear, the front or to either side of the Unit, always consider the drawbar end of the unit as the front. Standing at the rear of the unit facing the Exch cylinder has three rocker levers: ‘* The long rocker lever (E) is the exhaust lever. ‘* The center rocker lever is the injector lever. ‘© The short rocker lever (1) is the intake lever. Refer to the accompanying chart for valve rocker lever locations. ‘The crankshaft rotation is clockwise when viewed from the front of the engine. ‘The cylinders are numbered from the front gear cover end of the engine. ‘The engine firing order is 1-5-3-6-2-4. ‘The valves and injectors on the same cylinders are not adjusted at the same index mark on the accessory drive pulley on STC engines. ‘One pair of valves and one injector are adjusted at each pulley index mark before rotating the accessory drive tothe next index mark. ‘Two crankshaft revolutions are required to adjust all the valves and injectors. A WARNING A Do not pull or pry on the fan to manually rotate the ‘crankshaft. To do so can damage the fan blades. Dam- aged fan blades can cause premature fan failures which can result in serious personal injury or property dam- age. ‘The valve set marks are located on the accessory drive pulley. The marks align with a pointer on the gear cover. Use the accessory drive shaft to rotate the crankshaft.ut Maintenance Procedures at 1,500 Hours. ‘The adjustment can begin on any valve set mark. In the following example the adjustment will begin on the “A” valve set mark with cylinder number five valves closed and cylinder number three injector ready for adjustment. Rotate the accessory drive shaft clockwise unti the “A” valve set markon the accessory drive pulley is aligned with the pointer on the gear cover. ‘When the “A” mark is aligned with the pointer, the intake and exhaust valves for cylinder number five must be closed. If these conditions are not correct, oylinder number four injector and cylinder number two valves must be ready to set. Both valves are closed when both rocker levers are loose and can be moved from side to side. Loosen the injector adjusting screw locknut on cylinder number three. Tighten the adjusting screw until all the Clearance is removed from the injector train. Tighten the adjusting screw one additional turn to correctly seat the link. Loosen the injector adjusting screw until the STC tappet touches the top-cap of the injector. Be sure to loosen the adjusting screw enough, so there is 110 preload on the injector. This will be accomplished when the rocker lever is loose enough to move. Overhead Set Page 6-3S wit Maintenance Procedures at 1,500 Hours Place the STC tappet adjusting tool, Part No. 3823348, on the upper surface of the STC injector top-cap. Rotate the tool around the tappet until the tool's locating pin is inserted into one of the four holes in the top of the tappet. Apply thumb pressure to the tool handle to hold the tappet, in the maximum upward position. NOTE: Apply only enough force to the tool to hold the tappet in the maximum upward position. Excess force will cause the tool to break. A caution A An overtightened setting on the injector adjusting screw will produce increased stress on the injector train and ‘the camshaft injector lobe which can result in engine damage. Use torque wrench, Part No. 3376582, to tighten the ad- justing screw while holding the tappet in the maximum upward position. Torque Value: 0.6 to. 0.7 Nem [5 to 6 inb] Hold the adjusting screw in this position. The adjusting ‘screw must net turn when the locknut is tightened. Torque Value: * Without Torque Wrench Adapter: 61 Nem [45 fib] © With Torque Wrench Adapter (1): 47 Nem [35 ftb]un Maintenance Procedures at 1,500 Hours The tappet tool must be removed before rotating the crank- shaft fo prevent damage to the tappet. Remove the tappet adjusting tool. Check to make sure the injector push rod can be rotated by hand. if it can’t, the setting is too tight. ‘Adjust the valves on the appropriate cylinder according to the sequence chart before rotating the accessory drive to the next valve set mark. Select a feeler gauge for the correct valve lash specifica tion. Valve Lash Specification mm in intake 0.36 0.014 Exhaust 069 0.027 Insert the feeler gauge between the top of the crosshead and the rocker lever pad. ‘Two different methods for establishing valve lash clearance are described below. Either method can be used; however, the torque wrench method has proven to be the most con- sistent. It eliminates the need to feel the drag on the feeler gauge. * Torque Wrench Method: Use the inch pound torque wrench. Part No. 3376592, (normally used to set preload on top stop injectors), and tighten the ad- justing screw. Torque Value: 0.7 Nem [6 in-tb] ich Method: Tighten the adjusting screw until a light drag is felt on the feeler gauge.uit Maintenance Procedures at 1,500 Hours Hold the adjusting screw in this position. The adjusting ‘screw must not turn when the locknuttis tightened. Tighten the locknut. Torque Value: ‘+ Without Torque Wrench Adapter: 61 Nem (45 flb] ‘© With Torque Wrench Adapter (1): 47 Nem [35 ft-lb] ‘After tightening the locknut to the correct torque value, check to make sure the feeler gauge will slide backward and forward between the crosshead and the rocker lever with only a slight drag. Ifusing the touch method, attempt to insert a feeler gauge that ss 0.03 mm [0.001 inch] thicker between the crosshead land the rocker lever pad. The valve lash s not correct when a thicker feeler gauge will fi. After adjusting the valves, rotate the accessory drive and align the next valve set mark on the accessory drive pulley with the pointer on the gear cover.ut Maintenance Procedures at 1,500 Hours ‘Adjust the appropriate injector and valves following the Injector and Valve Adjustment Sequence Chart. Repeat the process to adjust all injectors and valves. ‘After adjusting all the injectors and valves, check the torque on the adjusting screw locknuts to make sure none were overlooked. It the valve cover gasket was not damaged, it can be used again. If the gasket was damaged, it must be discarded & and a new one used. Install the gasket on the cover. Install the cover on the rocker lever housing. ae Install the 16 isolators, spacers and capscrews inthe cover. \<\s7 Tighten the capscrews in the sequence shown. Torque Value: 15 Nem [130 in] 8 Water Pump Maintenance Check Every 1500 hours visually check the water pump body for

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