FORM PCD-22:: January, 1976 TING « MAINTENARICE MANUAL - | WITH SPARE PARTS LIST MODEL DXL75O0 INGLE STAGE, SCREW TYPE.AIR COMPRESSOR Ingersoll-Rand Company reserves the ri improvements with to make such chang previously. + Record the serial number of your unit here for ready reference lage so'}Pond Co, 1971 oa x0 m1 Ww v Page GENERAL DATA 5 ‘Typical General Data Decal 5 DESCRIPTION Twpieal Super Spiro- Flo Model XL Series Air Compressor 6 Cut: Away Top View of the Compressor General : 7 Air Flow 7 ‘Air and Oi] Flow Schematic 8 & 9 Operation 10 Operating Instructions 10 ‘Typical Operating Instruction n Decal LUBRICATION 12. Recommendations 12 General 13 Diagram of Typical Compressor Lubricating and Cooling Oil system 13 Compressor Lubricating and Cooling O11 14 Engine Lubricating Oil 4 SCHEDULED PREVENTIVE MAINTENANCE 13, Typical Preventive Mainten- ance Instruction Decal INDEN Section vi vit vi IX Page ADJUSTING PROCEDURES ‘Typical Speed and Pressure Regutator Adjusting Instruc- tion Decal TROUBLE SHOOTING General ‘Typical Unit Wiring Diagram ‘Trouble Shooting Chart 18 & OVERHAUL General Compressor Disassembly Compressor Keassembly Rotor Driven Gear Puller Plate Bearing Assembly Fixture SPAKE PARTS LIST General Introduction How To Use This Mustrated Paris Breakdown Recommended Spare Parts How To Order Parts List Table of Contents Parts List Drawings ” poasch) STS AND SPARF 16 16 7 Ww 17 19 20 20 27 ae PARTS POXES 191 oyGeneral Dats ‘ Page : ~ Figure 1-1. SECTION J GENERAL DATA FR] Ingersoll-Rand: GENERAL DATA 1m comPRESSOR moet OX1750 ‘CIOL DELIVERY OF COMPRESSOR 00.950 CEM'(21 2 MIND RATED OPERATING PRESSURE 125 PSIG (8.79 KG.CM DETRON DIESEL ALUSON WV. GENERAL MOTORS CORPORATION DIESEL ENGINE, SERIES 6V.71N sven MODEL 7063-7000 ENGINE SPEED AT FULL LOAD. teen 2100 RPI ENGINE SPEED AT NO LOAD 000 gem Eleeraicat StARING SYSTEM, 12 veut Bik CLEANER ‘BGNALDSON, FG crcloPAC Bim CLEANER PRIMARY ELEMENT ‘PART NO. 25109269 [OONALOSON REPLACEMENT PAR NO. Pi 7489), [IR CLEANER SAFETY ELEMENT PART NO. 25109271 [DONALDSON REPLACEMENT PART NO. PIi9372) at UBE OM FILER PUROLATOR, 25 MICRON (MAIN LUBE OM FLIER ELEMENT PAR NO. 35110827 [PUROLATOR REPLACEMENT PART NO Gé6d0671, BEARING LUBE Gl FILTER ‘PURGLATOR, 10 MICRON. BEARING LOBE OW FALTER ELEMENT PARTNO! 35107478 [PUROLATOR REPLACEMENT PART NO 637532) Compatssce LURE OM CAPACITY 35. US GANS (122.5 115s RECOMMENOED COMPRESSOR LUBRICANT USE A HEAVY-DUTY, DE TERGENT TYPE Olt CONFORMING 10 SPECIFICATION MILL-21086, GRADE SAE TOW FOR AN AMBIENT TEMPERATURE RANGE OF 125°F Yo 10°F (1.7°C 10-23 9°C) FOR AMBIENT TEMPERATURES BELOW Yorr ('21-3°€) AND ALIEBNATE TYPE COMPRESSOR LUBRICANTS ‘CONSULT COMPRESSOR OPERATING MANUAL. CAUTION: DO NOT MIX OS OF DIFFERENT TYPES OR BRANDS. ENGINE LUBE OM CAPACITY (INCLUDING O1L uve). 2001s. 19 915) ENGINE cOotaNT CaPaCitY T5is US cals (37 1S) Fun vanx cameirt ‘Sous cats 1363 118} USE NO "2-0 O1eSEL FFL Oil With MiNiiMUM CETANE NUMBER OF 45 PRIMATE RES BPSK:es 108t sauce Tet FRESSoRE Pies 27 eo ca) Uinctn ga Gan em) Hes 34 ‘a20 em wot 63 9) eM) Net Witch (INCLUDING ie il)" “9 028 uBs 4,094 KGS) GROSS WEIGHT [INCLUDING FUEL AND COOLANT) 9.967 185 14462 «GS aot musa By INGERSOLL RAND COMPANY PORTABLE COMPRESSOR DIVISION MocessiF xORDe CAROLINE 27028 Dace eteseereereCee ee eves eerrerereead /coecoarae nee BEES EEREECEe ‘Typical General Data Decal Found On UnitSECTION Tl DESCRIPTION E-1915-A Figure 2-2. Cut-Awav Top View of the Compressor Air EndAIR FLOW SYSTEM 33979039Lubrication Page 12 a SECTION IV € LUBRICATION Ma RECOMMENDATIONS i; Alternate lubricants should conform to the following specifications: 1 TABLE 4-1, LUBRICANT RECOMMENDATIONS A = epee 125°F (51, 79C) =10°F (-23. 3°C) -40°F (-40°C) AMBIENT TO TO TO TEMPERATURE | -10°F (-23.3°C) -40°F (-40°C) -65°F (-53. 9°C) 3 i iin 1-21048 ; 4 GRADE SAE 10W : | guages aE 4} COMPRESSOR | DEXRON® Automatic | DEXRON® Automatic | 3 LUBRICANT ‘Transmission Fluid | Transmission Fluid : Specification Specification Specification { MIL-L-23699B MIL-L-23699B, MIL-L-23699B, Synthetic Lubricant* | Synthetic Lubricant | Synthetic Lub \ f+ synthetic Jubricant conforming to Specification MIL-L-23699B is commonly known as JET I and is available world-wide. NOTE Replace the oil filter element every 1000 operating + hours or every twelve months, whichever comes rst. When using an oil conforming to Snecifica- tion MIL Bor DEXRAN@ a sorstie tra mission fluid drain and refill with new oit every hours or every twelve months, whichever comes first. When using @ synthetic lubricant conforming to Specification MIL- L-23699B it will only be necessary to change the lubricant every 3000 operating hours, or every two years, whichever comes first. However, the oil filter element MI stil] be changed every 1000 operating hours or every twelve months, whichever comes first. shorter oil ekange intervils may be necessary i * anit eneeated under averse coniltions. DEXRON® - Reg. T. M. of General Motors Corp.Labricat Page GENERAL Cwm compressor lubrication and cooling are accomplished by the compressor lubrica- ting oil. The oil is forced from the oil storage reservoir, under system pressure, to the ofl mi‘ cooler, The cooler is located at the radiator end of the unit in such a manner the engine fan Serves to cool both the engine jacket coolant and the compressor lubricating oil. When the *. compressor is operating at low capacity, some of the oil may by-pass the cooler through a y thermostatically controlled bypass valve. This valve by-passes varying amounts of oil, de- pending upon the temperature, until the oil being circulated reaches a temperature of 185°F (850C) thus maintaining a higher average oil temperature thereby reducing the possibility of | water vapor condensation in the oil. From the oil cooler, the oil goes directly to the main | oil filter, then to the compressor driven oil pump. Cooled oil is then pumped directly to the rotor bearings, gears, and in metered amounts directly into the rotor housing. All of the oil thus ‘troduced mixes with, and passes on with the air being compressed, thus removing t*~ heat of compression to a large degree. On its way to the final discharge connection the air passes through piping to the receiver-separator where the oil is removed from the air to col- lect in the oil storage reservoir. Primary separation of the oil takes place through a change in velocity and direction as the compressed air enter: parator, dropping out ° most of the oil from the air. Secondary separation takes place in the oil sepatator, which is located entirely within the receiver-separator. ‘Ihe vil separator consists of a series of + chambers packed with an oil diverting medium. the receiver: Any off accumulation in this secondary oi] separator is continu 6. scavenger line, which returi ly drained off by means the accumulated oil to the compressor. any OW FiureR on. cooLer ou TEMP ot evrass, ou stop contro. Oe e ou eweeK VALVE Figure 4-1. Diagram of Typical Compressor Lubricating and Cooling Oi) SvstenPare 1 GEMIPRESSOR LUBRICATING AND COOLING OIL, Normally these units are furnished with an initial supply of ofl sufficient to allow opera- tion of the unit for approximately 1000 hours; however, if a unit has been completely drained of all oil, the oil storage reservoir in the primary oil separator must be refilled with new oil before operating the uni When the ofl level gauge indicates low when the unit is shut down and is standing approxi~ mately level, or if the unit has been operated for 1000 hours (or 5000 hours, dependent upon the lubricant used), it should be completely drained of oil. If the unit has been operated under adverse conditions, or under long shutdown periods, an earlier change period may be neces- sary as bil deteriorates with time as well as by operating conditions. Complete replacement of the old oil with clean new oil every 500 to 1000 operating hours (or every twelve months, whichever comes first), depending upon operating conditions, is not only desirable, but is mst the accumulation of dirt, sludge, or oxidized oil products. sood insurance a: Completely drain the receiver-separator and the piping. After the nnit has been com- pletely drained of all old ofl, replace the drain plugs, making sure they are tight. If the oil is drained immediately after the unit has been run for some time, most of the sediment will he in suspension and, therefore, will drain more readily. @ Do not, under any circumstances, remove any ta drain plugs, or the off filler plug from the com- pressor lubricating and cooling oil system with- out first making sure the air receiver system has been completely relieved of all air pressure. Spee off mixtures are incompatible, and result nthe formation of varnishes, shellacs, or lae~ russ which may be insotuble. Such deposits sn cause serious troubles including clogging of the fier. Where possible, try to avoid mixing wnls of the same type but different brands. A brand change is best made at the time of a com- plete oil change. ENGINE LUBRICATING OIL Refer to engine operator's manual,SECTION \ SCHEDULED PREVE: Fa IVE MAINTENANCE Ingersoll-Rand. 1 PREVENTIVE MAINTENANCE 1. BIAIN CONDENSATE FROM RECEIVER SEPARATOR Daly. 2 CHECK COMPRESSOR OL LEVEL OAltY. “ADB OK ONLY WON “Low” maRK WHEN NOT RUNNING q 2 FLL FURL TANKS aT END OF WORKING DAY 10 PREVENT EONDINSATE DRAIN CONDINSATE aND SOREN EVERY Sx MONTHS 4 INSPECT ale citanta stavice GAUGE OF GAUGES, DAUtY SLAVICE craNts CLEMENT WHEN CAUoE shows ao ay FULL 'srttb, PRIMARY ELUMENT may BF CLEANED. OY WASHING GENTLY In WARM. DETERGENT SCLUTION arte ELEMENT TO DRY BELORE REPLACING 00 NOT BLOW ort ELEMENT WITH COMPRESSED AIR DO NOT AMEMMT IG qi CLEAN SAFETY FLEMENT. THIS SHOULD BE REPLACED. YeanLy BO NOT OM sLumeNTS 5. once Gite earTeRy nuecrRoLYTE LEVEL AND seecinIC GeaviTy WEERLY CEG TTEMINALS CLEAN AND Liowtur oxiaee 7 WUBRICATE ALOULAION LiNnAGES WeERiy 7 4 ALE EXTERIOR OF BADIAIOR AND OM COOLER CLEAN OF > ACCUMULATED Ol, Die! ano “CatAce 5 CHANGE COMPRESSOR LUBE OIL EVERY 1000 HOURS OF MORE FREDUINTLY IF OPERATING UNIT UNDIE auvEasE e ats ‘ 10. SEVICE CoMPAESSOH ON FILIERS AT EVERY On CHANGE DRAIN AND CLEAN SUMPS OF ACCUMULATED SiUDEE ee DISCARD ELEMENTS, INSPECT SUMPS AND ELEMENTS. fo EVIDENCE OF LACQUER FORMATION. “REMACE MLEMENTS With NEw ELEMENTS. NOTE. ON NEW On OvEENAUNED UNITS, REPLACE ELEMENTS AFTER FRET SO AND sso Moone THEREAFTER AT Excne OW ChaNGe 4 CAUTION. EVIDENCE OF LaCoUEE AVION 1S A WARNING | THE ACBE OW HAS MFAOFER CHAPACTERISIES AND ahroUNS 4 t : | "Bi Sa eres ce an | 12. REMOVE AND CLEAN ON UNE SeREEN AND ORIFICE WW SCAVENGED Lint EVERY t000 HOURS 13, APPLY GREASE 10 FUNNING GEAR LUBE FiTIINGS AND 10 SUP END OF speincs tvEay six MONTANE, MCLEAN. INSPECT AND REFACE WHEEL BLARINGS EVERY a 15. MAINTAIN ENGINE PEE ENGINE OPERATOR'S ManUAL Figure 5-1. Typical Preventive Maintenange Instruction Decal Found On Unit LASERS ea eo ORY ROR RRC EE PRED SHOTAdjusting Procedures Page 16 SECTION VI © ADJUSTING pRoceDURES FR] Ingersoll-Rand, SPEED AND PRESSURE REGULATOR ADJUSTING INSTRUCTIONS Cage KS J] eS on Paner a) it~ spe NORMALLY REGULATION REQUIRES NO ADJUSIING, UT if PROPER ADJUSIMEN! 15 LOST, PROCEED AS FOLLOWS 1. Wit UNIT storeeo ADJUST LENGTH OF BUTTERFLY VALVE LINK OD (A) SO THar Line ScRiRED ON BUTTERFLY VALVE SHATT() 15 60° ABOVE THE HORIZONTAL ADJUST LENGTH OF ENGINE THROTTLE Link ROD fe) $0 THAT LEVER (0) Is FiRaty AGAINST stOP Ie) SUARY UNIT. ADJUSI_ SERVICE VALVE AND ADJUSTING RNOB ON INSTRUMENT PANEL BFGULATOR IF) SO tat LEVER (D1 18 Furmiy AGAINST SIOP il AND DISchAROE PRESSURE GAUGI SHOWS 100 P5:G(7:02 KG/EM"| AOIUST KINGTK OF tngine THROTILE tink ROD. Ic) 10 HOLD HED AT 100 PSIG (7.03 KC VOM) 5 RAGE OFF ADJUSTING KNOB ON INSTRUMENT PANEL REGULATOR (1) sO That dtvER Jo} Just starts TO movt AWAY FROM STO 1) with PRESSURE HELD AT 100 POO (703 coven") CLOSE SERVICE VALVE COMPLETELY. BACK OFF ENGINE SLOW SPEED STOP scaew TO. INSURE THAT sUTTERFLY VALVE Is COMPLETELY COstD. AoJUsT LENGTH OF BUITIEe FLY VALVE Unk ROD IA) SO that FNGINE IDLES AT 1000 JO StECT ANY PRESSURE BETWEEN 60 AND 125 PSIG (5.62 10 879 KG/cm) CHANGE ADJUSTMENT OF FRESSURE ADJUSTING. KNOB ON INSTHUMENT PANEL BICULATOR 1 OBTAIN IME DESIRED DISCHARGE PRESSURE AI FULL SHED L0cw ADJUSTING ‘KNOB Figure 6-1. 1 Speed and Pressure Keguls sp Instruction Decal Found On Vita Trouble Shooting P Page SECTION VII e TROUBLE SHOOTING GENERAL i This section contains a trouble shooting chart, Table 7-1, which will aid and guide the i operating personnal by indicating possible troubles that may occur in the operation of your : unit. Trouble shooting for the diesel engine is not given in this instruction book. Refer to your engine Operator's Manual covering trouble shooting. The trouble shooting chart lists the probable causes of the troubles that may occur and the necessary remedies for correcting the troubles, and are listed in the chart in the order in which they are most apt to occur. i < The necessary remedies include servicing, adjusting or repair, and replacement of the components causing trouble. NOTE; F Please refer to the following pages for Table 7-1. 2 i = cana rizvaemeens| d5cNp ‘Mee eed Wome Figure 7-1. ‘Typical Unit Wiring Diagram 5rouble Shooting age 18‘Trouble Shootin; | INO: 2) ONTLOOHS PIUOOUWL ‘toe wTEvs.Overhaul Page 20 SECTION VI OVERHAUL GENERAL In addition to preventive maintenance, some components will require overhauling to maintain maximum output and performance of the unit, This book contains instructions for overhauling the compressor. These in~ structions cover disassembly and reassembly of the air end assembly. A complete over- haul of the air end assembly is recommended every 10,000 hours of service or every five years. 7 NOTE When the cost of labor to re~ move an air end, overhaul it and replace it in the unit is considered, the cost of bear- ings and shaft seal is but a small part of the total cost. Accordingly, it is suggested that whenever an air end is disassembled, for whatever reason, all the bearings and the shaft seal should be re- placed even though the old bearings do not appear to be Never strike or otherwise im- pact any part of any bearing, This can cause damage which may not be visible but which wil) eventually lead to the fail- ure of the bearing. some figures stamped on the intake flange over the center line of each rotor. Refer to Figure 1. These figures are the intake end clearances for each rotor in thousandths of an inch when the air end was first assembled. For ex- ample, "17" means a clearance of 0.017 inch, If an air end is to be dismantled and rebuilt it will be necessary to remoxsure the intake end clearances of each rotor and restamp these figures after the old figures nuve cen obliterated. COMPRESSOR DISASSEMBLY With the air end assembly removed from the unit and placed on a clean, heavy-duty work stand, disassembly of the compressor should be performed as follows: On newer air ends (those manu- : factured after January, 1971), 1. after the intake valve ig removed + ling. from the air end, you will notice NOTE First, remove the compressor coup- 4s Remove the three cap screws in the tapered hub in the center of the coupling.Her to Figure 2, Using two 3/8" - 16 x 4} p screws in the threaded holes in the hub, ick off the coupling. Refer to Figure 3, tub and the coupling can now be re- moved by hand. Refer to Figure 4, Re- gy cowie and drive shaft keys. ji There is a set screw in the flange ‘the tapered hub which will become ex- }sed after the coupling has been jacked This set screw must be backed off Pore the hub can be removed. Overhau! Page 21 Refer to Figure 5, 2, Remove the cap screws attaching the oil seal cover to the gear case; then, re~ move the cover and the ofl seal cover gasket, discarding the gasket. Refer to Figure 6. The stationary seal ring of the rotary-shaft- type oil seal will probably come off with the cover. Remove the seal ring from the cover and the balance of the oil seal parts off the drive shaft. Use extreme caution when Figure 5Overhaul Page 22 Figure 6 handling the oil seal parts to prevent dam- age to the sealing surfaces. 3. Remove the compressor gear case mmbly from the rotor housing. ‘This ‘Gan be done by first attaching a rope or chain sling to the gear case; then, remov- ing two opposite gear case to rotor housing attaching cap screws; and replacing these cap screws with studs, or headless bolts, approximately four to five inches (101.6 to 127.0 mm) long. These Hong studs, or head- Jess bolts, muy then act as guides » arating the gear case assembly from th housing. Remove the balance o! cap screws, The gear case assembly may now be jacked loose from the rotor hou by means of the two 3"- 13 threaded jack screw holes found in the gear case to rotor housing flange. The assembly may then be lifted off and out of the rotor housing. Refer to Figure 7. Remove and discard the gear case gasket, 4. Remove the allen head cap screws attaching the bearing retiaing plate to the e case. This can be cune by the use of Wfocket wrench and an extension through the access holes provided in the drive gear. Figure 7 Refer to Figure 8. The drive shaft and ball bearing assembly may now be pressed out of the gear case, Refer to Figure 9. 5. Remove the bearing lock nut. Place the drive shaft and ball bearing assemb!y ip § apress, with suitable blocking under the drive gear. By applying pressure on the coupling end of the drive shaft, the shaft cen be pressed out of the drive gear and the ball bearing. Remove the drive gear key. | i] sugerntenoemsitens Nem wipers move the eternal retaining ring from Grive suaft, Place the drive shaft and voller bearing inner race assembly in a press, with suitable blocking under the Leur'ng ‘nner race; then, press the inner race vif th svaft. 7. Place the rotor housing and rear hear- ing housing assembly in a vertical position that the rear bearing housing may be reilily removed, Remove the male rotor bearing $f i 4 6. Using the proper tool, carefully re~ | retainer cover by first removing the attech~ Ing cap screws; then, using jack screws in the holes provided, remove it, Refer to Figure 10. Remove and discard the henriag retainer cover to rear bearing housing '0” ring and any shims that may have been usoOvervent Figure 10 sa assembling the retainer cover to the rear "O" ring and any shims that may have been * bearing housing. uscd in asscmbling the oil pump to the rear beating housing. “8 Remove the complete oil pump from yar bearing housing. ‘This can be done 8, Disassemble the oil pump and inspect sist romoving the eight }""- 13 cap screws; the pump for worn parts. Depending on the ‘thes, using jack screws in the holes provided, extent of wear, either rebuild the pump or Uning the ofl pump clear of the bearing hous- replace it with a complete new pump. jug. Refer to Figure 11 and 12. Remove and discard the oil pump body to bearing housing 10. Remove the place bolts from the PRL meres- Overhaul sPage 24 male rotor driven gear retaining plate. Re~ move the rotor driven gear, and the key from the male rotor. CAUTION To assure that tooth hardness of the rotor driven gear will not be destroyed, do not use a flame- type torch to apply heat to the gear to assist in its removal. Figure 14 Use a gear puller plate and @ hydraulic ram to remove the gear. Refer to Figure 18. (NOTE: = The driven gear is pro- vided with three 1/2" ~ 13 tapped holes for this purpose. Refer to end of this section for # drawing on fabrication of a puller plate). 11. Remove the rear bearing housing assembly from the rotor housing. ‘This can Figure 15by first attaching cye bolts to two of > 13 tapped holes in the rear of the ig housing. Remove two opposite bear- using to rotor housing attaching cap s; then, replace these cap screws with ‘eet bolts, approximately four fe inches (101.6 to 127.0 mm) long. Jong studs, or headless bolts may as guides when separating the bear- sing from the rotor housing. Remove Elance of the attaching cap screws. The Ms housing may now be jacked loose the rotor housing, by means of the two 10 threaded jack screw holes found in ying housing to rotor housing Mange. fo Figure 14, With the aid of a hoist, bearing housing assembly only about ches, end is being done for inspec~ purposes only, lift the rear ring housing enough so that the rs are completely out of the lor housing. Inspection of the ) then be accomplished Cisturbing the disehia ge bearing adjustments, Overhaul Figure 17 To further disassemble the compressor air end assembly, first work some sort of material, such as rags, through the air in- take port of the rector housing into the rotor housing cylinder bores. ‘This must be done to absorb the shock of the rotors as they are pushed down out of the rear bearing housing into the rotor housing cylinder bores. Place wooden blocks, approximately 4" thick, on the flange of the rotor housing; then, lower the rear bearing housing assembly onto the blocks. 12, Remove the piace holts from the two bearing ~ iy plates, Remove she retaining pletos, Press the male and f rotors out of the rear bearing housing a hydraulic sam. Refer io Figure 18. os Soon as the inner raves of the bearings ive been cleared by the rotor shatts, the rotors will drop into the rotor housing cylinder bores, 13. Remove the rear bearing housing, Refer to Figure 16. {move and discard the rear beaging hea.s: rotor housing gasket, Top the thru » out of the rear bear- ing hoasing >" diameter drift through ihe thas e provided around the cuter race of each bearing. Refer to Figure 17.Overhaul Figure 18 14, Remove the rotors from the rotor housing. This can be done by first attacling an eye bolt to one of the 3" - 13 tapped holes in the end of the rotor shaft. Each rotor may en be lifted out of the rotor housing. Refer ‘igure 18. The inner races of the front roller bearings will remain with the rotors as they are removed from the rotor housing. Using the proper tool, remove the external retaining ring from the shaft of the female rotor; then, remove the roller bearing inner races from 1 ¢ hofts, Remove and ach rotor. vper tools, remove the ing internal retaining the rotor housing. Refer to Fig~ hemove the outer race of the drive shaft roller bearing, the spacer ring, refer to Figure 20, and the outer rages of the te rotor front roller bearings from the ro‘r housing, using a bearing puller, if n Figure 21‘Thoroughly clean all parts, using a non- Hamable safety solvent. Pay particular at- tation to the cleaning of the bearings so they ay be thoroughly inspected. Inspect the ings for wear, scoring or damage. In- pect the rotors and roller bearing inner races tor wear or damage. Inspect the rear bearing wasing face for scoring or damage. POMPRESSOR REASSEMBLY The procedure to be followed in reasgem- ig the compressor air end is essentially he reverse of the step-by-step procedure ously outlined under "COMPRFSSOR DEASSEMBLY". The following procedures ill result in obtaining proper clearances, 1, Make sure that all pipe plugs that pay have been removed from the rotor hous- placed and properly tightened, NOTE When reassembling the com- pressor air end make sure to Figure 22 use all new gaskets and "0" rings. Before assembling the "O" rings, always make sure they are thoroughly lub- ricated, using an automotive, wheel bearing grease. Re- placement sets of gaskets and "O" rings may be ordered from your nearest, Ingersoll-Rand It Company Construction and Min- ing Sales Office by part number. 1 Refer to the parts list covering 4 your specific unit for the cor- sect part number of the gasket ? O" ring set and the contents 2. Th aw ings ‘ow any indication of js wear, ui damage, they should be replaced { using complete new sei i i ] 3. Clean rotor housing, making sure there are no burrs, nicks or dirt particles which will give false clearance readings — this step is important, failure to observe it Can lead to Joss of the air end. Refer to Figure 22. Figure 29overhaul t age 28 ate 5 1 Install the'three roller bearings (with of female rotor shaft. MB respective Spacer and snap rings) in the intake end of the rotor housing. 8. Fit each rotor in its respective bore: in the rotor housing. ig 5. Hold the rotor housing in a stand with be ‘the rotor bores vertical and the intake end 9. Fit rear bearing housing gasket to Kiown, flange of rotor housing. iy yl 6. Clean both rotors, making sure there 10, Lay a straight edge across the rotor} ere no burrs, nicks or dirt particles which housing flange with the gasket in place and H Fr will give false clearance readings. Pay par- measure the total rotor to rotor housing end Hl cular attention to the end faces of each rotor clearance with fecler gauges. De this for j 4H —— this is important, cach rotor separately. Refer to Figure 24. iH It should be 0.018 to 0,024 inch, Note these | ff 7, Fit roller bearing inner races fo in- readings as shown in the example calculation } lake end of each rotor. Refer to Figure 23, on Table I. if eat bearing races in oil to 250°F for at least al '30 minutes to facilitate installation — do not 11. Make sure face of rear bearing hous- jf Se a hot plate; lo not use a flame; do not heat ing is free of } above 275°F, Install snap ring to intake end is important. i 5 i 4 TABLE! i] TYPICAL EXAMPLE OF AIR END CLEARANCE READINGS a Hi STEP NO, STEPS TO BE TAKEN | MALE Femate |, *y — i 10. Total End Clearance 0,022 0,019 | 1 a2, ‘Thickness of Rear Bearing Housing "A" 1,249 ee 13. Height of Rotor Spacer " 1,247 1245 4. Subtract “B" From * | a.ooe ft Eee i | | 4 | 4 TF ! | : : 4. Shims Required oo nove i | 23. Discharge End Clearance As M fot Ky After Assembly "C" 6.002 oo | 24, Intake End Clearance As Measured *Ier i,t Assembly "D! 0.019 0,025 | 25. Add "C" and “D", This Must Be Wit)ir ew 0,002 Of Tota! End Clearance Loge: In Step No. 10, : 0.021 0.018 } 5Figure 24 12, Measure the thickness of the bear- ng ouler race seat, is is dimension "A" Lio this for exch ro'ur. Note these measure- es shown, (Us a] ‘h micrometer re dimension "A' 13, Measure the height of the rotor bear- ofthe rotor lobes. Refer to Figure 26. sis dimension "B", This dimension "B" important. Use a depth micrometer to meas- ure dimension "B". Do this for each rotor and note these measurements as shown, 14, Perform arithmetic shown in example calculation to determine thickness of shim required for each rotor. 15, Install shims on each rotor shaft, Figure 27Overhaul Page 30 Figure 28 16. Install rear bearing housing (don't forget the gasket) and torque the bolts to 270 Ibs. ft. Refer to Table TT. 17, Install thrust bearings to each rotor » 10 face" (this means with the large S of the inner races together in the middle of the bearing pack). Refer to Fig~ ure 27. Do not install other way. Refer to Figure 28, WARNING: - Do not, under any circumstance ke or impact in any Figure 29 way the angular contact thist bearings, Se will lead to carly failure. lie ram with a fig specially made for this job on this er to Figure 29, doin Use a aydrau- 18, Install bearing retainer plates and re- Jerring to Table Il, torque place bolts (use new bolts each time unit is assembled) to 150 Ihs. ft. Refer to Figure 30, 19. Install bearing cover and oil pring ee ne at cnnFigure 32 with their "O" rings, Refer to Figure 31. y Refer to Table II and torque bolts to 75 Ibs. fh 20, Using a feeler gauge, make sure g is a gap between the oil pump and the BS: housing and between the bearing cover and the housing. Refer to Figure 32. This gap must be present to insure the bear- ings are pulled down tight in the housing. Older machines may have shims at this point. These shims should be discarded and should not be replaced. 21, The bufld up is now complete, |, Cheek the work as follows. 22. With a feeler gauge measure the discharge end clearance of each lobe of each f rotor. Refer to Figure 33. This can be done through the discharge port. This is dimen- sion "C". This dimension, as measured, must be within 0.001 inch of the discharge elearance tried for in the calculation done in Step 14. (It will usually be about 0. 001 } inch less than calculated due to metal de- formation when the covers are torqued down), . Thy Scharge clearance must be between 0. Band 0.004 inch. iit is not, vo back to Step 3 and start again, 23, With a feeler gauge through the air intake port, measure the intake end clearance of each lobe of each rotor. Refer to Figure 84. This is dimension "D". 24. Add dimension Cand "D", This sum should be with 0.002 inch of the total en: clearance measured in Step 10, If it is not. go back to Step 3 and start again. 25, This « end less the npletes assembly of the sir 26. With the rotor housing | ide, or inverted with the ran its pu own, inspect the male rotor drive shst veto make sure it is smooth and iree oi ia Install the driven gear key in the shaft kes- way and install the gear on the shaft, This can be done by first hesting the gear in oil to approximately 250°F, holding the tempe tre for at least one hour to make sure the gear is uniformly heated. Do not, under any circumstances, attempt to heat the gear with 2 flathe-type torch. It is alse recommended when installing the driven geur, to use scme type of anti Sve compound on the rotor giv ft\pverhaul Page 32 Figure 34 to aid in future disassembly. Re-install the Griven gear retaining plate. Tighten the re~ taining plate place bolts to the proper torque, as indicated in Table TI. 27. Install the drive shaft roller bear- BBinner race on the drive shatt. Careful warming of the inner race, to approximate- ly 250°F in oil will aid in the inner race be- ing easily assembled to the drive shaft, In- stall the external retaining ring on the drive shaft. Inspect the drive gear keyway on the drive shaft to make sure it is smooth and free of burrs. Also, inspect the keyway in the drive gear to make sure it is smooth and free of burrs, Install the drive gear key in the hes way of the drive shaft and in- stall the gear on the shaft. This ean be done by first heating the gear in a container of oi to approximately 250°F, holding the tempers- ture for at least one hour to make sure the ybeated. Do not, under any circumstances, attempt to heat the gear with a flame-type torch. It is also recommended, when installing the drive gear, to use some type of anti-seize compound on the drive shaft to aid in future disassembly. The ive gear must be installed tight up against Si bearing inner race. Check that gear is unifo: Figure 25 there is no gap by trying to get a feeler gauge Letween the gear and t ring inner race. If the gear is not completely “home on the shait, draw it off, reheat it and start over. Do not strike or impact the gear in any wav. This will transfer shock to the rear rotor bearings and damage them leading to early failure. Install the drive shaft ball bearing ‘retaining plate on the drive shaft; then, in- stall the ball bearing on the drive shaft, hest- ing the bearing to 250°F in oil before as: bling it on the shaft. Install the ball bearing lock nut on the drive shaft, NOTE. Do not forget to instali 1! 2 ing retuiner plate before +-- in the ball bearing, 28. Make sure that all pipe plugs that may have heen removed irom the gear vase are replaved and properly tightened. Set the gear case oa a clean workbench so that the gear case 1¢ engine bell housing is down, ssp port the giar case with wooden blocks, high engugb to nermit reinstallation of the drive shaft assercbl\. Install the drive shaft a. making sure the sembly |Figure 36 ball Learing is properly seated in the gear ease, Attach the Learing retaining plate to |; He gear case by means of the attaching al- ~ len head cap screws, tightening the cap screws to the proper torque as indicated in I. This ean be done only by the use , PM extension socket wrench and working: through the access holes provided in the drive gear. s,s 29, Turn the gear case over, making sure the gear case to rotor housing flange properly blocked. Carefully install a } uw ofl seal on the drive shaft. Using a ow oll seal cover yasket, install the oil y. seal cover on the gear ease, making sure je stationary seal ring of the oil seal is -- wroperly seated in the cover. Tighten the aver attaching cap screws, opposite from - each other, evenly and to the proper torque {2s indicated in Table Tl. 30. With the aid of a rope or chain ing, install the gear case assembly to the ror housing assembly using a new gear ‘ese gasket, ‘The use of two studs, or head- less bolts, epproximately four to five inches to 127.0 mm} long, opposite trom apped holes of the rotor hous the gear case assembly to the rotor housing assembly. Refer to Figure 35, Make sure the attaching cap screws and nuts, opposite from each other, are evenly tightened to the Proper torque. Refer to Table IL. 31. Install compressor coupling in re- verse of the method used to remove it. Ms sure the face of the tapered hub is flush with the end of the drive shaft. Refer to Figure 36. e 32, Making sure the reassembled com- pressor air end assembly is securely blocked in a horizontal position, rotate the rotors by means of the compressor coupting to check for proper reassersbly of the in end. NOTE: On a new replaceient compe air end as- sembly or on an overhaul of an air end where new rotors or 2 new housing has been install- ed, the'rotors may bind in the rotor housing. ‘There is nothing wrong if the rotors can be turned with a little effort, even though the seal strips on the rotor lobes are rubbing the housing. One of the purposes of the seal strips is to permit the air end to wear in, and to operate with the minimum possible radial clearance. Once an air end has operated for three or four hours, the rotors should turn very freely with little or no effort. After ro anbly, {7 is « ant to rick moly impor re itis the seo) {rips that are saysion the rotors to ii.re herd unt not semet’ 1 which could dense the air end wer vat is operated, Never strike or otherwise im- pact any part ring. This ean case diinage which may not be visihle but will eventually ead 10 the failure of he hearin ing Will aid in the reassembly of i I ; 1‘Overhaul Page 24 TABLE I TORQUE SPECIFICATIONS FOR AIR END, HEAT TREATED CAP SCREWS (Based On Clean, Dry Threads) CAP SCREW SIZE LBS. FT. 5/16" = 18 UNC-24 17 3/8" = 16 UNC-2A 31 7/16" - 14 UNC-2A 49 1/2" = 13 UNC-2A % 3/8" = 11 UNC-2A 150 3/4" = 10 UNC-2A 270 (Tolerance: + 10%)qu B1y7d 837d v39 WAAL YoLONSpare Parts List Page 37 a —— SECTION Ix . SPARE PARTS LIST This section, which cont: ins an illustrated parts breakdown, 5. Mlocating these parts which may be required in the maintenance of the unit. All of the com- fhe origigat yy sted i? the parts breakdown, are manufactured with the same precision as pie original equipment. For the greatest protection alware insist on genuine Ingersoll-Rand ee Parts for your compressor. » bas been prepared as an aid Ingersoll-Rand Company service facilities ‘Ingersoll-Rand Company Construction and Mini caled in the principal cities ot t {the Canadian Ingersoll-Rand Co and parts are available worldwide, There are ing Sales Offices and authorized distributors lo~ he United States. In Canada our customers are serviced by Meee camited. There are aiso Ingersoll-Rand Company sub- py sidiaries and authorized distributors located in the Principal cities throughout the free world, A list of sales offices w vill be found in the back of this publivation, Ail parts orders pertaining to your engine should he referred to Manufacturer's suthorized distr vour particular engine ‘ibutor or dealer, ByrRODUCTION « iustrated parts breakdown illustrates and lists the various assemblies, sub- a0 ‘tlies and detailed parts which make up this particular air compressor. This includes fe standard unit along with all of the options that are available, A series of illustrations F stow each part clearly and in its correct location relative to the other parts in the illustra- Sou. ‘The part number, the deseription of the part, the quantity of parts required, and the Fpart umber of the newt lgher assembly in which a particular part is used is shown on each Austration, The quantities specified are the number at parte pad per one assembly and are raat necessarily the total mum! er of cre no »uantity is specs arts used in the overall Pied the quantity is assumed in be one. f _tith description of a part is based upon the “noun first meen OF item name is always the first part of the descript assembly or sub-assembly, the abbreviations “assy” on Mthe previous conditions do not exist, the noun fer. The descriptive modifier mav be followed flower, inner, outer, front, eam, method, ice. the identifying ‘on. In the event the item 12 an Subassy" follows the noun name, name is followed by a single descriptive sci by words or abbreviations such as upper, rear, RH, LH, etc. when they are required to modify the part In referring to the rear, the front or to either side of the wnt feoeiver-separator as the rear of the unit, reesiver-separator, will det » always consider the Standing at the rvs: of the unit facing the ermine the right and left sides,Spare Par Page 36 HOW TO USE THIS ILLUSTRATED PARTS BREAKDOWN ay, ». Tura to the proper illustration as designated in the Parts List Table of Contents, ©: Tecate the desired part on the illustration by visual identification, RECOMMENDED SPARE PARTS Speéial selections of spare parts have been prepared a insurance against prolonged shutdown periods. These selected parts, called gasket sets and spare parts boxes, are 4 shown iemized in the rea “this publeston, "The contents of eek ga oe ey cn 4 parts box has been carefully selected so as to provide maximum protection for a unit aveh 4 are alum number of parts. Each itemized part in the gasket sets and spare parts botes are also identified in the parts list iMustrations, ‘These selected parts are identified with a Symbol designating the specific gasket set or spare parts box in which the part 1a supplied. is important to note the system of identifving those parts which are included with a tf Sef or kit of parts. The included part, or parts, is denoted by being indented from the pre- vious iteins as indicated in the level column, i.e., level 2 iteins are included with the pre- { vious level 3 item with level 2 items being included with “he previous level 2 items. Wren *: Lr Kit js ordered that bas indented level of parts following the set, the indented parts 7 alas included with that set. The quantities indicated are, in the case of level 2 items, { ite total quentity supplied in each spare parts box. The indented component parts listed as: level 2 or level 3 stems are the quantity required for a single level 1 item. ‘The quantities Specified in level 2 or level 3 items therefore, are not necessarily the total supplied ina spare parts box. HOW TO ORDER I Tae satisfactory ordering of juris by 9 perch tly dependent upon the > ex | use of all available information. by supplying vour neacest Ingersell- Rand Coa sax Cen i } straction and Mining Sales tice, or authorize drstrcbutor, with complete inf m, ou i MAT enable them to Bll your order vorreetly and 4a a\zid any unnecessary delays. i stave | thet ail avoidable errors may be eliminated, the following instructions are often on to the purchaser when ordering replacement parts a Always specify the mode! number of the unit as shown on the general data decal attached to the unit. b. Always speeify the serial risnher of the unit, 41'S IS IMPORTANT. ‘The serial : Dumber of the unit will be frand stomped on a plate attached to the unit, (The ae serial number of the unit i. oso p wntly siss.ped in the metal of the frame : side rail}, : > €. Always specify the form nomber of this pitdication. Oede Always specify the quantity as well as the deseri tion of the part, or parts, stration. exactly as it is given on the parts list 1] ic’ In the event parts are being fy tion and Mining Sales Office, important to include the serial rong Red te Sour nearest Ingersoll-Rand Company Construe- Pearle itorized distributor, for Inspection or repair, it te I number of the unit from which the parte were removed,Spare Parts List ol Page 40 i 3 PARTS LIST 7 : TABLE OF CONTENTS a FIGURE NO, TITLE DRAWING NO, PAGE NO. i at ts) Frame and Lifting Bail Front Axle, Hub and Drawhar Assembly 42 : Rear Axle, Hub and Wheel Assembly 85794601 43 Air End Complete with Regulator Linkage end utterly Valve 39795038 44 Bare Air Eni! Assembly 45 Air End Subassembly 46 ; Oi! Pump Complete 39794874 a7 iy Engine and Mounting, 35795277 48 i Fuel Tanks Complete 35795301 49 4 Engine Line Tubing 50 Radiator, Oil Cooler and Fan Housing 51 Radiator Assembly 52 : Battery and Mounting 38 Electrical Wiring 54 i Sneed and Pressure Regulator Complete 55 i} Oil Separator Complete 56 Discharge Piping 38795187 BT Sofety Valve Piping 35795194 58 Minimum Pressure Valve Complete 49794478 59 Oil Shutoff Valve Complete 95794429 60 Oil Temperature Bypass Valve Complete 35795095 Instrument snd Control Panel Supports 35795129 Instrument Panel and Control Panel 35795053 Compressor Lvaring Oil Filter Complete 35794404 Main Oi] Filter Complete 5795061 Air Line ‘Tubing 046 Oi} Tine Tubing, Sheet 1 Gil Line Tubing, Sheet 2 Starting Aid Kit Complete Air Intake System Engine Exhaust S Front Housing Rear Housing Fender, Right Hand Fender, Left Hand Housing Side Cover Housing Top Cover 7 | Housing Side Angle, Left Hand z 78 Mentification Plates 79 i Optional Egalpment, Parfex and Young Cooler 80pqS06S08 owe on nis 689015 SEvIISE {a ttubsing Is ON mows Ne artsaise CIenIs Ase Hub and pra Front90290186 on su. 2631409 Tp EG anBnassy 31Ky yy3 12S ¥I9E wi GON ONL Rear Axle,Seiazm sould eet! 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