Ingersoll-Rand XHP700WCAT Operation & Maintenance Manual
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Ingersoll-Rand XHP700WCAT Operation & Maintenance Manual

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Operation & Maintenance Manual
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
Book 22560825 (2/05)
Revised (09-12)
Compressor Models
XHP700WCAT
MHP825WCAT VHP750WCAT
SHP750WCAT
CODE:
CODE: B
CODE: D
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.

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Summary of Contents for Ingersoll-Rand XHP700WCAT

  • Page 1 This manual must be available to the personnel who operate and maintain this machine. Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative P.O.
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE FOREWORD ............5 Foreword.
  • Page 4 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE OPERATING INSTRUCTIONS ..........37 Operating Instructions .
  • Page 5 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE Reassembly ..............67 Ventilation .
  • Page 6 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE PARTS ORDERING ........... . . 101 Parts Ordering .

  • Page 7: Foreword

    Foreword...

  • Page 8: Foreword

    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.
  • Page 9 Foreword Operation & Maintenance Manual This machine has been designed and supplied for use only in the following specified conditions and applications: • Compression of normal ambient air containing no known or detectable additional gases, vapours or particles. • Operation within the ambient temperature range specified in the GENERAL INFORMATION section of this manual.
  • Page 10 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 11: Warranty

    Warranty...

  • Page 12: Warranty

    Oil-Free airends are fee-based and may require a maintenance agreement. Formal enrollment is required. Ingersoll-Rand will provide a new part or repaired part, at its election, in place of any part, which is found upon its inspection to be defective in material and workmanship during the period prescribed above.

  • Page 13: General Warranty Information

    Warranty Operation & Maintenance Manual General Warranty Information COMMENTS PORTABLE COMPRESSOR PACKAGE 12 MONTHS/2000 COVERS CONTROLS, HOURS SWITCHES, SHEET METAL, RADIATOR, OIL COOLER, RECEIVER, PIPEWORK, ELECTRICAL CIRCUIT ETC. AIREND 24 MONTHS/4,000 60 MONTHS/10,000 HOURS. HOURS EXTENDED LIMITED WARRANTY AVAILABLE ON MAJOR COMPONENTS.
  • Page 14 UNLIMITED MAJOR COMPONENTS COVERED. FURTHER EXTENDED WARRANTY ON MAJOR COMPONENTS PROVIDED VIA ENGINE SUPPLIER’S OWN APPROVED NETWORK AT TIME OF PURCHASE. INGERSOLL-RAND 4,000 EXTENDED WARRANTY OF 60 MONTHS/10,000 HRS. WHEN USING GENUINE INGERSOLL–RAND FLUIDS AND PARTS ON MAJOR COMPONENTS. KUBOTA (North America only)
  • Page 15 Warranty Operation & Maintenance Manual (Western Europe & Oceania) 2,000 NO EXTENDED WARRANTY AVAILABLE. (Central & South America, Asia, Middle 1,000 NO EXTENDED WARRANTY East & Africa) AVAILABLE. MITSUBISHI 2,000 2 YRS/4,000 HRS USING IR FLUIDS AND FILTERS VOLVO 2,000 2 YRS/4,000 HRS USING IR FLUIDS AND FILTERS PARTS...

  • Page 16: Warranty Registration

    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.
  • Page 17 The warranty and limitation of liability has been reviewed and understood by the owner/user. In the event that this unit is to be used within a nuclear facility, the owner/user shall notify Ingersoll-Rand of such use so that Ingersoll-Rand may arrange for appropriate nuclear liability protection from the owner-licensee of the facility.
  • Page 18 Operation & Maintenance Manual Warranty...

  • Page 19: Noise Emission

    Noise Emission...

  • Page 20: Noise Emission Control Maintenance Log

    Operation & Maintenance Manual Noise Emission Noise Emission Control Maintenance Log COMPRESSOR MODEL_________________________ SERIAL NO. __________________________________ USER UNIT NO. _______________________________ UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Engine Make & Model:_________________ Serial No.:__________________________ __________________________________ Purchaser or Owner:__________________ __________________________________ Address: ___________________________ Date Purchased:_____________________ The Noise Control Act of 1972 (86 Stat.

  • Page 21: Introduction

    Noise Emission Operation & Maintenance Manual Introduction The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air Compressors. The purpose of this book is to provide (1) the Maintenance Performance Schedule for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when.

  • Page 22: Fasteners

    Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer. J. Fuels and Lubricants Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand Company and Engine Manufacturer’s Operator and Maintenance Manuals.
  • Page 23 Noise Emission Operation & Maintenance Manual MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK OR HOURMETER MAINT/ LOCATION WORK DONE COMMENTS READING INSPECT DATE CITY/STATE BY (NAME)
  • Page 24 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 25: Safety Symbols

    Safety Symbols...

  • Page 26: Safety Symbols

    Operation & Maintenance Manual Safety Symbols Safety Symbols Look for these signs on machines manufactured in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor.
  • Page 27 Safety Symbols Operation & Maintenance Manual...
  • Page 28 Operation & Maintenance Manual Safety Symbols...
  • Page 29 Safety Symbols Operation & Maintenance Manual...

  • Page 30: Safety

    Operation & Maintenance Manual Safety Symbols Safety Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel. General Information All air pressure equipment installed in or connected to the machine must have safe Ensure that the operator reads and working pressure ratings of at least the understands the decals and consults the...

  • Page 31: Battery

    Safety Symbols Operation & Maintenance Manual Avoid Inhalation and that connections are secure. Ensure that adequate ventilation of the DO NOT ATTEMPT TO SLAVE START A cooling system and exhaust gases is FROZEN BATTERY SINCE THIS MAY maintained at all times. CAUSE IT TO EXPLODE.
  • Page 32 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 33: General Information - Msa (Srg/Hrg)

    General Information - MSA (SRG/ HRG)

  • Page 34: General Information - Msa (Srg/Hrg)

    Operation & Maintenance Manual General Information - MSA (SRG/HRG) General Information – MSA (SRG/HRG)
  • Page 35 General Information - MSA (SRG/HRG) Operation & Maintenance Manual...
  • Page 36 Operation & Maintenance Manual General Information - MSA (SRG/HRG) MODEL MHP825 SHP750 XHP700 VHP750 COMPRESSOR Actual free air delivery. (m3/min) (23,3) (21,5) (20,1) (21,5) Normal operating discharge pressure. (bar) (12) (17) (21) (14) Safety valve setting. (bar) (15) (25) (25) (17) Whisperized (W) °F...
  • Page 37 General Information - MSA (SRG/HRG) Operation & Maintenance Manual MODEL MHP825 SHP750 XHP700 VHP750 Power available at rated speed. (KW) (205) (205) (205) (205) Fuel tank capacity. (litre) (550) (550) (550) (550) Coolant capacity. 12.7 12.7 12.7 12.7 (litre) (48) (48) (48) (48)

  • Page 38: Sound Level Data ('W' Model)

    Operation & Maintenance Manual General Information - MSA (SRG/HRG) Sound Level Data (‘W’ model) A. To Pneurop code PN8NTC2. Equivalent continuous sound pressure level.* . Rated load 83 dB(A) Estimated (Operator position : 1m from machine) B. In compliance with 86/188/EEC. Average sound pressure level at 10m to 79/113/EEC.* 72dB(A)

  • Page 39: Operating Instructions

    Operating Instructions...

  • Page 40: Operating Instructions

    Operation & Maintenance Manual Operating Instructions Operating Instructions Commissioning Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the instructions given below in PRIOR TO STARTING. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

  • Page 41: Prior To Starting

    Operating Instructions Operation & Maintenance Manual WARNING If more than one compressor is connected to one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidently be pressurised/over pressurised by another.
  • Page 42 Operation & Maintenance Manual Operating Instructions CAUTION When refuelling:– • switch off the engine. • do not smoke. • extinguish all naked lights. • do not allow the fuel to come into contact with hot surfaces. • wear personal protective equipment. 5.
  • Page 43 Operating Instructions Operation & Maintenance Manual...

  • Page 44: Operating Controls And Instruments

    Operation & Maintenance Manual Operating Instructions Operating Controls and Instruments The operating controls and instruments are arranged on the control panel as shown above. A description of each panel device is as follows: 1. Panel Light: Illuminates the instrument control panel controlled by Switch 14. 2.
  • Page 45 Operating Instructions Operation & Maintenance Manual 7. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to high pressure in “IQ” air filters (if equipped). 8. Low Fuel Level: Fault indicator lamp. Indicates shutdown due to low fuel level. Lamp blinks at low fuel warning.

  • Page 46: Wedge Diagnostic Display Codes

    Operation & Maintenance Manual Operating Instructions Wedge Diagnostic Display Codes 1. High Compressor Temp: Fault indicator lamp. Indicates shutdown due to high compressor temperature. 2. Low Engine Oil Pressure: Fault indicator lamp. Indicates shutdown due to low engine oil pressure. 3.
  • Page 47 Operating Instructions Operation & Maintenance Manual 7. Restricted Air Filter: Alarm indicator lamp. Indicates engine/compressor air inlet filters need service. 8. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to high pressure in “IQ” air filters (if equipped). 9.
  • Page 48 Operation & Maintenance Manual Operating Instructions ALERT SHUTDOWN LIGHT DELAY CODE LIGHT BLINKS CODE STEADY (sec) Too Many Crank Attempts During CPRSR Autostart Malfunction. Engine Shut Itself Down: reason CPRSR unknown Malfunction. CPRSR Low AE Oil Pressure Malfunction. Disch. Temp (RT2) CPRSR Sensor Fault Malfunction.
  • Page 49 Operating Instructions Operation & Maintenance Manual ALERT SHUTDOWN LIGHT DELAY CODE LIGHT BLINKS CODE STEADY (sec) Battery Low Battery Voltage Charging Condition Low Engine Oil *Engine Oil Pressure <18 PSI Pressure Engine Coolant *Low Coolant Level - CUMMINS Level *Engine Coolant Temperature High Engine >...

  • Page 50: Caterpillar C-9 Engine Diagnostic And Event Flash Codes

    Operation & Maintenance Manual Operating Instructions Caterpillar C–9 Engine Diagnostic and Event Flash Codes Flash codes are used to represent diagnostic codes in the electronic system in order to alert the operator that a problem exists. Event codes refer to engine operating conditions and usually indicate a mechanical rather than an electrical system problem.
  • Page 51 Operating Instructions Operation & Maintenance Manual DIAGNOSTIC Description of Code Flash Code Speed/Timing Sensor Loss of signal Speed/Timing Sensor mechanical failure Loss of Secondary Engine Speed signal Secondary Engine Speed Sensor mechanical failure Engine Oil Temperature open/short to +batt Engine Oil Temperature open/short to ground Intake Manifold Air Temp open/short to +batt Intake Manifold Air Temp short to ground Injector Actuation Press Sensor mechanical failure...
  • Page 52 Operation & Maintenance Manual Operating Instructions EVENT Description of Code Flash Codes Engine Overspeed Shutdown Fuel Filter Restriction Derate Fuel Filter Restriction Shutdown High Engine Coolant Temperature Derate High Engine Coolant Temperature Shutdown High Engine Coolant Temperature Warning High Inlet Air Temperature Derate High Inlet Air Temperature Warning Low Engine Oil Pressure Derate Low Engine Oil Pressure Shutdown...

  • Page 53: Starting The Machine

    Operating Instructions Operation & Maintenance Manual Starting the Machine Ensure emergency stop button is reset. WARNING Under no circumstances should volatile fluids such as ether be used for starting this machine. All normal starting functions are incorporated in the key operated switch. Turn the keyswitch to (position 1);...

  • Page 54: Stopping The Machine

    Operation & Maintenance Manual Operating Instructions NOTE: In order to allow the machine to start at a reduced load, a valve, which is operated by a service air switch located on the instrument panel, is incorporated in the regulation system. (The valve automatically returns to the start position when the machine is switched off and air pressure relieved from the system).

  • Page 55: Emergency Stopping

    Operating Instructions Operation & Maintenance Manual CAUTION Never allow the machine to stand idle with pressure in the system. Emergency Stopping In the event that the unit has to be stopped in an emergency, PRESS THE EMERGENCY STOP SWITCH ON THE FRONT OF THE MACHINE. If the unit is not fitted with an emergency stop switch, rotate the start switch to the (0) off position.

  • Page 56: Decommissioning

    Operation & Maintenance Manual Operating Instructions Decommissioning When the machine is to be permanently decommissioned or dismantled, it is important to ensure that all hazard risks are either eliminated or notified to the recipient of the machine. In particular:– • Do not destroy batteries or components containing asbestos without containing the materials safely.

  • Page 57: Maintenance

    Maintenance...

  • Page 58: Maintenance

    Operation & Maintenance Manual Maintenance Maintenance Maintenance Interval Chart Maintenance Interval Chart Initial Daily Weekly Monthly Monthly. Monthly. Monthly. miles 500 hrs. 1000 hrs. 2000 hrs. /850 km Compressor Oil Level Engine Oil Level *Radiator Coolant Level Gauges/Lamps *Air Cleaner Service Indicators Fuel Tank (Fill at end of day)
  • Page 59 Maintenance Operation & Maintenance Manual Maintenance Interval Chart Initial Daily Weekly Monthly Monthly. Monthly. Monthly. miles 500 hrs. 1000 hrs. 2000 hrs. /850 km Air Cleaner System Compressor Heat Exchanger Exterior * Engine Heat Exchanger Exterior Fasteners, Guards Air Cleaner Elements R/WI *Disregard if not appropriate for this particular machine.
  • Page 60 Operation & Maintenance Manual Maintenance Maintenance Interval Chart Initial Monthly Monthly miles Daily Weekly Monthly Monthly Monthly 1500 2000 /850 500 hrs 1000 hrs Engine Coolant Conditioner *Fuel/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease.
  • Page 61 Maintenance Operation & Maintenance Manual Maintenance Interval Chart Initial Monthly Monthly miles Daily Weekly Monthly Monthly Monthly 1500 2000 /850 500 hrs 1000 hrs Fasteners Running Gear Linkage Running Gear Bolts(1) *Disregard if not appropriate for this particular machine. (1) or 3000 miles/5000km whichever is the sooner (2) or as defined by local or national legislation C = Check (adjust, clean or replace as necessary) CBT = Check before towing.
  • Page 62 Operation & Maintenance Manual Maintenance Initial 500 miles /850 Daily Weekly Monthly Monthly. Monthly. Monthly. 500 hrs. 1000 hrs 2000 hrs Separator tank (2) exterior Lubricator (Fill) * 2 Yrs 4 Yrs 6 Yrs Safety valve Hoses Separator tank (2) interior *Disregard if not appropriate for this particular machine.

  • Page 63: Routine Maintenance

    Maintenance Operation & Maintenance Manual Routine Maintenance This section refers to the various components which require periodic maintenance and replacement. The SERVICE MAINTENANCE INTERVAL CHART indicates the various components’ descriptions and the intervals when maintenance has to take place. Oil capacities, etc., can be found in the GENERAL INFORMATION section of this manual.

  • Page 64: Protective Shutdown System

    Operation & Maintenance Manual Maintenance Prior to attempting any maintenance work on a running machine, ensure that:– • the work carried out is limited to only those tasks which require the machine to run. • the work carried out with safety protection devices disabled or removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed.

  • Page 65: Scavenge Line

    Maintenance Operation & Maintenance Manual CAUTION Never remove or replace switches when the machine is running. Scavenge Line The scavenge line runs from the combined orifice/drop tube in the separator tank, to the orifice fitting located in the airend. Examine the orifice, check valve and hoses at every service or in the event of oil carryover into the discharge air.

  • Page 66: Inspection

    Operation & Maintenance Manual Maintenance Inspection Examine the filter element. CAUTION If there is any indication of the formation of varnishes, shellacs or lacquers on the filter element, it is a warning that the compressor lubricating and cooling oil has deteriorated and that it should be changed immediately.

  • Page 67: Inspection

    Maintenance Operation & Maintenance Manual Inspection Examine the filter element. Examine all hoses and tubes, and replace if necessary. Reassembly Thoroughly clean the orifice/drop tube and filter gasket contact area before reassembly. Install the new element. WARNING Do not remove the staple from the anti–static gasket on the separator element since it serves to ground any possible static build–up.

  • Page 68: Air Filter Element

    Operation & Maintenance Manual Maintenance WARNING Hot engine coolant and steam can cause injury. When adding coolant or antifreeze solution to the engine radiator, stop the engine at least one minute prior to releasing the radiator filler cap. Using a cloth to protect the hand, slowly release the filler cap, absorbing any released fluid with the cloth.

  • Page 69: Inspection

    Maintenance Operation & Maintenance Manual Inspection Check for cracks, holes or any other damage to the element by holding it up to a light source, or by passing a lamp inside. CAUTION If inspection reveals damage to the main element, the safety element must be replaced.

  • Page 70: Fuel Filter Water Separator

    Operation & Maintenance Manual Maintenance Fuel Filter Water Separator The fuel filter water separator contains a filter element which should be replaced at regular intervals (see the SERVICE/MAINTENANCE CHART). Caterpillar powered units are equipped with primary and secondary fuel filters. Charge Cooler Pipework:–...

  • Page 71: Battery

    Maintenance Operation & Maintenance Manual Battery WARNING Always disconnect battery cables before performing maintenance or service. Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion. The retaining clamp should be kept tight enough to prevent the battery from moving. Pressure System At 3 month intervals it is necessary to inspect the external surfaces of the system (from the airend through to the discharge valve(s)) including hoses, tubes, tube fittings and the...

  • Page 72: Engine Lubricating Oil

    Operation & Maintenance Manual Maintenance Engine Lubricating Oil The engine oil should be changed at the engine manufacturer’s recommended intervals. Refer to the SERVICE/MAINTENANCE CHART. Engine Lubricating Oil Specification Refer to the Engine Manufacturer’s Manual or Portable Compressor Fluid Chart. Engine Oil Filter Element The engine oil filter element should be changed at the engine manufacturer’s recommended intervals.

  • Page 73: Running Gear Wheel Bearings

    Maintenance Operation & Maintenance Manual CAUTION Some oil mixtures are incompatible and result in the formation of varnishes, shellacs or lacquers which may be insoluble. NOTE: Always specify INGERSOLL–RAND Pro–Tec oil for use at all ambient temperatures above –23°C. For extended warranty use only IR fluids. Refer to portable compressor fluids chart. Running Gear Wheel Bearings Wheel bearings should be packed with grease every 6 months.
  • Page 74 Operation & Maintenance Manual Maintenance MHP825, VHP750 Adjusting screw Orifice Separator tank Mini compressor Regulation pressure Manual blowdown valve transducer Auto blowdown Start/Run solenoid Unloader valve Unloader solenoid Panel pressure gauge...

  • Page 75: Speed And Pressure Regulation Adjustment

    Maintenance Operation & Maintenance Manual Speed and Pressure Regulation Adjustment Normally, regulation requires no adjusting, but if correct adjustment is lost, proceed as follows: Refer to the diagram above. A Adjusting screw Start the machine (Refer to STARTING INSTRUCTIONS in the OPERATING INSTRUCTIONS section of this manual).
  • Page 76 Operation & Maintenance Manual Maintenance XHP700, SHP750 Key: Air cylinder Regulation pressure Pressure transducer transducer Butterfly valve Start/Run solenoid Minimum pressure valve Mini compressor Pressure regulator Separator tank Unloader Solenoid Panel pressure guage Auto blowdown valve Relief valve Manual blowdown valve HR2 Airend Orifice Temperature sensor...

  • Page 77: Speed And Pressure Regulation Adjustment

    Maintenance Operation & Maintenance Manual Speed and Pressure Regulation Adjustment Normally, regulation requires no adjusting, but if correct adjustment is lost, proceed as follows: Refer to the diagram above. With the unit stopped, disconnect ballast spring ‘A’ from the butterfly lever. Loosen the two screws securing bracket ‘C’...

  • Page 78: Torque Values

    Operation & Maintenance Manual Maintenance Torque Values...
  • Page 79 Maintenance Operation & Maintenance Manual Wheel Torque Chart - Inch Wheel Torque Chart - Metric 1/2” lug nuts Torque (Ft- Torque Torque Lbs) (N-m) (Ft-Lbs) 13” wheel 80-90 M12 bolts 85-95 62-70 15” wheel 105-115 M14 bolts 145-155 107-115 16” wheel 105-115 M16 bolts 175-185...

  • Page 80: Portable Compressor Fluid Chart

    Operation & Maintenance Manual Maintenance Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change. NOTE: Fluids listed as “preferred”...
  • Page 81 Maintenance Operation & Maintenance Manual Recommended Ingersoll–Rand Fluids – Use of these fluids with original IR filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your IR representative. Ingersoll–Rand 1 gal. 5 gal. 55 gal. (208.2 220 gal.
  • Page 82 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 83: Machine Systems

    Machine Systems...

  • Page 84: Machine Systems

    Operation & Maintenance Manual Machine Systems Machine Systems Control System Schematic...
  • Page 85 Machine Systems Operation & Maintenance Manual Battery Pressure transducer, regulation system 0-100 PSIG Battery disconnect switch Plug, machine ID RS232C comms Relay-spst ECON Engine controller Thermistor, separator tank temperature -30-255°F Engine speed Thermistor, airend discharge temperature -30-255°F Caterpillar electronics ground ESTOP Emergency stop stud...
  • Page 86 Operation & Maintenance Manual Machine Systems 500Hz Base Frequency: 10%-90% plom=1350-1800 rpm...
  • Page 87 Machine Systems Operation & Maintenance Manual EMU CAT Low Pressure Electrical Parts MHP825, VHP750 PART QUANTITY PER DESCRIPTION NUMBERS MACHINE 22162572 IQ HARNESS OPTION 36899599 IQ FILTER SWITCH 36899615 IQ FILTER SWITCH 22102339 COOLANT LWL SWH 36896975 SW MASTER DISCONNECT 36920825 0–100 PRESS TRANS 54496773...
  • Page 88 Operation & Maintenance Manual Machine Systems PART QUANTITY PER DESCRIPTION NUMBERS MACHINE 22173579 WEDGE CONTROLLER 22202337 W1 CHASSIS HARNESS 54734116 W1 CHASSIS HARNESS DIAGRAM 22101968 INLET HEATER BREAKER 120 AMPS 36853521 INLET HEATER RELAY 89303127 EMERGENCY STOP OPERATOR 89303135 NC E–STOP CONTACT BLOCK...
  • Page 89 Machine Systems Operation & Maintenance Manual EMU CAT High Pressure Electrical Parts SHP750, XHP700 PART QUANTITY PER DESCRIPTION NUMBERS MACHINE 22162572 IQ HARNESS OPTION 36899599 IQ FILTER SWITCH 36899615 IQ FILTER SWITCH 22102339 COOLANT LWL SWH 36896975 SW MASTER DISCONNECT 36920825 0–100 PRESS TRANS 54765946...
  • Page 90 Operation & Maintenance Manual Machine Systems PART QUANTITY PER DESCRIPTION NUMBERS MACHINE 22173579 WEDGE CONTROLLER 22202337 W1 CHASSIS HARNESS 54734116 W1 CHASSIS HARNESS DIAGRAM 22101968 INLET HEATER BREAKER 120AMPS 89303127 EMERGENCY STOP OPERATOR 89303135 NC E–STOP CONTACT BLOCK...

  • Page 91: Fault Finding

    Fault Finding...

  • Page 92: Fault Finding

    Operation & Maintenance Manual Fault Finding Fault Finding Fault Finding FAULT CAUSE REMEDY No reaction Emergency stop actuated. Reset emergency stop button. from Batteries not connected. Connect batteries. instrument panel when Fuse at starter motor Replace fuse. key turned to ‘blown’.
  • Page 93 Fault Finding Operation & Maintenance Manual FAULT CAUSE REMEDY Engine starts Electrical fault. Test the electrical circuits. but will not Low engine oil pressure. Check the oil level and oil filter(s). run or engine shuts down Safety shut-down system Check the safety shut-down switches. prematurely.
  • Page 94 Operation & Maintenance Manual Fault Finding Refer also to the Engine Manufacturer’s Manual. FAULT CAUSE REMEDY Air discharge Engine speed too low. Check the air cylinder and air filter(s). capacity too Blocked air cleaner. Check the restriction indicators and replace the low.
  • Page 95 Fault Finding Operation & Maintenance Manual Refer also to the Engine Manufacturer’s Manual. FAULT CAUSE REMEDY Loose pipe/hose Check all pipe/hose connections. connections. Faulty safety valve. Check the relieving pressure. Replace the safety valve if faulty. DO NOT ATTEMPT A REPAIR.
  • Page 96 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 97: Options

    Options...

  • Page 98: Options

    Operation & Maintenance Manual Options Options IQ System Operating Instructions – 1 Three way valve Filters Ball valve 11/4” Aftercooler Ball valve 2” Minimum pressure valve Safety valve Separator tank...

  • Page 99: Iq System

    Options Operation & Maintenance Manual IQ System The IQ System is a complete, self–contained system which provides cooler, cleaner air than from a standard portable compressor. The system utilizes an integral aftercooler, high- efficiency filtration, and a patented condensate disposal system to provide the cool, clean air. The condensate disposal system injects all liquid condensed from the moisture separator and filters into the engine exhaust system where it is vaporized by heat.

  • Page 100: Low Ambient Option Operation

    Operation & Maintenance Manual Options Low Ambient Option Operation When the ambient temperature falls to the point that the aftercooler outlet temperature is approaching 45°F (7°C), the Temperature Control Unit (TCU), mounted on the rear of the control panel, will automatically adjust the louvers to control the cooling airflow through the aftercooler.

  • Page 101: Safety

    Options Operation & Maintenance Manual Verify the part number of new element vs. old element, as the two IQ filters are of different media. Safety CAUTION The compressor regulation system is adjusted to maintain regulated pressure at the separator tank. DO NOT adjust regulation to provide full regulation pressure at the service valve when the IQ System is enabled.
  • Page 102 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 103: Parts Ordering

    Parts Ordering...

  • Page 104: Parts Ordering

    Operation & Maintenance Manual Parts Ordering 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.

  • Page 105: Fasteners

    Parts Ordering Operation & Maintenance Manual 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 drawbar (front) will determine the right and left sides.

  • Page 106: How To Use Parts List

    Operation & Maintenance Manual Parts Ordering How to Use Parts List a. Locate the area or system of the compressor in which the desired part is used and find illustration page number. b. Locate the desired part on the illustration by visual identification and make note of part number and description.

  • Page 107: Airend Exchange Program

    Parts Ordering Operation & Maintenance Manual Airend Exchange Program Ingersoll–Rand offers an airend exchange program to benefit portable compressor users. Consult the Ingersoll–Rand representative for details. For parts, service or information regarding your local U.S, Latin America or Asia Pacific distributor, please contact: Facility: Telephone:...
  • Page 108 **Always use Ingersoll-Rand Replacement parts!**...
  • Page 109 © 2004 Ingersoll-Rand Company, Printed in the USA...

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