Ingersoll-Rand P600WIR Operating & Maintenance Manual
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Ingersoll-Rand P600WIR Operating & Maintenance Manual

Ingersoll-Rand P600WIR Operating & Maintenance Manual

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Operating & Maintenance Manual
P600WIR (7/170), HP450WIR (10/125),
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 22442594 (1/07)
Revised (10-12)
Compressor Models
VHP400WIR (14/115)
Code:
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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  • 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 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 Operating & Maintenance Manual TITLE PAGE FOREWORD ............9 Foreword.
  • Page 4 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE SAFETY ............. . 37 Safety .
  • Page 5 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE Sulfur Content: ............. . 66 Bio-Diesel Fuel .
  • Page 6 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE MAINTENANCE ............91 Maintenance .
  • Page 7 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE OPTIONS ............. 127 Options .
  • Page 8 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE...

  • Page 9: Foreword

    Foreword 22442594...

  • Page 10: Foreword

    Details of approved equipment are available from Ingersoll-Rand service departments. The use of repair parts / lubricants / fluids other than those included within the Ingersoll-Rand approved parts list may create hazardous conditions over which Ingersoll-Rand has no control.
  • Page 11 This machine is not intended and must not be used in potentially explosive atmospheres, including situations where flammable gases or vapours may be present. Use of the machine fitted with non Ingersoll-Rand approved components / lubricants / fluids. Use of the machine with safety or control components missing or disabled.
  • Page 12 Having incorrect voltage and /or frequency ratings. b. Containing computer equipment and / or similar electronics. The company accepts no responsibility for errors in translation of this manual from the original English version. © COPYRIGHT 2003 INGERSOLL-RAND COMPANY 22442594...

  • Page 13: Warranty

    Warranty 22442594...

  • Page 14: Warranty

    Warranty Warranty Ingersoll-Rand, through its distributor, warrants that each item of equipment manufactured by it and delivered hereunder to the initial will be free of defects in material and workmanship. With respect to the following types of equipment, the warranty period enumerated below will apply.
  • Page 15 H. Spare Parts - Six (6) months from date of installation. 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 16: General Warranty Information

    2 yrs/4000 hrs using IR fluids and filters DEUTZ 2000 Available at dealer INGERSOLL-RAND 4000 5 yrs/10,000 hrs when using genuine Ingersoll-Rand fluids and parts. Refer to operator’s manual. KUBOTA (North America only) 2000 Major components 36 mo/3000 hrs (parts only) (Western Europe & Oceania)

  • Page 17: Extended Limited Airend Warranty

    1. The original airend is returned assembled and unopened. 2. Submissions of proof that Ingersoll-Rand fluid, filters and separators have been used. Refer to the Operation and Parts manual for the correct fluids, filters and separator elements required.

  • Page 18: 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 P.O. Box 868 Mocksville, North Carolina 27028 Attn: Warranty Department NOTE: Completion of this form validates the warranty.
  • Page 19 Warranty Operating & Maintenance Manual WARRANTY Selling Distributor Servicing Distributor REGISTRATION Name Name _________________ Owner/User Name _______ ___________________ Address Address________________ Address________________ _________________ City_ City ___________________ City ___________________ ____________________ County County_________________ County_________________ __________________ State__________________ State __________________ State __________________ Zip code_______________ Zip code _______________ Zip code _______________ Telephone______________ Telephone______________...
  • Page 20 3. 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 21: Decals

    Decals 22442594...

  • Page 22: Decals

    Operating & Maintenance Manual Decals Decals Look for these signs on machines manufactured in Europe, 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. Graphic Form and Meaning of ISO Symbols 22442594...
  • Page 23 Decals Operating & Maintenance Manual 22442594...
  • Page 24 Operating & Maintenance Manual Decals 22442594...
  • Page 25 Decals Operating & Maintenance Manual 22442594...
  • Page 26 Operating & Maintenance Manual Decals 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 Decals Operating & Maintenance Manual 22442594...
  • Page 28 Operating & Maintenance Manual Decals 22442594...

  • Page 29: Noise Emission

    Noise Emission 22442594...

  • Page 30: Noise Emission

    Operating & Maintenance Manual Noise Emission Noise Emission This section pertains only to machines distributed within the United States. WARNING Tampering with noise control system prohibited Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
  • Page 31 Noise Emission Operating & Maintenance Manual Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor.

  • Page 32: Noise Emission Control Maintenance Log

    Operating & 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 33: Introduction

    Noise Emission Operating & 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 34: 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. 22442594...
  • Page 35 Noise Emission Operating & Maintenance Manual MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY WORK DESCRIPTION OF WORK OR HOUR METER MAINT/ INSPECT LOCATION ITEM NO. DONE BY COMMENTS READING DATE CITY/ STATE (NAME) 22442594...
  • Page 36 Operating & Maintenance Manual Noise Emission 22442594...

  • Page 37: Safety

    Safety 22442594...

  • Page 38: Safety

    Operating & Maintenance Manual Safety Safety WARNING Warnings call attention to instructions which must be followed precisely to avoid injury or death. CAUTION Cautions call attention to instructions which must be followed precisely to avoid damaging the product, process or its surroundings. NOTE: Notes are used for supplementary information.

  • Page 39: Compressed Air

    Safety Operating & Maintenance Manual This machine produces loud noise with the doors open or service valve vented. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open or service valve is vented. Never inspect or service unit without first disconnecting battery cables(s) to prevent accidental starting.

  • Page 40: Materials

    Operating & Maintenance Manual Safety Avoid bodily contact with compressed air. The safety valve located in the separator tank must be checked periodically for correct operation. 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.

  • Page 41: Battery

    Safety Operating & Maintenance Manual WARNING Avoid ingestion, skin contact and inhalation of fumes Should compressor lubricant come into contact with the eyes, then irrigate with water for at least 5 minutes. Should compressor lubricant come into contact with the skin, then wash off immediately. Consult a physician if large amounts of compressor lubricant are ingested.

  • Page 42: Transport

    Operating & Maintenance Manual Safety Transport When loading or transporting machines ensure that the specified lifting and tie down points are used. When loading or transporting machines ensure that the towing vehicle, its size, weight, towing hitch and electrical supply are all suitable to provide safe and stable towing at speeds either, up to the legal maximum for the country in which it is being towed or, as specified for the machine model if lower than the legal maximum.

  • Page 43: General Arrangement

    General Arrangement 22442594...

  • Page 44: General Arrangement

    Operating & Maintenance Manual General Arrangement General Arrangement 7/170 10/125 14/115 P600WIR HP450WIR VHP400WIR All dimensions in inches(mm) D Access items: A Instrument panel access door Fuel fill B Package air inlet Engine oil filter C Access items: Fuel filter Separator element &...
  • Page 45 General Arrangement Operating & Maintenance Manual 7/170 10/125 14/115 P600WIR HP450WIR VHP400WIR All dimensions in inches(mm) E Access items: A Instrument panel access door Radiator fill B Package air inlet F Package air outlet C Access items: G Track width Separator element &...

  • Page 46: Compressor

    Operating & Maintenance Manual General Arrangement Compressor Actual free air delivery. (7/170) (P600WIR) 17,0 m (600 CFM) Actual free air delivery. (10/125) (HP450WIR) 12,8 m (450 CFM) Actual free air delivery. (14/115) (VHP400WIR) 11,3 m (400 CFM) Normal operating discharge pressure. (7/170) (P600WIR) 7 bar (100 PSI) Normal operating discharge pressure.

  • Page 47: Lubricating Oil Specification

    In the event that Pro-Tec is not available and /or the end user needs to use an approved single grade engine oil, the complete system including separator/receiver, cooler and pipework must be flushed clear of the first fill fluid and new Ingersoll-Rand oil filters installed. 22442594...

  • Page 48: Engine

    -23°C(-9°F), SAE 10W, API CF-4/CG-4 b. for ambient temperatures below -23°C(-9°F), I-R Performance 500 only. Safety data sheets can be obtained on request from the lubricant supplier. For temperatures outside the specified ambient range, consult Ingersoll-Rand. Engine P600WIR(7/170), HP450WIR (10/125), VHP400WIR (14/115), Type/model.

  • Page 49: Commissioning

    General Arrangement Operating & Maintenance Manual 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 50 Operating & Maintenance Manual General Arrangement 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 pressurized/over pressurised by another.

  • Page 51: Operating Instructions

    Operating Instructions 22442594...

  • Page 52: Operating Instructions

    Operating & Maintenance Manual Operating Instructions Operating Instructions Prior to Starting 1. Place the unit in a position that is as level as possible. The design of the unit permits a 15 degree lengthways and sideways limit on out of level operation. It is the engine, not the compressor, that is the limiting factor.
  • Page 53 Operating Instructions Operating & Maintenance Manual CAUTION Use only a No. 2-D diesel fuel oil with a minimum octane number of 45 and a sulphur content not greater than 0.5%. CAUTION When refuelling:- • switch off the engine. • do not smoke. •...

  • Page 54: Control Panel

    Operating & Maintenance Manual Operating Instructions Control Panel Diagnostic / Auto Shutdown (Standard) 1. Compressor Fault - Needs attention. See Wedge diagnostic panel for more detail. 2. Engine Fault - Needs attention. See Wedge diagnostic panel for more detail. 3. Hourmeter - Records running time for maintenance. 4.

  • Page 55: Optional Controls

    Operating Instructions Operating & Maintenance Manual Optional Controls 8. Engine Speed Gauge - Indicates engine speed. 9. Discharge Air Temp. Gauge - Indicates in °F and °C. Normal operating range: 185°F/85°C to 248°F/120°C. 10. Engine Oil Pressure Gauge - Indicates engine oil pressure (psi (kPa)). 11.

  • Page 56: Wedge Diagnostic Display Panel

    Operating & Maintenance Manual Operating Instructions Wedge Diagnostic Display Panel. The Wedge diagnostic display panel is arranged as shown above. A description of each diagnostic indicator is as follows: 1. High Compressor Temp: Fault indicator lamp. Indicates shutdown due to high compressor temperature.

  • Page 57: Wedge Diagnostic Display Codes

    Operating Instructions Operating & Maintenance Manual 9. Low Battery Voltage: Alarm indicator lamp. Indicates battery or charging system requires service. 10. Engine Malfunction: Engine Fault code. Refer to service card or engine manual for codes and service requirements. 11. Malfunction Code (4 Digit): Compressor or engine fault. Refer to manual for list of codes and service requirements.
  • Page 58 Operating & Maintenance Manual Operating Instructions Alert Shutdown Light Delay Condition Code Light (Blinks) Code (Steady) (sec). Sep. Tank Pressure (PT1) CPRSR Malf. Sensor Fault Separator Tank Temp. CPRSR Malf. >247 deg.F) Machine ID Not Valid CPRSR Malf. Sep. Tank Temp. (RT1) CPRSR Malf.
  • Page 59 Operating Instructions Operating & Maintenance Manual Listing of Diagnostic Trouble Codes (DTCs) Displayed FMI* Definition Code Analog Throttle (B) Input Voltage High Analog Throttle (B) Input Voltage Low Analog Throttle (A) Input Voltage High Analog Throttle (A) Input Voltage Low Multi-state Throttle Input Voltage High Multi-state Throttle Input Voltage Low Engine Oil Pressure Extremely Low...
  • Page 60 Operating & Maintenance Manual Operating Instructions Listing of Diagnostic Trouble Codes (DTCs) Displayed FMI* Definition Code Engine Overspeed Moderate Sensor Supply Voltage High Sensor Supply Voltage Low Crankshaft Position Input Noise Crankshaft Position Input Pattern Error Auxiliary Engine Shutdown Switch Active External Engine Derate Switch Active 1076 Pump Control Valve Closure Too Long...

  • Page 61: Starting The Machine

    Operating Instructions Operating & Maintenance Manual Starting the Machine WARNING Under no circumstances should volatile liquids such as Ether be used for starting this machine. All normal starting functions are incorporated in the key operated switch. • Turn the key switch to position 1. The engine fault and compressor fault lamps will flash.

  • Page 62: Push After Warm Up

    Operating & Maintenance Manual Operating Instructions • Allow the engine to reach operating temperature. • At this point in the operation of the machine it is safe to apply full load to the engine. Push After Warm Up NOTE: In order to allow the machine to start at a reduced load, a valve, which is operated by a button located on the instrument panel, is incorporated in the regulation system.

  • Page 63: Emergency Stopping

    Operating Instructions Operating & 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. TURN THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO THE 0 (OFF) POSITION. Re-Starting After an Emergency If the machine has been switched off because of a machine malfunction, then identify and correct the fault before attempting to re-start.
  • Page 64 Operating & Maintenance Manual Operating Instructions 22442594...

  • Page 65: Engine Instructions

    Engine Instructions 22442594...

  • Page 66: Engine

    Operating & Maintenance Manual Engine Instructions Engine Engine Serial Number Plate Each engine has a 13-digit engine serial number. The engine's serial number plate is located on the right-hand side of cylinder block behind the fuel filter. Fuels, Lubricants and Coolant Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area.

  • Page 67: Bio-Diesel Fuel

    Engine Instructions Operating & Maintenance Manual Bio-Diesel Fuel Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM PS121, DIN 51606 or equivalent specification. It has been found that bio-diesel fuels may improve lubricity in concentrations up to a 5% blend in petroleum diesel fuel.

  • Page 68: Diesel Fuel Storage

    Minimizing the Effect of Cold Weather on Diesel Engines Ingersoll-Rand diesel engines are designed to operate effectively in cold weather. See your authorized engine distributor or servicing dealer for additional information and availability of cold weather aids.

  • Page 69: Diesel Engine Coolant

    Engine Instructions Operating & Maintenance Manual The following oil is preferred: • Pro-Tec™Engine Fluid Other oils may be used if they meet one or more of the following: • API Service Classification CI-4 • API Service Classification CH-4 • ACEA Specification E3 •...

  • Page 70: Supplemental Coolant Additives

    At each interval, drain the coolant, flush the cooling system, and refill with new coolant. Operating in Warm Temperature Climates Ingersoll-Rand engines are designed to operate using glycol base engine coolants. Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required.

  • Page 71: Engine Break-In Service

    Engine Instructions Operating & Maintenance Manual IMPORTANT: Water may be used as coolant in emergency situations only. Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added. Drain cooling system and refill with recommended glycol base engine coolant as soon as possible.

  • Page 72: Lubrication

    Operating & Maintenance Manual Engine Instructions Lubrication Lubrication and Maintenance Service Interval Chart NOTE: The Service intervals below are for standard industrial engines. See details in Sections which follow these charts. Item Lubrication and Maintenance Service Intervals 500 Hours/ 2000 Hours / Check Engine Oil and Coolant Level Daily As Required...

  • Page 73: Lubrication & Maintenance / Daily

    Engine Instructions Operating & Maintenance Manual Lubrication & Maintenance / Daily Daily Pre-starting Checks Do the following BEFORE STARTING THE ENGINE for the first time each day: Check engine oil level on dipstick. IMPORTANT: DO NOT add makeup oil until the oil level is BELOW the crosshatch marks on the dipstick.

  • Page 74: Cleaning Crankcase Vent Tube

    Operating & Maintenance Manual Engine Instructions 4. Turn filter element using a suitable filter wrench to remove. Discard oil filter element. Important: Filtration of oils is critical to proper lubrication. Always change filter regularly. 5. Apply clean engine oil to the new filter at the inner and outer seals and to filter threads.

  • Page 75: Replacing Fuel Filter Elements

    Engine Instructions Operating & Maintenance Manual Replacing Fuel Filter Elements Engine is equipped with a primary fuel filter (or pre-filter) with water bowl and a final filter. Both filters are replaced at the same 500-hour interval. CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury.

  • Page 76: Checking Belt Tensioner Spring Tension And Belt Wear (Automatic Tensioner)

    Operating & Maintenance Manual Engine Instructions 11. Open fuel shut-off valve and bleed the fuel system. Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner) Belt drive systems equipped with automatic (spring) belt tensioners cannot be adjusted or repaired. The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt.

  • Page 77: Checking Engine Electrical Ground Connections

    Engine Instructions Operating & Maintenance Manual Specification Spring Tension-Torque 18-22 N•m (13-16 Ib-ft) NOTE: Threads on belt tensioner roller cap screw are LEFT-HAND threads. Checking Engine Electrical Ground Connections Keep all engine ground connections clean and tight to prevent electrical arcing which can damage electronic components.

  • Page 78: Replacing Fan And Alternator Belts

    Operating & Maintenance Manual Engine Instructions Replacing Fan and Alternator Belts Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Lubrication and Maintenance/500 Hour/12 Month Section for additional information on the belt tensioner. 1. Inspect belts for cracks, fraying, or stretched out areas. Replace if necessary. 2.

  • Page 79: At Fuel Injection Pump

    Engine Instructions Operating & Maintenance Manual At Fuel Injection Pump 1. Loosen fuel return line at fuel injection pump. 2. Operate fuel supply pump primer lever or primer button on fuel filter base (if equipped). 3. As soon as fuel flow is free form air bubbles, tighten fuel return line to specification.

  • Page 80: Troubleshooting

    Operating & Maintenance Manual Engine Instructions Troubleshooting General Troubleshooting Information Troubleshooting engine problems can be difficult. In this section is a list of possible engine problems that may be encountered accompanied by possible causes and corrections. The illustrated diagrams and troubleshooting information are of a general nature.
  • Page 81 Engine Instructions Operating & Maintenance Manual Symptom Problem Solution Incorrect starting procedure. Verify correct starting procedure. No fuel. Check fuel in tank. Exhaust restricted. Check and correct exhaust Engine cranks but restriction. will not start Fuel filter plugged or full of Replace fuel filter or drain water water.
  • Page 82 Operating & Maintenance Manual Engine Instructions Symptom Problem Solution Defective thermostat. Remove and check thermostat. Below normal Defective temperature Check gauge, sender and Engine temperature gauge or sender. connections. Engine overloaded. Reduce load. Intake air restriction. Service air cleaner. Clogged fuel filter. Replace filter elements.
  • Page 83 Engine Instructions Operating & Maintenance Manual Symptom Problem Solution Improper type of fuel. Use proper fuel. Warm up engine to normal operating Low engine temperature. Engine emits white temperature. smoke Defective thermostat. Remove and check thermostat. Defective injection nozzles. See your authorized servicing dealer. Improper type of fuel.
  • Page 84 Operating & Maintenance Manual Engine Instructions Symptom Problem Solution Excessive electrical load from Remove accessories or install higher added accessories. output alternator. Excessive engine idling. Increase engine rpm when heavy electrical load is used. Undercharged Poor electrical connections on electrical system battery, ground strap, starter, or Inspect and clean as necessary.

  • Page 85: Displaying Of Diagnostic Trouble Codes (Dtcs)

    Engine Instructions Operating & Maintenance Manual Displaying of Diagnostic Trouble Codes (DTCs) Stored and active diagnostic trouble codes are output on the instrument panel according to the J1939 standard as a two-part code as shown on the tables in the Operating Instruction Section.

  • Page 86: Possible Causes Of Intermittent Faults

    Operating & Maintenance Manual Engine Instructions Possible causes of intermittent faults: • Faulty connection between sensor and actuator harness. • Faulty contact between terminals in connector. • Faulty terminal/wire connection. • Electromagnetic interference (EMI) from an improperly installed 2-way radio, etc., can cause faulty signals to be sent to the ECU.

  • Page 87: Removing Engine From Long Term Storage

    Engine Instructions Operating & Maintenance Manual 8. Clean the exterior of the engine with salt-free water and touch up any scratched or chipped painted surfaces with a good quality paint. 9. Coat all exposed (machined) metal surfaces with grease or corrosion inhibitor if not feasible to paint.

  • Page 88: Specifications

    Operating & Maintenance Manual Engine Instructions Specifications General Engine Specifications. ITEM 6IRF8TE Number of Cylinders Bore 106 mm (4.19 in.) Stroke 127 mm (5.0 in.) Displacement 6.8 L (414 cu in.) Compression Ratio 17.0:1 Aspiration Turbocharged Engine Firing Order 1-5-3-6-2-4 Valves Per Cylinder 1 Intake, 1 Exhaust Valve Clearance (Cold)

  • Page 89: Engine Crankcase Oil Fill Quantities

    Engine Instructions Operating & Maintenance Manual Engine Crankcase Oil Fill Quantities 6IRF8TE Crankcase Oil Capacity L (qt) 19.5 (20.6) Lubrication and Maintenance Records Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Section for detailed service procedures. 1. Keep a record of the number of hours you operate your engine by regular observation of hour meter.

  • Page 90: Emissions Control System Certification Label

    Operating & Maintenance Manual Engine Instructions Emissions Control System Certification Label CAUTION Statutes providing severe penalties for tampering with emissions controls may apply to the user or dealer. The emissions warranty applies only to those engines marketed by John Deere that have been certified by the United State Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB);...

  • Page 91: Maintenance

    Maintenance 22442594...

  • Page 92: Maintenance

    Operating & Maintenance Manual Maintenance Maintenance Initial 3 Monthly 6 Monthly 12 Monthly 500 miles Daily Weekly Monthly 250 hrs. 500 hrs. 1000 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) Oil Leaks...
  • Page 93 Maintenance Operating & Maintenance Manual Initial 3 Monthly 6 Monthly 12 Monthly 500 miles Daily Weekly Monthly 250 hrs. 500 hrs. 1000 hrs. /850 km Fasteners, Guards Air Cleaner R / WI Elements *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)
  • Page 94 Operating & Maintenance Manual Maintenance Initial Monthly Monthly Daily Weekly Monthly Monthly Monthly miles/ 1000 1500 250 hrs. 500 hrs. 850 km hrs. hrs. *Fuel/Water Separator Element Compressor Oil Filter Element Compressor Engine Oil Change *Water Pump Grease. Wheels (Bearings, Seals, etc.) *Engine Coolant...
  • Page 95 Maintenance Operating & Maintenance Manual Initial Monthly Monthly Daily Weekly Monthly Monthly Monthly miles/ 1000 1500 250 hrs. 500 hrs. 850 km hrs. hrs. Lights (running, brake, & turn) Pintle Eye Bolts *Brakes *Brake linkage Emergency stop Fasteners Running gear linkage Safety valve Running gear...
  • Page 96 Operating & Maintenance Manual Maintenance Initial 500 miles/850 Daily Weekly Monthly Monthly Monthly Monthly 250 hrs. 500 hrs. 1000 hrs. Scavenge line Pressure system Engine breather element Pressure gauge Pressure regulator Separator tank (2) exterior Lubricator (Fill) 2 Yrs 4 Yrs 6 Yrs Safety valve Hoses...

  • Page 97: Routine Maintenance

    Maintenance Operating & Maintenance Manual Routine Maintenance This section refers to the various components which require periodic maintenance and replacement. The SERVICE/MAINTENANCE 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 98: Protective Shutdown System

    Operating & Maintenance Manual Maintenance Prior to opening or removing panels or covers to work inside a machine, ensure that:- • anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts. •...

  • Page 99: Scavenge Line

    Maintenance Operating & 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 100: Compressor Oil Separator Element

    Operating & Maintenance Manual Maintenance Reassembly Clean the filter gasket contact area and install the new element by screwing in a clockwise direction until the gasket makes contact with the filter housing. Tighten a further ½ to ¾ of a revolution.

  • Page 101: Compressor Oil Cooler And Engine Radiator

    Maintenance Operating & Maintenance Manual 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. Do not use gasket sealant since this will affect electrical conductance. Reposition the cover plate, taking care not to damage the gasket, and replace the cover plate screws tightening in a criss-cross pattern to the recommended torque (refer to the TORQUE SETTING TABLE later in this section).

  • Page 102: Air Filter Elements

    Operating & Maintenance Manual Maintenance WARNING Follow the instructions provided by the antifreeze supplier when adding or draining the antifreeze solution. It is advisable to wear personal protective equipment to prevent skin and eye contact with the antifreeze solution. Air Filter Elements The air filter should be inspected regularly (refer to the SERVICE/MAINTENANCE CHART) and the element replaced when the restriction indicator shows red or every 6 Months (500 hours), whichever comes first.

  • Page 103: Cooling Fan Drive

    Maintenance Operating & Maintenance Manual CAUTION NEVER clean by blowing air inwards. Cooling Fan Drive Periodically check that the fan mounting bolts in the fan hub have not loosened. If, for any reason, it becomes necessary to remove the fan or re-tighten the fan mounting bolts, apply a good grade of commercially available thread locking compound to the bolt threads and tighten to the torque value shown in the TORQUE SETTING TABLE later in this section.

  • Page 104: Electrical System

    Operating & Maintenance Manual Maintenance Electrical System WARNING Always disconnect battery cables before performing maintenance or service. Inspect the safety shutdown system switches and the instrument panel relay contacts for evidence of arcing and pitting. Clean where necessary. Check the mechanical action of the components. Check the security of electrical terminals on the switches and relays i.e.

  • Page 105: Lubrication

    Maintenance Operating & Maintenance Manual CAUTION Check the wheel nut torque 20 miles (30 kilometres) after refitting the wheels (Refer to the TORQUE SETTING TABLE later in this section). Lubrication The engine is initially supplied with engine oil sufficient for a nominal period of operation (for more information, consult the Engine section of this manual).

  • Page 106: Compressor Oil Filter Element

    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 Compressor Oil Filter Element Refer to the SERVICE/MAINTENANCE CHART in this section for service intervals.

  • Page 107: Speed And Pressure Regulation Adjustment

    Maintenance Operating & 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 108 Operating & Maintenance Manual Maintenance 22442594...
  • Page 109 Maintenance Operating & Maintenance Manual 22442594...
  • Page 110 Operating & Maintenance Manual Maintenance Compressor Lubrication 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 111 Maintenance Operating & Maintenance Manual Preferred Ingersoll-Rand Fluids - Use of these fluids with original I-R filters can extend airend warranty. Refer to operator's manual warranty section for details or contact your I-R representative. Ingersoll-Rand 1 gal. (3.8 5 gal. (19.0 55 gal.
  • Page 112 Operating & Maintenance Manual Maintenance 22442594...

  • Page 113: Machine Systems

    Machine Systems 22442594...

  • Page 114: Machine Systems

    Operating & Maintenance Manual Machine Systems Machine Systems Battery Pressure transducer, separator tank 0- 500 PSIG RS232C comms Pressure transducer, regulation system 0-100 PSIG ECON Engine controller Plug, machine ID Isochronous governor Idle sel J50-G2 Wait to start lamp Relay-spst J50-K3 Inlet heater Thermistor, separator tank temperature -...

  • Page 115: Wedge To Engine Interface - Ir Engine

    Machine Systems Operating & Maintenance Manual Fuel temp Starter motor Manifold air temp Spare Oil pressure Display scroll POUT1 Engine key switch Low fuel shutdown POUT2 Solenoid, start/run Switch, service air POUT3 Comp fault lamp Air filter rest (option) POUT4 Engine fault lamp Spare POUT5...

  • Page 116: Harness System Schematic

    Operating & Maintenance Manual Machine Systems Harness System Schematic J1939 CAN Communications Schematic 22442594...

  • Page 117: Service Tools

    Service Tools 22442594...

  • Page 118: Service Tools

    Operating & Maintenance Manual Service Tools Service Tools Electronic Systems The following special tools are recommended to perform service procedures in this mannual. The tools can be purchased from Ingersoll-Rand or equivalent substitutes can be used. Tool Tool Description Fluke 87 Digital Multimeter...

  • Page 119: Service Tools

    Service Tools Operating & Maintenance Manual Service Tools Tool No Tool Description Tool Illustration Fluke 87 Digital multimeter Available from electrical and electronic parts distributors 54729660 Weather-Pack Terminal Removal Tool 54699632 Deutsch Terminal Removal Tool (Blue) 54699640 Deutsch Terminal Removal Tool (Red) 54699624 Deutsch Terminal Removal Tool (Yellow)
  • Page 120 Operating & Maintenance Manual Service Tools Tool No Tool Description Tool Illustration 54729728 PDA Service Tool 54699616 Deutsch Terminal Removal Tool 22073886 Packard Crimp Tool 22073878 Thermistor Simulator 54749635 Connector Repair Kit 54699657 Deutsch Terminal Removal Tool 54749643 Packard Metri-Pack Removal Tool 22442594...

  • Page 121: Electrical Parts

    Service Tools Operating & Maintenance Manual Electrical Parts PARTS QTY PER PARTS QTY PER DESCRIPTION DESCRIPTION NUMBERS MACHINE NUMBERS MACHINE 36920825 0-100 psi 54731427 FUEL LEVEL PRESSURE SENDER TRANSDUSER 54765946 0-500 psi 22173579 WEDGE PRESSURE CONTROLLER TRANSDUSER 36898922 THERMISTOR 22199061 W1 CHASSIS PROBE HARNESS...
  • Page 122 Operating & Maintenance Manual Service Tools 22442594...

  • Page 123: Fault Finding

    Fault Finding 22442594...

  • Page 124: Fault Finding

    Operating & Maintenance Manual Fault Finding Fault Finding FAULT CAUSE REMEDY No reaction from instrument panel Batteries not connected. Connect batteries. when key turned to Fuse at starter motor Replace fuse. (I) position. ‘blown’. Low battery charge. Check the fan belt tension, battery and cable connections.
  • Page 125 Top up the oil level and check for leaks. Dirty or blocked oil Clean the oil cooler fins. cooler. Incorrect grade of oil. Use Ingersoll-Rand recommended oil. Compressor Defective by-pass valve. Check the operation of the element and overheats. replace if necessary.
  • Page 126 Operating & Maintenance Manual Fault Finding FAULT CAUSE REMEDY Blocked scavenge line. Check the scavenge line, drop tube and orifice. Clean and replace. Excessive oil Perforated separator Replace the separator element. present in the element. discharge air. Pressure in the system Check the minimum pressure valve.

  • Page 127: Options

    Options 22442594...

  • Page 128: Options

    Operating & Maintenance Manual Options Options Options - Lubricator (For units manufactured in North America) Safety WARNING Ensure that the lubricator filler cap is re-tightened correctly after replenishing with oil. WARNING Do not replenish the lubricator oil, or service the lubricator without first making sure that the machine is stopped and the system has been completely relieved of all air pressure (Refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual).

  • Page 129: Prior To Starting

    Options Operating & Maintenance Manual Prior to Starting Check the lubricator oil level and replenish as necessary. Maintenance Check the lubricator oil level and replenish as necessary. Fault Finding FAULT CAUSE REMEDY No oil flow. Incorrect connection Reverse the nylon tube connections to the lubricator.

  • Page 130: Options - Iq System

    Operating & Maintenance Manual Options Options - IQ System 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. This will result in Coperation at excessive horsepower levels, causing overheating, reduced engine life, and reduced airend life.

  • Page 131: Operating Instructions

    Options Operating & Maintenance Manual NOTICE Do not operate at temperatures less that 2º C (35º F) unless equipped with low ambient IQ option. Operating Instructions Starting and use: Select desired air type using diverter valve and start machine normally. Using diverter valve, toggle between standard air and IQ air as required.

  • Page 132: Maintenance

    Operating & Maintenance Manual Options Maintenance Daily maintenance: Verify, during full-load (maximum compressed air delivery) that the IQ system filter restriction indicators do not show excessive restriction. Restriction indicators for primary and secondary filters are located on the filter heads. If so equipped, an automatic restriction indicator is located behind the filter mounting bracket and will shut down the compressor if restriction exceeds recommended values.
  • Page 133 © 2004 Ingersoll-Rand Company, Printed in the USA...

This manual is also suitable for:

Hp450wirVhp400wir7/17010/12514/115

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