Doosan Ingersoll Rand XHP750WCU Operation & Maintenance Manual
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Doosan Ingersoll Rand XHP750WCU Operation & Maintenance Manual

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OPERATION & MAINTENANCE MANUAL
COMPRESSOR MODELS
XHP750WCU
XP1060WCU
MHP825WCU
CODE:
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.
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 22258040 (10/08) Rev A
Revised (10-12)
HP935WCU
VHP750WCU
XHP750WCU
XP1060WCU
MHP825WCU
CODE: A
HP935WCU
VHP750WCU
CODE: B
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 Doosan Ingersoll Rand XHP750WCU

  • Page 1 Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between www.doosanportablepower.com Ingersoll-Rand Company and Doosan Company or the products of either. Book: 22258040 (10/08) Rev A Revised (10-12)
  • 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 ............7 Foreword.
  • Page 4 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE GENERAL INFORMATION ..........35 General Information - MSA (SRG/HRG) .
  • Page 5 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE Reassembly ..............73 Ventilation .
  • Page 6 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE...

  • Page 7: Foreword

    Foreword 22258040...

  • Page 8: Foreword

    Operation & Maintenance Manual Foreword Foreword The contents of this manual are considered to be proprietary and confidential to Ingersoll- Rand and should not be reproduced without the prior written permission of Ingersoll-Rand. Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll-Rand products described herein.
  • 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!** 22258040...

  • Page 11: Warranty

    Warranty 22258040...

  • Page 12: Warranty

    Operation & Maintenance Manual Warranty Warranty Ingersoll-Rand Portable Compressor Warranty Ingersoll-Rand, through its distributors, warrants to the initial user that each portable air compressor manufactured by it, will be free of defects in material and workmanship for a period of the earlier of twelve (12) months from shipment to or the accumulation of 2,000 hours of service by the initial user.

  • Page 13: General Warranty Information

    Warranty Operation & Maintenance Manual General Warranty Information Comments Portable Package 12 Months/ Covers controls, switches, sheet metal, Compressor 2,000 Hours radiator, oil cooler, receiver, pipework, electrical circuit etc. Airend 24 Months/ 60 months/10,000 hours. extended limited 4,000 Hours warranty available on major components. Refer to operator’s manual.
  • Page 14 Operation & Maintenance Manual Warranty John Deere (in 2,000 5 yrs/5,000 hrs using OEM fluids and filters with $250 Compressors) deductable (in Generators) 2,000 24 months/4,000 hrs. available from IR with use of genuine IR parts and oils at prescribed service intervals. Contact IR network.

  • Page 15: Warranty Registration

    Warranty Operation & Maintenance Manual Warranty Registration For Units Sourced from Mocksville, USA Complete Machine Registration Machines shipped to locations within the United States do not require a warranty registration unless the machine status changes (i.e. change of ownership). Machines shipped outside the United States require notification be made to initiate the machine warranty.
  • Page 16 Operation & Maintenance Manual Warranty 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________________ Telephone ________________ Complete the Applicable Blocks Owner/User Type of Business (check one only) Construction-Heavy...
  • Page 17 Warranty Operation & Maintenance Manual 22258040...
  • Page 18 **Always use Ingersoll-Rand Replacement parts!** 22258040...

  • Page 19: Noise Emission

    Noise Emission 22258040...

  • 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

    Operation & Maintenance Manual Noise Emission D. Fasteners All fasteners such as hinges, nuts, bolts, clamps, screws, rivets and latches should be inspected for looseness after each 100 hours of operation. They should be retightened, repaired, or - if missing - replaced immediately to prevent subsequent damage and noise emission increase.
  • Page 23 Noise Emission Operation & Maintenance Manual Table 1: 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) 22258040...
  • Page 24 **Always use Ingersoll-Rand Replacement parts!** 22258040...

  • Page 25: Safety Symbols

    Safety Symbols 22258040...

  • 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 22258040...
  • Page 28 Operation & Maintenance Manual Safety Symbols 22258040...
  • Page 29 Safety Symbols Operation & Maintenance Manual 22258040...
  • Page 30 **Always use Ingersoll-Rand Replacement parts!** 22258040...

  • Page 31: Safety

    Safety 22258040...

  • Page 32: Safety

    Operation & Maintenance Manual Safety Safety General Information Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the Operation and Maintenance manual, and the manual holder, are not removed permanently from the machine. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

  • Page 33: Materials

    Safety Operation & Maintenance Manual All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions. Avoid bodily contact with compressed air. The safety valve located in the separator tank must be checked periodically for correct operation.

  • Page 34: Battery

    Operation & Maintenance Manual Safety Battery Batteries contain corrosive liquid and produce explosive gas. Do not expose to naked lights. Always wear personal protective clothing when handling. When starting the machine from a slave battery ensure that the correct polarity is observed and that connections are secure. DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY SINCE THIS MAY CAUSE IT TO EXPLODE.

  • Page 35: General Information

    General Information 22258040...

  • Page 36: General Information - Msa (Srg/Hrg)

    Operation & Maintenance Manual General Information General Information - MSA (SRG/HRG) 22258040...
  • Page 37 General Information Operation & Maintenance Manual 22258040...
  • Page 38 Operation & Maintenance Manual General Information MODEL MHP825 XP1060 XHP750 VHP750 XP950 COMPRESSOR 1060 Actual free air delivery. (23,3) (29,9) (21,5) (21,5) (26,5) /min) Normal operating discharge pressure. (bar) (12) (21) (14) (10) Safety valve setting (bar) (15) (15) (25) (17) (14) Whisperized (W) operating ambient...

  • Page 39: Sound Level Data ('W' Model)

    General Information Operation & Maintenance Manual 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) (*Machine only:- at maximum load in open site conditions)
  • Page 40 **Always use Ingersoll-Rand Replacement parts!** 22258040...

  • Page 41: Operating Instructions

    Operating Instructions 22258040...

  • Page 42: 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 43 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 44: Prior To Starting

    Operation & Maintenance Manual 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. When the unit has to be operated out of level, it is important to keep the engine oil level near the high level mark (with the unit level).
  • Page 45 Operating Instructions Operation & Maintenance Manual CAUTION 8. Do not operate the machine with the canopy/doors in the open position as this may cause overheating and operators to be exposed to high noise levels. 9. Check the emergency stop. Rotate knob as indicated to release. 10.

  • Page 46: 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 47 Operating Instructions Operation & Maintenance Manual 20. Discharge Air Pressure Gage: Indicates pressure in receiver tank, normally from 0 psi(kPa) to the rated pressure of the machine. 21. Engine Tachometer: Indicates engine speed in RPM from 0 when stopped to full speed.

  • Page 48: 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 49 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 50 Operation & Maintenance Manual Operating Instructions ALERT SHUTDOWN DELAY CODE LIGHT BLINKS CODE LIGHT STEADY (sec) Disch. Temp (RT2) Sensor Fault CPRSR Malfunction. Sep. Tank Pressure (PT1) CPRSR Malfunction. CPRSR Malfunction. Sensor Fault Separator Tank Pressure >20 PSI During Start Attempt CPRSR Malfunction.
  • Page 51 Operating Instructions Operation & Maintenance Manual ALERT SHUTDOWN DELAY CODE LIGHT BLINKS CODE LIGHT STEADY (sec) *Engine Coolant High Engine Temp. Temperature>=220 deg. F IQ Filter Restriction IQ Filt. Rest High Discharge Temp. High Comp Temp. (RT2>247 deg. F) *CAN derived data 22258040...

  • Page 52: Cummins Engine Model Qsl-9S

    Operation & Maintenance Manual Operating Instructions Cummins Engine Model QSL-9s Displayed Code Definition Engine Control Module - Critical internal failure Engine Speed/Position Sensor Circuit - lost both of two signals from the magnetic pickup sensor Engine Speed/Position Sensor Circuit - lost one of two signals from the magnetic pickup sensor Intake Manifold Pressure Sensor #1 Circuit - shorted high Intake Manifold Pressure Sensor #1 Circuit - shorted low...
  • Page 53 Operating Instructions Operation & Maintenance Manual Displayed Code Definition Engine Speed High v Critical Engine Coolant Level Low - Critical Vehicle Speed Sensor Circuit - data incorrect Vehicle Speed Sensor Circuit - tampering has been detected Engine Brake Driver #1 Circuit - shorted low Fan Clutch Circuit - shorted low Fuel Temperature Sensor Circuit - shorted high Fuel Temperature Sensor Circuit - shorted low...
  • Page 54 Operation & Maintenance Manual Operating Instructions Displayed Code Definition Transmission Output Shaft (Tailshaft) Speed High - Warning Sensor Supply Voltage #1 Circuit - shorted low Intake Air Heater (Relay Enable) #1 Circuit - data incorrect Intake Air Heater (Relay Enable) #2 Circuit - data incorrect OEM Sensor Supply Voltage Circuit - shorted high Sensor Supply Voltage #1 Circuit - shorted high Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high...
  • Page 55 Operating Instructions Operation & Maintenance Manual Displayed Code Definition Injector Control Valve Electronic Filter (Transorb) Error Accelerator Pedal Idle Validation Circuit - shorted low OEM Commanded Dual Output Shutdown Engine Hot Shutdown 22258040...

  • Page 56: Starting The Machine

    Operation & Maintenance Manual Operating Instructions 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 57: Stopping The Machine

    Operating Instructions Operation & Maintenance Manual 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 58: Emergency Stopping

    Operation & Maintenance Manual Operating Instructions 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 59: Decommissioning

    Operating Instructions Operation & Maintenance Manual 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 60 **Always use Ingersoll-Rand Replacement parts!** 22258040...

  • Page 61: Maintenance

    Maintenance 22258040...

  • Page 62: 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) *Fuel/Water Separator Drain Oil Leaks...
  • Page 63 Maintenance Operation & Maintenance Manual *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. CR = Check and report D = Drain G = Grease...
  • Page 64 Operation & Maintenance Manual Maintenance Initial Monthly miles/ Daily Weekly Monthly Monthly. Monthly. Monthly. .1500 500 hrs. 1000 hrs 2000 hrs Engine coolant conditioner *Fuel/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease. *Wheels (Bearings, Seals, etc.) *Engine Coolant...
  • Page 65 Maintenance Operation & Maintenance Manual *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. CR = Check and report D = Drain G = Grease...
  • Page 66 Operation & Maintenance Manual Maintenance Initial Daily Weekly Monthly Monthly. Monthly. Monthly. miles 500 hrs. 1000 hrs 2000 hrs /850 km 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 67: 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 68 Operation & 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 69: Protective Shutdown System

    Maintenance Operation & Maintenance Manual Protective Shutdown System Refer to the Wedge diagnostic display codes table for a listing of shutdown conditions. Low engine fuel level switch At three month intervals, test the low engine fuel level switch circuit as follows: •...

  • Page 70: Compressor Oil Filter

    Operation & Maintenance Manual Maintenance Compressor Oil Filter Refer to the MAINTENANCE INTERVAL CHART in this section for the recommended servicing intervals. Removal WARNING Do not remove the filter(s) 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 71: Compressor Oil Separator Element

    Maintenance Operation & Maintenance Manual Compressor Oil Separator Element Refer to the SERVICE MAINTENANCE INTERVAL CHART in this section for service intervals. Removal WARNING Do not remove the filter(s) 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 72: Compressor Oil Cooler & Engine Radiator Air Charge Cooler

    Operation & Maintenance Manual Maintenance CAUTION Start the machine (refer to PRIOR TO STARTING and STARTING THE UNIT in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the machine is put back into service. Compressor Oil Cooler & Engine Radiator Air Charge Cooler When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator, the efficiency is impaired.

  • Page 73: Air Filter Element

    Maintenance Operation & Maintenance Manual Air Filter Element The air filter should be inspected regularly (refer to the SERVICE MAINTENANCE INTERVAL CHART) and the element replaced when the restriction indicator lamp illuminates. The dust collector box(es)should be cleaned daily (more frequently in dusty operating conditions) and not allowed to become more than half full.

  • Page 74: Ventilation

    Operation & Maintenance Manual Maintenance Ventilation Always check that the air inlets and outlets are clear of debris etc. CAUTION NEVER clean by blowing air inwards. Cooling Fan Drive Periodically check that the fan mounting bolt in the fan hub has not loosened. If, for any reason, it becomes necessary to remove the fan or re-tighten the fan mounting bolt, 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 75: Electrical System

    Maintenance Operation & Maintenance Manual 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 76: Running Gear/Wheels

    Operation & Maintenance Manual Maintenance Running Gear/Wheels Check the wheel nut torque 20 miles (30 kilometres) after refitting the wheels. Refer to the TORQUE SETTING TABLE later in this section. The bolts securing the running gear to the chassis should be checked periodically for tightness (refer to the SERVICE/MAINTENANCE CHART for frequency) and re-tightened where necessary.

  • Page 77: Compressor Lubricating Oil

    Maintenance Operation & Maintenance Manual Compressor Lubricating Oil Refer to the SERVICE / MAINTENANCE CHART in this section for service intervals. NOTE: If the machine has been operating under adverse conditions, or has suffered long shutdown periods, then more frequent service intervals will be required.

  • Page 78: Running Gear Wheel Bearings

    Operation & Maintenance Manual Maintenance Running Gear Wheel Bearings Wheel bearings should be packed with grease every 6 months. The type of grease used should conform to specification MIL-G-10924. XP1060, HP935, MHP825, VHP750 Adjusting screw Orifice Separator tank Regulation pressure Manual blowdown Mini compressor transducer...

  • Page 79: Speed & Pressure Regulation Adjustment

    Maintenance Operation & Maintenance Manual Speed & 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 80 Operation & Maintenance Manual Maintenance XHP750, SHP825 Regulation pressure Air cylinder Pressure transducer transducer Minimum pressure Butterfly valve Start/Run solenoid valve Mini compressor Pressure regulator Separator tank Unloader Solenoid Panel pressure guage Auto blowdown valve Manual blowdown Relief valve HR2 Airend valve Orifice Temperature sensor...

  • Page 81: Speed & Pressure Regulation Adjustment

    Maintenance Operation & Maintenance Manual Speed & 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 82: Torque Values

    Operation & Maintenance Manual Maintenance Torque Values 22258040...
  • Page 83 Maintenance Operation & Maintenance Manual Table 1: Wheel Torque Chart - Inch Wheel Torque Chart - Metric 1/2” lug nuts Torque (Ft-Lbs) Torque (N-m) Torque (ft-Lbs) 13” Wheel 80-90 15” Wheel 105-115 M12 Bolts 85-95 62-70 16” Wheel 105-115 M14 Bolts 145-155 107-115 16.5”...

  • Page 84: 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 85 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. 5 gal. 220 gal.
  • Page 86 **Always use Ingersoll-Rand Replacement parts!** 22258040...

  • Page 87: Machine Systems

    Machine Systems 22258040...

  • Page 88: Control System Schematic

    Operation & Maintenance Manual Machine Systems Control System Schematic 22258040...
  • Page 89 Machine Systems Operation & Maintenance Manual Battery Plug, machine ID Battery disconnect switch Relay-spst Thermistor, separator tank temperature RS232C comms -30 - 255°F Thermistor, airend discharge temperature ECON Engine controller -30 - 255°F Engine speed ESTOP Emergency stop Frequency throttle. Range = 150Hz(1200 RPM) to Start compressor 375Hz(1800 RPM) at 24VDC...
  • Page 90 Operation & Maintenance Manual Machine Systems 22258040...
  • Page 91 Machine Systems Operation & Maintenance Manual CUMMINS QSL-9 LOW PRESSURE ELECTRICAL PARTS MHP825, XP1060, VHP750, HP935, XP950 PART NUMBERS QTY PER MACHINE DESCRIPTION 22162572 IQ HARNESS OPTION 36899599 IQ FILTER SWITCH 36899615 IQ FILTER SWITCH 54474572 COOLANT LEVEL SWITCH 36896975 SW MASTER DISCONNECT 36920825 0-100 PRESSURE TRANS...
  • Page 92 Operation & Maintenance Manual Machine Systems CUMMINS QSL-9 HIGH PRESSURE ELECTRICAL PARTS XHP750, SHP825 PART NUMBERS QTY PER MACHINE DESCRIPTION 22162572 IQ HARNESS OPTION 36899599 IQ FILTER SWITCH 36899615 IQ FILTER SWITCH 54474572 COOLANT LEVEL SWITCH 36896975 SW MASTER DISCONNECT 36920825 0-100 PRESSURE TRANS 54765946...

  • Page 93: Fault Finding

    Fault Finding 22258040...

  • Page 94: Fault Finding

    Operation & Maintenance Manual Fault Finding Fault Finding FAULT CAUSE REMEDY No reaction from Emergency stop Reset emergency stop button. instrument panel actuated. when key turned to Batteries not connected. Connect batteries. (I) position. Fuse at starter motor Replace fuse. ‘blown’.
  • Page 95 Fault Finding Operation & Maintenance Manual FAULT CAUSE REMEDY Engine starts but Electrical fault. Test the electrical circuits. will not run or Low engine oil pressure. Check the oil level and oil filter(s). engine shuts down prematurely. Safety shut-down Check the safety shut-down switches. system in operation.
  • Page 96 Operation & Maintenance Manual Fault Finding FAULT CAUSE REMEDY Air discharge Engine speed too low. Check the air cylinder and air filter(s). capacity too low. Blocked air cleaner. Check the restriction indicators and replace the element(s) if necessary. High pressure air Check for leaks.
  • Page 97 Fault Finding Operation & Maintenance Manual FAULT CAUSE REMEDY Safety valve Operating pressure too Check the setting and operation of the operates. high. regulator valve piping. Incorrect setting of the Adjust the regulator. regulator. Faulty regulator. Replace the regulator. Inlet valve set Refer to SPEED AND PRESSURE incorrectly.
  • Page 98 **Always use Ingersoll-Rand Replacement parts!** 22258040...

  • Page 99: Options

    Options 22258040...

  • Page 100: Options

    Operation & Maintenance Manual Options Options IQ System Operating Instructions - 1 Three way valve Filters ¼” Aftercooler Ball valve1 Ball valve2” Minimum pressure valve Safety valve Separator tank 22258040...

  • Page 101: 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.

  • Page 102: 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 103: Safety

    Options Operation & Maintenance Manual • Remove and replace the filter element, being careful not to damage outer wrap. 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.
  • Page 104 **Always use Ingersoll-Rand Replacement parts!** 22258040...
  • Page 105 © 2004 Ingersoll-Rand Company, Printed in the USA...

This manual is also suitable for:

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