Ingersoll-Rand 120001 Operation And Maintenance Manual Download Page 57

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Portable Compressor 7/20

11---1/(11---2 blank)

SEPTEMBER 2003

11. PIPING AND INSTRUMENTATION SYSTEM

Air discharge

Sonic orifice (restricts flow)

Pressure gauge

Separator tank

Safety valve

Compressor

Engine

Oil filter

Oil cooler

AIR
OIL
AIR/OIL

Figure 11---1.

PIPING AND INSTRUMENTATION SYSTEM

Summary of Contents for 120001

Page 1: ...his 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...

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Page 3: ...for manufacture and supply the product s 7 20 to which this declaration relates is are in conformity with the provisions of the above directives using the folloving principal standards EN29001 EN292...

Page 4: ...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 5: ...Title 0 A 0 B Blank 0 i v 0 vi Blank 0 1 1 0 1 2 Blank 0 2 1 0 2 2 Blank 0 3 1 3 6 0 4 1 4 6 0 5 1 5 3 0 5 4 Blank 0 6 1 6 2 0 7 1 7 4 0 8 1 8 3 0 8 4 Blank 0 9 1 9 11 0 9 12 Blank 0 10 1 10 2 0 11 1...

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Page 7: ...1 AVOID INHALATION 6 1 6 3 2 AVOID INGESTION SKIN CONTACT AND INHALATION OF FUMES 6 2 6 4 BATTERY 6 2 6 5 RADIATOR 6 2 6 6 TRANSPORT 6 2 6 7 SAFETY CHAINS CONNECTIONS AND THEIR ADJUSTMENT 6 2 7 GENER...

Page 8: ...MENT 9 8 9 22 RUNNING GEAR WHEEL BEARINGS 9 8 9 23 SPEED AND PRESSURE REGULATION ADJUSTMENT 9 8 9 24 DRIVE BELT REPLACEMENT ADJUSTMENT 9 9 9 25 TORQUE VALUES 9 10 9 26 COMPRESSOR LUBRICATION 9 10 10 E...

Page 9: ...2 COOLING SYSTEM 13 9 13 6 3 PERIODIC SERVICE 13 10 13 6 4 AIR INTAKE SYSTEM 13 12 13 6 5 ENGINE ELECTRICAL 13 12 13 6 6 SERVICE AND MAINTENANCE 13 12 13 7 COLD WEATHER OPERATION 13 13 13 8 ENGINE MA...

Page 10: ...E 9 11 10 1 ELECTRICAL SYSTEM 10 1 10 2 SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM 10 2 10 3 SCHEMATIC DIAGRAM FOR AMERICAN SAE LIGHTING SYSTEM 10 2 11 1 PIPING AND INSTRUMENTATION SYSTEM 11 1...

Page 11: ...AR UNBRAKED VERSION KNOTT 7 3 7 6 FIXED HEIGHT RUNNING GEAR BRAKED VERSION KNOTT 7 4 7 7 VARIABLE HEIGHT RUNNING GEAR BRAKED VERSION KNOTT 7 4 7 8 WHEELS AND TYRES 7 4 9 1 MAINTENANCE SCHEDULE 9 1 9 2...

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Page 13: ...erial No Not illustrated Option AR As required BR Brazil CN China DE Germany DK Denmark ES Spain FI Finland FR France GB Great Britain English HA High ambient machine IT Italy NL Holland NO Norway PT...

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Page 15: ...has no control Therefore Ingersoll Rand cannot be held responsible forequipment inwhichnon approved repairpartsare installed Ingersoll Rand reserves the right to make changes and improvements to prod...

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Page 17: ...ation of 4 000 hours of operation by the initial user F Ingersoll Rand Engines The earlier of twenty four 24 months from shipment to or the accumulation of 4 000 hours of operation by the initial user...

Page 18: ...RNATOR 12 MONTHS 2 000 HOURS CONTACT I R NETWORK FOR WARRANTY PARTS ONLY NO LABOUR ENGINE SEE BELOW 9 kVA 550 kVA PACKAGE 12 MONTHS 2 000 HOURS COVERS CONTROLS SWITCHES SHEET METAL ELECTRICAL CIRCUIT...

Page 19: ...RANTY PROVIDED VIA ENGINE SUPPLIER S OWN APPROVED NETWORK AT TIME OF PURCHASE HONDA 12 UNLIMITED WARRANTY PROVIDED VIA ENGINE SUPPLIER S OWN APPROVED NETWORK YANMAR 12 UNLIMITED WARRANTY PROVIDED VIA...

Page 20: ...defects in major components rotors housings gears and bearings and is automatically available when the following conditions are met 1 The original airend is returned assembled and unopened 2 Submissio...

Page 21: ...their local dealer to initiate warranty You must provide proof of the in service date when requesting engine warranty repairs 3 3 2 For Units Sourced From Mocksville USA A Complete Machine Registrati...

Page 22: ...ignature Company Address Post Zip Code Country Phone Number Service Provider Details Service Provider Distributor Branch Office Machine Details Serial Number Model Date of start up Fax Number e mail P...

Page 23: ...urised vessel WARNING Hot and harmful exhaust gas WARNING Maintain correct tyre pressure Refer to the GENERAL INFORMATION section of this manual Information Instructions WARNING Flammable liquid WARNI...

Page 24: ...ating and Maintenance manual and manual holder from this machine Do not stack Do not operate the machine without the guard being fitted Do not stand on any service valve or other parts of the pressure...

Page 25: ...ration or maintenance of this machine is undertaken When parking use prop stand handrake and wheel chocks Compressor oil filling Diesel fuel No open flame Parking brake Rough Service Designation Wet L...

Page 26: ...ed air pressure Can cause serious injury or death Close service valve and operate tool to vent trapped air before performing any service WARNING WARNING Yellow background Indicates the presence of a h...

Page 27: ...ING Disconnected Air Hoses Whip CAN cause serious injury or death When using air tools attach safety device OSHA Valve at source of air supply for each tool Falling off machine CAN cause serious injur...

Page 28: ...NES SHIPPED TO MARKETS IN NORTH AMERICA Sheet 3 of 3 4 2 FREE SAFETY DECALS To promote communication of Safety Warnings on products manufactured by the Portable Compressor Division in Mocksville N C S...

Page 29: ...of any noise control device or an element of design incorporated into this compressor in compliance with the noise control act 2 The use of this compressor after such a device or an element of design...

Page 30: ...after discovery If severe enough to cause serious noise problems and efficiency loss shutdown immediately and correct the leak s B SAFETY AND CONTROL SYSTEMS Repair or replace all safety and control s...

Page 31: ...ondition and operation as recommended in 13 KUBOTA D1005 ENGINE section of this manual J FUELS AND LUBRICANTS Use only the types and grades of fuels and lubricants recommended in the Ingersoll Rand Re...

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Page 33: ...unit with guards covers or screens removed Keep hands hair clothing tools blow gun tips etc well away from moving parts 6 2 COMPRESSED AIR Compressed aircanbedangerousifincorrectlyhandled Before doin...

Page 34: ...ight does not exceed the maximum gross weight of the machine by limiting the equipment load limited by the capacity of the running gear NOTE Gross mass on data plate is for the basic machine and fuel...

Page 35: ...Portable Compressor 7 20 7 1 SEPTEMBER 2003 7 GENERAL INFORMATION 7 20 VARIABLE HEIGHT RUNNING GEAR 7 20 FIXED HEIGHT RUNNING GEAR Figure 7 1 GENERAL INFORMATION...

Page 36: ...R Performance 500 Ingersoll Rand Pro TecTM compressor fluid is factory fitted for use at all ambient temperatures above 23 C 9 F NOTE Warranty may be extended only by continuous use of Pro TecTM and I...

Page 37: ...ine section 7 4 FIXED HEIGHT RUNNING GEAR Unbraked version KNOTT Table 7 4 FIXED HEIGHT RUNNING GEAR UNBRAKED VERSION KNOTT ITEM VALUE SHIPPING WEIGHT 430 kg 948 lb MAXIMUM GROSS WEIGHT 500 kg 1 102 l...

Page 38: ...BLE HEIGHT RUNNING GEAR Braked version KNOTT Table 7 7 VARIABLE HEIGHT RUNNING GEAR BRAKED VERSION KNOTT ITEM VALUE SHIPPING WEIGHT 470 kg 1 036 lb MAXIMUM GROSS WEIGHT 500 kg 1 102 lb MAXIMUM HORIZON...

Page 39: ...rs of darkness ensure that the lights are functioning correctly where fitted Ensure that all transport and packing materials are discarded Ensure that the correct fork lift truck slots or marked lifti...

Page 40: ...E Open the service valve s to ensure that all pressure is relieved from the system Close the service valve s F Canopy CAUTION DO NOT OPERATE THE MACHINE WITH THE CANOPY IN THE OPEN POSITION AS THIS M...

Page 41: ...nt panel to the 0 OFF position 8 6 RE STARTING AFTER AN EMERGENCY If the machine has been switched off because of a machine malfunction thenidentifyand correct thefault beforeattempting to re start If...

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Page 43: ...From Fuel Filters C Coolant Leaks C Header Tank Cap C Fan Alternator Belts C Battery Connections Electrolyte C Tire Pressure and Surface C Wheel Lug Nuts C Hoses Oil Air Intake etc C Automatic Shutdo...

Page 44: ...ning gear bolts 1 C Scavenge line C Pressure system C Engine breather element C Pressure gauge C Pressure regulator C Separator tank 2 exterior CR Lubricator Fill C 2 000 Hours 2 Years 2 Years 4 Years...

Page 45: ...wn e g pressurised components electrically live components removed panels covers and guards extreme temperatures inflow and outflow of air intermittently moving parts safety valve discharge etc approp...

Page 46: ...r plate Remove the separator element B Inspection Examine the filter element Examine all hoses and tubes and replace if necessary C Reassembly Thoroughly clean the orifice drop tube and filter gasket...

Page 47: ...drain any sediment or condensate that may have accumulated in the tank 9 12 FUEL FILTER WATER SEPARATOR The fuel filter water separator contains a filter element which should be replaced at regular i...

Page 48: ...andbrake pivot The brake actuators must not be pre tensioned if necessary loosen the brake linkage 7 on the brake equalisation assembly 8 Check that brake actuators and bowden cables 11 operate smooth...

Page 49: ...re adjust ifnecessary A Important Check the brake actuators and bowden cables 11 The brake actuators must not be pre tensioned Ixcessive operation of the handbrake lever which may have been caused by...

Page 50: ...9 22 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 9 23 SPEED AND PRESSURE REGULATION ADJUS...

Page 51: ...ting screw and pivot Airend towards engine to slacken belt and remove belt from pulleys Fit new belt over pulleys pivot Airend away from engine and re engage adjusting screw Adjust drive belt tighteni...

Page 52: ...Fan to hub 16 20 12 15 Lifting bail to frame 39 47 29 35 Band clamp on oil pipes 96 119 71 88 Radiator Cooler to baffle 12 15 9 11 Running gear rear to chassis 82 93 63 69 Running gear drawbar to axle...

Page 53: ...40 6 I R XHP 505 I R XHP 1001 I R Performance 500 Mil L 46167 34 5 500 10 52 50 125 12 18 10 65 below 12 10 I R XHP 1001 I R XHP 505 Consult Factory Recommended Ingersoll Rand Fluids Use of these flui...

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Page 55: ...USE TS1 HIGH AIR TEMPERATURE SWITCH AIREND TS2 ENGINE HIGH WATER TEMPERATURE SWITCH PS1 ENGINE OIL PRESSURE SWITCH D1 D2 DIODE BLOCKING FP FUEL PUMP NP 1 4 NODE POINT RT1 RELAY TEMPERATURE SWITCH SV1...

Page 56: ...O Orange P Purple R Red S Grey U Blue W White Y Yellow Figure 10 2 SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM 1 Stop turn left hand 2 Tail left hand 3 Front side marker left hand 4 Front side...

Page 57: ...PIPING AND INSTRUMENTATION SYSTEM 1 Air discharge 2 Sonic orifice restricts flow 3 Pressure gauge 4 Separator tank 5 Safety valve 6 Compressor 7 Engine 8 Oil filter 9 Oil cooler 1 2 3 4 5 6 7 8 9 AIR...

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Page 59: ...S MANUAL CAUTION IF THE NYLON TUBES TO THE LUBRICATOR ARE DISCONNECTED THEN ENSURE THAT EACH TUBE IS RE CONNECTED IN THIS ORIGINAL LOCATION 12 2 GENERAL INFORMATION Oil capacity 2 l 0 53 gal Oil speci...

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Page 61: ...tributor All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication Ingersoll Rand reserves the right to...

Page 62: ...Mini Pump Injection pressure 13 73 MPa 1 991 psi Injection timing Before T D C 19 Compression ratio 23 Fuel Diesel Fuel No 2 D ASTM D975 Lubricant API classification above CD grade Dimensions length x...

Page 63: ...sed engine operation will be impaired Engine failure or malfunction resulting from use of such improper fuel will not be warranted by Ingersoll Rand To help avoid fuel system or engine damage please r...

Page 64: ...ngine startability performance oil consumption wear and the potential for seizure etc Always ensure that lubricants with the correct viscosity for the operating temperature are used Refer to Figure 13...

Page 65: ...TING FAN BELT 1 Fan belt 2 Bolt and nut A deflection of between A 7 9 mm 0 28 0 35 in under load of 100 N 22 1 lbf 1 2 2 A Figure 13 5 FAN BELT TENSION Table 13 3 FAN BELT TENSION Proper fan belt tens...

Page 66: ...osition 3 Place the speed control lever at more than half OPERATION A C D 2 1 B 1 Speed control lever 2 Engine stop lever A IDLE B OPERATION C START D STOP Figure 13 7 PLACE THE SPEED CONTROL LEVER A...

Page 67: ...CONDITION STOP THE ENGINE IMMEDIATELY If the engine coolant temperature gage where fitted shows an overheat condition or you have reason to suspect the engine may be overheating take the following st...

Page 68: ...to remove the cartridge type oil filter element taking care to prevent any oil spillage into the enclosure C Replacing the oil filter cartridge CAUTION BE SURE TO STOP THE ENGINE BEFORE CHANGING THE O...

Page 69: ...ately leave and keep yourself away fromthe machine Do not open the hood and any other part 4 Keep yourself and others well away from the engine for further 10 minutes or while the steam blown out 5 Ch...

Page 70: ...uelto the upper limit Do notoverfill No 2 D is a distillate diesel fuel of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 Table 13 6 GRADE OF DIESEL FUEL ACCORDING...

Page 71: ...UEL PIPES CAN CAUSE FIRES Check the fuel pipes every 50 hours of operation When if If the clamp band is loose apply oil to the screw of the band and tighten the band securely If the fuel pipes made of...

Page 72: ...element is clogged air intake resistance becomes greater and the dustindicator signalturnstored indicating the elementneeds to be changed When the signal turns tored replace the element Then pressthe...

Page 73: ...n the non metallic components of the cooling system and because of its low boiling point NOTE High silicate antifreeze is not recommended because of causing serious silica gelation problems NOTE Usage...

Page 74: ...d maintenance Table 13 8 SERVICE INTERVAL Interval Item Every 50 hours Check of fuel pipes and clamp bands See Table 13 9 INTERVAL OF ENGINE OIL Change of engine oil Cleaning of air cleaner element 1...

Page 75: ...regulation As the engine owner you are responsible for the performance of the required maintenance on the engine according to the above instruction Please see the Warranty Statement in detail Table 13...

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Page 77: ...side the fan cowl Excessive oil present in the discharge air Blocked scavenge line Perforated separator element Pressure in the system is too low Check the scavenge line drop tube and orifice Clean an...

Page 78: ...High compressor oil temperature Water present in fuel system Faulty relay Test the electrical circuits Check the oil level filter s Check the safety shut down switches Check the fuel level and fuel sy...

Page 79: ...mpression Bad valve or excessive wear of rings pistons and liners cause insufficient compression Replace with new parts Battery is discharged and the engine will not crank Charge the battery In winter...

Page 80: ...use Engine revolution suddenly decreases or increases Check the adjustments injection timing and the fuel system Unusual sound is heard suddenly Check all moving parts carefully Engine must be Color o...

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