Ingersoll-Rand HP935 Operation And Maintenance Manual Download Page 2

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HP935, VHP750, MHP825, XHP750, XP1060

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.

Summary of Contents for HP935

Page 1: ...E MARCH 2003 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...

Page 2: ...HP750 MHP825 XHP750 XP1060 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 reproductiv...

Page 3: ...Speed pressure regulation Torque settings table Compressor lubrication 44 MACHINE SYSTEMS Electrical system Piping instrumentation system 49 FAULT FINDING 51 OPTIONS 53 PARTS ORDERING ABBREVIATIONS S...

Page 4: ...should be of good quality procured from a reputable manufacturer and wherever possible be of a type approved by Ingersoll Rand clearly rated for a pressure at least equal to the machine maximum allowa...

Page 5: ...suitable filtration and purity checks Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION of this manual Use of the machine where there is any actual...

Page 6: ...to the Ingersoll Rand Engine and Airend combination The earlier of sixty 60 months from shipment to or the accumulation of 10 000 hours of operationby the initial user The starter alternator fuel inj...

Page 7: ...ALTERNATOR 12 MONTHS 2 000 HOURS EXTENDED WARRANTY OF 24 MONTHS 4 000 HRS FOR LIGHTSOURCE INTRODUCED 8 16 99 ENGINE SEE BELOW ENGINES MONTHS HOURS COMMENTS CATERPILLAR 12 UNLIMITED EXTENDED WARRANTY P...

Page 8: ...00 HRS USING IR FLUIDS AND FILTERS VOLVO 24 2 000 2YRS 4 000 HRS USING IR FLUIDS AND FILTERS PARTS MONTHS HOURS COMMENTS INGERSOLL RAND 6 UNLIMITED PARTS ONLY AVAILABLE FROM IR NETWORK AIREND EXCHANGE...

Page 9: ...d to 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 Subm...

Page 10: ...tn Customer Service Department Note Completion of this form validates the warranty Engine Registration I R powered machines do not require separate engine registration Deutz require a separate engine...

Page 11: ...keep a copy for your records and mail form to Ingersoll RandCompany P O Box 868 Mocksville North Carolina 27028 Attn Warranty Department Note Completion of this form validates the warranty Engine Reg...

Page 12: ...rvice Provider Details Company Name Service Provider Distributor Contact Name Branch Office Signature Company Address Machine Details Product Type Model Serial Number Engine Serial Number Engine Model...

Page 13: ...red Orange Background CAUTION Indicates the presence of a hazard which WILL or can cause injury or property damage if ignored Yellow Background NOTICE Indicates important set up operating or maintenan...

Page 14: ...km hr Do not operate without guard in place Rotating fan blade Can cause serious injury Access lifting bail from inside machine Falling off machine Can cause serious injury or death Door under pressur...

Page 15: ...re that decals are present on the machines Replace decals that are not readable FREE SAFETY DECALS This engine is equipped with an electric heater starting aid DO NOT USE ETHER ENGINE DAMAGE WILL OCCU...

Page 16: ...e purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the compressor after such a device or element of design has been removed or ren...

Page 17: ...so that the purchaser or owner can record what maintenance was done by whom where and when Detailed instructions on the maintenance items below are given on the following page MAINTENANCE SCHEDULE IT...

Page 18: ...that their noise containment function is reduced should be repaired or replaced before the next operation interval Doors access panels and hatch closures especially should be checked and adjusted at...

Page 19: ...HP935 VHP750 MHP825 XHP750 XP1060 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK OR COMMENTS HOURMETER READING MAINT INSPECT DATE LOCATION CITY STATE...

Page 20: ...pressurised by another Compressed air must not be used for a direct feed to any form of breathing apparatus or mask The discharged air contains a very small percentage of compressor lubricating oil a...

Page 21: ...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...

Page 22: ...GENERAL INFORMATION MSA SRG HRG 20 HP935 VHP750 MHP825 XHP750 XP1060 SRG HRG...

Page 23: ...1 8 1 8 1 Operating ambient temperature range W F C 14 115 10 46 14 115 10 46 14 115 10 46 14 115 10 46 14 115 10 46 14 115 10 46 14 115 10 46 Operating ambient temperature range HA F C 14 122 10 50 1...

Page 24: ...ended only by continuous use of Pro Tec and Ingersoll Rand oil filters and separators No other oil fluids are compatible with Pro TecTM No other oils fluids should be mixed with Pro TecTM because the...

Page 25: ...tion of the machine ensure that there is sufficient clearance for ventilation and exhaust requirements observing any specified minimum dimensions to walls floors etc Adequate clearance needs to be all...

Page 26: ...ontent not greater than 0 5 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...

Page 27: ...o compressor system fault Refer to Fault Code List 10 Low Battery Voltage Alarm indicator lamp Indicates battery or charging system requires service 11 Engine Malfunction Engine Fault code Refer to se...

Page 28: ...Oil Temperature 252 deg F 5 CPRSR Malfunction Intake Manifold Temperature 180 deg F 6 CPRSR Malfunction Water In Fuel CUMMINS 8 CPRSR Malfunction Engine Not Responding To Throttle command 10 CPRSR Ma...

Page 29: ...t Going To Max RPM Prior To Load 57 CPRSR Malfunction Serial Comm Problem 70 CPRSR Malfunction CAN Bus Problem 71 CPRSR Malfunction Communication With Autostart Module Lost 73 CPRSR Malfunction 0 Dedi...

Page 30: ...et Pressure open short to batt 273 04 102 04 Turbo Outlet Pressure short to ground 26 274 03 108 03 Atmospheric Pressure open short to batt 26 274 04 108 04 Atmospheric Pressure short to ground 27 110...

Page 31: ...lant Temperature Shutdown 017 0110 15 High Engine Coolant Temperature Warning 64 025 0172 16 High Inlet Air Temperature Derate 64 027 0172 15 High Inlet Air Temperature Warning 46 039 0100 18 Low Engi...

Page 32: ...o run unloaded for a short period of time to reduce the engine temperature Turn the ON OFF start switch to the 0 off position NOTE As soon as the engine stops the automatic blowdown valve will relieve...

Page 33: ...machine In particular Do not destroy batteries or components containing asbestos without containing the materials safely Do not dispose of any pressure vessel that is not clearly marked with its relev...

Page 34: ...Alternator Belts C Battery Connections Electrolyte C Tire Pressure and Surface C Wheel Lug Nuts C Hoses Oil Air Intake etc C Automatic Shutdown System C Air Cleaner System C Compressor heat exchanger...

Page 35: ...ck C Shutdown Switch Settings T Scavenger Orifice Related Parts C Oil Separator Element R Feed Pump Strainer Cleaning C Valve Clearance Check C Lights running brake turn CBT Pintle Eye Bolts CBT Brake...

Page 36: ...l C 2 Yrs 4 Yrs 6 Yrs Safety valve C Hoses R Separator tank 2 interior C Disregard if not appropriate for this particular machine 1 or 3000 miles 5000km whichever is the sooner 2 or as defined by loca...

Page 37: ...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...

Page 38: ...compressor oil refer to LUBRICATION later in this section CAUTION Start the machine refer to PRIOR TO STARTING and STARTING THE UNIT in the OPERATING INSTRUCTIONS section of this manual and check for...

Page 39: ...ANCE CHART Caterpillarpowered units are equipped with primary and secondary fuel filters CHARGE COOLER PIPEWORK Inspect all hoses and clips on the charge cooler pipe work Engine damage will occur if t...

Page 40: ...ions or has suffered long shutdown periods then more frequent service intervals will be required WARNING DO NOT under any circumstances remove any drain plugs or the oil filler plug from the compresso...

Page 41: ...er to STARTING INSTRUCTIONS in the OPERATING INSTRUCTIONS section of this manual Adjust the service valve on the outside of the machine to maintain normal operating discharge pressure refer to GENERAL...

Page 42: ...e pivot shaft K fully clockwise until the valve is closed Position lever L approximately 10 after vertical and tighten screw D Keep the butterfly lever in the closed position and with the the air cyli...

Page 43: ...D MARKING TYPICAL RECTANGULAR TORQUE PATTERN CAPSCREW OR NUT THREAD SIZE AND PITCH TYPICAL SQUARE TORQUE PATTERN Nm FT LBF Nm FT LBF 1 4 20 11 8 16 12 5 16 18 24 17 33 25 3 8 16 42 31 59 44 7 16 14 67...

Page 44: ...MARKING TYPICAL RECTANGULAR TORQUE PATTERN CAPSCREW OR NUT THREAD SIZE AND PITCH TYPICAL SQUARE TORQUE PATTERN Nm FT LBF Nm FT LBF Nm FT LBF M6 X 1 0 11 8 15 11 18 13 M8 X 1 25 26 19 36 27 43 31 M10...

Page 45: ...F to 125 F 10 C to 52 C 10 F to 65 F 12 C to 18 C below 10 F 12 C IR XHP1001 IR XHP 505 Consult Factory IR XHP505 IR XHP1001 IR PER FORMANCE 500 IR PRO TEC 100 300 PSI RATED OPERATING PRESSURE 350 PS...

Page 46: ...MACHINE SYSTEMS 44 HP935 VHP750 MHP825 XHP750 XP1060 CONTROL SYSTEM SCHEMATIC...

Page 47: ...r PT1 Pressure transducer separator tank 0 225 PSIG 9 235 9270 0 300 12 235 0 225 PSIG HP935 VHP750 MHP825 XP1060 0 500 PSIG 21 215 17 235 XHP750 PT2 Pressure transducer regulation system 0 100 PSIG P...

Page 48: ...ROLLER FREQ THT ENGINE ECM WEDGE TO ENGINE INTERFACE ENGINE ECM DIAGNOSTIC INTERFACE CONTROLL PANEL HARNESS SOLENOID VALVES 24VDC HEATERS GUAGES HOURMETER CONTROL PANEL SWITCHES WEDGE CONTROLLER SPEED...

Page 49: ...S SENDER 1 36841138 COMP ENGINE TEMP SENDER 2 36757581 COMP OIL PRESS SW 1 36850691 COMPRESSOR MOTOR 1 35577873 RELAY MAGNETIC 24 VOLT K1 1 36841526 CONTROL HEATER 2 36854677 REGULATOR HEATER 1 223197...

Page 50: ...ESTRICTION INDICATOR SWITCH 2 36870608 ENGINE OIL PRESS SENDER 1 36841138 COMP ENGINE TEMP SENDER 2 36757581 COMP OIL PRESS SW 1 36850691 COMPRESSOR MOTOR 1 35577873 RELAY MAGNETIC 24 VOLT K1 1 368415...

Page 51: ...or oil level and oil cooler Check the fan drive Water present in fuel system Check the water separator and clean if required Faulty relay Check the relay in the holder and replace if necessary Engine...

Page 52: ...in the MAINTENANCE section of this manual Loose pipe hose connections Check all pipe hose connections Faulty safety valve Check the relieving pressure Replace the safety valve if faulty DO NOT ATTEMP...

Page 53: ...ng systems or any manual adjustment to prevent freezing of the compressed air system All drain points for the condensate handling system are heated with 24VDC heaters which are integral to the compres...

Page 54: ...d will shut down the compressor if restriction exceeds recommended values Weekly Maintenance Remove Y strainer screens at the bottom of the moisture separator and both filters and clean out any residu...

Page 55: ...y and in location relative to the other parts in the assembly The part number the description of the part and the quantity of parts required are shown on each illustration or on adjacent page The quan...

Page 56: ...ited to the exact terms contained herein If purchaser s order form is used for acceptance of an offer it is expressly understood and agreed that the terms and conditions of such order form shall not a...

Page 57: ...oppage impairment of other goods loss by reason of shutdown or non operation increased expenses of operation or claims of customers of Purchaser for service interruption whether or not such loss or da...

Page 58: ...751 1579 US Canada 336 751 4325 Latin America 336 751 4325 Asia Pacific Facility Office hours Monday Friday 8 00 a m to 5 30 p m EST Telephone 44 0 1942 257 171 Fax 44 0 1942 523 417 Facility Office...

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Page 61: ...Printed in the United Kingdom...

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