Ingersoll-Rand R4-11 kW, Product Maintenance Information

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EN
EN-2 80448517 Rev A
CONTENTS
ABOUT THIS MANUAL
PERSONNEL
SAFETY
Proper use, inspections and maintenance increases the life and usefulness
of the compressor. It is extremely important that anyone involved with
maintaining the compressor be familiar with the servicing procedures of
these compressors and be physically capable of conducting the procedures.
These personnel shall have skills that include:
1. Proper and safe use and application of mechanics common hand
tools as well as special
Ingersoll Rand
or recommended tools.
2. Safety procedures, precautions and work habits established by
accepted industry standards.
Some maintenance procedures are technical in nature and require
specialized tools, equipment, training and experience to accomplish
correctly. In such situations, only allow
Ingersoll Rand
trained technicians
to perform maintenance on this compressor. Service or inspections beyond
the procedures given in this manual shall not be attempted by operating
personnel.
For additional information contact the
Ingersoll Rand
factory or the nearest
service provider.
Before undertaking any work on the compressor, ensure that the electrical
supply has been isolated, locked off, tagged and the compressor has been
relieved of all pressure. For VSD units, ensure the compressor is electrically
isolated for at least 15 minutes before commencing any maintenance work.
Ensure the compressor’s remote start/stop feature has been switched off
prior to any maintenance. See the Safety Information manual for additional
information.
Ingersoll Rand
cannot know of or provide all the procedures by which
repairs may be conducted and the hazards and/or results of each method. If
maintenance procedures not specifically recommended by the manufacturer
are conducted, ensure that safety is not endangered by the actions taken.
If you are unsure of a maintenance procedure or step, place the compressor
in a safe condition before consulting technical assistance.
The use of other than genuine
Ingersoll Rand
replacement parts may result
in safety hazards, decreased performance and increased maintenance and
may invalidate all warranties.
For additional information contact the Ingersoll Rand factory or the nearest
service provider.
The purpose of this manual is to provide maintenance and troubleshooting guidelines for the compressor.
For supporting documentation refer to Table 1.
Table 1: Product Manuals
Publication Product
Part/Document Number by Region
Americas EMEA * Asia Pacific
Safety Information Manual R4-160kW 80446313 80446156 80446321
Maintenance Manual R4-11kW 80448517 80448525 80448533
Product Manual R4-11kW 80448483 80448491 80448509
Parts Information Manual R4-11kW 80448541
* Europe, Middle East and Africa
Product specification sheets and reference drawings are also available.
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
AIR COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sampling Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Changing Coolant Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Checking Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Changing Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspecting Airend/Pressure System/Receiver . . . . . . . . . . . . . . . . . . . . 5
Cleaning / Checking Scavenge Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning / Checking Blowdown Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking Minimum Pressure Check Valve (MPCV) . . . . . . . . . . . . . . . 6
Changing Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning Air Cooled Combination Cooling System . . . . . . . . . . . . . . . 6
Removing / Installing Air Cooled Cooler . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking High Airend Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning Motor Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removing / Replacing Starter Box Power Drive Element (PDM)
Filter Element (For VSD Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning / Checking Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning / Installing Package Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . 7
Monitoring Fluid and Performing Shock Pulse Bearing Analysis . . 7
Aftermarket Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Changing Pulleys / Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
R4-11 INTEGRATED DRYER MAINTENANCE . . . . . . . . . . . . . . . . . 15
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly of the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Decommissioning the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . 18
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
RELEASED 16/Dec/2014 10:49:53 GMT