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Machine Systems

Operation & Maintenance Manual

Key

BAT

Battery

PT2

Pressure transducer, regulation
system 0-100 PSIG

BDS

Battery disconnect switch

Plug, machine ID

RS232C comms

Relay-spst

ECON

Engine controller

RT1

Thermistor, separator tank
temperature -30-255°F

Engine speed

RT2

Thermistor, airend discharge
temperature -30-255°F

Caterpillar electronics ground
stud

ESTOP

Emergency stop

Frequency throttle.
Range=500Hz Base frequency
10%-90% pwm, 1350-1800 RPM
at 24VDC

Start compressor

Flywheel magnetic pickup

Switch inputs

POUT1

Engine key switch

Starter solenoid

POUT2

Solenoid, start/run

SW1

IQ filter restriction

POUT3

Low fuel warning beacon

SW2

Alert, low fuel

POUT4

Spare

SW3

Low fuel shutdown

POUT5

Start relay

SW4

Switch, service air

POUT6

Start compressor

SW5

Air filter rest (option)

POUT7

Hour meter

SW6

Switch, airend oil pressure
(12PSI N.O.)

POUT8

Solenoid, unloader

SW7

Spare

PT1

Pressure transducer, separator
tank.

SW8

Switch, start

0-225 PSIG-9/235, 9270, 0/300, 12/235

SWB

Switch battery disconnect

0-225 PSIG-HP935, VHP750, MHP825,
XP1060

Transducer excitation

0-500 PSIG-XHP750, XHP650, SHP825

WCON

Wedge controller

Содержание MHP825WCAT

Страница 1: ...x 868 501 Sanford Ave Mocksville N C 27028 Book 22560825 2 05 Revised 09 12 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of tradem...

Страница 2: ...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 cau...

Страница 3: ...d Air Leaks 19 B Safety and Control Systems 19 C Acoustic Materials 19 D Fasteners 20 E Enclosure Panels 20 F Air Intake and Engine Exhaust 20 G Cooling Systems 20 H Isolation Mounts 20 I Engine Opera...

Страница 4: ...Stopping the Machine 52 Emergency Stopping 53 Re Starting After an Emergency 53 Monitoring During Operation 53 Decommissioning 54 MAINTENANCE 55 Maintenance 56 Maintenance Interval Chart 56 Routine Ma...

Страница 5: ...pecification 70 Engine Oil Filter Element 70 Compressor Lubricating Oil 70 Running Gear Wheel Bearings 71 Speed and Pressure Regulation Adjustment 73 Speed and Pressure Regulation Adjustment 75 Torque...

Страница 6: ...TS Operation Maintenance Manual TITLE PAGE PARTS ORDERING 101 Parts Ordering 102 General 102 Description 102 Fasteners 103 Markings and Decals 103 How to Use Parts List 104 How to Order 104 Airend Exc...

Страница 7: ...5 Foreword...

Страница 8: ...mponents bearing the appropriate certification Where ASME certification is valid All components accessories pipes and connectors added to the compressed air system should be of good quality procured f...

Страница 9: ...ainst Ingersoll Rand The company accepts no responsibility for errors in translation of this manual from the original English version TABLE 1 IMPROPER USES Use of the machine to produce compressed air...

Страница 10: ...8 Always use Ingersoll Rand Replacement parts...

Страница 11: ...9 Warranty...

Страница 12: ...ee based and may require a maintenance agreement Formal enrollment is required Ingersoll Rand will provide a new part or repaired part at its election in place of any part which is found upon its insp...

Страница 13: ...ILABLE ON MAJOR COMPONENTS REFER TO OPERATOR S MANUAL ENGINE SEE BELOW 2 5kVA 8kVA GENERATORS PACKAGE 12 MONTHS 2 000 HOURS CONTACT IR NETWORK FOR WARRANTY PARTS ONLY NO LABOUR ALTERNATOR 12 MONTHS 2...

Страница 14: ...USING OEM FLUIDS AND FILTERS WITH 250 DEDUCTABLE IN GENERATORS 24 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 D...

Страница 15: ...Y AVAILABLE MITSUBISHI 24 2 000 2 YRS 4 000 HRS USING IR FLUIDS AND FILTERS VOLVO 24 2 000 2 YRS 4 000 HRS USING IR FLUIDS AND FILTERS PARTS MONTHS HOURS COMMENTS INGERSOLL RAND 6 UNLIMITED PARTS ONLY...

Страница 16: ...your records and mail form to Ingersoll Rand Company Portable Compressor Division P O Box 868 Mocksville North Carolina 27028 Attn Warranty Department NOTE Completion of this form validates the warran...

Страница 17: ...nment municipal state county etc Quarry Shallow Oil Gas Rental rental center rental fleet etc Building Contractor Water well Utility Company gas electric water etc Industrial plant use Other specify _...

Страница 18: ...Operation Maintenance Manual Warranty 16...

Страница 19: ...17 Noise Emission...

Страница 20: ...ch subsequent purchaser that this air compressor was designed built and equipped to conform at the time of sale to the first retail purchaser with all applicable U S EPA Noise Control Regulations This...

Страница 21: ...diately and correct the leak s B Safety and Control Systems Repair or replace all safety and control systems or circuits as malfunction occurs No compressor should be operated with either system bypas...

Страница 22: ...be inspected after each 100 hours of operation for loose damaged or deteriorated components Repairs or replacements should be made before the next period of use G Cooling Systems All components of th...

Страница 23: ...Operation Maintenance Manual 21 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK OR COMMENTS HOURMETER READING MAINT INSPECT DATE LOCATION CITY STATE WOR...

Страница 24: ...22 Always use Ingersoll Rand Replacement parts...

Страница 25: ...23 Safety Symbols...

Страница 26: ...inform your DANGER WARNING CAUTION NOTICE Indicates the presence of a hazard which WILL cause serious injury death or property damage if ignored Indicates the presence of a hazard which CAN cause seri...

Страница 27: ...Safety Symbols Operation Maintenance Manual 25...

Страница 28: ...Operation Maintenance Manual Safety Symbols 26...

Страница 29: ...Safety Symbols Operation Maintenance Manual 27...

Страница 30: ...ncorrectly handled Before doing any work on the unit ensure that all pressure is vented from the system and that the machine cannot be started accidentally Ensure that the machine is operating at the...

Страница 31: ...xpose 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...

Страница 32: ...30 Always use Ingersoll Rand Replacement parts...

Страница 33: ...31 General Information MSA SRG HRG...

Страница 34: ...Operation Maintenance Manual General Information MSA SRG HRG 32 General Information MSA SRG HRG...

Страница 35: ...General Information MSA SRG HRG Operation Maintenance Manual 33...

Страница 36: ...mperature F C 248 120 248 120 248 120 248 120 COMPRESSOR Cooling system Oil Injection Oil capacity Gallons Litres 18 5 70 19 8 75 19 8 75 18 5 70 Maximum oil system temperature F C 248 120 248 120 248...

Страница 37: ...ailable Power available at rated speed hp KW 275 205 275 205 275 205 275 205 Fuel tank capacity gal litre 145 550 145 550 145 550 145 550 Coolant capacity gal litre 12 7 48 12 7 48 12 7 48 12 7 48 Max...

Страница 38: ...nly at maximum load in open site conditions C US EPA 76dB A Site Running Gear SRG High Speed Running Gear HSRG Further information may be obtained by request through Ingersoll Rand customer services d...

Страница 39: ...37 Operating Instructions...

Страница 40: ...king materials are discarded Ensure that the correct fork lift truck slots or marked lifting tie down points are used whenever the machine is lifted or transported When selecting the working position...

Страница 41: ...ays 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 CAUTION Do not...

Страница 42: ...s relieved from the system Close the service valve s 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 n...

Страница 43: ...Operating Instructions Operation Maintenance Manual 41...

Страница 44: ...tch 14 2 High Compressor Temp Fault indicator lamp Indicates shutdown due to high compressor temperature 3 Low Radiator Coolant Level Alarm indicator lamp Indicates engine coolant needs service 4 Low...

Страница 45: ...ts 13 Inlet Heater Wait to Start Lamp Indicates engine manifold pre heater is energized Wait until lamp extinguishes before engaging starter 14 Panel Light Switch Controls panel lamp 1 15 Service Air...

Страница 46: ...shutdown due to low engine oil pressure 3 High Engine Coolant Temp Fault indicator lamp Indicates shutdown due to high engine water temperature 4 Low Fuel Level Fault indicator lamp Indicates shutdown...

Страница 47: ...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 requir...

Страница 48: ...e 35 CPRSR Malfunction 1 Safety Valve Open 36 CPRSR Malfunction 2 CAN derived data Separator Tank Temp 247 deg F 50 CPRSR Malfunction 3 Machine ID Not Valid 51 CPRSR Malfunction 0 Sep Tank Temp RT1 Se...

Страница 49: ...e Oil Pressure Low Coolant Level CUMMINS Engine Coolant Level Engine Coolant Temperature 215 deg F High Engine Temp Engine Coolant Temperature 220 deg F High Engine Temp 10 IQ Filter Restriction IQ Fi...

Страница 50: ...njector Actuation Pressure open short to batt Injector Actuation Pressure open short to ground 17 High Injection Actuation Pressure 18 Injection Actuation Control Valve open short 21 5 Volt Sensor DC...

Страница 51: ...emp open short to batt Intake Manifold Air Temp short to ground 39 Injector Actuation Press Sensor mechanical failure 42 Engine Timing calibration required 51 System Voltage intermittent erratic 53 El...

Страница 52: ...erate High Engine Coolant Temperature Shutdown High Engine Coolant Temperature Warning 64 High Inlet Air Temperature Derate High Inlet Air Temperature Warning 46 Low Engine Oil Pressure Derate Low Eng...

Страница 53: ...valve The wedge controller will execute a lamp test The low engine oil pressure and low battery lamps will flash indicating proper communication between wedge and engine ECM Inlet Heater Wait to Star...

Страница 54: ...the MAINTENANCE section of this manual and to the ENGINE MANUFACTURER S MANUAL Stopping the Machine Close the service valve Allow the machine to run unloaded for a short period of time to reduce the e...

Страница 55: ...een switched off because of a machine malfunction then identify and correct the fault before attempting to re start If the machine has been switched off for reasons of safety then ensure that the mach...

Страница 56: ...chine 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 relevan...

Страница 57: ...55 Maintenance...

Страница 58: ...Engine Oil Level C Radiator Coolant Level C Gauges Lamps C Air Cleaner Service Indicators C Fuel Tank Fill at end of day C D Fuel Water Separator Drain C Oil Leaks C Fuel Leaks C Drain Water From Fuel...

Страница 59: ...Check before towing CR Check and report D Drain G Grease R Replace T Test WI or when indicated if earlier Refer to specific sections of the operator s manual for more information Air Cleaner System C...

Страница 60: ...or Element R Compressor Oil Filter Element R Compressor Oil R Engine Oil Change R CAT Engine Oil Filter R CAT Water Pump Grease R Wheels Bearings Seals etc C Engine Coolant C R Fuel Filter Element Ser...

Страница 61: ...replace as necessary CBT Check before towing CR Check and report D Drain G Grease R Replace T Test W I or when indicated if earlier Refer to specific sections of the operator s manual for more informa...

Страница 62: ...eplace as necessary CBT Check before towing CR Check and report D Drain G Grease R Replace T Test W I or when indicated if earlier Refer to specific sections of the operator s manual for more informat...

Страница 63: ...dequately trained competent and have read the Maintenance Manuals Prior to attempting any maintenance work ensure that all air pressure is fully discharged and isolated from the system If the automati...

Страница 64: ...y long hair etc is made safe warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen Upon completion of maintenance tasks and prior to returning...

Страница 65: ...ne and tube are clear of any obstruction each time the compressor lubricant is changed as any blockage will result in oil carryover into the discharge air Compressor Oil Filter Refer to the MAINTENANC...

Страница 66: ...f a revolution 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...

Страница 67: ...ect all hoses and tubes to the separator tank cover plate Replace the compressor oil refer to LUBRICATION later in this section CAUTION Start the machine refer to PRIOR TO STARTING and STARTING THE UN...

Страница 68: ...antifreeze solution It is advisable to wear personal protective equipment to prevent skin and eye contact with the antifreeze solution Air Filter Element The air filter should be inspected regularly r...

Страница 69: ...ilation 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 h...

Страница 70: ...ENANCE INTERVAL CHART inspect all of the intake lines to the air filter and all flexible hoses used for air lines oil lines and fuel lines Periodically inspect all pipework for cracks leaks etc and re...

Страница 71: ...laced before the machine is put back into service Tire Pressure See the GENERAL INFORMATION section of this manual Running Gear Wheels Check the wheel nut torque 20 miles 30 kilometres after refitting...

Страница 72: ...se conditions 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...

Страница 73: ...h may be insoluble NOTE Always specify INGERSOLL RAND Pro TecTM oil for use at all ambient temperatures above 23 C For extended warranty use only IR fluids Refer to portable compressor fluids chart Ru...

Страница 74: ...e 72 Key A Adjusting screw E Orifice I Separator tank B Mini compressor F Regulation pressure transducer J Manual blowdown valve C Auto blowdown valve G Start Run solenoid K Unloader D Unloader soleno...

Страница 75: ...achine to maintain normal operating discharge pressure refer to GENERAL INFORMATION and full speed position If the tachometer moves away from the full speed position before normal operating discharge...

Страница 76: ...13 Pressure transducer 2 Butterfly valve 8 Start Run solenoid 14 Minimum pressure valve 3 Mini compressor 9 Pressure regulator 15 Separator tank 4 Unloader Solenoid 10 Panel pressure guage 16 Auto blo...

Страница 77: ...he screws holding bracket C to the main bracket J Allow the cylinder to return to its extended position and reconnect the ballast spring A IMPORTANT Ensure all components are aligned and move freely S...

Страница 78: ...Operation Maintenance Manual Maintenance 76 Torque Values...

Страница 79: ...Torque Ft Lbs Torque N m Torque Ft Lbs 13 wheel 80 90 M12 bolts 85 95 62 70 15 wheel 105 115 M14 bolts 145 155 107 115 16 wheel 105 115 M16 bolts 175 185 129 137 16 5 wheel 105 115 M18 bolts 205 215 1...

Страница 80: ...warranty Compressor oil carryover oil consumption may be greater with the use of alternative fluids Design Operating Pressure Ambient Temperature Specification 100 psi to 300 psi 10 F to 125 F 23 C to...

Страница 81: ...manual warranty section for details or contact your IR representative Ingersoll Rand Preferred Fluids 1 gal 3 8 Litre 5 gal 19 0 Litre 55 gal 208 2 Litre 220 gal 836 Litre Preferred IR Pro TecTM 3689...

Страница 82: ...80 Always use Ingersoll Rand Replacement parts...

Страница 83: ...81 Machine Systems...

Страница 84: ...Operation Maintenance Manual Machine Systems 82 Machine Systems Control System Schematic...

Страница 85: ...at 24VDC SC Start compressor G2 Flywheel magnetic pickup SI Switch inputs POUT1 Engine key switch SS Starter solenoid POUT2 Solenoid start run SW1 IQ filter restriction POUT3 Low fuel warning beacon S...

Страница 86: ...Operation Maintenance Manual Machine Systems 84 5 500Hz Base Frequency 10 90 plom 1350 1800 rpm 55...

Страница 87: ...36785319 MAG SPEED SENSOR 1 36898922 THERMISTOR PROBE 2 36840841 SOLENOID VALVE 2 36847838 AIR FILTER RESTRICTION INDICATOR SWITCH 2 36870608 ENGINE OIL PRESS SENDER 1 36841138 COMP ENGINE TEMP SENDER...

Страница 88: ...TROLLER 1 22202337 W1 CHASSIS HARNESS 1 54734116 W1 CHASSIS HARNESS DIAGRAM N A 22101968 INLET HEATER BREAKER 120 AMPS 1 36853521 INLET HEATER RELAY 1 89303127 EMERGENCY STOP OPERATOR 1 89303135 NC E...

Страница 89: ...MAG SPEED SENSOR 1 36898922 THERMISTOR PROBE 1 36842300 START RUN SOLENOID VALVE 1 36842318 COMPRESSOR SOLENOID VALVE 1 36847838 AIR FILTER RESTRICTION INDICATOR SWITCH 2 36870608 ENGINE OIL PRESS SEN...

Страница 90: ...73579 WEDGE CONTROLLER 1 22202337 W1 CHASSIS HARNESS 1 54734116 W1 CHASSIS HARNESS DIAGRAM N A 22101968 INLET HEATER BREAKER 120AMPS 1 89303127 EMERGENCY STOP OPERATOR 1 89303135 NC E STOP CONTACT BLO...

Страница 91: ...89 Fault Finding...

Страница 92: ...l starvation Check the fuel level and fuel system components Replace the fuel filter if necessary Relay failed Replace the relay Faulty stop solenoid Check the stop solenoid Engine stops while in serv...

Страница 93: ...n the holder and replace if necessary Engine Overheats Low water level Check the level and replenish if necessary Blocked radiator Stop the machine and clean the cooling fins with compressed air or st...

Страница 94: ...nd recommended oil Defective by pass valve Check the operation of the element and replace if necessary Recirculation of cooling air Move the machine to avoid recirculation Reduced cooling air from fan...

Страница 95: ...re Close the discharge valve and allow the machine to run on idle before stopping Faulty inlet valve Check for free operation of the inlet valve s Machine goes to full pressure when started Inlet valv...

Страница 96: ...94 Always use Ingersoll Rand Replacement parts...

Страница 97: ...95 Options...

Страница 98: ...Maintenance Manual Options 96 Options IQ System Operating Instructions 1 Key 1 Three way valve 5 Filters 2 Ball valve 11 4 6 Aftercooler 3 Ball valve 2 7 Minimum pressure valve 4 Safety valve 8 Separ...

Страница 99: ...em and delivers air quality equivalent to a standard oil flooded portable compressor If the IQ System is enabled by proper setting of the selector valve the compressed air first enters the aftercooler...

Страница 100: ...unted inside the control panel and 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...

Страница 101: ...cessive horsepower levels causing overheating reduced engine life and reduced airend life CAUTION Excessively restricted filter elements may cause an increase in the amount of aerosol water and oil ca...

Страница 102: ...100 Always use Ingersoll Rand Replacement parts...

Страница 103: ...101 Parts Ordering...

Страница 104: ...cities throughout the free world Special order parts may not be included in this manual Contact the Mocksville Parts Department with the unit serial number for assistance with these special parts Desc...

Страница 105: ...btain fasteners locally rather than ordering from the factory These parts are identified in tables that will be found at the rear of the parts illustrations Any fastener that has not been identified b...

Страница 106: ...nstructions are offered as a guide to the purchaser when ordering replacement parts a Always specify the model number of the unit as shown on the general data decal attached to the unit b Always speci...

Страница 107: ...ts or information regarding your local distributor Europe Middle East Africa please contact Office hours Monday Friday 8 00 a m to 4 30 p m GMT Facility Telephone Fax Ingersoll Rand Company 501 Sanfor...

Страница 108: ...106 Always use Ingersoll Rand Replacement parts...

Страница 109: ...2004 Ingersoll Rand Company Printed in the USA...

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