Ingersoll-Rand HP600A-WCU User manual

COMPRESSOR
MODELS
HP600A-WCU
XP600A-WCU
P750A-WCU
HP750A-WCU
XP825A-WCU
P900A-WCU
. . .
·:INGERSOlLMND.
CONSTRUCTION & MINING
Portable Compressor Division
P.O. Box 868
~vme.N.C.27028
Book PIN 35386598 1992)
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COMPRESSOR NOISE EMISSION CONTROL:
INFORMATION ....-.,. ..
THIS COMPRESSOR CONFORMS TOU.S. E.PA. REGULATIONS FOR NOISE
EMISSK>NS APPLICABLE TO PORTABLE AIR COMPRESSORS, THE FOl·
LOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PR~
HIBITED BY THE NOISE CONTROL ACT OF 1972;, ~:
(A) THE REMOVAL OR RENDERING INOPERATIVE. OTHER THAN FOR
THE PURPOSE OF MAINTENANCE, REPAIR, OR REPlACEMENT, OF ANY
NOISE .CONTROL DEVICE OR ELEMENT OF DESIGN INCORPORATED
INTO ~ COMPRESSOR IN COMPLIANCE WITH THE NOISE CONTROl
ACT; ,".' ,
. "
(B) THE USE OF THIS COMPRESSOR AFTER SUCH DEVICE OR
ELEMENT OF DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE.
NOTE; The above Infannatlon applies only to units that are built In
compliance with the U.S. Environmental Protection Agency.
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•••• ~ •• ~~~ ••••• -
0.1 SAFETY WARNINGS (Book 35386598, 8192)
, I
IMPORTANT
SAFETY INSTRUCTIONS
LOOK FOR THESE SIGNS 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.
(Red Background)
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(Orange Background)
(Yellow Background)
NOTle6
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__.... .l;:.
.• , : .i_••.
•! • to J 'l-t'.... ."_ ;'4 ... : ....
.. .,
(Blue Background)
Indicates the presence of a hazard
which WILL cause severe injury,
death or property damage, if ig-
nored.
Indicates the presence of a hazard
which CAN cause severe injury,
death or property damage, if ignored.
Indicates the presence of a hazard
which WILL or can cause injury or
property damage, if ignored.
Indicates important set-up, operat-
ing or maintenance information.
•••••••••••••••••••••• •• ~~~~~~~w
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•
If the model number on this air compressor contains the let1ers "BAP", the
compressor is suitable for use in breathing air services. In the absence of
such a designation, the compressor is not considered as capable of
air of breathing quality. For a compressor to be capable of use in breathing air
services, it must be fit1ed with additional specialized equipment to properly
filter and/or purify the air to meet all applicable federal, state and local laws,
rules, regulations and codes, such as, but not limited to, OSHA 29 CFR
1910.134, Compressed Gas Association Commodity Specification
G-7.1-1966, Grade 0 Breathing Air, and/or Canadian Standards Association.
Should the Purchaser and/or User fail to add such specialized equipment and
proceeds to use the compressor for breathing air service, the Purdlaser/User
assumes all liability resulting therefrom without any responsibility or liability
being assumed by Ingersoll-Rand Company.
TAMPERING WITH
NOISE CONTROL
SYSTEM PROHIBITED
Federal law prohibits the follow-
ing acts or the causing thereof:
{1} The removal or rendering in-
operative by any persons, other
than for purposes of mainte-
nance, repair, or replacement, of
any device or element of design
incorporated into any new com-
pressor for the 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 device or
element of design has been re-
moved or rendered inoperative
by any person.
Among those acts included in
the prohibition against tampering are
these:
(1) Removal or rendering
inoperative any of the following:
The engine exhaust system or
parts thereof
The air intake system or
parts thereof
Enclosure or parts thereof
(2) Removal of any of the
following:
fan shroud
vibration mounts
sound absorption materia!
(3) Operation of the compres-
sor with any of the enclosure
doors
The Purchaser is urged to include the above provisions in any agreement
for any resale ollhis compressor.
0.2 SAFETY WARNINGS ( Book 35386598,
8/92)
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'~I•••••••••••••••••••••••••••••
0.31 SAFETY WARNINGS ( Book 35386598, 8/92J
DANGER I
Air discharged from this ma-
chine may contain carbon mon-
oxide or other contaminants
which will cause severe injury or
death. Do not breathe this air.
I WARNING I
Never operate unit without first
observing all safety warnings
and carefully reading the opera-
tion and maintenance manual
shipped from the factory with
this machine.
This machine contains high
pressure air which can cause
severe injury or death from hot
oil and flying parts. Always re-
lieve pressure before removing
caps, plugs, covers or other
parts from the pressurized air
system.
I WARNING,
Never operate the engine of this ma-
chine inside a building without ade-
quate ventilation. Avoid breathing
exhaust fumes when working on or
near the machine.
Do not alter or modify this machine
without the express written consent
of Ingersoll-Rand Company.
Air pressure can remain trapped in an
air supply line which can result in seri-
ous injury or death. Always vent air
supply line at tool or vent valve before
performing any service.
Unrestricted air flow through a hose
end will result in a whipping action
which can cause severe injury or
death. Always attach a safety flow re-
strictor to each hose "at the source of
"supply or branch line" in accordance
with OSHA Reg. 29CFR Sect.
1926.302(b).
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I WARNING I
Do NOT remove the cap from a
hot radiator.
A battery contains sulfuric acid
and can give off gases which
are potentially explosive. No
sparks, open flame or smoking
near battery. See operator's
manual for instructions on use
of booster cables. In case of
accident, flush skin or eyes
with water. Immediately obtain
medical help.
This machine produces loud
noise with the doors open or ser-
vice valve vented. Extended ex-
posure to loud noise can cause
hearing loss. Always wear hear-
ing protection when doors are
open or service valve is vented.
Rotating fan blade can cause
severe injury. Stop this ma-
chine before performing main-
tenance.
Do not store or transport
material in or on the unit.
I WARNING I
Never run unit with guards, covers
or screens removed. Keep hands,
hair, clothing, tools, blow gun tips,
etc. well away from moving parts.
Do not use petroleum products
(solvents or fuels) under high pres-
sure as this can penetrate the skin
and result in serious illness. Wear
eye protection while cleaning unit
with compressed air to prevent de-
bris from injuring eye(s}.
Always make sure wheels, tires
and tow bar connectors are in safe
operating condition and tow bar is
properly connected before towing.
Towing this vehide at. excessive
speeds orwith underrated tow vehicle
can result in loss ofdriving control and
greater stopping distances. Always
determine the maximum safe towing
-speed and tow vehicle rating before
towing. See General Data Decal lo-
cated on machine or specifications in
this manual, Section 2 for maximum
speed and gross weight for compari-
son.

•
0.5 SAFETY WARNING:i:Sj 1(( EBl~O~Ok~3::538~6~598~. 8~/9~2 ---'
I CAUTION!
1M ••• M ••••
Use Extreme care to avoid
contacting hot surfaces (en-
gine exhaust manifold and
piping, air receiver and air dis-
charge piping, etc.),
Do not connect the air dis-
charge on this unit onto a com-
mon header with any other
unit of any description, or any
other source of compressed
air, without first making sure a
check valve is used between
the header and the unit. If this
unit is connected in parallel
with another unit of higher dis-
charge pressure and capacity,
a safety hazard could occur in
a back-flow condition.
! NOTICE I
Towing Speed Umit
2 Wheel and Tandem
4 Wheel - 50 mph
4 Wheel (wagon steering) - 20 mph
Ether is an extremely volatile, high-
ly flammable gas. USE SPARING-
LYI If too much is injected, the un-
controlled explosion may result in
costly damage to the engine.
Never allow the unit to sit stopped
with pressure in the receiver-sepa-
rator system. As a precaution, open
the service valve.
Disconnect battery before servicing
unit.
Collapsing jackstand can cause
personal injury or property
damage. Stand to one side and
insure pin is FULLY inserted.
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SAFETY WARNINGS
TABLE OF CONTENTS/ FOREWORD
GENERAL DATA
OPERATING INSTRUCTIONS
PREVENTIVE MAINTENANCE
LUBRICATION
PRESSURE REGULATION ADJUSTMENT
TROUBLE SHOOTING
PARTS ORDERING INFORMATION
PARTS LIST
Section
_1.~
TABLE OF CONTENTS (Book 35386598.8/92)
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I 1.11 FOREWORD (Book 35386598,8192)1 1
During the preparation of this manual every effort was made to ensure the ade-
quacy and accuracy of the contents. Only in this manner can the owner be pro-
vided with a tool that will aid him in obtaining maximum performance and trou-
ble-free service from the compressor. Since all classes of equipment require
a certain amount of attention, the purpose of this manual is to acquaint an oper-
ator with the functions, operation and lubrication of the compressor. This man-
ual also provides the owner with the maintenance requirements applicable to
the various components designed or selected for incorporation into this unit.
Special attention has been given in an effort to make sure that only compo-
nents built with the very best materials and the finest workmanship have been
used, thus reducing the maintenance requirement to a bare minimum.
Before starting the compressor, the instructions should be carefully read to ob-
tain athorough knowledge of the duties to be performed. Take pride in the com-
pressor, keep it clean, and in good mechanical condition. For complete protec-
tion and minimum down-time to facilitate the maintenance effort that is re-
quired, it is suggested that a complete set of recommended spares be kept on
hand during and after the first few months of operation. For recommended
spares, replacement parts or information regarding the condition or operation
of your unit or for major servlclnp not covered in this manual, consult your near-
est sales office, autonomous company or authorized distributor. Be sure to
specify the model and serial number of the compressor during any correspon-
dence with a company representative.
In addition to preventive maintenance, the compressor airend may require
overhauling to maintain maximum output and performance of the unit. Your
Ingersolf-Rand Company Construction Equipment Group Sales Offices and
authorized distributors as well as Ingersoll-Rand Intemational autonomous
companies and authorized distributors now have a compressor airend ex-
change program, therefore we do not recommend overhaul of the airend by
the customer. However, we do recognize the fact that circumstances may
warrant field overhaul of the airend. Prior to any disassembly or reassembly
of the airend we strongly suggest the owner contact the Customer Service
Department, Ingersolf-Rand Company, Mocksville, North Carolina, 27028 for
their advice and suggestions.
For the purpose of encouraging proper malntenance,lngersolf-Rand Company
is providing a Maintenance Log Book (Form PCD685) with each compressor
shipped from the factory. This Log Book contains a performance schedule for
all required noise emission control maintenance. Space is provided in this log
book so that the owner of this compressor can note what maintenance was
done, by whom, where and when.

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••••••••••
e·
•••••••
• _. jl
XP600A P750A HP750A XPB25A P900A
Model HP600A
Rated Delivery:
825
900
600 750 750
-cfm 600 390 425
355 355
-litres/sec 285 285
Rated Pressure: 100
125 100 150 125 -psi 150
1050 875 700
-kPa 1050 875 700
Cummins Engine Model:
225 225
1
290 290 290
LT10C- 225
Engine (Diesel) _________ ---1800
Full Load Speed-rpm--__________ 00
---- --- 12
No Load Speed-rpm- - ------- - -- - - - --
-- --- 24
Electrical Systenr-voIL __________________
Overaillengtll--1n. (mm) ____________________ 192 (4877)
) -------- 79 (2007)
Overall widtb-in, (mm - - - - - - - - - - - --
. ) -------- 91 (2311)
Overall heighHn. (mm _____________
. ------------ 68 (1727)
Track wid~n. (mm) - - - - - - - - --
-------- 9900 (4490)
Weight, ready to rurHb. (kg) - - - - - - - - E
. R --------- 8.75x16.5/
Tire Size/Load ange ___________
( Jd) ----- 75 psi (520 kPa)
Inflation Pressure co ____________
Maximum Safe Towing Speed - - - - - - - - - - - - 50 mph (80 km I hr)
Fluid Capacities . ____ 23.0 U.S. Gallons (87Iitres)
Compressor Lubricant, Refill - - - - - .
~ 100 U S Gallons (380 litres)
Fuel Tank (Use clean DIESEL fuel) ----- ..
Engine Crankcase Lubricant
-
-------
9.0 U.S. Gallons (34 litres)
(including filter)
15.0 U.S. Gallons (57 litres)
Engine Coolant (Radiator) - - - - - - - - --

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•••••••••••••••••••••••••••••••••
2.1 OPERATING CONTROLSIINST.. Book 35386598,8/92
G
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1. Compressor Discharge Pressure Gauge -
Indicates pressure in receiver tank, normally from
o psi (kPa) to the rated pressure of the machine.
2. Lamp - Controlled by Switch 11 below.
3. Engine Tachometer - Indicates engine
speed in RPM from 0when stopped to full
speed.
4. Discharge Air Temperature Gauge-
Indicates in OF and °c. Normal operating range:
18SoF/8SoC to 230 °F/11 0-c.
5. Fuel Level Gauge - Indicates amount of fuel
in tanks.
6. Engine 011Pressure Gauge - See En'gine
Operation Manual for normal range.
continued -
[ J
36516649

7. Hounneter - Records running time for maintenance purposes.
8. Voltmeter - Indicates battery condition.
9. Engine Water Temperature Gauge - Indicates coolant
temperature, with normal operating range from
1£'O°F{82°C) to 21O°F(99°C).
CONTROLS
10. Power Switch - Flip "On" to operate, "Off'to stop.
11. Lights Switch - Operates Lamp 2 and those within gauges.
12. Heaters Switch - Activates control system heaters for
operation below 32°F(°C).
13. Service Air Button - After warm up. provides full air pressure
at the service outlet.
14. Bypass Button - Bypasses automatic shutdown circuit.
15. Start Button - Activates the engine starter.
16. Ether Inject Button - Injects a measured shot.
USE SPARINGLY.
DIAGNOSTICS / AUTOMATIC SHUTDOWN
17. High Compressor Temperature - 248°F(120°C) or more.
18. Low Engine 011 Pressure - 12 psi or less.
19. High Engine Ternperature s- Coolant above 215°F (102°C).
20. Low Fuel Level- Comes on first as a warning and
eventually triggers a shutdown.
21. Altemator Not Charging - Needs attention.
22. Low Coolant Level- Dangerously low; needs attention.
23. Air Filters Restricted - Need servicing.
_._-' -
L

I CAUTION~
.......•.•
• Failure to follow these instruc-
tions could result in very serious
personal injury or death.
• Do net store or transport material
or equipment in or on compressor.
• Towing vehicle must have a trailer
capacity of 10,000 Ibs. (4550 kg)
minimum and dual rear wheels.
• Hydraulic brakes do not work
while backing.
BEFORE TOWING
• Engage the parking brake and
chock wheel of the compressor.
The brakes are engaged when the
brake lever is in a horizontal posi-
tion .
• Check the mounting bolts for the
brake actuator and pintle eye for
any looseness or wear. Tighten or
replace these as required. Ensure
that there are two (2) nuts per pintle
eye bolt.
Torque: Brake actuator mounting
bolts:
290 Ibs.-ft. (390 N. m).
Pintle eye mounting bolts:
170 Ibs.-ft. (230 N. m).
• Check brake fluid level and top-oft
reservoir as required. Use Dot -3
fluid.
O STRUCTIONS Book 35386598, 8/92
3. OPERATING IN
.. ft It •••• " " " • " " " 4!t 4!t e • 4!Left, ••••••• e l.9 It 9
• Check condition of the brake
lines, hoses and cables for any
damage (leaks, abrasions, cuts,
fraying, dents, etc.). Make ad-
justments, repairs or. replace-
ment as required at this time.
• Position the tow vehicle to
align its hitch with the pintle eye
of the compressor.
• Engage the parking brake and
chock the wheels of the compres-
sor.
• Stand ASIDE while:
- Operating the jack at the draw-
bar of the compressor to seat the
pintle eye onto the hitch. of the
tow vehicle. Secure the hitch.
• Attach safety chains by cross-
ing under brake actuato~ allow-
ing enough slack for turninq,
• Attach brake actuator break-
away chain to the tow vehicle di-
rectly above the hitch.
• If so equipped, connect the
plug for the running lights to the
tow vehicle.
• Raise and swing up the [ack.:
and fully insert the pin to lock in
the up position.
• Remove the compressor
wheel chocks and release the
compressor parking brakes

3.1 OPERATING INSTRUCTIONS Book 35386598, 8/92
TOWING NOTICE
• Check the operation of the com-
pressor brakes by performing a
sudden stop from approximately
5mph(8kmJhr).All four (~)wheels
on the trailer should lock-up and
skid the tires. If this doesn't hap-
pen, the brake system should be oil, compressor oil, radiator cool-
checked and corrections made. ant, etc.) should be checked and
•The maximum safe towing speed topped-off while the unit is levet.
is50mph(80kmJhr)underdry road
conditions and slower under ad- BEFORE STARTING
verse conditions.
DISCONNECT AND SET-UP
o Engage parking brakes and chock
wheels of both tow vehicle and
compressor.
• Stand ASIDE while:
- Withdraw pin, swing jack down
and fully insert pin to lock in down
position.
- Disconnect safety chains from tow
vehicle.
- Disconnect brake actuator chain
from tow vehicle.
- If so equipped, disconnect run-
ning light plug from the tow vehicle.
- Operate drawbar jack to raise
pintle eye from hitch of tow vehicle.
• Move tow vehicle.
• Level the compressor while
standingto one side of thedrawbar.
This compressor is designed to
operate in a maximum out-oHe-
vel condition of fifteen degrees
(15), from the horizontal, in any
direction. All fluid levels (engine
I CAUTION~
'M PM ••• PM.
Do not connect the air
discharge on this unit into a
common header with any
other unit of any descnonon,
or any other source of
compressed air, without first
making sure a check valve is
used between the header
and the unit. If this unit is
connected in parallel with
another unit of higher
discharge pressure and
capacity, a safety hazard
could occur in a back-flow
condition.
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~,"Ii Ii.. iii•• ,. lit ~ ..... i -
•••••••••••••
BEFORE STARTlNG{cont'd)
I WARNING I
Unrestricted air flow from a
hose will result In a whipping
motion of the hose which can
cause severe injury or death. A
safety device must be attached
to the hose at the source of
supply to reduce pressure in
case of hose failure or other
sudden pressure release.
Reference: OSHA regulation
29 CFR Section 1926.302 (b).
• Open service valve to ensure
pressure is relieved in receiver-
separator system. Close valve
in order to build up full air pres-
sure and ensure proper oil circu-
lation .
• Check battery for proper con-
nections and condition .
• Check the compressor lubricating
oil level. The proper oil level is mid-
way on the sight gauge. Add oil if
the level falls to the bottom of the
sight gauge WHEN THE UNIT IS
RUNNING AT FULL LOAD. Do not
overfill. If necessary, refer to Sec- ~
lion 5 - Lubrication for recom-
mended lubricant.
• Check the engine lubricating oil
level. Add oil if Iowan dipstick. Re-
fer to the engine Manual for recom-
mended Jubricant
I NOTICE I
The use of water alone in this eng ina
can result in major engine failure. See
Engine Manual for proper coolant.
• The engine coolant level is
monitored by a sensor in the ra-
diator top tank with a lamp on the
control panel. See page 2.1/2.2.
It is recommended to check the
coolant level and condition at the
filler neck periodically .
• Check the fuel level. Add only
CLEAN DIESEL fuel for maximum
service from the engine. Refer to
the engine Operator's Manual for
fuel specifications.
I NOTICE I
To minimize oondensation (water)
in the fuel tank, fill the tank at the
end of each day.
I WARNING I
This machine produces loud
noise with doors open. Ex·
tended exposure to loud noise
can cause hearing loss. Wear
hearing protection when doors
or valve (s) are open.
•••
3.2 OPERATING INSTRUCTIONS
-
Book 35386598, 8/92
-~-------~~~~~-'''~~''~~''~~~=-~Ak~------------~--------------------------------------------------~
Ak .... _
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3.3 OPERATING INSTRUCTIONS Book 35386598,
8192 .:
r
- Close the side doors to maintain
a cooling air path and to avoid re-
circulation of hot air, This will max-
imize the life of the engine, and
compressor and protect the. hear-
ing of surrounding personnel.
Be sure no one is IN or ON the
compressor unit.
I CAUTION~
.....•..• -
Exercise extreme caution when
using a booster battery to start.
To [urnp-etart, connect the ends
of one booster cable to the posi-
tive (+) terminals of each battery.
Then connect one end of the oth-
er cable to the negative (-) termi-
nal of the booster battery and the
other end to the engine block
NOT TO THE NEGATIVE (-) TER-
MINAL OF THE WEAK BATTERY.
After starting:
a. Reduce engine speed to
Idle.
b. Disconnect the negative (-)
cable from engine block;
then from booster battery.
c. Disconnect posItive (+)
cable from both batteries.
STARTING
-In freezing weather, flip HEATERS
switch "On" and wait sixty (60) seconds.
This applies heat to the control system
components for easier starting. Leave
this switch "On"while operating at these
temperatures .
STARTING cont'd
- Flip the POWER switch to "On", All
DIAGNOSTICS lamps will light (glow)
for two (2) seconds. Then all lamps
should go off except for ALTERNATOR
NOT CHARGING and LOW ENGINE
OIL PRESSURE.
Ether Is an extremely volatile, high.
Iy flammable gas. Use sparlnglyl If
too much Is Injected, the uncon-
trolled explosion may result In cost-
ly damage to the engine.
-In cold weather, press the ETHER IN-
JECT button once and release', Then,
while cranking, presslrelease hutton
QfiQSl every five (5) seconds. This in-
jects a measured amount of ether to
the engine.
- Press both the STAAT and the BY-
PASS buttons to crank the engine.
DO NOT OPERATE THE STARTER
MOTOR FOR MORETHAN TEN (1 O)
SECONDS WITHOUT ALLOWING
AT LEAST ONE MINUTE COOLING
TIME BETWEEN START AT-
TEMPTS.
- Release the START button when the
engine starts and sustains running. If
the engine does not start atteracouple
of attempts" refer 'to Section 7 -
Trouble Shooting.
. ~~~~~~-~-----------------------
%€ .

• Release the BYPASS button after two
(2)to three (3) seconds.
• All DIAGNOSTIC lamps should be
off. If not, stop the machine and in-
vestigate.
• Watch the gauges while the unit
warms up for five (5) to ten (10) min-
utes or until the coolant temperature
reaches 140
0
F (60
0
C).
• Push the SERVICE AIR button. The
engine should go to full speed and
the discharge pressure rise to slight-
ty over rated pressure. If there is no
air being consumed, the compres-
sor will unload (intake be throttled or
closed) and the engine speed drop
to the no load speed.
• Compressor is now ready to furnis.h
air when the service valve IS
opened.
STOPPING
• Close air service valve (~).
• Allow the unit to run at "no load"
tor 3 to 5 minutes to reduce the
engine temperatures.
• Flip ail toggle switches to "Off".
NOTICE
Once the engine stops, the auto-
matic blowdown valve will begin
to relieve all pressure from the re-
ceiver: separator system.
I. ~~~;~'?~ J
Never allow the unit to sit stopped
with pressure in the receiver-se-
parator system. As a precautlon,
after the .automatic blowdown pe-
riod (2 minutes), open the manual
blowdown valve.
EQUIPMENT PROTECTION
NOTICE
Do NOT wire around or bypass a
shutdown sensor or switch.
All units in this family of machines
are protected by five (5) sens~rs or
switches at the followmg locations:
(1) High engine COOLANT tem-
perature in the engine.
(2) Low engine oil pressure, in the
engine.
(3) Low Fuel Level.
High Discharge AIR Tempera-
ture-
-{4) At the airend outlet.
(5) In the top cover on the separa-
tor tank.
Book 35366598, 8/92

3.5 OPERATING CONTROLSIINST. Book 35386598, 8/92
AUTOMATIC SHUTDOWN IDIAGNOSTICS
Should any of these problem situations occur, the
unit will automatically shutdown and stop. BEFORE
restarting the unit or flipping the POWER switch to
"OW, check the DIAGNOSTICS area on the instru-
ment panel.
The upper four (4) lamps are electronically Mlatched"
to only respond to the first or primary signal for a
shutdown. In other words, if the automatic shut-
down is the result of one of these four problems,
only that particular problem lamp will be lit. And the
lamp will remain lit as long as the batteries provide
power.
Refer to OPERATING CONTROLS AND INSTRU-
MENTS, page 2.1/2.2 forthe various problem signal
criteria (OF,psi, etc.). The indicated problem area
should be inspected for a physical cause (low fluid,
broken fan belt, evidence of excessive heat, etc.)
and corrections made.
Sensors (1) through (4) will automatically reset
when the problem condition is corrected. The latter
sensor (5 ) employs a fusible material that melts at
approximately 280° F (138°C). This fusible sensor
MUST be replaced if activated. This would indicate
a serious airend system problem that must bathor-
oughly investigated and corrected before returning
the unit to operation.
Other possible causes for an unexpected shutdown
are listed on the Trouble Shooting chart in Section
7.

Hoses 4.7 Preventive Maint. Schedule. .. 4.18
CONTENTS
General 4.0 Compressor Oil Filter 4.8
Scheduled Maintenance 4.0 Fasteners. . . . . . . . • . . . . . . . . .. 4.9
Compressor Oil Level 4.1 Compressor Oil 4.9
Air Cleaner 4.1 Running Gear. . . . .. . . . . . . . . .. 4.10
Gauges ·4.4 Receiver-5eparator System 4.11
Fuel Tank 4.4 Scavenge Une . . . • . . . . . . . . . . 4.12
Battery 4.4 Separator Element 4.13
Tires 4.4 Separator Element 4.14
Automatic Shutdown System .. 4.5 Exterior Finish Care 4.15
Compressor Oil Cooler 4.6 Cooling Fan Drive. . . . . . .. . . .. 4.16
Radiator 4.6 Brake System 4.16
GENERAL
In addition to periodic Inspections, many of the components in these units require
periodic servicing to provide maximum output and performance. Servicing may
consist of pre-operation and post- operation procedures to be performed by the
operating or maintenance personnel. The primary function of preventive mainte-
nance is to prevent failure, and consequently, the need for repair. Preventive
maintenance is the easiest and the least expensive type of maintenance. Main-
taining your unit and keeping it clean at all times will facilitate servicing.
Refer to the engine Operator's Manual furnished with the unit for the specific re-
quirements on preventive maintenance for the engine.
SCHEDULED MAINTENANCE
Th e schedule on page 4-16 is based on normal operation of the unit. This page
can be reproduced and used as a checklist by the service personnel. Inthe event
unusual environmental operating conditions exist, the schedule should be ad-
justed accordingly.
(Book 35386598,8/92) I
••••••

4. 1 PREVENTIVE MAINTENANCE ( Book 35386598,8/92)
COMPRESSOR OIL LEVEL
The oil level is most consistent when the unit is RUNNING AT
FULL LOAD and should be checked at this time. The optimum
operating level is midway of the sight tube on the side of the re-
ceiver tank. See the decal beside the sight tube. If the oil level
is not in the "OK" range, make appropriate corrections (Add or
Drain).·A totally filled sight tube in which the level is not visible
indicates an over-full condition and requires that oil be drained.
AIR CLEANER
This unit is equipped with an AIR FILTERS RESTRICTED lamp
on the instrument panel, covering both the engine and the com-
pressor. This should be checked daily during operation. If the
lamp glows (red) with the unit operating at full speed, servicing
of the cleaner element is necessary.
Also weekly squeeze the rubber valve (precleaner dirt dump) on
each air cleaner housing to ensure that they are not clogged.
NOTIC E: Holes or cracks downstream of the air cleaner housi ng
will cause the restriction indicators to be ineffective .
. :
I--I'-~-_-----. -_ --~----------.. -=-~",..,.-~-.- -_ ~ .....- --.---,.,._- - - - ...~__ ~__!I!!l_ -_ ..._ ... __ =:-c_.;...;;::'---''''-,_....;;;; ___

GAUGES
The instruments or gauges
are essential for safety, maxi-
mum productivity and long
service life of the machine. In-
spect the gauges and test any
diagnostic lamps prior to
start-up. During operation
observe the gauges and any
lamps for proper functioning.
Refer to Section 2, Operating
Controls, for the normal read-
ings. To test the diagnostic
lamps, refer to the instruc-
tions on the control panel.
FUEL TANK
This unit is equipped with
multiple tanks.. Using clean
fuel in the fuel tanks is vitally
important and every precau-
tion should be taken to ensure
that only CLEAN fuel is either
poured or pumped into the
tank.
When filling the fuel tank on
this unit, by methods other
than a pump and hose, use a
CLEAN non-metallic funnel.
Every six months the drain plug
should be removed trom the tank so
that any sediment or accumulated
condensate may be drained. When
replacing a drain plug, make sure it
is tightened securely.
BATTERY
Heavy-duty, diesel cranking
type batteries were installed at
the factory and these should be
inspected weekly. Keep the bat-
tery posts-to-cable connections
clean, tight and lightly coated
with a grease. In non-sealed
batteries, the electrolyte level in
each cell should cover the top of
the plates. If necessary, top-up
with clean distilled water.
TIRES
A weekly Inspection is recom-
mended. The proper inflation pres-
sure for the tires is listed in Section
2- .specifications. Tires that have
cuts or cracks or little tread should
be repaired or replaced. Monthly
check the wheel lug nuts for tight-
ness.