Ingersoll-Rand VHP300 Installation and operation manual

Operating & Maintenance Manual
Compressor Models
VHP300, HP375, XP375, P425 WIR
CODE: A & B
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
Book 22442578 (02/05)
Revised (10-12)
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 belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.

QUALITY POLICY
We will supply products and services 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 cause cancer, birth defects, and
other reproductive harm.

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TABLE OF CONTENTS
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FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Extended Limited Airend Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Complete Machine Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine Registration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
NOISE EMISSION CONTROL MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A. Compressed Air Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
B. Safety and Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
C. Acoustic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
D. Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
E. Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F. Air Intake and Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
G. Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
H. Isolation Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
I. Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
J. Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Safety Chains/Connections and Their Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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GENERAL ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lubricating Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Prior to Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Diagnostic/Auto Shutdown (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Starting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Push After Warm Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Dual Pressure when Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Emergency Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Re-Starting After an Emergency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Monitoring During Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Engine Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Fuels, Lubricants and Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Required Fuel Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Sulfur Content: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Bio-Diesel Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Handling and Storing Bio-Diesel Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Minimizing the Effect of Cold Weather on Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Supplemental Coolant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Coolant Drain Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Operating in Warm Temperature Climates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Lubrication and Maintenance Service Interval Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Lubrication & Maintenance/Daily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Daily Pre-starting Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Changing Engine Oil and Replacing Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
To change engine oil and oil filter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Cleaning Crankcase Vent Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Replacing Fuel Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner). . . . . . . . . . . . 76
Checking Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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Checking Tensioner Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking Engine Electrical Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes . . . . . . . . . 77
Replacing Fan and Alternator Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Bleeding the Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
At Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
At Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Do Not Modify Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
General Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Precautions for Welding on Engines Equipped with Electronic Engine Control Unit (ECU). . . . 80
Displaying of Diagnostic Trouble Codes (DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Intermittent Fault Diagnostics (With Electronic Controls). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Suggestions for diagnosing intermittent faults:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Possible causes of intermittent faults: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Engine Storage Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Preparing Engine for Long Term Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Removing Engine from Long Term Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Engine Crankcase Oil Fill Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Lubrication and Maintenance Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Using Lubrication and Maintenance Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Emission System Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Emissions Control System Certification Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Productive Shutdown System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Compressor Oil Cooler and Engine Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Air Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fuel Filter Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Charge Air Cooler Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Tyres/Tyre/Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Running Gear/Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Engine Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Engine Lubricating Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Engine Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Compressor Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Compressor Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Running Gear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Speed and Pressure Regulation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
MACHINE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Machine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Wedge to Engine Interface - IR Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Harness System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
J1939 CAN Communications Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
SERVICE TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Electronic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electrical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
FAULT FINDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

7
TABLE OF CONTENTS
Operating & Maintenance Manual
TITLE PAGE
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Options - Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Prior to Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

8
**Always use Ingersoll-Rand Replacement parts!**

22442578 9
Foreword

Operating & Maintenance Manual Foreword
10 22442578
Foreword
The contents of this manual are considered to be proprietary and confidential to Ingersoll-
Rand and should not be reproduced without the prior written permission of Ingersoll-Rand.
Nothing contained in this document is intended to extend any promise, warranty or
representation,expressedorimplied,regardingtheIngersoll-Randproductsdescribedherein.
Any such warranties or other terms and conditions of sale of products shall be in accordance
with the standard terms and conditions of sale for such products, which are available upon
request.
This manual contains instructions and technical data to cover all routine operation and
scheduled maintenance tasks by operation and maintenance staff. Major overhauls are
outside the scope of this manual and should be referred to authorised Ingersoll-Rand service
department.
The design specification of this machine has been certified as complying with EC directives.
As a result:
a. Any machine modifications are strictly prohibited, and will invalidate EC
certification.
b. A unique specification for USA/Canada is adopted and tailored to the territory.
All components, accessories, pipes and connectors added to the compressed air system
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 pressureat least equal to the machine maximum allowable working
pressure.
• compatible with the compressor lubricant/coolant.
• accompanied with instructions for safe installation, operation and maintenance.
Details of approved equipment are available from Ingersoll–Rand Service departments.
The use of repair parts/lubricants/fluids other than those included within the Ingersoll–Rand
approved parts list may create hazardous conditions over which Ingersoll–Rand has no
control. Therefore Ingersoll–Rand cannot be held responsible for equipment in which non–
approved repair parts are installed.
Ingersoll–Rand reserves the right to make changes and improvements to products without
notice and without incurring any obligation to make such changes or add such improvements
to products sold previously.
The intended uses of this machine are outlined below and examples of unapproved usage are
also given, however Ingersoll–Rand cannot anticipate every application or work situation that
may arise.
IF IN DOUBT CONSULT SUPERVISION.

Foreword Operating & Maintenance Manual
22442578 11
This machine has been designed and supplied for use only in the following specified
conditions and applications:
• Compression of normal ambient air containing no known or detectable additional
gases, vapours or particles.
• Operation within the ambient temperature range specified in the GENERAL
INFORMATION section of this manual.
UNITS MANUFATURED IN NORTH AMERICA: Generation of electricity at 120V (1ph) at 60
Hertz.
UNITS MANUFATURED IN EUROPE: Generation of electricity not applicable.
The use of the machine in any of the situation types listed in table 1:–
a) Is not approved by Ingersoll–Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll–Rand.
The company accepts no responsibility for errors in translation of thismanual from the original
English version.
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity checks.
Use of the machine outside the ambient temperature range specified in the GENERAL
INFORMATION SECTION of this manual.
This machine is not intended and must not be used in potentially explosive atmospheres,
including situations where flammable gases or vapours may be present.
Use of the machine fitted with non Ingersoll–Rand approved components/lubricants/ fluids.
Use of the machine with safety or control components missing or disabled.
Use of the machine for storage or transportation of materials inside or on the enclosure
except when contained within the toolbox.
GENERATOR
Use of the generator to supply load(s) greater than those specified.
Use of unsafe or unserviceable electrical equipment connected to the generator.
Use of electrical equipment:
(a) Having incorrect voltage and/or frequency ratings.
(b) Containing computer equipment and/or similar electronics.

12 22442578
**Always use Ingersoll-Rand Replacement parts!**

22442578 13
Warranty

Operating & Maintenance Manual Warranty
14 22442578
Warranty
Ingersoll-Rand, through its distributor, warrants that each item of equipment manufactured by
it and delivered hereunder to the initial user will be free of defects in material and
workmanship.
With respect to the following types of equipment, the warranty period enumerated below will
apply.
A. Aftercoolers - The earlier of nine (9) months from date of shipment to or six (6)
months from start up by initial user.
B. Portable Compressors, Portable Generator Sets (GENSET), Portable
Light Towers and Air Dyers - The earlier of twelve (12) months from shipment
to or the accumulation of 2,000 hours of service by the initial user.
C. Portable Compressor Air Ends - The earlier of twenty-four (24) months from
shipment to or the accumulation of 4,000 hours of service by the initial user. For
Air ends, the warranty against defects will include replacement of the complete
Air End, provided the original Air End, is returned assembled and unopened.
Portable Compressor Airend Limited Optional Warranty - The earlier of
sixty (60) months from shipment to or the accumulation of 10,000 hours of
service. The optional warrantyis limited to defects in rotors, housings, bearings
and gears and provided all the following conditions are met:
The original airend is returned assembled and unopened.
Continued use of genuine Ingersoll-Rand parts, fluids, oils and filters.
Maintenance is performed at prescribed intervals.
D. Genset Generators - The earlier of twenty-four (24) months form shipment to
or the accumulation of 4,000 hours of service by the initial user.
E. Portable Light Tower Generators - The earlier of twelve (12) months from
shipment to or the accumulation of 2,000 hours of service by the initial user.
Light Source model only, the earlier of twenty-four (24) months from shipment
to or the accumulation of 4,000 hours of service.
F. Ingersoll-Rand Engines - The earlier of twenty-four (24) months from
shipment to or the accumulation of 4,000 hours of service.
G. Ingersoll-Rand Platinum Drive Train Warranty (Optional) - Platinum drive
train pertains 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
service. The starter, alternator, fuel injection system and all electrical
components are excluded from the extended warranty. The airend seal and
drive coupling are included in the warranty (air-end drive belts are not
included). The optional warranty is automatically available when meeting the
following conditions:
The original airend is returned assembled and unopened.
Continued use of genuine Ingersoll-Rand parts, fluids, oils and filters.

Warranty Operating & Maintenance Manual
22442578 15
Maintenance is performed at prescribed intervals.
It is the obligation of the user to provide verification that these conditions have
been satisfied when submitting warranty claims.
H. Spare Parts - Six (6) months from date of installation
Ingersoll-Randwillprovideanew part orrepairedpart, at itselection,in place ofanypart which
is found upon its inspection to be defective in material and workmanship during the period
prescribed above. Such part will be repaired or replaced without charge to the initial user
during normal working hours at the place of business of an Ingersoll-Rand distributor
authorized to sell the type of equipment involved or other establishment authorized by
Ingersoll-Rand. User must present proof of purchase at the time of exercising warranty.
Theabovewarrantydoesnotapplytofailuresoccurring as a resultofabuse;misuse,negligent
repairs, corrosion, erosion and normal wear and tear, alterations or modifications made to the
product without express written consent of Ingersoll-Rand; or failure to follow the
recommended operating practices and maintenance procedures as provided in the product’s
operating and maintenance publications.
AccessoriesorequipmentfurnishedbyIngersoll-Rand,but manufactured by others,including,
but not limited to, engines, shall carrywhatever warranty the manufacturers have conveyed to
Ingersoll-Rand and which can be passed on to the initial user.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED,
(EXCEPT THAT OF TITLE) AND THERE ARE NO WARRANTIES OF MERCHANTABILITY
OR OF FITNESS FOR A PARTICULAR PURPOSE.

Operating & Maintenance Manual Warranty
16 22442578
General Warranty Information
GENERAL WARRANTY Extended
Coverage
Portable Compressor Package 1 yr/2000 Hours
Airend 2 yrs/4000 Hours
5 yrs/10,000 Hours
Limited Warranty, major
components (refer to
operator’s manual).
Portable Genset 8KW,
11KW, 20 KVA thru
575KVA Package 1 yr/2000 Hours None
Generator 2 yrs/4000 Hours None
Portable Genset 3.5KW
thru 7.0KW and 10KW Package 1 yr/2000 Hours
(parts only) None
Generator 1 yr/2000 Hours
(parts only) None
Light Tower Package 1 yr/2000 Hours
Generator 1 yr/2000 Hours 2 yrs/4000 hours, for Lightsource introduced
8/16/99.

Warranty Operating & Maintenance Manual
22442578 17
NOTE: Actual warranty times may change. Consult the manufacturer’s
warranty policy as shipped with each new product.
ENGINES
CATERPILLAR Months Hours Extended Coverage
12 unlimited Available at dealer
CUMMINS 24 2000 Major components 3 yrs/10,000 hrs
Available at dealer
JOHN DEERE (in compressors) 24 2000 5 yrs/5000 hrs using OEM fluids and filters
with $250 deductible
(in generators as of 1/1/01) 24 2000 2 yrs/4000 hrs using IR fluids and filters
DEUTZ 24 2000 Available at dealer
INGERSOLL-RAND 24 4000 5 yrs/10,000 hrs when using genuine Ingersoll-Rand fluids and parts. Refer to
operator’s manual.
KUBOTA (North America only) 24 2000 Major components 36 mo/3000 hrs (parts
only)
(Western Europe & Oceania) 24 2000 None
(Central & South America, Asia,
Middle East & Africa) 12 1000 None
MITSUBISHI 24 2000 2 yrs/4000 Hours using IR fluids and filters
VOLVO 24 2000 2 yrs/4000 Hours using IR fluids and filters
HONDA 12 unlimited None
VANGUARD 24 unlimited None
PARTS
Months Hours Coverage
Ingersoll-Rand 6 No Limit Parts Only
AIREND EXCHANGE
Airend Months Hours Extended Coverage
12 2000 2 yrs/4000 Hours - available from IR.

Operating & Maintenance Manual Warranty
18 22442578
Extended Limited Airend Warranty
Ingersoll-Rand Portable Compressor Division is pleased to announce the availability of
extended limited airend warranty. Announcement of the extended warranty coincides with the
introduction of Pro-TecTM Compressor Fluid. Pro-TecTM Compressor Fluid is an amber
coloured fluid specially formulated for Portable Compressors and is being provided as the
factory filled fluid for all machines except1XHP650/900/1070
All machines have the standard airend warranty - The earlier of 24 months from shipment to,
or the accumulation of 4000 hours of service by the initial user.
The warranty against defects will include replacement of the complete Airend, provided the
original airend is returned assembled and unopened.
The optional limited warranty is the earlier of 60 months from shipment to, or the accumulation
of 10,000 hours of service. The optional warranty is limited 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. Submissions of proof that Ingersoll-Rand fluid, filters and separators have been
used. Refer to the Operation and Parts manual for the correct fluids, filters and
separator elements required.
3. Submissions of proof that maintenance intervals have been followed.
*BARE AIREND - pertains to major airend parts (rotors, housings, gears and bearings).
**AIRENDCOMPONENTS -pertainsto auxiliary attachmenttothebare airend (seals, pumps,
valves, tubes, hoses, fittings and filter housing).
1XHP650/900/1070 will continue to use XHP505 and will have the extended warranty when
above conditions are met.
WARRANTY TIME *BARE AIREND **AIREND COMPONENTS
STANDARD 2YRS/4,000HRS 100% PARTS &
LABOUR 100% PARTS & LABOUR
OPTIONAL 5YRS/10,000HRS 100% PARTS &
LABOUR 0%
Pro-TecTM and XHP505 Compressor Fluids are available from your local Ingersoll-
Rand branch or distributor.
For units operating within the USA & Canada, call the Mocksville Product Support
Department on 1-800-633-5206

Warranty Operating & Maintenance Manual
22442578 19
Warranty Registration
For Units Sourced From Mocksville, USA
Complete Machine Registration
Machines shipped to locations within the United States do not require a warranty registration
unless the machine status changes (i.e. change of ownership).
Machines shipped outside the United States require notification be made to initiate the
machine warranty.
Fill out the Warranty Registration Form in this section, keep a copy for your records and
mail form to:
Ingersoll-Rand Company
P.O. Box 868
Mocksville, North Carolina 27028
Attn: Warranty Department
NOTE: Completion of this form validates the warranty.
Engine Registration:
I-R powered machines do not require separate engine registration.
John Deere requires a separate engine registration be completed and mailed direct to John
Deere.
Separate engine registration material is included with this literature package for John Deere
powered machines.
All other engine manufacturers do not require a separate engine registration.
You MUST present proof of in-service date at time of requesting engine warranty service.

Operating & Maintenance Manual Warranty
20 22442578
Complete the Applicable Blocks
Owner/User Type of Business (check one only)
Selling Distributor Servicing Distributor WARRANTY REGISTRATION
Name____________________ Name____________________ Owner/User Name__________
Address__________________ Address__________________ Address__________________
City_____________________ City_____________________ City _____________________
County___________________ County___________________ County___________________
State____________________ State____________________ State ____________________
Zip code__________________ Zip code__________________ Zip code__________________
Telephone________________ Telephone________________ Telephone ________________
 Construction-Heavy
(highway, excavation, etc.)
 Asphalt Contractor  Coal Mining  Other Mining
 Construction-Light
(carpentry, plumbing,
pools, mason, etc.)
 Government
(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 __________________
 Exploration  Utility Contractor
Model S/N Unit S/N Engine S/N Date delivered
Unit-Hours Airend S/N Truck S/N Truck Engine S/N
SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT
1. The Purchaser has been instructed and/or has read the manual and understands proper
preventative maintenance, general operation and safety precautions.
2. The warranty and limitation of liability has been reviewed and understood by the owner/user.
3. In the event that this unit is to be used within a nuclear facility, the owner/user shall notify
Ingersoll-Rand of such use so that Ingersoll-Rand may arrange for appropriate nuclear liability
protection from the owner-licensee of the facility.
4. Ingersoll-Rand reserves the right to make design changes or modifications of Ingersoll-Rand
products at anytime without incurring any obligation to make similar changes or modifications
on previously sold units.