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Ingersoll-Rand 7120 manual

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Table of contents for the manual

  • Page 1

    7/120, 9/1 10, 10/105, 14/85 7/170, 10/125, 14/1 15 This manual contains important safety information and must be made available to personnel who operate and maintain this machine. 7/120 9/1 10 –> SERIAL No : 320001 10/105 14/85 C.C.N. : 22191225 GB DA TE : SEPTEMBER 2003 OPERA TION AND MAINTENANCE MANUAL 7/170 10/125 14/1 15[...]

  • Page 2

    Machine models represented in this manual may be used in various locations world–wide. Machines sold and shipped into European Union T erritories require that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modificati[...]

  • Page 3

    Machine models represented in this manual may be used in various locations world – wide. Machines sold and shipped into European Union T erritories require that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modifica[...]

  • Page 4

    1 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) 1 CONTENTS 2 FOREWORD 3 W ARRANTY 9 DECALS 13 SAFETY 16 GENERAL INFORMA TION Dimensions Data 21 OPERA TING INSTRUCTIONS Commissioning Prior to starting Starting Stopping Emergency stopping Re – starting Monitori[...]

  • Page 5

    2 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) 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 contain[...]

  • Page 6

    3 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) W ARRANTY 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[...]

  • Page 7

    4 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) GENERAL W ARRANTY INFORMA TION GENERAL W ARRANTY Extended Coverage Portable Compressor Package 1 year/2000 hrs Airend 2 yrs/4000 hrs 5 yrs/10,000 hrs Limited warranty , major compo- nents (refer to operator ’ s [...]

  • Page 8

    5 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) P ARTS Months Hours Coverage Ingersoll – Rand 6 No Limit Parts Only AIREND EXCHANGE Months Hours Extended Coverage Airend 12 2000 2 yrs/4000 hrs – available from IR. Note: Actual warranty times may change. Con[...]

  • Page 9

    6 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Extended Limited Airend W arrant y Ingersoll – Rand Portable Compressor Division is pleased to announce the availability of extended limited airend warranty . Announcement of the extended warranty coincides with[...]

  • Page 10

    7 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) W ARRANTY REGISTRA TION FOR UNITS SOURCED FROM HINDLEY GREEN, UK Com plete Machine Registration T o initiate the machine warranty , fill out the ” W arranty Registration ” form 83242 1 1/99 supplied as part of[...]

  • Page 11

    8 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Sellin g Distributor Servicin g Distributor W ARRANTY REGISTRA TION Name Name Owner/User Name Address Address Address City City City County County County State State State Zip code Zip code Zip code T elephone T e[...]

  • Page 12

    9 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) DECALS Look for these signs on machines manufactured in Europe, which point out potential hazards to the safety of you and others. Read and understand thoroughly . Heed warnings and follow instructions. If you do [...]

  • Page 13

    10 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) 0  C W ARNING – Flammable liquid . W ARNING – Before connecting the tow bar or commencing to tow consult the operation and maintenance manual. W ARNING – For operating temperature below 0  C, consult [...]

  • Page 14

    11 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Do not stand on any service valve or other parts of the pressure system. Do not operate with the doors or enclosure open. Do not use fork lift truck from this side. XX km/h Do not exceed the trailer speed limit. [...]

  • Page 15

    12 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Replace any cracked protective shield. Oil drain. Engine Oil Fuel level/point Pressure control Malfunction Battery charging condition Low pressure High pressure Engine malfunction High compressor temperature Comp[...]

  • Page 16

    13 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) SAFETY W ARNINGS W arnings call attention to instructions which must be followed precise l y t o a v o i d i n j u r y o r d e a t h . CAUTIONS Cautions call attention to instructions which must be followed preci[...]

  • Page 17

    14 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Whenever the machine is stopped, air will flow back into the compressor system from devices or systems downstream of the machine unless the service valve is closed. Install a check valve a t the machine service v[...]

  • Page 18

    15 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Ensure front (towing eye) section is set level When raising towing eye, set rear joint first, then front joint. When lowering towing eye, set front joint first, then rear joint. After setting, fully tighten each [...]

  • Page 19

    16 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) MANUF ACTURED IN EUROPE FRONT VIEW SIDE VIEW REAR VIEW T OP VIEW 7/120 9/1 10 10/105 14/85 P425A WIR XP375A WIR HP375A WIR VHP300A WIR All dimensions in inches(mm) A Instrument panel access door B Package air inl[...]

  • Page 20

    17 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) MANUF ACTURED IN EUROPE FRONT VIEW SIDE VIEW REAR VIEW T OP VIEW 7/170 10/125 14/1 15 P600WIR HP450WIR VHP400WIR All dimensions in inches(mm) A Instrument panel access door B Package air inlet C Access items: Sep[...]

  • Page 21

    18 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) COMPRESSOR Actual free air delivery . 12,0 m 3 min – 1 (425 CFM) (7/120) (P425A WIR) Actual free air delivery . 10,5 m 3 min – 1 (375 CFM) (9/1 10) (XP375A WIR) Actual free air delivery . 10,5 m 3 min – 1 ([...]

  • Page 22

    19 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) BELOW – 23  C( – 9 _ F) Mandatory: IR Performance 500 Ingersoll – Rand Pro – Tec TM compressor fluid is factory – fitted, for use at all ambient temperatures above – 23  C( – 9  F). NOTE: W[...]

  • Page 23

    20 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) V ARIABLE HEIGHT RUNNING GEAR (European Only) Braked version (7/120) ( 9/1 10), (10/105), (14/85) Shipping weight. 1965kg (4331Lbs) Maximum weight. 2200kg (4850Lbs) Maximum horizontal towing force. 2009kg (4429Lb[...]

  • Page 24

    21 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) OPERA TING INSTRUCTIONS PRIOR T O ST ARTING 1. Place the unit in a position that is as level as possible. The design of the unit permits a 15 degree lengthways and sideways limit on out of level operation. It is [...]

  • Page 25

    22 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) 8 4 91 0 11 12 1 3 5 13 6 7 14 Control Panel 2 DIAGNOSTIC/AUT O SHUTDOWN (ST ANDARD) 1. Compressor fault – Needs attention. See Wedge diagnostic panel for more detail. 2. Engine Fault – Needs attention. See W[...]

  • Page 26

    23 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) WEDGE DIAGNOSTIC DISPLA Y P ANEL. The W edge diagnostic display panel is arranged as shown above. A description of each diagnostic indicator is as follows. 1. High Compressor T emp : Fault indicator lamp. Indicat[...]

  • Page 27

    24 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Wedge Diagnostic Display Codes If the fault indicator lamp is illuminated, refer to the Alert/Shutdown list below . If the fault indicator lamp is illuminated, refer to the Engine diagnostic list below . ALERT/SH[...]

  • Page 28

    25 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Alert Shutdown Condition Code Light (Blinks) Code Light (Steady) Delay (sec.) Dedicated Lights: Low Fuel Level Fuel Level Fuel Level 3 Air Filter Restriction (Option) Soiled Filter Low Battery V oltage Battery Ch[...]

  • Page 29

    26 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Listing of Diagnostic Trouble Codes (DTCs) Displayed Code FMI* Definition 16 Fuel T emperature Moderately High 190 0 Engine Overspeed Extreme 16 Engine Overspeed Moderate 620 3 Sensor Supply V oltage High 4 Senso[...]

  • Page 30

    27 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) ST ARTING THE MACHINE W ARNING: Under no circumstances should volatile liquids such as Ether be used for starting this machine. 1 3 2 All normal starting functions are incorporated in the key operated switch. . T[...]

  • Page 31

    28 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) If the machine has been switched of f for reasons of safety , then ensure that the machine can be operated safely before re – starting. Refer to the PRIOR TO ST ARTING and ST ARTING THE UNIT instructions earlie[...]

  • Page 32

    29 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) ENGINE Engine Serial Number Plate Each engine has a 13 – digit engine serial number . The engine ’ s serial number plate is located on the right – hand side of cylinder block behind the fuel filter . Fuels,[...]

  • Page 33

    30 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) IMPORT ANT : DO NOT store diesel fuel in galvanized containers. Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes. If fuel contains water, a zinc gel will also [...]

  • Page 34

    31 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Diesel Engine Coolant The engine cooling system is filled to provide year – round protection against corrosion and cylinder liner pitting, and winter freeze protection to – 37  C ( – 34  F). Low silic[...]

  • Page 35

    32 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Lubrication and Maintenance Service Interval Chart NOTE: The Service intervals below are for standard industrial engines. See details in Sections which follow these charts. Item Lubrication and Maintenance Servic[...]

  • Page 36

    33 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Lubrication & Maintenance/Daily Daily Pre – starting Checks Do the following BEFORE ST ARTING THE ENGINE for the first time each day: Check engine oil level on dipstick. IMPORT ANT : DO NOT add makeup oil u[...]

  • Page 37

    34 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Engine is equipped with a primary fuel filter (or pre – filter) with water bowl and a final filter . Both filters are replaced at the same 500 – hour interval. CAUTION: Escaping fluid under pressure can penet[...]

  • Page 38

    35 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes NOTE: If system is to be filled with coolant that does not contain SCAs, the coolant must be precharged. Through time and use, the concen[...]

  • Page 39

    36 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) At Fuel Injection Nozzles IMPORT ANT : Always use a backup wrench when loosening or tightening fuel lines at nozzles and/or injection pump to avoid damage. 1. Using two open – end wrenches, loosen two fuel line[...]

  • Page 40

    37 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Symptom Problem Solution Engine cranks but will not start Incorrect starting procedure. V erify correct starting procedure. No fuel. Check fuel in tank. Exhaust restricted. Check and correct exhaust restriction. [...]

  • Page 41

    38 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Symptom Problem Solution Engine runs irregularly or stalls frequently Low coolant temperature. Remove and check thermostat. Clogged fuel filter . Replace fuel filter element. W ater , dirt, or air in fuel system.[...]

  • Page 42

    39 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Symptom Problem Solution Low oil pressure Low oil level. Add oil. Improper type of oil. Drain, fill crankcase with oil of proper Viscosity and quality . High oil consumption Crankcase oil too light. Use proper vi[...]

  • Page 43

    40 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Symptom Problem Solution Engine overheats Engine overloaded. Reduce load. Low coolant level. Fill radiator to proper level, check radiator and hoses for loose connections or leaks. Faulty radiator cap. Have techn[...]

  • Page 44

    41 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Symptom Problem Solution Battery uses too much W ater Cracked battery case. Check for moisture and replace as necessary . Defective battery . T est battery . Battery charging rate too high. T est charging system.[...]

  • Page 45

    42 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Intermittent Fault Diagnostics (With Electronic Controls) Intermittent faults are problems that periodically “ go away ” . A problem such as a terminal that intermittently doesn ’ t make contact can cause a[...]

  • Page 46

    43 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Removing Engine from Long T erm Storage Refer to the appropriate section for detailed services listed below or have your authorized servicing dealer or engine distributor perform services that you may not be fami[...]

  • Page 47

    44 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Number of Cylinders 4 Bore 106 mm (4.19 in.) Stroke 127 mm (5.0 in.) Displacement 4.5 L (276 cu in.) Compression Ratio 17.0:1 Aspiration T urbocharged Engine Firing Order 1 – 3 – 4 – 2 V alves Per Cylinder [...]

  • Page 48

    45 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) The EP A and CARB warranties only apply to new engines having the certification label affixed to the engine and sold as stated above in the geographic areas. The presence of an EU number in the third line of the [...]

  • Page 49

    46 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) MAINTENANCE Initial 500 miles /850 km Daily W eekly Monthly 3 Mont hly . 250 hrs. 6 Mont hly . 500 hrs 12 Monthly . 1000 hrs Compressor Oil Level C Engine Oil Level C *Radiator Coolant Level C Gauges/Lamps C *Air[...]

  • Page 50

    47 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Initial 500 miles /850 km Daily Weekly Monthly 3 Monthly . 250 hrs. 6 Monthly . 500 hrs 12 Monthly . 1000 hrs 18 Monthly . 1500 hrs *Fuel/W ater Separator Element R Compressor Oil Filter Element R Compressor Oil [...]

  • Page 51

    48 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Initial 500 miles /850 km Daily W eekly Monthly 3 Mont hly . 250 hrs. 6 Mont hly . 500 hrs 12 Monthly . 1000 hrs Scavenge line C Pressure system C Engine breather element C Pressure gauge C Pressure regulator C S[...]

  • Page 52

    49 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) . anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts. . the machine cannot be started accidently or otherwis[...]

  • Page 53

    50 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Disconnect all hoses and tubes from the separator tank cover plate. Remove the drop – tube from the separator tank cover plate and then remove the cover plate. Remove the separator element. Inspection Examine t[...]

  • Page 54

    51 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) FUEL F IL TER W ATER SEP ARA TOR Th e fuel filter water separator contains a filter element which should be replaced at regular intervals (see the SER VICE/MAINTENANCE CHAR T ). CHARGE AIR COOLER PIPEWORK Inspect[...]

  • Page 55

    52 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) The brake actuators must not be pre – tensioned – if necessary loosen the brake linkage [7] on the brake equalisation assembly [8]. Check that brake actuators and cables [1 1] operate smoothly . 7 Brake linka[...]

  • Page 56

    53 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Check the play in the brake linkage [7] and re – adjust if necessary . Important Check the brake actuators and cables [1 1]. The brake actuators must not be pre – tensioned. Excessive operation of the handbra[...]

  • Page 57

    54 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) SPEED AND PRESSURE REGULA TION ADJUSTMENT Normally , regulation requires no adjusting, but if correct adjustment is lost, proceed as follows: Refer to the diagram above. A: Adjusting screw Start the machine (Refe[...]

  • Page 58

    55 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) T ABLE 1 INCH F ASTENERS NOMINAL DESIGN T ORQUE 8AE J249 GRADE 5 (HEAD MARKING) 8AE J249 GRADE 8 (HEAD MARKING) TYPICAL RECT ANGULAR TORQUE P A TTERN CAPSCREW OR NUT THREAD SIZE AND PITCH TYPICAL SQUARE T ORQUE P[...]

  • Page 59

    56 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) T ABLE 2 METRIC F ASTENERS NOMINAL DESIGN T ORQUE PROPERTY GRADE 8.8 (HEAD MARKING) PROPERTY GRADE 10.9 (HEAD MARKING) PROPERTY GRADE 12.9 (HEAD MARKING) TYPICAL RECT ANGULAR TORQUE P A TTERN CAPSCREW OR NUT THRE[...]

  • Page 60

    57 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) COMPRESSOR LUBRICA TION Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine a[...]

  • Page 61

    58 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) MACHINE SYSTEMS KEY BA T Battery CO RS232C comms ECON Engine controller IG Isochronous governor J50 – G2 W ait to start lamp J50 – K3 Inlet heater P51 Coolant temp P52 Inject P53 Crank sensor P54 Fuel temp P5[...]

  • Page 62

    59 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) WEDGE CONTROLLER CAN HI CAN LO CAN SHLD KEY SWITCH ANALOG THROTTLE RANGE= 1.10VDC (1400RPM) TO 3.7VDC (2400RPM) ANALOG THROTTLE ENGINE CONTROLLER FIGURE 2 – 1 WEDGE TO ENGINE INTERF ACE – IR ENGINE CONTROLL P[...]

  • Page 63

    60 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) ENGINE CM TERMINA TOR J1939 CAN COMMUNICA TIONS SCHEMA TIC FIGURE 2 – 3 ENGINE DIAGNOSTICS JACK WEDGE CONTROLLER TERMINA TOR[...]

  • Page 64

    61 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) SER VICE TOOLS Electronic Systems The following special tools are recommended to perform service procedures in this manual. The tools can be purchased from Ingersoll – Rand or equivalent substitutes can be used[...]

  • Page 65

    62 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) SER VICE T OOLS T ool No. T ool Description T ool Illustration Fluke 87 Digital Multimeter Available from electrical and electronic parts distributors. 54729660 W eather – Pack T erminal Removal T oo l 54699632[...]

  • Page 66

    63 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) 54729728 PDA Service T ool 54699616 Deutsch T erminal Removal T ool 22073886 Packard Crimp T ool 22073878 Thermistor Simulator 54749635 Connector Repair Kit 54699657 Deutsch T erminal Removal T ool 54749643 Packa[...]

  • Page 67

    64 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) ELECTRICAL P ARTS P ARTS NUMBERS DESCRIPTION QTY PER MACHINE P ARTS NUMBERS DESCRIPTION QTY PER MACHINE 36920825 0 – 100 psi PRESSURE TRANSDUCER 1 54765946 0 – 500 psi PRESSURE TRANSDUCER 1 36898922 THERMIST [...]

  • Page 68

    F AUL T FINDING 65 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) F AUL T CAUSE REMEDY No reaction from instrument Batteries not connected. Connect batteries. panel when key turned to (I) position. Fuse at starter motor ‘ blown ’ . Replace fuse. Engine fails[...]

  • Page 69

    F AUL T FINDING 66 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) Compressor overheats. Low oil level. T o p up the oil level and check for leaks. Dirty or blocked oil cooler . Clean the oil cooler fins. Incorrect grade of oil. Use Ingersoll – Rand recommended[...]

  • Page 70

    OPTIONS 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) 67 OPTIONS – Lubricator (For units manufactured in North America) SAFETY W ARNING: Ensure that the lubricator filler cap is re – tightened correctly after replenishing with oil. W ARNING: Do not replenis[...]

  • Page 71

    OPTIONS 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) 68 OPTIONS – Dual pressure SAFETY W ARNING: Any pneumatic equipment that is, or may be connected to the machine must be suitable for use with at least the higher , rated pressure. OPERA TING INSTRUCTIONS C[...]

  • Page 72

    OPTIONS 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) 69 MAINTENANCE Daily maintenance: V erify , during full – load (maximum compressed air delivery) that the IQ system filter restriction indicators do not show excessive restriction. Restriction indicators f[...]

  • Page 73

    70 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) P ARTS ORDERING GENERAL This publication, which contains an illustrated parts breakdown, has been prepared as an aid in locating those parts which may be required in the maintenance of the unit. All of the compre[...]

  • Page 74

    71 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) MARKINGS AND DECALS NOTICE Do not paint over safety warnings or instructional decals. If safety warning decals become illegible, immediately order replacements from the factory . Part numbers for original individ[...]

  • Page 75

    72 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) W arranties applicable to material and equipment supplied by the Company but wholly manufactured by others shall be limited to the warranties extended to the Company by the manufacturer which are able to be conve[...]

  • Page 76

    73 7/120 (P425AWIR), 9/1 10 (XP375AWIR), 10/105 (HP375A WIR), 14/85 (VHP300AWIR), 7/170 (P600WIR), 10/125 (HP450WIR), 14/1 15 (VHP400WIR) T elephone: +44 (0) 1942 257 171 Fax: +44 (0) 1942 523 417 Facility: Office hours: Monday – Friday 8:00 a.m. to 4:30 p.m. (GMT) For information on how to order parts or information regarding your local distribu[...]