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P90 P101 P110 P130 HP95 P150 P180

HP140 7/51OPERATION AND MAINTENANCE MANUAL

C.C.N. : 89297972 GBDATE : MARCH 2001

This manual containsimportant safety informationand must be made available topersonnel who operate andmaintain this machine.

415000P180, HP140 –>

402000P150 –>

312200P130, HP95 –>

312200P110 –>

210000P101 –>

210000P90 –>SERIAL No :

SERIAL No :

SERIAL No :

SERIAL No :

SERIAL No :

SERIAL No :

4150007/51 –>SERIAL No :

Doosan

test stamp

Doosan

Date

Machine models represented in this manual may be used in various locations worldwide. Machines sold andshipped into European common market countries requires that the machine display the EC Mark and conformto various directives. In such cases, the design specification of this machine has been certified as complying withEC directives. Any modification to any part is absolutely prohibited and would result in the CE certification andmarking being rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

98/37/EC, 93/68/EEC, 89/336/EEC

WE,

INGERSOLL–RAND COMPANY LIMITEDSWAN LANE

HINDLEY GREENWIGAN WN2 4EZ

UNITED KINGDOM

DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY, THEPRODUCT(S)

P90 P101 P110 P130 HP95 P150 P180 HP140 7/51

TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONSOF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

EN29001 : EN292, EN60204–1, EN1012–1, PN8NTC2, EN50081, EN50082

ISSUED AT HINDLEY GREEN ON 01/01/2001 BY H.SEDDON, QUALITY ASSURANCEMANAGER.

H. SEDDON

CONTENTS & ABBREVIATIONS1

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

CONTENTS

1 CONTENTS

2 FOREWORD

4 ISO SYMBOLS

7 SAFETY

10 GENERAL INFORMATIONDimensionsData

18 OPERATING INSTRUCTIONSCommissioningPrior to startingStartingStoppingEmergency stoppingRe–startingMonitoring during operationDecommissioning

22 MAINTENANCERoutine maintenanceLubricationSpeed & pressure regulationTorque settings table

29 MACHINE SYSTEMSElectrical systemPiping & instrumentation system

33 FAULT FINDING

35 OPTIONS

Lubricator.Safety.General Information.Operating Instructions.Maintenance.Fault Finding.

Cold Start Aid.Safety.General Information.Operating Instructions.Maintenance.Fault Finding.

Generator.Safety.General Information.Operating Instructions.Maintenance.Fault Finding.

ABBREVIATIONS & SYMBOLS

#### Contact Ingersoll–Rand for serial number

–>#### Up to Serial No.####–> From Serial No.

* Not illustrated† OptionWDG Generator optionAUS AustraliaAR As requiredAUS AustraliaD GermanyDK DenmarkE SpainF FranceGB Great BritainI ItalyN NorwayNL NetherlandsP PortugalS SwedenSF FinlandF.H.R.G. Fixed height running gearV.H.R.G. Variable height running gear

FOREWORD 2

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

The contents of this manual are considered to be proprietary andconfidential to Ingersoll–Rand and should not be reproduced withoutthe prior written permission of Ingersoll–Rand.

Nothing contained in this document is intended to extend anypromise, warranty or representation, expressed or implied, regardingthe Ingersoll–Rand products described herein. Any such warranties orother terms and conditions of sale of products shall be in accordancewith the standard terms and conditions of sale for such products, whichare available upon request.

This manual contains instructions and technical data to cover allroutine operation and scheduled maintenance tasks by operation andmaintenance staff. Major overhauls are outside the scope of thismanual and should be referred to an authorised Ingersoll–Rand servicedepartment.

The design specification of this machine has been certified ascomplying with EC directives. As a result:

(a) Any machine modifications are strictly prohibited, and will invalidateEC certification.

(b) This machine must not be used in USA/Canada. (Where ECcertification is not valid, and other certification will be required.)

All components, accessories, pipes and connectors added to thecompressed 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 pressure at least equal to the machine maximumallowable working pressure.. compatible with the compressor lubricant/coolant.. accompanied with instructions for safe installation, operation andmaintenance.

Details of approved equipment are available from Ingersoll–RandService departments.

The use of repair parts / lubricants / fluids other than those includedwithin the Ingersoll–Rand approved parts list may create hazardousconditions over which Ingersoll–Rand has no control. ThereforeIngersoll–Rand cannot be held responsible for equipment in whichnon–approved repair parts are installed.

Ingersoll–Rand reserves the right to make changes andimprovements to products without notice and without incurring anyobligation to make such changes or add such improvements toproducts sold previously.

The intended uses of this machine are outlined below and examplesof unapproved usage are also given, however Ingersoll–Rand cannotanticipate every application or work situation that may arise.

IF IN DOUBT CONSULT SUPERVISION.

This machine has been designed and supplied for use only in thefollowing specified conditions and applications:. Compression of normal ambient air containing no known ordetectable additional gases, vapours. or particles. Operation within the ambient temperature range specified in theGENERAL INFORMATION section of this manual.

. Generation of electricity at 110v (1ph), 230v (1ph), 230v (3ph) and400v (3ph) / 230v (1ph) nominal at 50 Hertz with centre tap earth.(WDG)

The use of the machine in any of the situation types listed intable 1:–a) Is not approved by Ingersoll–Rand,b) May impair the safety of users and other persons, andc) May prejudice any claims made against Ingersoll–Rand.

TABLE 1

Use of the machine to produce compressed air for:a) direct human consumptionb) indirect human consumption, without suitable filtration and puritychecks.

Use of the machine outside the ambient temperature range

specified in the GENERAL INFORMATION SECTION of this manual.

Use of the machine where there is any actual or foreseeable risk of

hazardous levels of flammable gases or vapours.

Use of the machine fitted with non Ingersoll–Rand approvedcomponents / lubricants / fluids.

Use of the machine with safety or control components missing or

disabled.

WDG

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.

The company accepts no responsibility for errors in translation ofthis manual from the original English version.

COPYRIGHT 2001INGERSOLL–RAND COMPANY

EXTENDED LIMITED AIREND WARRANTY

Ingersoll–Rand Portable Compressor Division is pleased toannounce the availability of extended limited airend warranty.Announcement of the extended warranty coincides with theintroduction of Pro–Tec� Compressor Fluid. Pro–Tec� CompressorFluid is an amber coloured fluid specially formulated for PortableCompressors and is being provided as the factory filled fluid for allmachines.

All machines have the standard airend warranty – The earlier of 24months from shipment to, or the accumulation of 4000 hours of serviceby the initial user*.

The warranty against defects will include replacement of thecomplete Airend, provided the original Airend is returned assembledand unopened.

The optional limited warranty is the earlier of 60 months fromshipment to, or the accumulation of 10,000 hours of service. Theoptional warranty is limited to defects in major components (rotors,housings, gears and bearings), and is automatically available when thefollowing conditions are met:

1. The original airend is returned assembled and unopened.

2. Submissions of proof that Ingersoll–Rand fluid, filters andseparators have been used. Refer to the Operation and Parts manualfor the correct fluids, filters and separator elements required.

3. Submissions of proof that maintenance intervals have beenfollowed.

FOREWORD3

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

WARRANTY TIME *BARE AIREND **AIREND COMPONENTS

STANDARD 2YRS / 4,000HRS 100% PARTS & LABOUR 100% PARTS & LABOUR

OPTIONAL 5YRS / 10,000HRS 100% PARTS & LABOUR 0%

*BARE AIREND – pertains to major airend parts (rotors, housings,gears and bearings).

**AIREND COMPONENTS – pertains to auxiliary attachments to thebare airend (drive coupling, seals, pumps, valves, tubes, hoses, fittingsand filter housing).

Pro–Tec� Compressor Fluids are available from your localIngersoll–Rand branch or distributor.

Where climatic conditions dictate that the other Ingersoll–RandCompressor Fluids (XHP505 or Performance 500) must be used, theextended warranty will apply if the above conditions are met.

ISO SYMBOLS 4

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk . WARNING – Pressurised component orsystem.

WARNING – Hot surface.

WARNING – Pressure control. WARNING – Corrosion risk. WARNING – Air/gas flow or Air discharge.

X,XBAR

WARNING – Pressurised vessel. WARNING – Hot and harmful exhaust gas.WARNING – Maintain correct tyre pressure.

(Refer to the GENERAL INFORMATIONsection of this manual).

0�C

WARNING – Flammable liquid .WARNING – Before connecting the tow bar

or commencing to tow consult theoperation and maintenance manual.

WARNING – For operating temperaturebelow 0 �C, consult the operation and

maintenance manual.

ISO SYMBOLS5

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

WARNING – Do not undertake anymaintenance on this machine until the

electrical supply is disconnected and the airpressure is totally relieved.

WARNING – Consult the operation andmaintenance manual before commencing

any maintenance.

Do not breathe the compressed air from thismachine.

Do not remove the Operating and Maintenancemanual and manual holder from this machine. Do not stack. Do not operate the machine without the guard

being fitted.

Do not stand on any service valve or otherparts of the pressure system.

Do not operate with the doors or enclosureopen. Do not use fork lift truck from this side.

XXkm/h

Do not exceed the trailer speed limit. No naked lights. Do not open the service valve before theairhose is attached.

Use fork lift truck from this side only. Emergency stop. Tie down point

ISO SYMBOLS 6

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

Lifting point. On (power). Off (power).

Read the Operation and Maintenance manualbefore operation or maintenance of this

machine is undertaken.

When parking use prop stand, handrake andwheel chocks. Compressor oil filling

SAFETY7

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

WARNINGSWarnings call attention to instructions which must be followed

precisely to avoid injury or death.

CAUTIONSCautions call attention to instructions which must be followed

precisely to avoid damaging the product, process or its surroundings.

NOTESNotes are used for supplementary information.

General Information

Ensure that the operator reads and understands the decals andconsults the manuals before maintenance or operation.

Ensure that the Operation and Maintenance manual, and themanual holder, are not removed permanently from the machine.

Ensure that maintenance personnel are adequately trained,competent and have read the Maintenance Manuals.

Make sure that all protective covers are in place and that thecanopy/doors are closed during operation.

The specification of this machine is such that the machine is notsuitable for use in flammable gas risk areas. If such an application isrequired then all local regulations, codes of practice and site rules mustbe observed. To ensure that the machine can operate in a safe andreliable manner, additional equipment such as gas detection, exhaustspark arrestors, and intake (shut–off) valves may be required,dependant on local regulations or the degree of risk involved.

Under no circumstances should volatile liquids such as Ether beused for starting this machine.

A weekly visual check must be made on all fasteners/fixing screwssecuring mechanical parts. In particular, safety–related parts such ascoupling hitch, drawbar components, road–wheels, and lifting bail

should be checked for total security.

All components which are loose, damaged or unserviceable, must

be rectified without delay.

Compressed air

Compressed air can be dangerous if incorrectly handled. Beforedoing any work on the unit, ensure that all pressure is vented from thesystem and that the machine cannot be started accidentally.

Ensure that the machine is operating at the rated pressure and thatthe rated pressure is known to all relevant personnel.

All air pressure equipment installed in or connected to the machinemust have safe working pressure ratings of at least the machine ratedpressure.

If more than one compressor is connected to one commondownstream plant, effective check valves and isolation valves must befitted and controlled by work procedures, so that one machine cannotaccidently be pressurised / over pressurised by another.

Compressed air must not be used for a direct feed to any form ofbreathing apparatus or mask.

The discharged air contains a very small percentage of compressorlubricating oil and care should be taken to ensure that downstreamequipment is compatible.

If the discharged air is to be ultimately released into a confinedspace, adequate ventilation must be provided.

When using compressed air always use appropriate personalprotective equipment.

All pressure containing parts, especially flexible hoses and theircouplings, must be regularly inspected, be free from defects and bereplaced according to the Manual instructions.

Avoid bodily contact with compressed air.

The safety valve located in the separator tank must be checkedperiodically for correct operation.

Materials

The following substances may be produced during the operation ofthis machine:. brake lining dust. engine exhaust fumes

AVOID INHALATION

Ensure that adequate ventilation of the cooling system and exhaustgases is maintained at all times.

The following substances are used in the manufacture of thismachine and may be hazardous to health if used incorrectly:

. compressor lubricant

. engine lubricant

. preservative grease

. rust preventative

. diesel fuel

. battery electrolyte

AVOID INGESTION, SKIN CONTACT AND INHALATION OFFUMES

Components of a non–metallic fibrous material may contain smallquantities of white asbestos. When handling, dismantling orassembling these components, the following must be observed:

. Always operate in a well ventilated area.

. Dispose of waste in a sealed container.

. Use water to damp down dust.

. Avoid inhalation of dust particles.

Should compressor lubricant come into contact with the eyes, thenirrigate with water for at least 5 minutes.

Should compressor lubricant come into contact with the skin, thenwash off immediately.

Consult a physician if large amounts of compressor lubricant areingested.

Consult a physician if compressor lubricant is inhaled.

Never give fluids or induce vomiting if the patient is unconscious orhaving convulsions.

Safety data sheets for compressor and engine lubricants should beobtained from the lubricant supplier.

Battery

Batteries contain corrosive liquid and produce explosive gas. Donot expose to naked lights. Always wear personal protective clothingwhen handling. When starting the machine from a slave battery ensurethat the correct polarity is observed and that connections are secure.

DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERYSINCE THIS MAY CAUSE IT TO EXPLODE.

SAFETY 8

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

Generator (WDG)

The generator set is designed for safety in use. However, theresponsibility for safe operation rests with those who install, use andmaintain it. The following safety precautions are offered as a guide,which, if conscientiously followed, will minimise the possibility ofaccidents throughout the useful life of this equipment.

Emergency Stop Controls

Important Note:– In addition to the key operated emergency stopcontrol on the main control panel, a second control is provided at thesocket control panel in the event of electrical hazards associated withgenerator operation. Use this second control to immediately isolate allelectrical power to all sockets, then use the key control to stop theengine.

Operation of the generator must be in accordance with recognisedelectrical codes and local health and safety codes.

The generator set should be operated by those who have beentrained in its use and delegated to do so, and who have read andunderstand the operator’s manual. Failure to follow the instructions,procedures and safety precautions in the manual may increase thepossibility of accidents and injuries.

Do not start the generator set unless it is safe to do so. Do notattempt to operate the generator set with a known unsafe condition. Fita danger notice to the generator set and render it inoperative bydisconnecting the battery and disconnecting all ungroundedconductors so others who may not know of the unsafe condition will notattempt to operate it until the condition is corrected.

An earth point is provided beneath the socket outlets.

The generator set should only be used with the earth pointconnected directly to the general earth/ground mass. An earth spike kitis available as an optional extra for this purpose (refer to the partscatalogue).

WARNING: DO NOT OPERATE THE MACHINE UNLESS IT HASBEEN SUITABLY EARTHED.

Generator sets must be connected to the load only by trained andqualified electricians who have been delegated to do so, and whenrequired by applicable regulations, their work should be inspected, andaccepted by the inspection agency having authority, prior to attemptingto operate the generator set.

Do not make contact with electrically energised parts of thegenerator set and/or interconnecting cables or conductors with anypart of the body or with any non–insulated conductive object.

Make sure the generator set is effectively grounded in accordancewith all applicable Regulations prior to attempting to make or break loadconnections and prior to attempting operation.

Do not attempt to make or break electrical connections to generatorsets standing in water or on wet ground.

Prior to attempting to make or break electrical connections at thegenerator set, stop the engine, disconnect the battery and disconnectand lock out the ungrounded conductors at the load end.

Keep all parts of the body and any hand–held tools or otherconductive objects, away from exposed live parts of the generator setengine electrical system. Maintain dry footing, stand on insulatingsurfaces and do not contact any other portion of the generator set whenmaking adjustments or repairs to exposed live parts of the generatorset engine electrical system.

Replace the generator set terminal compartment cover as soon asconnections have been made or broken. Do not operate the generatorset without the terminal cover secured firmly in place.

Close and lock all access doors when the generator set is leftunattended.

Do not use extinguishers intended for Class A or Class B fires onelectrical fires. Use only extinguishers suitable for class BC or classABC fires.

Keep the towing vehicle or equipment carrier, generator set,connecting cables, tools and all personnel at least 3 metres from allpower lines and buried power cables, other than those connected to thegenerator set.

Attempt repairs only in clean, dry, well lighted and ventilated areas.

Connect the generator set only to loads and/or electrical systemsthat are compatible with its electrical characteristics and that are withinit’s rated capacity.

Transport

When loading or transporting machines ensure that the specifiedlifting and tie down points are used.

When loading or transporting machines ensure that the towingvehicle, its size, weight, towing hitch and electrical supply are allsuitable to provide safe and stable towing at speeds either, up to thelegal maximum for the country in which it is being towed or, as specifiedfor the machine model if lower than the legal maximum.

Where driver license restrictions apply, ensure that the maximumtrailer weight does not exceed 750kg (by limiting the equipment load).

Note:Gross mass (on data plate) is for the basic machine and fuel only,

excluding any fitted options, tools, equipment and foreign materials.

Before starting the machine after installation, test the insulationresistance of the windings. The automatic voltage regulator (AVR) iffitted should be disconnected and the rotating diodes either shorted outwith temporary links or disconnected. Any control wiring must also bedisconnected.(WDG)

Before towing the machine, ensure that:–

. the tyres and towing hitch are in a serviceable condition.

. the canopy is secure.

. all ancillary equipment is stored in a safe and secure manner.

. the brakes and lights are functioning correctly and meet necessary road traffic requirements.

. break-away cables/safety chains are connected to the towing vehicle.

The machine must be towed in a level attitude in order to maintaincorrect handling, braking and lighting functions. This can be achievedby correct selection and adjustment of the vehicle towing hitch and, onvariable height running gear, adjustment of the drawbar.

To ensure full braking efficiency, the front (towing eye) section mustalways be set level.

When adjusting variable height running gear:–

. Ensure front (towing eye) section is set level

When raising towing eye, set rear joint first, then front joint.

SAFETY9

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

When lowering towing eye, set front joint first, then rear joint.

When parking always use the handbrake and, if necessary, suitablewheel chocks.

Safety chains / connections and their adjustment

The legal requirements for the joint operation of the breakawaycable and safety chains are as yet unidentified by 71/320/EEC or UKregulations. Consequently we offer the following advice / instructions.

Where brakes only are fitted:

a) Ensure that the breakaway cable is securely coupled to thehandbrake lever and also to a substantial point on the towing vehicle.

b) Ensure that the effective cable length is as short as possible, whilststill allowing enough slackness for the trailer to articulate without thehandbrake being applied.

Where brakes and safety chains are fitted:

a) Loop the chains onto the towing vehicle using the towing vehiclehitch as an anchorage point, or any other point of similar strength.

b) Ensure that the effective chain length is as short as possible whilststill allowing normal articulation of the trailer and effective operation ofthe breakaway cable.

Where safety chains only are fitted:

a) Loop the chains onto the towing vehicle using the towing vehiclehitch as an anchorage point, or any other point of similar strength.

b) When adjusting the safety chains there should be sufficient freelength in the chains to allow normal articulation, whilst also being shortenough to prevent the towbar from touching the ground in the event ofan accidental separation of the towing vehicle from the trailer.

GENERAL INFORMATION 10

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P90/P101FIXED HEIGHT RUNNING GEARUnbraked version (M&E)

P90/P101FIXED HEIGHT RUNNING GEARBraked version (M&E)

GENERAL INFORMATION11

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

VARIABLE HEIGHT RUNNING GEARUnbraked version (M&E)

P90/P101

P90/P101VARIABLE HEIGHT RUNNING GEARBraked version (M&E)


P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P110/P130/HP95P101WDG/P110WDG/P130WDGFIXED HEIGHT RUNNING GEARBraked version (M&E)

VARIABLE HEIGHT RUNNING GEARBraked version (M&E)

P110/P130/HP95P101WDG/P110WDGP130WDG


P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P150FIXED HEIGHT RUNNING GEARBraked version (M&E)

P150VARIABLE HEIGHT RUNNING GEARBraked version (M&E)


P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P180, HP140, 7/51FIXED HEIGHT RUNNING GEARBraked version (M&E)

P180, HP140, 7/51VARIABLE HEIGHT RUNNING GEARBraked version (M&E)


P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

COMPRESSOR

Actual free air delivery. 2,6 m3 min–1

(P90)


(P101)


(P110)


(P130)


(HP95)


(P150)


(P180, 7/51)


(HP140)

Normal operating discharge pressure. 7 bar

Normal operating discharge pressure. 10,3 bar (HP95 & HP140)

Maximum allowable pressure. 8,6 bar

Maximum allowable pressure. 11,7 bar (HP95 & HP140)

Safety valve setting. 10 bar

Safety valve setting. 13 bar (HP95 & HP140)

Maximum pressure ratio (absolute). 7,5 : 1

Operating ambient temperature. –10�C –> +46�C

Maximum discharge temperature. 120�C

Cooling system. Oil injection

Oil capacity. 7,0 litres

Oil capacity. 9,1 litres (P150)

Maximum oil system temperature. 120�C

Maximum oil system pressure. 8,6 bar

Maximum oil system pressure. 11,7 bar (HP95 & HP140)

Note:To start the compressor in ambient temperatures below –10�C, the

cold start kit option will be required.In addition, to start the compressor in ambient temperatures

between –15�C and –20�C, the engine oil must be changed to 5W40.It is essential that 15W40 oil is used in ambient temperatures above0�C.

LUBRICATING OIL SPECIFICATION(for the specified ambient temperatures).

ABOVE –23�CRecommended: Pro–Tec�Approved: SAE 10W, API CF–4/CG–4

BELOW –23�CMandatory: IR Performance 500

Ingersoll–Rand Pro–TecTM compressor fluid is factory–fitted, foruse at all ambient temperatures above –23�C.

NOTE: Warranty may be extended only by continuous use ofPro–Tec� and Ingersoll–Rand oil filters and separators.

No other oil/fluids are compatible with Pro–Tec TM

No other oils/fluids should be mixed with Pro–TecTM because theresulting mixture could cause damage to the airend.

In the event that Pro–TecTM is not available and / or the end userneeds to use an approved single grade engine oil, the complete systemincluding separator / receiver, cooler and pipework must be flushedclear of the first fill fluid and new Ingersoll–Rand oil filters installed.When this has been completed, the following oils are approved:

a) for ambient temperatures above –23�C,SAE 10W, API CF–4/CG–4

b) for ambient temperatures below –23�C,I–R Performance 500 only.

Safety data sheets can be obtained on request from the lubricantsupplier.

For temperatures outside the specified ambient range, consultIngersoll–Rand.

ENGINE

Type/model. Deutz F2L1011FNumber of cylinders. 2 (P90 & P101)

Type/model. Deutz F3L1011FNumber of cylinders. 3 (P110, P130, HP95 & P150)

Type/model. Deutz F4L1011FNumber of cylinders. 4 (P180, HP140 & 7/51)

Oil capacity. 6,5 litres (P90 & P101)

Oil capacity. 6,0 litres (P110, P130, HP95)

Oil capacity. 5,5 litres (P150)

Oil capacity. 10,5 litres (P180, HP140 & 7/51)

Speed at full load. 2900 revs min–1

(P90, P101, P130 & HP95)


(P110)


(P150, P180, HP140 & 7/51)

Speed at idle. 1800 revs min–1

Speed at idle. 1600 revs min–1

(P180, HP140 & 7/51)

Electrical system. 12V negative earth

Power available at 2900 revs min–1 20,5 kW (P90 & P101)

Power available at 2500 revs min–1 30,5 kW (P110)

Power available at 2900 revs min–1 32,2 kW (P130 & HP95)

Power available at 3000 revs min–1 33,8 kW (P150)


P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

Power available at 3000 revs min–1 42,0 kW (P180, HP140 & 7/51)

Fuel tank capacity 42 litres (P90, P101, P110, P130 & HP95)

Fuel tank capacity 70 litres (P150, P180, HP140 & 7/51)

SOUND LEVEL DATA (’W’ model)

A) To Pneurop code PN8NTC2.Equivalent continuous sound pressure level.*

. Rated load 84 dB(A)

. No load 81 dB(A) (P90 & P101)

. No load 79 dB(A) (P110, P130 & HP95)

. No load 80 dB(A) (P150, P180, HP140 & 7/51)

(Operator position :–1m from machine)

Sound power level (84/533/EEC) 100 dB(A)

B) In compliance with 86/188/EEC.

Average sound pressure level at 10m to 79/113/EEC.* 72 dB(A)

(*Machine only :– at maximum load in open site conditions)

FIXED HEIGHT RUNNING GEARUnbraked version (M&E) (P90 & P101)

Shipping weight. 675 kg

Maximum gross weight. 700 kg

Maximum horizontal towing force. 865 kgf

Maximum vertical coupling load(nose weight). 75 kgf

VARIABLE HEIGHT RUNNING GEARUnbraked version (M&E) (P90 & P101)





FIXED HEIGHT RUNNING GEARBraked version (M&E) (P90 & P101)





VARIABLE HEIGHT RUNNING GEARBraked version (M&E) (P90 & P101)





WHEELS AND TYRES (P90 & P101)

Number of wheels. 2 x 41/2 J

Tyre size. 145 R13

Tyre pressure. 2,4 bar (35 lbf in–2)

FIXED HEIGHT RUNNING GEARBraked version (M&E) (P110, P130 & HP95)





VARIABLE HEIGHT RUNNING GEARBraked version (M&E) (P110, P130 & HP95)





WHEELS AND TYRES (P110, P130 & HP95)


Tyre size. 155 R13


FIXED HEIGHT RUNNING GEARBraked version (M&E) (WDG) (P110WDG & P130WDG)





VARIABLE HEIGHT RUNNING GEARBraked version (M&E) (WDG) (P110WDG & P130WDG)






P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

FIXED HEIGHT RUNNING GEARBraked version (M&E) (P150)





VARIABLE HEIGHT RUNNING GEARBraked version (M&E) (P150)





FIXED HEIGHT RUNNING GEARBraked version (M&E) (P180, HP140 & 7/51)





VARIABLE HEIGHT RUNNING GEARBraked version (M&E) (P180, HP140 & 7/51)





WHEELS AND TYRES (P180 HP140 & 7/51)


Tyre size. 165 R13


Further information may be obtained by request throughIngersoll–Rand customer services department.

OPERATING INSTRUCTIONS 18

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

COMMISSIONING

Upon receipt of the unit, and prior to putting it into service, it isimportant to adhere strictly to the instructions given below in PRIOR TOSTARTING.

Ensure that the operator reads and understands the decals andconsults the manuals before maintenance or operation.

Ensure that the position of the emergency stop device is known andrecognised by its markings. Ensure that it is functioning correctly andthat the method of operation is known.

Before towing the unit, ensure that the tyre pressures are correct(refer to the GENERAL INFORMATION section of this manual) andthat the handbrake is functioning correctly (refer to theMAINTENANCE section of this manual). Before towing the unit duringthe hours of darkness, ensure that the lights are functioning correctly(where fitted).

Ensure that all transport and packing materials are discarded.

Ensure that the correct fork lift truck slots or marked lifting / tie downpoints are used whenever the machine is lifted or transported.

When selecting the working position of the machine ensure thatthere is sufficient clearance for ventilation and exhaust requirements,observing any specified minimum dimensions (to walls, floors etc.).

Adequate clearance needs to be allowed around and above themachine to permit safe access for specified maintenance tasks.

Ensure that the machine is positioned securely and on a stablefoundation. Any risk of movement should be removed by suitablemeans, especially to avoid strain on any rigid discharge piping.

Attach the battery cables to the battery(s) ensuring that they aretightened securely.

WARNING: All air pressure equipment installed in or connectedto the machine must have safe working pressure ratings of at leastthe machine rated pressure, and materials compatible with thecompressor lubricant (refer to the GENERAL INFORMATIONsection).

WARNING: If more than one compressor is connected to onecommon downstream plant, effective check valves and isolationvalves must be fitted and controlled by work procedures, so thatone machine cannot accidently be pressurised / over pressurisedby another.

WARNING: If flexible discharge hoses are to carry more than 7 barpressure then it is recommended that safety retaining wires areused on the hoses.

OPERATING INSTRUCTIONS19

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

PRIOR TO STARTING

1. Place the unit in a position that is as level as possible. The designof the unit permits a 15 degree lengthways and sideways limit on outof level operation. It is the engine, not the compressor, that is the limitingfactor.

When the unit has to be operated out of level, it is important to keepthe engine oil level near the high level mark (with the unit level).

CAUTION: Do not overfill either the engine or the compressor with oil.

2. Check the engine lubrication oil in accordance with the operatinginstructions in the Engine Operator’s Manual.

3. Check the compressor oil level in the sight glass located on theseparator tank.

4. Check the diesel fuel level. A good rule is to top up at the end of eachworking day. This prevents condensation from occurring in the tank.

CAUTION: Use only a No. 2–D diesel fuel oil with a minimum octanenumber of 45 and a sulphur content not greater than 0,5%.

CAUTION: When refuelling:–. switch off the engine.. do not smoke.. extinguish all naked lights.. do not allow the fuel to come into contact with hot surfaces.. wear personal protective equipment.

5. Drain the fuel filter water separator of water, ensuring that anyreleased fuel is safely contained.

6. Open the service valve(s) to ensure that all pressure is relievedfrom the system. Close the service valve(s).

7. CAUTION: Do not operate the machine with the canopy/doors inthe open position as this may cause overheating and operators to beexposed to high noise levels.

Check the air restriction indicator(s). Refer to the MAINTENANCEsection of this manual.

When starting or operating the machine in temperatures below orapproaching 0�C, ensure that the operation of the regulation system,the unloader valve, the safety valve, and the engine are not impairedby ice or snow, and that all inlet and outlet pipes and ducts are clear ofice and snow.

OPERATING INSTRUCTIONS 20

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

STARTING THE MACHINE

WARNING: Under no circumstances should volatile liquids suchas Ether be used for starting this machine.

All normal starting functions are incorporated in the key operatedswitch.

. Turn the key switch to position 1, the alternator charge light willilluminate.

. Turn the key switch to position 3 (engine start position).

. Release to position 2 when the engine starts.

. Release to position 1 when the alternator charge light isextinguished.

At temperatures below 0�C or if there is difficulty starting first time:

. Open the service valve fully, with no hose connected.

. Complete starting sequence above.

. Close service valve as soon as engine runs freely.

. Do not allow machine to run for long periods with service valveopen.

. Allow the engine to reach operating temperature.

. At this point in the operation of the machine it is safe to apply full loadto the engine.

NOTE: Wear hearing protection at all times when the engine is startedwith the top open and air is flowing from the valve.

STOPPING THE MACHINE

. Close the service valve.

. Allow the machine to run unloaded for a short period of time toreduce the engine temperature.

. Turn the start switch to the 0 (off) position.

NOTE: As soon as the engine stops, the automatic blowdown valve willrelieve all pressure from the system.

If the automatic blowdown valve fails to operate, then pressure mustbe relieved from the system by means of the service valve(s).

CAUTION: Never allow the machine to stand idle with pressure in thesystem.

EMERGENCY STOPPING

In the event that the unit has to be stopped in an emergency, TURNTHE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TOTHE 0 (OFF) POSITION.

RE–STARTING AFTER AN EMERGENCY

If the machine has been switched off because of a machinemalfunction, then identify and correct the fault before attempting tore–start.

If the machine has been switched off for reasons of safety, thenensure that the machine can be operated safely before re–starting.

Refer to the PRIOR TO STARTING and STARTING THE UNITinstructions earlier in this section before re–starting the machine.

MONITORING DURING OPERATION

Should any of the safety shut-down conditions occur, the unit willstop. These are:

. Low engine oil pressure

. High air discharge temperature

. High engine oil temperature.

. Alternator not charging the electrical system.

. Low engine fuel level.

CAUTION: To ensure an adequate flow of oil to the compressor at lowtemperature, never allow the discharge pressure to fall below 3,5 bar.

OPERATING INSTRUCTIONS21

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

DECOMMISSIONING

When the machine is to be permanently decommissioned ordismantled, it is important to ensure that all hazard risks are eithereliminated or notified to the recipient of the machine. In particular:–

. Do not destroy batteries or components containing asbestoswithout containing the materials safely.

. Do not dispose of any pressure vessel that is not clearly markedwith its relevant data plate information or rendered unusable by drilling,cutting etc.

. Do not allow lubricants or coolants to be released into land surfacesor drains.

. Do not dispose of a complete machine without documentationrelating to instructions for its use.

MAINTENANCE 22

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

PERIOD ITEM MAINTENANCEInitial/500miles (850km)

Brakes. Check and adjust the brakelinkage.Check and adjust the wheelbrakes.

Daily Oil level. Check and refill as required.

Air filter(s). Clean the dust collector box(es).

Fuel tank. Refill to prevent condensation.

Emergencystop (Frontpanel).

Test the operation of the device.

Lubricator (iffitted).

Replenish the oil.

Earth leakagecircuit breaker(WDG)(Socketpanel).


Fixing screws Check – (see “safety section”)

Weekly/50hours

Safetyshutdownsystem.

Check the electrical connections.

Engine. Refer to the Engine Manufacturer’sManual.

Compressoroil filter.

Replace after the first 50 hoursfrom new.

Fan drivebelt(s).

Check for correct tension andexcessive wear.Re–tension/replace as necessary.

Monthly/150hours

Oil cooler. Check for the build up of foreignmatter. Clean if necessary byblowing out with air or pressurewash.


Replace after the first 150 hoursfrom new.

Hoses. Inspect.

Running gear. Apply grease to the steeringlinkage grease points (Ifapplicable).

3months/250hours


Test the operation of the switches.

Safety valve. Operate the safety valve manuallyto verify that the valve mechanismis functioning correctly and that asmall amount of air is released.

Brakes. Check and adjust the brake linkageat 3000 miles (5000 km) or 3months (whichever is the sooner)to compensate for any stretch in theadjustable cables. Check andadjust the wheel brakes tocompensate for wear.

Running gear. Check the bolts securing therunning gear to the chassis andre–tighten where necessary (Referto the TORQUE SETTING TABLEwithin this manual). Reset the tabwasher. Check and adjust thebrakes and brake cables. Adjustand grease the linkages. Check thetowing eye bolts under the bellowscover (If applicable).

Earth leakagecircuit breaker(WDG)(Socketpanel).


PERIOD ITEM MAINTENANCE3, 6, 30months/250,500, 2500hours

Engine. Refer to the Engine Manufacturer’sManual.

6months/500ho rs


Replace.

hoursCompressoroil.

Replace.

Hoses. Inspect.

Scavenge line. Clean if necessary.

Fan drivebelt(s).

Replace.

Pressuresystem.

Inspect all components fordamage, deterioration or leaks.Replace as necessary.

Running gear. Grease all nipples.

Wheelbearings.

Pack with grease.

1 year/1000hours

Air filterelements.

Replace.

Enginebreather.

Clean the element.


Test the operation of the switches.

Compressoroil.

Replace.

Pressuregauge.

Remove from the machine andcheck the calibration. Replace ifnecessary.

Pressureregulator.

Check that the regulator functionscorrectly.

1 year/1000hours or asdefined bylocal ornationall i l ti

Separatortank.

Fully inspect all external surfaces,welds and fittings. Report anyexcessive corrosion, mechanicalor impact damage, leakage or otherdeterioration.

legislationRunning gear. Remove trailing arms and clean

and grease bushes.

2 years/2000hours

Safety valve. Remove from the machine andcheck for the correct operatingpressure. Adjust as necessary.

4 years/4000hours

Hoses. Replace.

6 years/6000hours or asdefined bylocal ornationallegislation.

Separatortank.

Remove the cover plate and anynecessary fittings. Clean theinterior thoroughly and inspect allinternal surfaces and welds.

As required. Separatorelement.

Replace if damaged.

Battery. Clean and grease the terminals.

Fuel filterwaterseparator.

Refer to the Engine Manufacturer’sManual.

MAINTENANCE23

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

ROUTINE MAINTENANCE

This section refers to the various components which requireperiodic maintenance and replacement.

The SERVICE/MAINTENANCE CHART indicates the variouscomponents’ descriptions and the intervals when maintenance has totake place. Oil capacities, etc., can be found in the GENERALINFORMATION section of this manual.

For any specification or specific requirement on service orpreventative maintenance for the engine, refer to the EngineManufacturer’s Manual.

Compressed air can be dangerous if incorrectly handled. Beforedoing any work on the unit, ensure that all pressure is vented from thesystem and that the machine cannot be started accidentally.

If the automatic blowdown fails to operate, then pressure must begradually relieved by operating the manual blowdown valve. Suitablepersonal protective equipment should be worn.

Ensure that maintenance personnel are adequately trained,competent and have read the Maintenance Manuals.

Prior to attempting any maintenance work, ensure that:–

. all air pressure is fully discharged and isolated from the system. Ifthe automatic blowdown valve is used for this purpose, then allowenough time for it to complete the operation.

. The discharge pipe / manifold area must be kept depressurised byopening the discharge valve, whilst keeping clear of any airflow fromit.((P110, P130 & HP95)

NOTE: Pressure will always remain in the part of the system betweenthe minimum pressure valve and the discharge valve after operation ofthe auto blowdown valve.

THIS PRESSURE MUST BE RELIEVED BY CAREFULLY:

(a) DISCONNECTING ANY DOWNSTREAM EQUIPMENT.

(b) OPENING THE DISCHARGE VALVE TO ATMOSPHERE.

(USE HEARING PROTECTION IF NECESSARY).

. the machine cannot be started accidently or otherwise, by postingwarning signs and/or fitting appropriate anti–start devices.

. all residual electrical power sources (mains and battery) areisolated.

Prior to opening or removing panels or covers to work insidea machine, ensure that:–

. anyone entering the machine is aware of the reduced level ofprotection and the additional hazards, including hot surfaces andintermittently moving parts.

. the machine cannot be started accidently or otherwise, by postingwarning signs and/or fitting appropriate anti–start devices.

Prior to attempting any maintenance work on a runningmachine, ensure that:–

. the work carried out is limited to only those tasks which require themachine to run.

. the work carried out with safety protection devices disabled orremoved is limited to only those tasks which require the machine to berunning with safety protection devices disabled or removed.

. all hazards present are known (e.g. pressurised components,electrically live components, removed panels, covers and guards,extreme temperatures, inflow and outflow of air, intermittently movingparts, safety valve discharge etc.).

. appropriate personal protective equipment is worn.

. loose clothing, jewellery, long hair etc. is made safe.

. warning signs indicating that Maintenance Work is in Progress areposted in a position that can be clearly seen.

Upon completion of maintenance tasks and prior to returningthe machine into service, ensure that:–

. the machine is suitably tested.

. all guards and safety protection devices are refitted.

. all panels are replaced, canopy and doors closed.

. hazardous materials are effectively contained and disposed of.

PROTECTIVE SHUTDOWN SYSTEM

Comprises:

. Low engine oil pressure switch

. High discharge air temperature switch

. High engine oil temperature switch

. Alternator drive belt failure circuit.

. Low engine fuel level switch.

Low engine oil pressure switch.

At three month intervals, test the engine oil pressure switch circuitas follows:

. Start the machine.

. Connect a wire between the switch terminal and a suitable earthpoint. The machine should shutdown.

NOTE: Do not press the load button.

At twelve month intervals, test the engine oil pressure switch as fol-lows:

. Remove the switch from the machine.

. Connect it to an independent low pressure supply (either air or oil).

. The switch should operate at 1,0 bar.Replace the switch.

Temperature switch(es).

At three month intervals, test the temperature switch circuit(s) asfollows:


. Disconnect each switch in turn. The machine should shutdown.

. Re–connect the switch.

NOTE: Do not press the load button.

High discharge air temperature switch.

At twelve month intervals, test the air discharge temperature switchby removing it from the machine and immersing in a bath of heatedoil. The switch should operate at 120�C. Replace the switch.

MAINTENANCE 24

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

High oil temperature switch.

At twelve month intervals, test the oil temperature switch by remov-ing it from the machine and immersing in a bath of heated oil. Theswitch should operate at 130�C. Replace the switch.

Alternator drive belt failure circuit.

At twelve month intervals test the alternator drive belt failure circuitas follows:

. Remove the drive belt from the machine.

. Turn the key switch to position 1, the alternator charge light will il-luminate.


. The machine should shutdown when the key switch is returned toposition 1.

Low engine fuel level switch.

At three month intervals, test the low engine fuel level switch circuitas follows:


. Disconnect the switch, the machine should shutdown.

. Re–connect the switch.

At twelve month intervals, test the low engine fuel level switch byremoving and operating the float manually.

CAUTION: Never remove or replace switches when the machineis running.

SCAVENGE LINE

The scavenge line runs from the combined orifice/drop tube in theseparator tank, to the orifice fitting located in the airend.

Examine the orifice, check valve and hoses at every service or inthe event of oil carryover into the discharge air.

It is good preventative maintenance to check that the scavenge lineand tube are clear of any obstruction each time the compressorlubricant is changed as any blockage will result in oil carryover into thedischarge air.

COMPRESSOR OIL FILTER

Refer to the MAINTENANCE CHART in this section for therecommended servicing intervals.

Removal

WARNING: Do not remove the filter(s) without first making surethat the machine is stopped and the system has been completelyrelieved of all air pressure. (Refer to STOPPING THE UNIT in theOPERATING INSTRUCTIONS section of this manual).

Clean the exterior of the filter housing and remove the spin–onelement by turning it in a counter–clockwise direction.

Inspection

Examine the filter element.

CAUTION: If there is any indication of the formation of varnishes,shellacs or lacquers on the filter element, it is a warning that thecompressor lubricating and cooling oil has deteriorated and that itshould be changed immediately. Refer to LUBRICATION later in thissection.

Reassembly

Clean the filter gasket contact area and install the new element byscrewing in a clockwise direction until the gasket makes contact withthe filter housing. Tighten a further 1/2 to 3/4 of a revolution.

CAUTION: Start the machine (refer to PRIOR TO STARTING andSTARTING THE UNIT in the OPERATING INSTRUCTIONS sectionof this manual) and check for leakage before the machine is put backinto service.

COMPRESSOR OIL SEPARATOR ELEMENT

Normally the separator element will not require periodicmaintenance provided that the air and oil filter elements are correctlymaintained.

If, however, the element has to be replaced, then proceed asfollows:

Removal

WARNING: Do not remove the filter(s) without first making surethat the machine is stopped and the system has been completelyrelieved of all air pressure. (Refer to STOPPING THE UNIT in theOPERATING INSTRUCTIONS section of this manual).

Disconnect all hoses and tubes from the separator tank cover plate.Remove the drop–tube from the separator tank cover plate and thenremove the cover plate. Remove the separator element.

Inspection

Examine the filter element. Examine all hoses and tubes, andreplace if necessary.

Reassembly

Thoroughly clean the orifice/drop tube and filter gasket contact areabefore reassembly. Install the new element.

WARNINGDo not remove the staple from the anti–static gasket on the

separator element since it serves to ground any possible staticbuild–up. Do not use gasket sealant since this will affect electricalconductance.

Reposition the cover plate, taking care not to damage the gasket,and replace the cover plate screws tightening in a criss–cross patternto the recommended torque (refer to the TORQUE SETTING TABLElater in this section).

Replace the drop–tube and reconnect all hoses and tubes to theseparator tank cover plate.

Replace the compressor oil (refer to LUBRICATION later in thissection).

MAINTENANCE25

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HP95 P150 P180 HP140 7/51

CAUTION: Start the machine (refer to PRIOR TO STARTING andSTARTING THE UNIT in the OPERATING INSTRUCTIONS sectionof this manual) and check for leakage before the machine is put backinto service.

COMPRESSOR OIL COOLER

When grease, oil and dirt accumulate on the exterior surfaces of theoil cooler, its efficiency is impaired. It is recommended that each monththe oil cooler be cleaned by directing a jet of compressed air, (carryingif possible a non–flammable cleaning solvent) over the exterior core ofthe cooler. This should remove any accumulation of oil, grease and dirtfrom the exterior core of the cooler so that the entire cooling area canradiate the heat of the lubricating and cooling oil into the air stream.

AIR FILTER ELEMENT

The air filter should be inspected regularly (refer to theSERVICE/MAINTENANCE CHART) and the element replaced whenthe restriction indicator shows red or every 1000 hours, whichevercomes first. The dust collector box(es) should be cleaned daily (morefrequently in dusty operating conditions) and not allowed to becomemore than half full.

Removal

CAUTION: Never remove and replace element(s) when the machineis running.

Clean the exterior of the filter housing and remove the filter elementby releasing the nut.

Inspection

Check for cracks, holes or any other damage to the element byholding it up to a light source, or by passing a lamp inside.

Check the seal at the end of the element and replace if any sign ofdamage is evident.

Reassembly

Assemble the new element into the filter housing ensuring that theseal seats properly.

Secure the element in the housing by hand tightening the nut.

Reset the restriction indicator by depressing the rubber diaphragm.

Assemble the dust collector box parts, ensuring that they arecorrectly positioned.

Before restarting the machine, check that all clamps are tight.

NOTE: In the event that a new filter element is not readily available, theelement can be re–used after cleaning. In this case the followingprocedure must be carried out:

Clean the element by directing a jet of clean, dry compressed air,no more than 5 bar, at an angle of 45 degrees to the outside of theelement. Carefully blow any dust from each fold of the element.

Compressed air cleaning is only recommended when a newelement is not available.

VENTILATION

Always check that the air inlets and outlets are clear of debris etc.

CAUTION: NEVER clean by blowing air inwards.

COOLING FAN DRIVE

Periodically check that the fan mounting bolt in the fan hub has notloosened. If, for any reason, it becomes necessary to remove the fanor re–tighten the fan mounting bolt, apply a good grade of commerciallyavailable thread locking compound to the bolt threads and tighten to thetorque value shown in the TORQUE SETTING TABLE later in thissection.

The fan belt(s) should be checked regularly for wear and correcttensioning.

FUEL SYSTEM

The fuel tank should be filled daily or every eight hours. To minimisecondensation in the fuel tank(s), it is advisable to top up after themachine is shut down or at the end of each working day. At six monthintervals drain any sediment or condensate that may haveaccumulated in the tank(s).

HOSES

All components of the engine cooling air intake system should bechecked periodically to keep the engine at peak efficiency.

At the recommended intervals, (see theSERVICE/MAINTENANCE CHART), inspect all of the intake lines tothe air filter, and all flexible hoses used for air lines, oil lines and fuellines.

Periodically inspect all pipework for cracks, leaks, etc. and replaceimmediately if damaged.

ELECTRICAL SYSTEM

WARNING: Always disconnect the battery cables beforeperforming any maintenance or service.

Inspect the safety shutdown system switches and the instrumentpanel relay contacts for evidence of arcing and pitting. Clean wherenecessary.

Check the mechanical action of the components.

Check the security of electrical terminals on the switches and relaysi.e. nuts or screws loose, which may cause local hot spot oxidation.

Inspect the components and wiring for signs of overheating i.e.discolouration, charring of cables, deformation of parts, acrid smellsand blistered paint.

BATTERY

Keep the battery terminals and cable clamps clean and lightlycoated with petroleum jelly to prevent corrosion.

The retaining clamp should be kept tight enough to prevent thebattery from moving.

PRESSURE SYSTEM

At 500 hour intervals it is necessary to inspect the external surfacesof the system (from the airend through to the discharge valve(s))including hoses, tubes, tube fittings and the separator tank, for visiblesigns of impact damage, excessive corrosion, abrasion, tightness andchafing. Any suspect parts should be replaced before the machine isput back into service.

MAINTENANCE 26

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

TYRES/TYRE PRESSURE

See the GENERAL INFORMATION section of this manual.

RUNNING GEAR/WHEELS

Check the wheel nut torque 20 miles (30 kilometres) after refittingthe wheels. Refer to the TORQUE SETTING TABLE later in thissection.

Lifting jacks should only be used under the axle.

The bolts securing the running gear to the chassis should bechecked periodically for tightness (refer to theSERVICE/MAINTENANCE CHART for frequency) and re–tightenedwhere necessary. Refer to the TORQUE SETTING TABLE later in thissection.

M&EWHEEL BRAKE ADJUSTMENT

Ensure that the handbrake lever is fully released and that thecoupling head is fully extended.

Each wheel brake must be adjusted in turn whilst rotating the wheelin the forward towing direction.

Refer to the diagram above.

1: Adjust the brakes until they lock–up by using adjuster A.

Release adjuster A until only a slight resistance is felt during wheelrotation.

Adjust nuts B and lock with the equaliser C parallel to the axle.

Take up the play with nut D behind the equaliser but withoutpre–loading the brakes (the wheels should rotate freely). Ensure thatall locknuts are secured. The overrun lever play dimension E should notbe greater than 14mm (fixed height running gear) or 16mm (variableheight running gear). The spring free length dimension F should be190mm.

2: When the unit is pushed backwards whilst parked, the brakes adopttheir reverse mode and the spring store extends to maintain the parkedcondition. The handbrake will then feel less tensioned but the unit willremain stationary.

CAUTION: Check the wheel nut torque 20 miles (30 kilometres) afterrefitting the wheels (Refer to the TORQUE SETTING TABLE later inthis section).

MAINTENANCE27

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

LUBRICATION

The engine is initially supplied with engine oil sufficient for a nominalperiod of operation (for more information, consult The EngineManufacturer’s Manual).

CAUTION: Always check the oil levels before a new machine is put intoservice.

If, for any reason, the unit has been drained, it must be re–filled withnew oil before it is put into operation.

ENGINE LUBRICATING OIL

The engine oil should be changed at the engine manufacturer’srecommended intervals. Refer to the Engine Manufacturer’s Manual.

ENGINE LUBRICATING OIL SPECIFICATION

Refer to the Engine Manufacturer’s Manual.

ENGINE OIL FILTER ELEMENT

The engine oil filter element should be changed at the enginemanufacturer’s recommended intervals. Refer to the EngineManufacturer’s Manual.

COMPRESSOR LUBRICATING OIL

Refer to the SERVICE/MAINTENANCE CHART in this section forservice intervals.

NOTE: If the machine has been operating under adverse conditions,or has suffered long shutdown periods, then more frequent serviceintervals will be required.

WARNING: DO NOT, under any circumstances, remove any drainplugs or the oil filler plug from the compressor lubricating andcooling system without first making sure that the machine isstopped and the system has been completely relieved of all airpressure (refer to STOPPING THE UNIT in the OPERATINGINSTRUCTIONS section of this manual).

Completely drain the receiver/separator system including the pipingand oil cooler by removing the drain plug(s) and collecting the used oilin a suitable container.

Replace the drain plug(s) ensuring that each one is secure.

NOTE: If the oil is drained immediately after the machine has beenrunning, then most of the sediment will be in suspension and willtherefore drain more readily.

CAUTION: Some oil mixtures are incompatible and result in theformation of varnishes, shellacs or lacquers which may be insoluble.

NOTE: Always specify INGERSOLL–RAND Pro–TecTM oil for useat all ambient temperatures above –23�C.

COMPRESSOR OIL FILTER ELEMENT

Refer to the SERVICE / MAINTENANCE CHART in this section forservice intervals.

RUNNING GEAR WHEEL BEARINGS

Wheel bearings should be packed with grease every 6 months. Thetype of grease used should conform to specification MIL–G–10924.

MAINTENANCE 28

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

SPEED AND PRESSURE REGULATION ADJUSTMENT

Normally, regulation requires no adjusting, but if correct adjustmentis lost, proceed as follows:

Refer to the diagram above.

A: Throttle armB: Adjusting screw

Start the machine (Refer to STARTING INSTRUCTIONS in theOPERATING INSTRUCTIONS section of this manual).

Inspect the throttle arm on the engine governor to see that it isextended in the full speed position when the engine is running atfull–load speed and the service valve is fully open. (Refer to theGENERAL INFORMATION section of this manual).

Adjust the service valve on the outside of the machine to maintain7 bar (HP95 = 10,3bar) without the throttle arm moving from the fullspeed position. If the throttle arm moves away from the full speedposition before 7 bar (HP95 = 10,3bar) is attained, then turn theadjusting screw clockwise to increase the pressure. Optimumadjustment is achieved when the throttle arm just moves from its fullspeed position and the pressure gauge reads 7,2 bar.(HP95 = 10,5bar).

Close the service valve. The engine will slow to idle speed.

CAUTION: Never allow the idle pressure to exceed 8,6bar on thepressure gauge, otherwise the safety valve will operate.

TORQUE VALUES

ft lbf Nm

Airend to engine 29–35 39–47

Air filter to bracket 16–20 22–27

Autella clamp to exhaust 9–11 12–15

Baffle to frame 9–11 12–15

Blowdown solenoid valve 21–26 28–35

Discharge manifold to frame 29–35 39–47

Drive pins to engine flywheel 57–69 77–93

Drop Leg 53–63 72–85

Engine/airend to chassis 54–58 73–78

Euro–Loc adaptor to separator tank 58–67 78–91

Exhaust flange to manifold 17–21 23–28

ft lbf Nm

Fan guard 9–11 12–15

Fan to hub 12–15 16–20

Lifting bail bracket to engine 29–35 39–47

Oil pipe (–12jic) 71–88 96–119

Radiator/Cooler to baffle 9–11 12–15

Running gear front to chassis 63–69 82–93

Running gear rear to chassis 63–69 82–93

Separator tank cover 40–50 54–68

Separator tank to frame 18–22 24–30

Service pipe (–20jic) 106–133 143–180

Sight glass 40–50 54–68

Wheel nuts 50–80 67–109

ELECTRICAL SYSTEM29

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P90, P101, P110, P130, P150, P180, HP95, HP140, 7/5188126537–CRev 0007/97

ELECTRICAL SYSTEM 30

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

KEY

B Battery 12 Volt

CF1 Control fuse 5A

D1–3 Diode

G Alternator

h Hour meter

IL1 Lamp, alternator charge

IL3 Lamp, Low fuel

LFS Low fuel level switch

M Starter motor

PB1 Pushbutton, load

PS1 Oil pressure switch

R1 Relay, safety shut-down

R3 Relay, start inhibit

R4 Relay, oil temperature switch (engine)

R5 Relay, low fuel

S Key–switch

SV1 Solenoid, fuel

SV2 Solenoid, load

TS1 Air temperature switch (airend)

TS2 Air temperature switch (discharge)

TS3 Oil temperature switch (engine)

B Black

G Green

K Pink

N Brown

O Orange

P Purple

R Red

S Grey

U Blue

W White

Y Yellow

ELECTRICAL SYSTEM31

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

KEY

1 Plug

2 Light (right hand)

3 Fog light

4 Light (left hand)

B Black

G Green

K Pink

N Brown

O Orange

P Purple

R Red

S Grey

U Blue

W White

Y Yellow

32 PIPING AND INSTRUMENTATION SYSTEM

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

KEY

1 Air discharge

2 Minimum pressure valve

3 Pressure gauge

4 Separator tank

5 Safety valve

6 Compressor

7 Engine

8 Oil cooler

9 Oil filter

10 Thermostatic valve

Air

Oil

Air/oil

FAULT FINDING33

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

FAULT CAUSE REMEDYEngine failsto start.

Low batterycharge.

Check the fan belt tension, batteryand cable connections.

Bad earthconnection.

Check the earth cables, clean asrequired.

Looseconnection.

Locate and make the connectiongood.

Fuelstarvation.

Check the fuel level and fuelsystem components. Replace thefuel filter if necessary.

Relay failed. Replace the relay.

Engine controlnot in ’run’position.

Check the speed cylinder and stopposition.

Enginestarts b t

Electrical fault Test the electrical circuits.starts butstalls whenthe switchreturns to

Alternator lightbulb failed orloose.

Replace or re–tighten the bulb asappropriate.

returns toposition I. Low engine oil

pressure.Check the oil level and the oilfilter(s).

Faulty relay Check the relays.

Faultykey–switch

Check the key–switch.

Enginestarts b t

Electrical fault. Test the electrical circuits.starts butwill not runor engineshuts downprematurely.

Loose lightbulb.

Check that all lights are lit when theignition is switched on. Check thatall lights are extinguished when thestarter is operated.prematurely.

Low engine oilpressure.

Check the oil level and oil filter(s).

Safetyshut-downsystem inoperation.

Check the safety shut-downswitches.

Fuelstarvation.

Check the fuel level and fuelsystem components. Replace thefuel filter if necessary.

Switch failure. Test the switches.

Highcompressor oiltemperature.

Check the compressor oil level andoil cooler. Check the fan drive.

Water presentin fuel system.

Check the water separator andclean if required.

Faulty relay. Check the relay in the holder andreplace if necessary.

EngineOverheats.

Reducedcooling airfrom fan.

Check the fan and the drive belts.Check for any obstruction insidethe cowl.

Enginespeed toohigh.

Incorrectthrottle armsetting.

Check the engine speed setting.

Faultyregulatorvalve.

Check the regulation system.

FAULT CAUSE REMEDYEnginespeed toolow.

Incorrectthrottle armsetting.

Check the throttle setting.

Blocked fuelfilter.

Check and replace if necessary.

Blocked airfilter.

Check and replace the element ifnecessary.

Faultyregulatorvalve.

Check the regulation system.

Prematureunloading.

Check the regulation and theoperation of the air cylinder.

Excessivevibration.

Engine speedtoo low.

See ”Engine speed too low”

Leaking oilseal.

Improperlyfitted oil seal.

Replace the oil seal.

Refer also to the Engine Manufacturer’s Manual.

Airdischargecapacity too

Engine speedtoo low.

Check the air cylinder and airfilter(s).

capacity toolow. Blocked air

cleaner.Check the restriction indicators andreplace the element(s) ifnecessary.

High pressureair escaping.

Check for leaks.

Incorrectly setregulationsystem.

Reset the regulation system. Referto SPEED AND PRESSUREREGULATION ADJUSTMENT inthe MAINTENANCE section of thismanual.

Compressoroverheats.

Low oil level. Top up the oil level and check forleaks.

Dirty orblocked oilcooler.

Clean the oil cooler fins.

Incorrectgrade of oil.

Use Ingersoll–Randrecommended oil.

Recirculationof cooling air.

Move the machine to avoidrecirculation.

Faultytemperatureswitch.

Check the operation of the switchand replace if necessary.

Reducedcooling airfrom fan.

Check the fan and the drive belts.Check for any obstruction insidethe fan cowl.

Excessive oilpresent inthe

Blockedscavenge line.

Check the scavenge line, drop tubeand orifice. Clean and replace.

thedischargeair.

Perforatedseparatorelement.

Replace the separator element.

Pressure inthe system istoo low.

Check the minimum pressure valveor sonic orifice.

FAULT FINDING 34

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

FAULT CAUSE REMEDYSafety valveoperates.

Operatingpressure toohigh.

Check the setting and operation ofthe regulator valve piping.

Incorrectsetting of theregulator.

Adjust the regulator.

Faultyregulator.

Replace the regulator.

Inlet valve setincorrectly.

Refer to SPEED AND PRESSUREREGULATION ADJUSTMENT inthe MAINTENANCE section of thismanual.

Loosepipe/hoseconnections.

Check all pipe/hose connections.

Faulty safetyvalve.

Check the relieving pressure.Replace the safety valve if faulty.DO NOT ATTEMPT A REPAIR.

FAULT CAUSE REMEDYOil is forcedback into theair filter.

Incorrectstoppingprocedureused

Always employ the correctstopping procedure. Close thedischarge valve and allow themachine to run on idle beforestopping.

Faulty inletvalve.

Check for free operation of the inletvalve(s).

Faultydischargecheck valve.

Remove the valve from thedischarge pipe and check theoperation.

Machinegoes to fullpressurewhenstarted.

Inlet valve setincorrectly.

Refer to SPEED AND PRESSUREREGULATION ADJUSTMENT inthe MAINTENANCE section of thismanual.

Machine failsto load whenthe loadbutton ispressed.

Faulty loadsolenoid.

Replace the solenoid. Check theelectrical circuit by feeling formovement whilst depressing theload button.

OPTIONS35

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

LUBRICATORSAFETY

WARNING: Ensure that the lubricator filler cap is re–tightenedcorrectly after replenishing with oil.

WARNING: Do not replenish the lubricator oil, or service thelubricator without first making sure that the machine is stoppedand the system has been completely relieved of all air pressure(Refer to STOPPING THE UNIT in the OPERATINGINSTRUCTIONS section of this manual).

CAUTION: If the nylon tubes to the lubricator are disconnected thenensure that each tube is re–connected in its original location.

GENERAL INFORMATION

Oil capacity: 2 litres

Oil specification:Refer to the Tool Manufacturer’s Manual.

OPERATING INSTRUCTIONS

COMMISSIONING

Check the lubricator oil level and fill as necessary.

PRIOR TO STARTING

Check the lubricator oil level and replenish as necessary.

MAINTENANCE

Check the lubricator oil level and replenish as necessary.

FAULT FINDING

FAULT CAUSE REMEDY

No oil flow. Incorrectconnection.

Reverse the nylon tubeconnections to the lubricator.

COLD START AIDSAFETY

Refer to the SAFETY SECTION in this manual.

GENERAL INFORMATION

The Cold start aid is fitted to machines to assist in starting the enginein temperatures of between 0�C and –10�C.


STARTING THE UNIT

Refer to section 5 PRIOR TO STARTING and STARTING THEUNIT.

Follow the instructions given in section 5 STARTING THE UNIT,depressing the Cold Start Button for 30 seconds immediately prior toturning the keyswitch to position III (engine start position). The ColdStart indicator light will illuminate whilst the button is depressed.

MAINTENANCE

Refer to the MAINTENANCE section of this manual.

FAULT FINDING

Refer also to the FAULT FINDING section in this manual.

FAULT CAUSE REMEDY

Engine failsto start.

Looseconnectionson the coldstartharness/wiring

Check the connections and tightenas necessary.

Engine failsto start.

Cold startrelay faulty.

Replace the relay.

OPTIONS 36

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

Revision 00

07/94

93165348

KEY

CSK� Cold start device

IL2 Lamp, cold start

PB2 Pushbutton, cold start

PHC Pre–heat coil

PHR Pre–heat relay

� Option

B Black

G Green

K Pink

N Brown

O Orange

P Purple

R Red

S Grey

U Blue

W White

Y Yellow

OPTIONS37

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

GENERATOR(WDG)

SAFETY

Refer to the SAFETY SECTION in this manual.

GENERAL INFORMATION

Rated output. 4,8 kW @ 0,8 Power factor (PF) lagging

Rated voltage 110V 1ph or 230V 1ph or 230V 3ph or 400V 3ph + 230V 1ph @ 3000 rpm

Voltage regulation +/– 6%

Maximum continuous output 6 kVA @ 0,8 PF

Rotor type Brushless(110/230V 1ph)

Rotor type Rotating armature with sliprings(230V 3ph / 400V 3ph + 230V 1ph)

De–rating factors at 0.8 pf continuous load:Air in temp 20°C ContinuousAir in temp 30°C 5,7 KVA @ 0.8 p.f

continuousAir in temp 46°C 4,5 KVA @ 0.8 p.f

continuous

De–rating factors for intermittant load:Air in temp 20–35°C,55 mins/hr @ 0.8, 5 mins off loadAir in temp 35–40°C,50 mins/hr @ 0.8, 10 mins off loadAir in temp 40°C + ,45 mins/hr @ 0.8, 15 mins off load

Socket outlets:110V 1ph & 230V 1ph 1 x 32 amperes

2 x 16 amperes230V 3ph 1 x 16 amperes400V 3ph + 230V 1ph 400V 3ph = 1 x 16 amperes

230V 1ph = 2 x 16 amperes

Earth leakage protection is provided by a single residual currentdevice. Miniature circuite breakers (MCB) are fitted to provide bothovercurrent and short circuit protection for the generator.

Each socket outlet is protected by a spring loaded weather-proofcover.


A mode selector switch is provided to switch the machine betweencompressor and generator mode.

CAUTION: Do not start or stop the machine with thecompressor/generator mode switch in the Generator position.

When the switch is in the Generator position the normally–opensolenoid valve switches to the closed position and air in the line to theengine speed control cylinder vents to the atmosphere via the solenoidexhaust port. This causes the cylinder to move to its maximum speedposition. The engine will now maintain maximum speed as the air linefrom the pressure regulator valve to the solenoid valve is now closed.

When the switch is returned to the Compressor position, thesolenoid valve is de–energised thus returning it to its normally openposition. The engine speed cylinder would then respond via thepressure regulator valve according to the air demand.

When connecting electrical equipment to any of the socket outlets,it is recommended that the appropriate MCB is in the OFF positionbefore making the connection, switching the MCB to the ON positionimmediately prior to using the equipment.

PRIOR TO STARTING (GENERATOR) (WDG)

If the generator should become exposed or saturated withmoisture/water deposits, it must be safely dried off before attemptingto make any part or conductor electrically live. This should be done bywiping away excess water, then running the engine with no electricalloads connected, until the generator is completely dry.

Ensure all persons concerned are suitably competent with electricalinstallations.

Ensure that there is a safe working procedure which has beenissued by supervisory personnel, and that it is understood by allpersons concerned with the operation of the generator.

Ensure that the safety procedure to be applied is based on theappropriate national regulations.

Ensure that the safety procedure is followed at al times.

Ensure that suitable guidance codes are available to indicate safeworking practices, and any hazards to avoid.

Before starting the engine and switching in the generator load,ensure that :–

. The system has been inspected and earthed.

. No persons are in a hazardous position.

. Any warnings necessary have been suitably displayed (whereapplicable).

Ensure compressor / generator mode switch is set to compressor.

OPTIONS 38

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

STARTING THE MACHINE

WARNING: Under no circumstances should volatile liquids suchas Ether be used for starting this machine.

CAUTION: Do not start or stop the machine with thecompressor/generator mode switch in the Generator position.

All normal starting functions are incorporated in the key operatedswitch.

. Turn the key switch to position 1, the alternator charge light willilluminate.


. Release to position 2 when the engine starts.

. Release to position 1 when the alternator charge light isextinguished.

At temperatures below 0�C or if there is difficulty starting first time:

Push and release button ‘A’.

. Allow the engine to reach operating temperature.

. At this point in the operation of the machine it is safe to apply full loadto the engine.

NOTE: Wear hearing protection at all times when the engine is startedwith the top open and air is flowing from the valve.

STOPPING THE MACHINE

. Close the service valve.

. Allow the machine to run unloaded for a short period of time toreduce the engine temperature.

. Turn the start switch to the 0 (off) position.

NOTE: As soon as the engine stops, the automatic blowdown valve willrelieve all pressure from the system.

If the automatic blowdown valve fails to operate, then pressure mustbe relieved from the system by means of the service valve(s).

CAUTION: Never allow the machine to stand idle with pressure in thesystem.

EMERGENCY STOPPING

In the event that the unit has to be stopped in an emergency, TURNTHE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TOTHE 0 (OFF) POSITION.

RE–STARTING AFTER AN EMERGENCY

If the machine has been switched off because of a machinemalfunction, then identify and correct the fault before attempting tore–start.

If the machine has been switched off for reasons of safety, thenensure that the machine can be operated safely before re–starting.

Refer to the PRIOR TO STARTING and STARTING THE UNITinstructions earlier in this section before re–starting the machine.

MONITORING DURING OPERATION

Should any of the safety shut-down conditions occur, the unit willstop. These are:

. Low engine oil pressure

. High air discharge temperature

. High engine oil temperature.

. Alternator not charging the electrical system.

. Low engine fuel level.

CAUTION: To ensure an adequate flow of oil to the compressor at lowtemperature, never allow the discharge pressure to fall below 3,5 bar.

OPTIONS39

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

DECOMMISSIONING

When the machine is to be permanently decommissioned ordismantled, it is important to ensure that all hazard risks are eithereliminated or notified to the recipient of the machine. In particular:–

. Do not destroy batteries or components containing asbestoswithout containing the materials safely.

. Do not dispose of any pressure vessel that is not clearly markedwith its relevant data plate information or rendered unusable by drilling,cutting etc.

. Do not allow lubricants or coolants to be released into land surfacesor drains.

. Do not dispose of a complete machine without documentationrelating to instructions for its use.

MAINTENANCE

General

Ensure all electrical equipment is properly maintained andcontrolled.

Ensure all earth connections are secure and regularly maintained.

Earth leakage circuit breaker (ELCB)

The earth leakage circuit breaker must be mechanically tested dailyby pushing the test button with the machine in its no load condition. TheELCB should trip to the off (down) position.

The earth leakage circuit breaker should also be tested every 3months. A proprietary test meter should be used to induce live to earthpreset flow at each socket outlet. This current flow will produce therequired earth fault check. The test should be conducted in accordancewith appropriate national standards.

Instruments and controls

A Voltmeter is provided to indicate the output voltage.

Miniature circuit breakers provide over–current protection. In theevent of excess current the appropriate circuit breaker will trip to theOFF position.

Note: The current trip rating is quoted at a nominal 40°C ambienttemperature.

An earth leakage circuit breaker provides additional protection inthe event of a leakage to earth in excess of 30 milliamperes on theconnected appliance or in the connections to the generator.

For alternator maintenance refer to Mecc Alte operation andmaintenance manual.

OPTIONS 40

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

FAULT FINDING

FAULT CAUSE REMEDYNo output. Load plugs not

fitted intosocket outletscorrectly.

Ensure that the load plugs are fittedcorrectly into the socket outlets.

No output. Looseconnection.

Remove end cover and terminalbox lid and check for looseconnections. Rectify the fault asnecessary.

Faulty rectifier. Check the rectifier bridge which islocated inside the rear housing.

Faultycapacitor.

Check the capacitors.

The No loadvoltage is lowbut increaseswhen a load isapplied.

Check the capacitors andassociated wiring.

The No loadvoltage fallswhen a load isapplied.

Check the current transformer andassociated wiring.

Loss ofresidualmagnetic field

Refer to Mecc Alte maintenancemanual

No output. Outputwinding(s)damaged.

Measure the voltage across thewinding(s). Replace the generatorif damaged.

Field windingdamaged.

Replace the generator.

Generatorfails toprovidemaximumoutput.

Engine is notrunning at fullspeed.

Check the engine speed with atachometer. ConsultIngersoll–Rand if the engine isfound to be running slow (Refer tosection 4 General Information).

Drive belt isnot tensionedcorrectly.

Re–tension the drive belt.

Drive pulley isloose on thedrive shaft.

Check the drive pulley and tightenas required.

FAULT CAUSE REMEDYThe outputvoltagecollapseswhen a loadisconnected

Overloadcondition.

Check and reset each circuitbreaker. If the condition persiststhen investigate the cause andrectify the fault as necessary. (seealso ’Circuit breaker trips’)

connected.Short circuit. Check for a short circuit and rectify

the fault as necessary.

Incorrectwiring.

Check the wiring and rectify thefault as necessary.

Circuitbreakertrips.

Overloadcondition.

Check and reset each circuitbreaker. If the condition persiststhen investigate the cause andrectify the fault as necessary. (seealso ’Circuit breaker trips’)

Short circuit. Check for a short circuit and rectifythe fault as necessary.

Fault inappliance.

Check the appliance and rectify thefault as necessary.

A circuitbreaker failsto re–setwhilst themachinerunning .

Circuit breakerlatchingmechanismfaulty.

Repair or replace as necessary.

Refer to Engine Manufacturer’s manual and Mecc Altemanufacturer’s manua l

OPTIONS41

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P90, P101, P110, P130, P150, P180, 7/51D.C. Control Circuit Schematic Diagram.

OPTIONS 42

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P90, P101, P110, P130, P150, P180, 7/51D.C. Control Circuit Schematic Diagram.

KEY

B Battery 12V

D1–3 Diode

CF1 Fuse, control5A

CSK Kit–Cold start aid

(Option)

G Alternator

h Hourmeter

IL1 Lamp, alternator charge

IL2 Lamp, cold start

IL3 Lamp, Low fuel

LFS Switch, low fuel level

M Motor, starter

PB1 Pushbutton, load

PHR Relay, preheat (cold start)

PHC Coil, preheat (cold start)

PS1 Switch, oil pressure

R1 Relay, safety shutdown

R3 Relay, start inhibit

R4 Relay, oil temperature switch

Engine

R5 Relay, low fuel

S Switch, start

SV1 Solenoid, fuel

SV2 Solenoid, load

SV3 Solenoid, speed

TS1 Switch, air temperature

Airend

TS2 Switch, air temperature

Discharge

TS3 Switch, oil temperature

Engine

GEN Generator(Option)

GEN 1 Generator(Option)(P101)

B Black

G Green

LG Light green

K Pink

N Brown

O Orange

P Purple

R Red

S Grey

U Blue

W White

Y Yellow

* See AC control circuit schematic

For details of interlock schematic, refer to respectiveelectrical power scematic diagram.

OPTIONS43

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P90/101 110V 1phA.C. Electrical Power Schematic Diagram.

KEY

CB1 Circuit breaker

63A

CB2 Circuit breaker

32A

CB3 Circuit breaker

16A

CB4 Circuit breaker

16A

G Alternator

K1 Contactor

PB Pushbutton

R Resistor

S1 Switch, start

S2 Switch

SK1 Socket outlet 32A



SV3 Valve, solenoid

V Voltmeter

VF1 FuseVoltmeter

VF2 FuseVoltmeter

* See DC control circuit schematic

OPTIONS 44

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P110, P130, P150, P180, 7/51 110V 1phA.C. Electrical Power Schematic Diagram.

KEY

CB1 Circuit breaker

63A

CB2 Circuit breaker

32A

CB3 Circuit breaker

16A

CB4 Circuit breaker

16A

G Alternator

K1 Contactor

PB Pushbutton

R Resistor

S1 Switch, start




SV3 Valve, solenoid

V Voltmeter

VF1 FuseVoltmeter

VF2 FuseVoltmeter


OPTIONS45

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P110, P130, P150, P180, 7/51 230V 1phA.C. Electrical Power Schematic Diagram.

KEY

CB1 Circuit breaker

32A

CB2 Circuit breaker

16A

CB3 Circuit breaker

16A

G Alternator

K1 Contactor

PB Pushbutton

R Resistor

S1 Switch, start




SV3 Valve, solenoid

V Voltmeter

VF1 FuseVoltmeter

VF2 FuseVoltmeter


OPTIONS 46

P90 P101 P110 P130

HP95 P150 P180 HP140 7/51

P110, P130, P150, P180, 7/51 400V 3ph + 230V 1phA.C. Electrical Power Schematic Diagram.

KEY

CB1 Circuit breaker

32A

CB2 Circuit breaker

10A

CB3 Circuit breaker

10A

G Alternator

K1 Contactor

PB Pushbutton

R Resistor

R1 Resistor

S1 Switch, start




SV3 Valve, solenoid

V Voltmeter

VF1 FuseVoltmeter

VF2 FuseVoltmeter


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