Tabla De Contenido; About This Manual; Personnel; Safety - Ingersoll Rand R4-11 kW Manual Del Usuario

EN
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
AIR COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sampling Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Changing Coolant Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Checking Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Changing Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspecting Airend/Pressure System/Receiver . . . . . . . . . . . . . . . . . . . . 5
Cleaning / Checking Scavenge Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning / Checking Blowdown Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking Minimum Pressure Check Valve (MPCV) . . . . . . . . . . . . . . . 6
The purpose of this manual is to provide maintenance and troubleshooting guidelines for the compressor.
For supporting documentation refer to Table 1.
Publication
Safety Information Manual
Maintenance Manual
Product Manual
Parts Information Manual
* Europe, Middle East and Africa
Product specification sheets and reference drawings are also available.
Proper use, inspections and maintenance increases the life and usefulness
of the compressor. It is extremely important that anyone involved with
maintaining the compressor be familiar with the servicing procedures of
these compressors and be physically capable of conducting the procedures.
These personnel shall have skills that include:
1. Proper and safe use and application of mechanics common hand
tools as well as special Ingersoll Rand or recommended tools.
2. Safety procedures, precautions and work habits established by
accepted industry standards.
Before undertaking any work on the compressor, ensure that the electrical
supply has been isolated, locked off, tagged and the compressor has been
relieved of all pressure. For VSD units, ensure the compressor is electrically
isolated for at least 15 minutes before commencing any maintenance work.
Ensure the compressor's remote start/stop feature has been switched off
prior to any maintenance. See the Safety Information manual for additional
information.
Ingersoll Rand cannot know of or provide all the procedures by which
repairs may be conducted and the hazards and/or results of each method. If
maintenance procedures not specifically recommended by the manufacturer
are conducted, ensure that safety is not endangered by the actions taken.
EN-2
RELEASED 16/Dec/2014 10:49:53 GMT
CONTENTS

ABOUT THIS MANUAL

Table 1: Product Manuals
Product
R4-160kW
R4-11kW
R4-11kW
R4-11kW

PERSONNEL

SAFETY

Changing Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning Air Cooled Combination Cooling System . . . . . . . . . . . . . . . 6
Removing / Installing Air Cooled Cooler . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking High Airend Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning Motor Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removing / Replacing Starter Box Power Drive Element (PDM)
Filter Element (For VSD Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning / Checking Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning / Installing Package Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . 7
Monitoring Fluid and Performing Shock Pulse Bearing Analysis . . 7
Aftermarket Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Changing Pulleys / Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
R4-11 INTEGRATED DRYER MAINTENANCE . . . . . . . . . . . . . . . . . 15
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly of the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Decommissioning the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . 18
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Part/Document Number by Region
Americas EMEA *
80446313 80446156
80448517 80448525
80448483 80448491
80448541
Some maintenance procedures are technical in nature and require
specialized tools, equipment, training and experience to accomplish
correctly. In such situations, only allow Ingersoll Rand trained technicians
to perform maintenance on this compressor. Service or inspections beyond
the procedures given in this manual shall not be attempted by operating
personnel.
For additional information contact the Ingersoll Rand factory or the nearest
service provider.
If you are unsure of a maintenance procedure or step, place the compressor
in a safe condition before consulting technical assistance.
The use of other than genuine Ingersoll Rand replacement parts may result
in safety hazards, decreased performance and increased maintenance and
may invalidate all warranties.
For additional information contact the Ingersoll Rand factory or the nearest
service provider.
Asia Pacific
80446321
80448533
80448509
80448517 Rev A