section 09_service and maintenance

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Sierra Main Training

Service and MaintenanceIndustrial Air Solutions

IR Global Service Education Team

Ingersoll-Rand Proprietary Information. Rev March 2004

DAILY CHECKS

SUMP OIL LEVEL

OIL FILTER DELTA P

AIR FILTER DELTA P

CONDENSATE DRAIN OPERATION CHECK OPERATION & RECORD ALL

TEMPS / PRESSURES


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INITIAL 150 HOURS

CHANGE OIL AND FILTER

CHECK / CLEAN CONDENSATE DRAINS

CHECK OPERATION & RECORD ALL TEMPS /

PRESSURES


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4000 HOURS

CLEAN CRANKCASE BREATHER ASSEMBLY

CHECK / CLEAN CONDENSATE STRAINERS

CHECK / REPLACE AIR FILTER

CHE

CK/

CLEAN

COOLERS CALIBRATE ALL TRANSDUCERS / RTDS

CHECK BLOWDOWN VALVE FUNCTION

CHECK ELECTRICAL CONNECTIONS


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8000 HOURS

AS 4000 HOURS PLUS -

CHANGE OIL AND FILTER

INSPE

CT /

CLEAN OIL PUMP STRAINER CHECKCONTACTORS

CHECK ALL ELECTRICAL CONNECTIONS

CHECK GRUB SCREWS ON COUPLINGS

CHECK / ADJUST INLET VACUUM


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GENERAL CHECKS

REFER TO MOTOR DATA SECTION FOR

LUBRICATION INSTRUCTIONS

CHECK AND RECORD MOTOR CURRENT ANDLINE VOLTAGE DURING EACH SERVICE VISIT


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INITIAL

150 HOURS

Check Sump Oil Level

Check Oil & Air Filter Pressure Differential

Condensate Valve Operation

Check & Record Pressures + Temps

Check & Record Voltages + Currents

Change Bearing Oil Filter

Change Bearing Oil

Clean Module Breather Assembly

Check / Clean Condensate Strainers

Replace Air Inlet Filter Elements

Check All Starter Electrical Connections

Check Contactors

Overhaul Blowdown Valve Assembly

Overhaul Hydraulic Load Cylinder

Overhaul Condensate Drain Valves

Overhaul Load Solenoid ValveOverhaul Discharge Check Valve

Check / Clean coolers

Lubricate Main Motor Bearings (Check Nameplate)

Check / Replace Drive Coupling Inserts

Check Main Oil Seal

Take IR30 Shock+Vibration Readings & Oil Sample

ACTION 6000 8000 10000

CARRIED OUT AT THESE INTERVALS (RUNNING HOURS)

WEEKLY 2000 4000 12000 14000 16000


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Motor Servicing

Grease motor every 3 months for 3600 RPMAnd 6 months for 1800 RPM.

For severe duty reduce interval by one half

Only grease motor when power has beenremoved from the unit

Remove outlet plugs

Grease gun fitting and spring loaded outlets or

plug are arranged at each end on the motor

housing.


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Add volume of grease to each bearing perfollowing: (camera film container = 2cu.in.)

FRAME 1800 3600

182 - 215 0.5 0.5 CU.IN.

254 - 286 1.0 1.0 CU.IN. 324 - 365 1.5 1.5 CU.IN.

404 - 449 2.5 1.0 CU.IN.

Run motor for about 30 minutes prior to

replacing outlet plug

Use specified grease motor greases

Be consistent with grease used! Do not mix

synthetic with mineral !!!! turns grease to

jelly

Motor Servicing


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Cooling Fan And Motor

Neither the fan nor the fan motor have

serviceable parts. If a problem occurs

with either of these components the part

must be replaced or rebuilt in the case ofthe motor.

Fan motor should be greased at the

same interval as the main motor.


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MOTOR SHAFTCOMPRESSOR

SHAFT

B

AC

50-100 HP

A N/A

B N/AC = .14 + - .060

Compressor coupling aligns against

a spacer on the shaft

SPACER 50-100

ONLY

125 - 200 HP

C = .16 + - .080

Motor Shaft Diameter A B

2.375 .75 .37

2.125 1.0 .62


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Sierra


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Air Filter

Replace every 4000 hours/6 months operation or as

site conditions require

Never change filter while unit is running


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Oil & Oil Filter

Always change the oil filter whenever theoil is to be replaced.

Originally IR used SL-200 now Ultra

Coolant Change initial oil at 150 hours

Thereafter every 8000 hours or 12

months operation, which ever comesfirst


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Gearcase Breather

Clean gearcase breather every 4000 hours or 6months operation, whichever occurs first

Normal gearcase static pressure


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Oil Pump

There are no serviceable parts with the oilpump, therefore if problems are

encountered with pump operation either

the pump and/or the pump coupling must

be replaced


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Airends

There are no serviceable parts within theairend so when a problem develops which

is determined to be internal to the airend,

the airend will have to be replaced


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Airend

Special tool for gear removal

Gear Lock Nut Torque's:

r 50-100

1st Stage - 75 lb/ft 2nd Stage - 35 lb/ft

r 125-200

1st Stage - 162 lb/ft

2nd Stage - 75 lb/ft

LOCTITE 222 on threads


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Sierra Driven Gear Removal #1


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Coolers

Coolers may be cleaned in unit using a noncaustic cleaning solution that is non

corrosive to aluminum

Cover air filter, main motor, 1SV and fanmotor to keep cleaning solution and rinse

from contaminating components


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Shaft Seal Leaks?

Axial movement 0.008-0.050

Radial movement 0.00075 (radial play)


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50-100 Sierra Jackshaft Sealing With Oil Drain

Scavenge to

Gearcase Below oil

level.

Coupling End

LoctiteH

Loctite 511

Loctite ???

Loctite 242


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125-200 Sierra Jackshaft Sealing With Oil Drain

Scavenge to Gearcase Below oil level.

Coupling End

Loctite H

Loctite 511

Loctite ???

Loctite 242

14mm

Loctite 620

Loctite 511


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MARMON COUPLING

UNDER NORMAL OPERATINGCONDITIONS THE MARMON

TYPE COUPLING SHOULD

GIVE MANY YEARS OF

TROUBLE FREE SERVICE,

HOWEVER IF THE 2nd STAGE

AIREND

MUST BE REMOVED

USE THE FOLLOWING

PROCEDURE FOR

REINSTALLATION

IF RUBBER SEALS ON

COUPLING HAVE BECOME

HARD AND BRITTLE A NEWCOUPLING SHOULD BE

ORDERED


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CONDENSATE DRAIN

THE CONDENSATE DRAINS

SHOULD BE CHECKED FOR

PROPER OPERATION EVERY 8

HOURS OF OPERATION OR

DAILY.

THE CONDENSATE DRAIN Y-STRAINER SHOULD BE

CLEANED AFTER THE FIRST

150 HOURS OPERATION AND

INSPECTED ONCE A YEAR,

EVERY 8000 HOURS OR ANY

TIME THAT AIR DOES NOTPURGE FROM DRAIN VALVES

WHEN THE VALVE IS OPEN.


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OIL PUMP

THERE ARE NO

SERVICEABLE PARTS

WITH THE OIL PUMP,

THEREFORE IF PROBLEMS

ARE ENCOUNTERED WITH

PUMP OPERATION EITHER

THE PUMP AND/OR THE

PUMP COUPLING MUST BE

REPLACED


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AIRENDS

THERE ARE NO

SERVICEABLE PARTS

WITHIN THE AIREND SO

WHEN A PROBLEMDEVELOPS WHICH IS

DETERMINED TO BE

INTERNAL TO THE

AIREND, THE AIREND WILL

HAVE TO BE REPLACED


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S


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Si M i T i i


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Check Valve Inspection

To be inspected annually

Check valve kit available

Gasket special material for high temp

Si M i T i i


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Cycles per minute ervice ours

3

ver Minute

Inlet Valve Service Calculator

Si M i T i i


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Inlet vacuum

75 kW 0.64 / 0.67 BAR

90 kW 0.65 / 0.77 BAR

110 kW 0.76 / 0.81 BAR

132 kW 0.82 / 0.85 BAR

150 kW 0.82 / 0.85 BAR

( PERFECT VACUUM IS 1.0132 BAR)



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Control Valve Servicing

Three major componentsr Inlet valve

Nothing serviceable

Adjust to .012 unloadedr Hydraulic cylinder

Rebuild kit available

r Blowdown valve

Rebuild kit available



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Blowdown Valve



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Blowdown Valve



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Blowdown Valve



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Blowdown Valve



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Inlet Valve Assembly



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IR Global Service Education TeamIngersoll-Rand Proprietary Information. Rev March 2004



S i d M i


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S i d M i t


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S i d M i tI d t i l Ai S l ti


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0.3 mm





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INLET VALVE

HYDRAULIC CYLINDER COMPLETE

S37 - 75kW CPN 39862859

S90 - 150kW CPN 39862826

HYDRAULIC CYLINDER KITS

S37 - 75kW CPN 39862875

S90 - 150kW CPN 39862834




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INLET VALVE

BLOWDOWN VALVE COMPLETE

S37 - 75kW CPN 39862867

S90 - 150kW CPN 39862396

BLOWDOWN VALVE KITS

S37 - 75kW CPN 39876016

S90 - 150kW CPN 39876008

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