LR450 - MMD Equipment
Contents
1. Parts List ITEM QTY PART NUMBER DESCRIPTION 1 6 302764 ISOLATOR 2 1 308577 FRAME 3 1 120 66020 TRAY 4 1 308731 BATTERY 5 4 120 36992 INSERT 6 8 929104 100 BOLT 7 10 1938004 062 WASHER 8 10 1938604 071 WASHER 9 1 120 14966 BRACKET 10 2 120 26804 BOLT 11 1 308579 TRAY 12 1 960212 075 ELBOW 13 4 1 900000 030 PLUG 14 2 970312 075 ELBOW 15 1 960204 025 ELBOW 16 2 1308592 TANK 17 8 937806 094 WASHER 18 16 1938206 071 WASHER 19 8 1 929806 100 BOLT 20 2 1 902915 015 PLUG 21 6 970306 038 ELBOW 22 2 307179 CAP 23 2 302382 SENDER 24 1 960412 075 NIPPLE 25 1 960612 075 TEE 26 2 974812 075 CONNECTOR 27 1 900000 010 PLUG 28 2 929104 075 BOLT 29 1 308595 GUARD 30 2 925305 283 NUT 31 2 929806 600 BOLT 32 2 970712 075 CONNECTOR 33 1 80216 KIT 34 4 925506 198 NUT 35 2 929806 450 BOLT 36 1 308597 LIFTBAIL 37 4 938210 112 WASHER 38 4 937810 156 WASHER 39 4 929810 150 BOLT 40 2 900000 015 PLUG 41 2 304643 BULKHEAD 42 2 301922 075 VALVE 43 1 308630 BRACKET 44 2 960012 075 ELBOW 45 2 989712 075 ELBOW 46 2 938605 071 WASHER 47 2 938005 078 WASHER 48 2 929105 100 BOLT 49 1 308637 BRACKET 50 1 308638 SWITCH 51 2 1 929705 075 BOLT 52 1 922112 050 NIPPLE 53 1 960112 075 CONNECTOR 40 308754 11 1 2010 Parts and Illustration Section 11 1 Frame System continued2. 4 925510 329 NUT 4 929810 300 BOLT 8 929812 350 BOLT 1 303445 GASKET 8 925512 382 NUT 1 308648 HOSE ASSY 1 308658 GASKET 2 301786 500 CLAMP 2 301786 400 CLAMP 2 301785 500 HOSE 3 301785 400 HOSE 1 308740 HOSE ASSY 6 304785 075 FITTING 2 304785 025 FITTING 8 583 FT 304783 025 HOSE 9 333 FT 304783 075 HOSE 11 5 FT 304783 150 HOSE 4 304785 150 FITTING 1 120 90624 HOSE 1 301397 INSERT 1 120 90728 ELBOW 1 300033 250 CLAMP 1 300033 400 CLAMP 2 120 11563 CLAMP 58 308754 11 1 2010 Parts and Illustration Section 11 11 Engine Air Oil Schematic E 3 1440N 3YSHdSOWLV 1308 3NTIV 4 1 5 uly EL s SNL 1 1314 Mu 1303 7313 _ ML iid as MNVL 1303 1 Alddns 1303 MNVL 1304 2 1009 ANYL TINI Q39NVHO 1 aN 10 3AWA Oh WO ANISNS 3304 009 5 XJ9YVYHOOAYNL WOMHJ Q3SSdHdWOO P JV IJIN mmsEmm Q N393I 308754 11 1 2010 59 Parts and Illustration Section 11 12 Airend Air Oil Schematic ATMO
3. Service and Maintenance Manual LR 450 Portable Air Compressor This manual must be read carefully before using your MMD Equipment Compressor Store in a safe and convenient location for future reference For technical support Phone 800 433 1382 Outside USA Email nick luciano mmdequipment com Website www mmdequipment com 308754 11 1 2010 308754 11 1 2010 Contents Manual Change amp LAS 7 d 1 2 NE 8 PAPAS TII Pa 8 M Mam C S T General Safety OVSIVIEW pa Ov RUN PEN ha MESE RS 9 3 2 Salet Precautions decet auia UM fent I UL IRR RAD IARE 10 2o Safety and Information Decals keit edits ted cut n UR ax cH 12 PSC EG MELO INS RR Tor 4 T Specification lt 5 demas eb o pF KR Spp EUM MURS 15 Description of Compori nts eoe eeeeee eeu ee roce c o no teo trn ono eo s erar ees ena ua sara nnssecns 21 MEI OQ cc 16 3 2 Dive OUI ast ind Nd nde Ended 16 x Ege i dicli C 16 5 4 Separator Sy
4. ee ee eee 16 20 5 16 Digital Control Panel 19 ETOUFDIIEDGT ERE 19 Tachome 19 19 locu a e EE 19 CS E open dui n 19 5 18 Emergency Stop IB OMe setas heparin sored uence anor udis indi beum UE 19 5 19 A Frame Drawbar and ECL nt rante vod hui eve netu mp 20 5 20 R nno EEE EEEE EEEE EEES 20 52k PVD 5 E E E E E E E E 20 522 Breakaway WC 20 Instalati 21 24 6 1 System Installation 1 21 6 2 Towing he Machine esre E 21 6 3 Parking the Machine e n EAEE 21 64 Placing the TOME 22 6 5 Service ETN 22 6 6 Remote Drains qo koh iiri reple 22 6 7 Mo RTT 22 6 8 Die Startup und antc 23 6 9 Machine 23 6 10 Check cibo T
5. Se 198 Q I 8 8 5 HOLIMS NMOGLNHS HOLIMS NMOGLNHS 39nv9 MOSS3HdWO 3univaadwal MOSS3HdWOOD GA 8t Sd 8 Sd M OvA WNNIVN SO eri HNIVW SO 1903 LSA ZdvWOW SI OdVWOA SI z 5 9 M079 98 E Mc 18 ozel loc TES OLA 019 50 HOLIMS 1VO14 NVd se 9g AON3OMN3IN3 2 M079 QC e zs ZA A339I SI 2018 3asn4 HOLIMS HOLIMS HOLIMS TIVLEN3332IO 9317114 HOSS3HdWOD iu f 3ATVA HOLIMS NOILISOd _ 0123138 010 138 os Tana ON E 3 2 AV T3 3 4 236 099 2 4 t HOLIMS P ISSSONONOS HOLIMS v aarivinoas AVM E GION310S avoiNn avo1 ON 308754 11 1 2010 61
6. M UPS 58 11 11 Brennen Onl ScheMatiC osseedatibvaiconitemee quiste relin eienenn qui eden eun 59 11 12 Airend Air Oil 60 11 13 System Wiring LNA AU sede is Sates VV etd uM bh Nd died 61 6 308754 11 1 2010 Manual Change History 1 1 Revision List LOCATION DESCRIPTION OF CHANGE INITIALS 7 308754 11 1 2010 Welcome 2 1 General Information Thank you for choosing the LR 450 Portable Compressor Before operating this system read over this manual and become well ac quainted with your new machine Doing this will increase your safety em m and maximize the life of the machine of its machines As result sometimes there may be slight differences between a given version of the manual and the machine While this manual is written to be as accurate as possible MMD equipment strives to continually improve efficiency and performance C 2 2 Overview TheLR 450 Portable Compressor is a strategically designed system It integrates all major components on a single environmentally sealed frame which is enclosed in a tough weather resistant canopy The LR 450 s rotary screw design guarantees continuous air output of up to 450 SCFM standard cubic feet per minute at 100 PSI pounds per square inch With remote fluid drains and hinged doors virtually all components are accessible for maintenance
7. 308754 11 1 2010 41 Parts and Illustration Section 11 2 Engine System Parts List PART NUMBER DESCRIPTION 1 1 1308457 ENGINE 2 1 1308529 FAN 3 1 1303340 COUPLING 4 2 1308580 BRACKET 5 1 1308581 BRACKET 6 1 1308582 BRACKET 7 1 970412 106 ELBOW 8 4 929808 350 BOLT 9 4 938208 112 WASHER 10 4 120 16832 WASHER 11 4 925508 262 NUT 12 8 938210 112 WASHER 13 4 925510 329 NUT 14 4 929810 250 BOLT 15 8 938912 200 WASHER 16 8 938812 250 WASHER 17 8 929212 350 BOLT 18 8 938810 220 WASHER 19 8 929210 300 BOLT 20 3 1308631 CONNECTOR 21 1 1308674 TUBE 22 6 1303589 CLAMP 23 1 303588 CLAMP 24 1 1308673 TUBE 25 1 1308635 ADAPTER 26 1 1308634 CLAMP 27 1 1308738 SPACER 28 4 929208 750 BOLT 29 4 938808 200 WASHER 42 308754 11 1 2010 Parts and Illustration Section 11 2 Engine System continued 308754 11 1 2010 43 Parts and Illustration Section 11 3 Compressor System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 3908446 120 AIREND 2 1 1308552 ADAPTER 3 1 303983 VALVE 4 6 938812 250 WASHER 5 6 938912 200 WASHER 6 1 1308583 BRACKET 7 1 1308584 ADAPTER 8 1 126 64754 GASKET 9 1 926102 240 O RING
8. not removing oil Check return line depth and connections repair from separator element as necessary eparator element damaged Replace element 37 308754 11 1 2010 Troubleshooting 9 1 Troubleshooting Chart continued Prbem Cause Remedy 2 2 Unit operating in area with limited fresh air Reposition unit or open up confinement Fan belts are loose or broken Tighten or replace onoi cookers Clean oil cooler thoroughly be careful not to Compressor damage fins overheating Oil cooler internally restricted Clean internal tubes of cooler Unit operating in area with limited fresh 5 Reposition unit or open up confinement esh air Fan belts are loose or broken Tighten or replace Clean radiator thoroughly be careful not to Engine damage fins overheating Repair or replace pump 9 2 Parts and Service Contact Information Phone 800 433 1382 Outside USA Email nick luciano mmd equipment com Website http www mmdequipment com N OTI When calling for technical support please have machine serial number and this manual available 38 308754 11 1 2010 Warranty 10 1 Warranty CONTACT MMD EQUIPMENT FOR WARRANTY Phone 800 433 1382 Outside USA Email nick luciano mmdequipment com Website www mmdequipment com 39 308754 11 1 2010 11 1 Frame System Parts and Illustration Section
9. 23 6 11 Initial St rtup Prepar t sssrinin 24 612 ninal Starp eree H 24 curii emer 25 26 7 I Ron une Operating cas cric rtp td ctv ota teal ma eR 25 Routine Startup 25 Startup Pro Ce QU hU UM Y E UR RUE 25 Routine Shutdown 26 7 2 Emergency Stop aethere ri nip HA Ip DUE 26 4 308754 11 1 2010 Contents 1 Maintenance COVEFVIGOW sedes ba n 27 522 Manmtenance SOHC sep qut men ua ks 27 28 5 9 Recommended Spare Parts 28 8 4 Parts and Service Contact Mil OPI O Weis coats ert Forte re Dii eec petu rui uris 28 8 5 Maintenance Bor MER Rc 29 8 6 Separator Element Replace mie tit sia duh duh Ur MM 30 8 7 Engine Air Filter 1 euis tavi tinc gn itd etd nde 3l 8 9 COmpresSsor 7 PO 32 34 CTI IET LISTINO OT 32 Addins Compressor OW PN 33 Changing 33 34
10. If the temperature reaches 200 a warning will display on the control panel The system will shut down if the temperature reaches 220 F Compressor Discharge Pressure Parameter This feature displays a failure if the system pressure of the air compressor exceeds 150 PSI If the pressure reaches 150 PSI the system will shut down IV Compressor Discharge Temperature Parameter This feature displays a failure if the compressor discharge temperature exceeds 240 If the temperature reaches 240 F the system will shut down VI Hourmeter The hourmeter records the total number of operating hours It serves as a guide in following the recommended maintenance schedule The hourmeter will only run when the engine is operating VII Tachometer This feature displays the speed of the engine If the speed of the engine reaches 2600 RPM or drops below 1400 RPM a warning will display on the controller If the speed of the engine reaches 2700 RPM or drops below 1300 RPM the system will shut down VIII Fuel Level This feature displays the percentage of fuel in the fuel tanks When the fuel levelis at 1596 a warning will display on the control panel The system will shut down when the fuel level is at 0 IX Battery This feature displays the voltage level of the battery If the voltage is at 11 5 volts a warning will display on the control panel The system will shut down if the voltage reaches 7 6 volts 5 17 Gauges The LR 450 is a
11. precautions or by failure to exercise the ordinary caution and due care required while operating or handling this equipment even though not expressly specified In addition to following these safety guidelines the operator should follow any company specific guide lines and procedures Consult your immediate supervisor for specific company safety guidelines and or procedures The following safety symbols are used throughout this manual to draw attention to important information Ifthe information is not carefully read and the instructions are not followed severe injury death and or damage to property and equipment may occur D AN G E Indicate s an imminently hazardous situation which if not avoided will result in death or serious injury Indicate s a potentially hazardous situation which if not avoided could result in death or serious injury Indicate s a potentially hazardous situation which if not avoided could result in minor or moderate injury Indicate s a potentially unsafe situation or practice N which if not avoided can result in property and or equipment damage only 9 308754 11 1 2010 Safety 3 2 Safety Precautions The following safety precautions are a general guide to safe operation of the equipment This is a pressurized system Do not attempt to remove any part of this machine without first completely relieving D A N G E R entire system of pressure Do not attempt t
12. 10 10 938810 220 WASHER 11 12 938210 112 WASHER 12 4 937810 156 WASHER 13 4 929810 175 BOLT 14 14 938916 225 WASHER 15 14 938816 350 WASHER 16 6 929212 450 BOLT 17 2 929216 350 BOLT 18 1 970804 025 ADAPTER 19 1 304720 VALVE 20 1 1303341 BUSHING 21 1 1308591 FLANGE 22 2 902915 020 PLUG 23 4 929216 140 BOLT 24 2 987305 025 ELBOW 25 1 987302 025 ELBOW 26 1 1301421 SWITCH 27 2 1907600 005 BUSHING 28 1 970812 075 ADAPTER 29 1 922212 000 NIPPLE 30 1 1901606 030 ELBOW 31 1 960124 150 CONNECTOR 32 8 929316 300 BOLT 33 2 1308623 BRACKET 34 2 929808 350 BOLT 35 2 938208 112 WASHER 36 2 120 16832 WASHER 37 2 925508 262 NUT 38 4 925510 329 NUT 39 4 929810 200 BOLT 40 2 961904 025 TEE 41 1 987205 025 CONNECTOR 42 1 1301422 SWITCH 43 10 929310 850 BOLT 44 1 964804 025 TEE 45 1 1307682 VALVE 46 1 922204 000 NIPPLE 47 1 301040 001 SWITCH 44 308754 11 1 2010 Parts and Illustration Section 11 3 Compressor System continued 308754 11 1 2010 45 Parts and Illustration Section 11 4 Discharge System Parts List PART NUMBER DESCRIPTION 1 1 308490 2 2 922132 000 NIPPLE 3 1 1984116 125 ELBOW 4 1 1901515 080 ELBOW 5 1 907606 050 BUSHING 6 1 1902615 060 ELBOW 7 1 922224 000 NIP
13. 8 9 Compressor OIl COD GE ttes onde iiu eit nim adiu 34 5 T0 Compressor OIl EAE oec coi eod tr UD 34 8 11 Engine Cooling System OX pep pe ERE NE 35 rl M 35 E E ieee aie 35 36 Ines 36 i i RM 36 Dd cara C A M 36 5 21 3 9 1 Tr ublesh oting td Rte NUR 37 9 2 Parts and Service Contact 38 hri H PRNGS 1 Wattanty POMC E 39 Parts and Illustration Section c cscssosssossoosscsssesssessveseonssosssessoessesssonsesssoosees40 O IEL Frame Syste TE T mI 40 TU Eee S SUP TEL ies E 42 113 Compressor St 44 11 4 Discharge 46 1 48 116 Elec cal NR 50 TET Exhaust VS ede 52 3 308754 11 1 2010 Contents Parts and Illustration Section 1 44 61 11 8 Air Filter RE TN 54 NES iE SLC MT 56 TO EIOS US BELA
14. BATTERY PRIOR TO ELECTRICAL SYSTEM SERVICE WORK OR ANY WELDING 104 90031 Electrical Shock NOTICE 12 VOLT NEGATIVE GROUND SYSTEM ONNECT NEGATIVE BATTERY TERMINAL TO GROUND Negative Ground System 12 Fan Guard Read the operators manual before starting this unit Failure to adhere to instructions can result in severe personal injury Read Manual 308754 11 1 2010 Safety 3 3 Safety and Information Decals continued NOTICE DO NOT OVERFILL RESEVOIR WARNING SECURE HITCH AND WITH COMPRESSOR LEVEL CHECK FLUID IN SIGHT GLASS WITHIN 15 20 MINUTES OF SHUTDOWN ADD FLUID ONLY IF LEVEL IS AT OR BELOW BOTTOM OF GLASS 104 90120 SAFETY CHAINS BEFORE TOWING OBSERVE POSTED SPEED LIMITS DO NOT 55 MPH Overfill FILLED AT FACTORY WITH DEXRON III A T F 104 901 14 AVOID INJURY DO NOT LIFT USE JACKSTAND TO RAISE DRAWBAR Compressor Oil Do Not Lift 4 DANGER Discharge air used Connect alr hoses only in full compliance for breathing will with OSMA Standard 29 cause severe injury or death Consult filtration specialist for additional PINCH POINT CFR 192 302 5 7 The required satety devices should be Pinch Point tested In accordance ir manufacturers endations y that they reduce pressure in case of hose failure and will mot nuisance trip with the hose tool comb nations in use filtratio
15. Compressor Oil Filter The compressor oil filter is a full flow spin on canister It has been specially designed to handle the full system pressure The oil filter is mounted downstream of the separator tank to ensure all contaminants are prevented from being passed on to the compressor oil cooler An oil filter restriction indicator is located on the oil filter head This indicator serves as a maintenance tool A check filters warning will display on the control panel when the filter needs to be serviced I7 308754 11 1 2010 Description of Components 5 11 Compressor Oil Thermal Valve The compressor oil thermal valve is a thermostatically controlled bypass valve that allows varying amounts of oil depending upon the temperature to bypass the oil cooler The oil thermal valve directs oil flow back to the compressor airend until the system reaches 180 F Once at system operating temperature the valve shifts directing the flow through the oil cooler before returning to the compressor airend 5 12 Minimum Pressure Valve To ensure there is adequate pressure to produce proper oil flow throughout the system a spring loaded normally closed minimum pressure valve is set to maintain at least 50 PSI in the separator tank 5 13 Blowdown Valve The blowdown valve is a shuttle valve that vents system pressure to atmosphere when the system is shut down This is done to prevent the high torque load that would be required to overcome the static pr
16. Record serial numbers for main components in the system I Machine Serial Number Compressor Airend Serial Number III Engine Serial Number IV Separator Tank Serial Number V Digital Control Panel Serial Number 6 10 Check Fluid Levels The machine is factory filled prior to shipment The proper fluid levels are also listed in the maintenance section I Separator Tank Oil Level Halfway on the separator tank sightglass IL Engine Radiator Coolant Level Bottom of the radiator fill neck III Engine Coolant Recovery Bottle Fill to the cold line IV Engine Oil Level Full on the dipstick 23 308754 11 1 2010 Installation 6 11 Initial Start up Preparation I Reconnect battery terminals Ensure the red cable is connected to the battery s positive terminal and the black cable is connected to the battery s negative terminal Verify fluid levels and refill if necessary III Verify all electrical connections are secure IV Check all hose connections for leaks V Close all service valves 6 12 Initial Startup At this point the system is ready to test for functionality Be sure to complete all of the previous steps prior to continuing I Press the AUTO button on the controller IL Check the controller for warnings or error codes Press the RUN button on the controller to begin the startup sequence The machine will cycle through a preheat cranking and warm up pe
17. System Parts List PART NUMBER DESCRIPTION QTY 1 1 308598 PANEL 2 1 308599 DOOR 3 1 308600 PANEL 4 1 1308601 PANEL 5 1 308602 PANEL 6 1 308604 PANEL 7 1 308605 PANEL 8 1 308606 PANEL 9 1 308607 COVER 10 1 308608 PANEL 11 1 1308610 PANEL 12 1 1308611 PANEL 13 4 924305 166 NUT 14 20 943103 025 RIVET 15 4 1305137 SPRING 16 4 308588 HINGE 17 4 1308612 STUD 18 4 303229 BRACKET 19 4 308613 PLUG 20 24 990702 075 SCREW 21 24 938602 049 WASHER 22 26 924302 130 NUT 23 2 1308609 DOOR 24 27 984006 071 WASHER 25 27 990906 094 WASHER 26 27 990806 100 BOLT 27 6 984004 071 WASHER 28 56 991005 075 BOLT 29 6 990904 062 WASHER 30 2 990804 150 BOLT 31 2 308627 LATCH 32 2 1308603 PANEL 33 2 991004 075 BOLT 34 4 990804 075 BOLT 35 2 1308625 BUMPER 36 1 308651 DOOR 37 1 80215 KIT 38 991102 050 SCREW 39 4 977004 062 WASHER 40 4 938604 071 WASHER 41 2 924304 145 NUT 42 2 929104 100 BOLT NS 1 80221 KIT 56 308754 11 1 2010 308754 11 1 2010 57 Parts and Illustration Section 11 9 Canopy System continued X d BB gg BLK L A i 8 EN 8 7 Parts and Illustration Section 11 10 Hose System Parts List lt PART NUMBER DESCRIPTION
18. airend the compressed air and hot oil flow into a steel ASME coded pressure vessel rated at 250 PSI that acts as an oil reservoir This tank is the first of two stages in separating the oil and compressed gas mixture From the bottom of the separator tank oil is forced to the oil filter IL Separator Element Atthe top of the separator tank is the separator element The separator element removes the oil mist from the air as it is passed on to the minimum pressure valve As the air oil mist passes through the outside of the media oil gathers on the interior walls and settles to the bottom of the element Collected oil is returned to the compressor airend through the oil return line The separator will filter the oil concentration in the air to less than 3 parts per million 5 5 Pressure Relief Valve Separator Tank Relief Valve This valve vents separator tank pressure to atmosphere should the pressure inside the tank exceed 175 PSI 16 308754 11 1 2010 Description of Components 5 6 Fuel Tanks The LR 450 fuel system consists of two 24 gallon fuel tanks The primary fuel tank 15 located on the curb side of the machine The auxiliary fuel tank is located on the road side of the machine The fuel tanks are joined together to function as one 48 gallon fuel tank Both tanks can be filled from either fuel tank Use only low sulfur diesel when fueling this machine 5 7 Engine Air Filter The engine air filter is a two stage dry type in
19. and service Instrumentation clearly displays pressures temperatures RPM and hours of operation Other features including a spin on compressor oil filter and a drop in separator element reduce the time and costs associated with routine maintenance The LR 450 also has enhanced safety features to protect your valuable resources minimum pressure valve high compressor oil temperature shutdown high discharge pressure shutdown automatic blowdown device pressure relief valve and clearly displayed warning information decals 8 308754 11 1 2010 Safety 3 General Safety Overview Remember safety is basically common sense While there are standard safety rules each situation has its own peculiarities that cannot always be covered by rules Therefore with your experience and common sense you are in a position to ensure the safety of yourself and others Lack of attention to safety can result in accidents personal injury reduction in efficiency and worst of all Loss of Life Watch for safety hazards and correct them promptly Understanding the proper operation of this equipment is critical to its safe operation The owner lessor and or operator of this equipment is hereby notified and forewarned that any failure to observe the safety and operating guidelines may result in injury and or damage MMD Equipment expressly dis claims responsibility or liability for any injury or damage caused by failure to observe these specified
20. exceed 30 PSI Reverse flush the element by directing the compressed air up and down the pleats in the filter media from the inside of the element Continue reverse flushing until all dust is removed Should any oil or greasy dirt remain on the filter surface the element should be replaced When cleaning an element the element will be damaged if you exceed the recommended maximum air pressure of 30 PSI C Ifthe cleaned element is to be stored for later use it must be stored in a clean container VII Install the air filter element VIII Install the rear cover and tighten clamps Install with rubber evacuator cup down IX Verify the control panel does not show a filter warning 31 308754 11 1 2010 Maintenance 8 8 Compressor Oil It is important that the compressor oil be of a recommended type and inspected and replaced as stated in this manual The combination of a separator element loaded with dirt and oxidized oil products together with increased air veloc ity as a result of this clogged condition may produce a critical point while the machine is in operation where igni tion can take place and could cause a fire in the separator tank The following are general characteristics for a rotary screw lubricant Due to the impossibility of establishing limits on all physical and chemical properties of lubricants which can affect their performance in the compressor over a broad range of environmental influences the responsibility f
21. prior to each move 95 ft 165 MONTHS 27 308754 11 1 2010 Maintenance 8 2 Maintenance Schedule continued INTERVAL DESCRIPTION EVERY 500 HOURS OR 6 2 Check radiator hoses and clamps MONTHS 6 Check integrity of engine mounts 1 Install new air filter element 2 Check all door gaskets hinges and latches 1 YEAR 4 Check Emergency Stop button functionality 5 Check separator tank pressure relief valve 6 Clean cooler fins on all coolers Compressor oil and oil filter is to be changed after the first 50 N 0O TI hours of operation After this normal intervals are to be followed N Check engine s operator manual for required service maintenance intervals 8 3 Recommended Spare Parts List PART NUMBER DESCRIPTION 303386 Compressor Oil Filter 308585 Separator Element EVERY 1000 HOURS OR 3 Clean and flush engine cooling system 308806 Engine Oil Filter 308807 Engine Air Filter Element 308759 SCA20G Shaft Seal Repair Kit 8 4 Parts and Service Contact Information Phone 800 433 1382 Outside USA Email nick luciano mmdequipment com Website http www mmdequipment com 28 308754 11 1 2010 Maintenance 8 5 Maintenance Log Accum Service Performed Parts Service Work EE 29 308754 11 1 2010 Maintenance 8 6 Separator Element Replacement When the oil vapor in the discharge air becomes excessive the separator element may need replacing
22. should only be repaired by qualified service technicians Dirt that clogs the cooling fins of the radiator should be removed The use of an air stream or high pressure steam cleaner should be done with caution so as to not damage the delicate fins Bent cooling fins will reduce the cooling capability of the radiator 35 308754 11 1 2010 Maintenance 8 11 Engine Cooling System Maintenance continued IL Engine Radiator continued B Radiator Pressure Cap If coolant continually spills from radiator through the overflow the radiator cap should be tested and or replaced with a 13 PSI rated cap Be sure cap is tightened to the proper secure position III Engine Fan Check the engine fan for cracks loose bolts and bent or damaged blades Replace damaged fans immediately Do not run system if any of the conditions exist Make sure the hex head bolts mounting the fan to the water pump pulley are properly torqued to 29 ft Ibs Never use the fan to rotate the engine The blade s can be AWARNING damaged causing a fan failure which can result in personal injury or property damage IV Engine V Belt Visually inspect the engine v belt Replace belt if cracked or frayed Check engine manual for proper belt tension 8 12 Battery The battery supplied with the LR 450 has been selected to have ample cold cranking amperes for quick starts in cold weather Keep the battery fully charged and if replacement is necessary the new battery must be of eq
23. the cooldown sequence C Press the ENTER button on the control panel to start the cooldown sequence The engine will run through a cooldown sequence that will last approximately three minutes The purpose of the cooldown sequence is to properly decrease system pressure before shutdown To protect the drive coupling from damage the system pressure must be below 50 PSI before the machine shuts down DO NOT press the OFF button two times consecutively or during the cooldown sequence This will bypass the cooldown sequence A DANG ER Bypassing the cooldown sequence will cause excessive wear on the drive coupling Damage to the drive coupling due to improper shut down WILL void the drive coupling warranty 7 2 Emergency Stop Procedure In the event of an emergency and the LR 450 must be stopped suddenly the machine is equipped with an Emergency Stop switch This should only be used in the case of an emergency This should not be used as a routine shutdown device Using the emergency stop button for standard shutdown WILL cause excessive wear on the drive coupling Damage to the drive coupling due to improper shutdown will void the drive coupling warranty If the emergency stop button must be used do not operate this machine until the problem has been resolved I Emergency Shutdown Procedure A Press the Emergency Stop button on the control panel B Reset Emergency Stop button C Correct source of emergency situation prior t
24. 199 TANK 5 17 938004 062 WASHER 6 17 938604 071 WASHER 7 17 929104 100 BOLT 8 15 938206 071 WASHER 9 15 937806 094 WASHER 10 4 929806 150 BOLT 11 2 929806 300 BOLT 12 9 929806 100 BOLT 13 6 938605 071 WASHER 14 6 938005 078 WASHER 15 6 929105 075 BOLT 16 1 960104 025 CONNECTOR 17 1 308617 PANEL 18 6 929704 050 BOLT 19 1 1308618 GROMMET 20 2 980100 300 CLAMP 21 1 308615 BRACKET 22 2 929705 050 BOLT 23 1 1308616 BRACKET 24 2 929705 100 BOLT 25 2 925305 283 NUT 26 2 960124 150 CONNECTOR 27 1 308457 36 ENGINE 28 2 308457 35 ENGINE 48 308754 11 1 2010 Parts and Illustration Section 11 5 Cooler System continued 2190741087 308754 11 1 2010 49 Parts and Illustration Section 11 6 Electrical System ITEM QTY PART DESCRIPTION 1 1 308675 ASSY 2 1 960232 200 ELBOW 3 2 300022 075 VALVE 4 1 1300022 200 VALVE 5 1 922132 000 NIPPLE 6 2 922212 000 NIPPLE 7 1 308644 CONTROLLER 8 1 308663 BOX 9 1 308669 10 1 1308670 ADAPTER 11 1 1308671 SWITCH 12 1 1308460 GAUGE 13 1 1308672 PLATE 14 2 929704 050 BOLT 15 4 929706 075 BOLT 16 4 925306 347 NUT 17 4 929706 100 BOLT 18 2 981504 075 SCREW 19 1 308693 GAUGE NS 1 1308721 SWITCH NS 1 301040 001 SWITCH NS 1 1308661 VALVE NS 1 308662 CONNECTOR NS 1 1308725 CABLE NS 1 308753 CABLE NS 1 1308752 HAR
25. NESS 50 308754 11 1 2010 Parts and Illustration Section 11 6 Electrical System continued gt fe AG SS GY 51 308754 11 1 2010 Parts and Illustration Section 11 7 Exhaust System ITEM QTY PART DESCRIPTION 1 1 304067 MUFFLER 2 2 1304071 3 4 1980100 300 CLAMP 4 1 308576 PIPE 5 1 150 90915 6 2 1300915 300 ELBOW 7 1 1300639 300 8 1 1308626 9 4 925305 283 NUT 10 4 929705 100 BOLT 11 1 40037 ASSY 12 3 1938808 200 WASHER 13 3 1925908 125 NUT NS 1 1300033 450 CLAMP NS 1 1303381 BLANKET 22 308754 11 1 2010 Parts and Illustration Section 11 7 Exhaust System continued 2 Q x 4 e p COIT e N gt A Gr gt Se a B o 53 308754 11 1 2010 Parts and Illustration Section 11 8 Air Filter System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 1308563 ASSY 2 1 308564 ASSY 3 2 308565 BAND 4 2 1300067 BAND 5 12 938206 071 WASHER 6 4 937806 094 WASHER 7 8 929806 100 BOLT 8 4 925506 198 NUT 54 308754 11 1 2010 Parts and Illustration Section 11 8 Air Filter System continued 308754 11 1 2010 55 Parts and Illustration Section 11 9 Canopy
26. PLE 8 3 960124 150 CONNECTOR 9 1 1303387 THERMOSTAT 10 1 1961624 125 NIPPLE 11 1 1303386 FILTER 12 1 1303385 HEAD 13 1 1303379 VALVE 14 2 1902915 010 PLUG 15 1 1960212 100 ELBOW 16 1 1960024 150 ELBOW 17 1 120 63815 SIGHT GLASS 18 4 938208 112 WASHER 19 4 937808 125 WASHER 20 4 929808 150 BOLT 21 1 1301466 150 CAP 22 1 1308585 ELEMENT 23 1 1301827 VALVE 24 1 902915 010 PLUG 25 1 1300057 VALVE 26 1 1987504 025 CONNECTOR 27 1 987504 025 CONNECTOR 28 1 1304210 TUBE 29 1 977604 025 ELBOW 30 1 987204 025 CONNECTOR 31 1 1987302 025 ELBOW 32 3 961904 025 TEE 33 2 960404 025 NIPPLE 34 1 1922104 060 NIPPLE 35 1 903668 VALVE 36 1 1960232 200 ELBOW 37 1 1304004 VALVE 38 1 987304 025 ELBOW 39 1 1902915 020 PLUG 40 1 964804 025 TEE 41 1 1308461 SENDER 42 1 1308721 SWITCH 43 3 907600 005 BUSHING 44 1 987205 025 CONNECTOR 45 2 987305 012 ELBOW 46 1 125 16672 VALVE 47 1 922202 070 NIPPLE 48 1 1901115 005 ELBOW 49 1 1901315 010 CROSS 50 1 1922204 000 NIPPLE 51 3 987305 025 ELBOW 46 308754 11 1 2010 Parts and Illustration Section 11 4 Discharge System continued 47 308754 11 1 2010 Parts and Illustration Section 11 5 Cooler System Parts List PART NUMBER DESCRIPTION 1 1 308578 BULKHEAD 2 1 308619 GUARD 3 1 1308512 COOLER ASSY 4 1 1150 90
27. SPHERE MANUAL LOAD UNLOAD VALVE ATMOSPHERE DISCHARGE AIR lt gt NK FILTER e AIR SERVICE VALVES i LOAD UNLOAD SOLENOID INLET E N C VALVE E MIN PRESS IN VALVE PROPORTIONAL bt CONTROL OPEN 9 50 PSIG VALVE i BLOWDOWN en AWE M ATMOSPHERE 2 E S E E E 22 2 PRESS RECIRCULATION RELIEF AIR END m CHECK VALVE VALVE VALVE 175 PSIG HO TENOR T EIOS DON NC _ T B a lt gt THERMOSTAT LEGEND BY PASS VALVE OL 4 INLET AR OIL aep PIETER COOLER Wer AR COMPRESSOR OIL DRAIN DRY AIR VALVE SCAVENGE LINE CONTROL LINE OIL LINE ATMOSPHERE 308754 11 1 2010 60 Parts and Illustration Section 11 13 System Wiring Diagram 01 91 11 WS OIVW3HOS 2 19 1 OGv 1 9cOLN 1 NVI 99 2 22 M3MOd 9d Tana 4 94 WHO N3MOd 5d 9 N9IS 9d N9IS 9d 18 3Sv9 9d V MINVIS SO 15 e 18 WOLVNH3ITV _ 5 8
28. This should not be necessary more than once a year under normal operating conditions I Replacement Procedure A Shut down machine and allow to cool for approximately 10 minutes B Verify entire system pressure is relieved before proceeding N 0 C E When disconnecting hoses be sure to note the location to ensure there is no confusion when reconnecting Disconnect the 2 hose from the minimum pressure valve Disconnect the 5 16 tubes from the regulator valve Disconnect the 1 8 tube from the blowdown valve Disconnect the 1 4 tube from the oil return line N 0 Note the location of separator tank lid so that it can be reinstalled in the same orientation G Remove the ten 5 8 bolts holding the separator tank lid in place The separator tank lid has a pickup tube installed and N 0O TI C E damaging or moving the tube will affect the machines functionality H Liftand remove the lid from the package I Remove the separator element Substitute filters may have inadequate working pressure limits resulting in filter leakage or rupture Replacement filters must be the same quality and type as the original separator element The separator element flange must have a gasket on each side to seal the lid on one side and the vessel on the other The staple in each gasket acts as a static ground and must not be MMC removed Install anew element Reinstall the separator tank lid Reinstall the t
29. anel The control panel will ask to start cool down sequence 3 Press the ENTER button on the control panel to start the cool down sequence The engine will run through a cool down sequence that will last three minutes WARNING DO NOT press the OFF button two times consecutively or during the cool down sequence This will bypass the cool down sequence Bypassing the cool down sequence will cause excessive wear on the drive coupling Damage to the drive coupling due to improper shutdown WILL void the drive coupling warranty 308804 Start up Shutdown Procedure 14 308754 11 1 2010 Specifications 4 Specification Sheet Engine Speed 2500 Isuzu 3 0L 4C YL Turbo Diesel Engine Fuel Specification Low Sulfur Diesel SCA20G with 1 20 Gear Compressor Oil Capacity 13 Gallons Engine IS LAG HAS W Ambient Conditions SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE 103 00 m 86 66 r 66 90 1 00 69 35 74 00 Of es 39 25 5 42 00 137 87 i 72 76 r 166 12 167 12 15 308754 11 1 2010 Description of Components 5 Engine The LR 450 contains an Isuzu 4 cylinder diesel engine This engine has been specially modified to handle the rugged duty requ
30. e machine is level to assure oil level in sightglass will be accurate B Remove any dirt around the separator tank fill cap to prevent contamination from entering the system Do not remove caps plugs or other components when the system is running or pressurized Stop system and relieve AWARNING all internal pressure before doing so Failure to comply with this warning will cause damage to property and serious bodily harm Remove the separator tank fill cap Inspect and clean the fill cap Replace if necessary Dexron IIL ATF can then be added until the oil level reaches halfway in the sightglass Do not over fill the separator tank This will cause oil carryover in the discharge line and at blowdown Do not replace fill cap with a pipe cap serious injury or dam A CAUTION age could result Replacement filters must be the same quality and type as the original MMD Equipment fill cap Replace fill cap and tighten immediately Changing Compressor Initially the compressor oil and oil filter should be replaced after the first 50 hours of operation then every 500 hours or 6 months If the oil appears dirty or has a foul smell it should be replaced immediately A Verify the machine is level to assure oil level sightglass will be accurate B Remove any dirt around the separator tank fill cap to prevent contamination from entering the system Do not remove caps plugs or other components when the syste
31. e to equipment and property Use only MMD Equipment approved replacement parts Never place machine on a grade more than 15 degrees Never operate the machine in an enclosed area Keep doors closed on the machine during operation N 0 Check engine s operator manual for required service and maintenance intervals N O T I C Nevertow trailer unless all electrical lights are connected and working properly 11 308754 11 1 2010 Safety 3 3 Safety and Information Decals This machine is supplied with a full complement of safety and identification decals These decals are affixed to the unit during final assembly These decals must be clearly visible and undamaged Should any of these decals become illegible or damaged immediately replace the decal WARNING 2 4 OIL FILL OR ANY FITTING 104 90115 operate without in place DANGER HOT EXHAUST SYSTEM RELIEVE AIR PRESSURE BEFORE LOOSENING COMME ees ALLOW SYSTEM TO COOL DOWN Hot Exhaust Pressurized System PRESSURE HOT OIL SHUT OFF COMPRESSOR amp PULL PRESSURE RELIEF VALVE TO RELIEVE PRESSURE BEFORE OPENING OR SERIOUS BODILY HARM MAY OCCUR 104 90112 Hot Pressurized Oil HOT COOLANT NEVER OPEN RADIATOR CAP WHEN ENGINE IS HOT CHECK COOLANT LEVEL IN RECOVERY TANK 104 90040 Hot Coolant TO AVOID ELECTRICAL SHOCK AND MACHINE DAMAGE DISCONNECT
32. en 5 8 bolts Uniformly tighten the bolts in a crisscross pattern to a torque of 220ft Ib Reconnect all hoses and ensure they are correctly located and tightened properly Start machine and check for any leaks 30 308754 11 1 2010 Maintenance 8 7 Engine Air Filter Replacement I Loosen the clamps that secure the engine air filter s rear cover to the filter housing Remove and clean the rear cover III Remove the air filter element IV Clean the canister with a damp cloth inside and out DO NOT blow dirt out with compressed air Never blow dirt out of the interior of the filter housing This A CAUTION may introduce dust downstream of the filter Instead use a clean damp cloth V Priortocleaning an element check the element for damage Damaged air filter elements must be replaced A Place a bright light inside the element to inspect for damages or leaks B Inspect all seals and seal contact surfaces on the housing Should faulty seals be evident correct the condition immediately VI If element is undamaged clean the air filter element A The maximum number of times that an element should be cleaned is 2 times however the element should be used no longer than a period of 1 year without changing Do not strike the element against any hard surfaces for clean ing as it may possibly rupture the element Do not oil element B Whencleaning the element with compressed air never let the air pressure
33. essure The blowdown valve is stamped with an and a The side is connected to dry air from the separator tank and the side is the pilot signal coming from the compressor inlet valve 5 14 Manual Load Unload Valve This turn valve is used to limit the compressor system pressure When the valve is in the closed posi tion the system will build to the regulator setting If the valve is in the open position the system will build to approximately 45 PSI 5 15 Discharge Pressure Regulator Valve This valve located downstream of the separator element is used to set the desired discharge pressure This valve will send a pneumatic signal to the inlet valve to start closing when the pressure exceeds the set point This signal will also adjust the speed of the engine This system has a maximum operating pressure of 100 PSI and a standby pressure of 130 PSI 5 16 Digital Control Panel The LR 450 incorporates a digital control panel that monitors and records numerous parameters I Engine Oil Pressure Parameter This feature displays the oil pressure inside the engine block When the pressure drops below 20 PSI a warning will display on the control panel The system will shut down when the engine oil pressure drops below 15 PSI 18 308754 11 1 2010 Description of Components 5 16 Digital Control Panel continued Engine Coolant Temperature Parameter This feature displays the temperature of the engine coolant
34. he LR 450 is equipped with four service valves A 2 NPT service valve and two 3 4 NPT service valves are located in the rear of the machine underneath the control panel Located in the front of the machine is a remote 3 4 NPT service valve 6 6 Remote Drain Ports The engine oil radiator compressor oil fuel and environmental pan drains are all located behind the curbside tire underneath the machine Remove the 3 4 NPT plugs 1 4 for the radiator to drain the fluids from the machine The engine oil and the compressor oil drains utilize a ball valve to control the oil flow These valves are located next to the battery on the curb side of the machine 6 7 Auxillary Fuel Tank Use the two 3 8 NPT ports located in front of the curbside tire underneath the machine to connect an auxiliary fuel tank Connect the fuel return line to the port closest to the tire Connect the fuel feed line to the remaining port 22 308754 11 1 2010 Installation 6 8 Pre Startup Inspection This inspection must be done prior to initial system startup I Check all assemblies clamps fittings hose connections nuts and bolts to ensure they are properly tied and secured Remove all tools rags and installation equipment from the area III Check all valves to ensure they are in the correct operating position A Engine Oil Drain Valve Closed B Compressor Oil Drain Valve Closed C Manual Cold Start Valve Closed 6 9 Machine Documentation
35. his system only in full compliance with all pertinent O S H A Federal State and Local codes or requirements in addition to MMD Equipment and any company s regulations The LR 450 utilizes a specially designed system controller that electronically controls all aspects of the compressor s operation Follow the instructions carefully Improper use of the control panel will cause damage to the drive coupling Damage to the drive coupling due to improper use will void the warranty I Routine Start up Preparation Verify service valves are closed Verify fluid levels and refill if necessary Check battery cable connections for corrosion Check the condition of the engine fan belt Check for fuel oil and or coolant leaks Press the AUTO button on the control panel and check for warnings or error codes moO gt IL Routine Start up Procedure A Press the RUN button on the control panel to begin the start up sequence The machine will cycle through a preheat cranking and I C warm up period This will last approximately three minutes Machine is ready for use when the system pressure reaches 100 PSI B Openthe service valves to begin using air 25 308754 11 1 2010 Operation 7 1 Routine Operating Procedures continued III Routine Shutdown Procedure A Close all service valves B Press the OFF button on the control panel The control panel will display COOLDOWN as a question to start
36. ired for its operation This engine is setup to run on low sulfur diesel fuel The engine speed is regulated electronically by the machine controller 5 2Drive Coupling Power from the engine is transmitted to the compressor input shaft through a specially designed drive coupling The drive coupling consists of a highly torsionally flexible rubber disc that mates with an engine flywheel flange The coupling provides a torque limitation to protect from system overloads 5 3 Compressor Airend The LR 450 airend is a positive displacement oil flooded rotary screw type unit employing one stage of compression to achieve the desired pressure Components include a housing stator two screws rotors bearings and bearing supports Power from the engine flywheel is transferred through a gear set to the male rotor The female rotor is driven by the male rotor There are five lobes on the male rotor while the female rotor has six roots In operation two helical grooved rotors mesh to compress air Inlet air is trapped as the male lobes roll down the female grooves pushing trapped air along compressing it until it reaches the discharge port at the end of the stator and delivers smooth flowing pulse free air Being an oil flooded system the oil serves three purposes lubricates the rotating parts and bearings serves as a cooling agent for the compressed air and seals the running clearances 5 4 Separator System I Separator Tank From the compressor
37. k Place any retractable stand in a full up and locked position with the stand horizontal Carefully inspect the tires and check the tire pressure Test all running tail stop and directional lights Make sure that all lights and reflecting surfaces are clean and in good condition Close and latch the doors and access panels Set the parking brake in the towing vehicle Only then remove chocks or blocks from machine wheels 6 3 Parking The Machine I II III IV V Chock or block the wheels Disconnect the electrical connection Disconnect the safety chains and wrap them around the drawbar Lower front jack to raise machine off the towing vehicle s hitch Move the towing vehicle clear of the machine 21 308754 11 1 2010 Installation 6 4 Placing The Machine The first step to installing the LR 450 is parking the system on a solid level surface This machine is designed to run at a 15 grade maximum If you must park on any grade park across the grade so that the machine does not tend to roll The machine must be supplied ample ambient air as the system will overheat if the cooling air intake s temperature exceeds ambient conditions 3 4 SERVICE VALVE 2 SERVICE VALVE RADIATOR DRAIN ENVIROMENTAL PAN DRAIN 3 4 SERVICE 4 COMPRESSOR VALVE OIL DRAIN FUEL DRAIN ENGINE OIL DRAIN 3 8 NPT AUXILLARY FUEL TANK FUEL RETURN LINE 3 8 NPT AUXILLARY FUEL TANK FUEL FEED LINE 6 5 Service Valves T
38. lso equipped with two analog gauges compressor discharge pressure gauge and fuel level gauge 5 18 Emergency Stop Button In the case of a dangerous situation the LR 450 is equipped with an emergency stop button The emergency stop button is to only be used when imminent danger is present Using the emergency stop button for standard shutdown WILL cause excessive wear on the drive coupling of the system Damage to the drive coupling due to improper shut down WILL void the warranty for the drive coupling 19 308754 11 1 2010 Description of Components 5 19 A Frame Drawbar and Hitch The A frame drawbar and hitch connects the towing vehicle and the machine This drawbar has been designed to handle the rugged duty required for its operation 5 20 Running Gear Axle wheel and tires are all sized for their job This machine is equipped with a single axle The design of the machine plus the axle design makes towing at highway speed possible 5 21 Safety Chains Safety chains should be attached on opposite sides of the machine s drawbar and crossed under the drawbar when passed forward to the towing vehicle so as to cradle the drawbar in the event of a breakaway Slack should be sufficient to permit full turns 5 22 Breakaway Switch The cable for the breakaway switch should be attached to the towing hitch of the vehicle being used to tow the compressor In the event of a breakaway the trailer breaks will engage stopping the trailer i
39. m is running or pressurized Stop system and relieve all AWARNING internal pressure before doing so Failure to comply with this warning will cause damage to property and serious bodily harm Remove the separator tank fill cap Inspect and clean the fill cap Replace if necessary Drain oil from the bottom of the separator tank If compressor oil filter change is required proceed to section 8 10 Compressor Oil Filter mmn 33 308754 11 1 2010 Maintenance 8 8 Compressor Oil continued III Changing Compressor Oil continued Dexron can now be added until the oil level reaches halfway in sightglass Do not over fill the separator tank This will cause oil carryover in the discharge line and at blowdown Do not replace fill cap with a pipe cap serious injury or dam A CAUTION age could result Replacement filters must be the same quality and type as the original MMD Equipment fill cap Replace fill cap and tighten immediately I Run system briefly to see if more oil needs to be added and to ensure there are no leaks 8 9 Compressor Oil Cooler Any sign of leakage from the compressor oil cooler justifies a pressure test to assure its integrity Cooler leaks should only be repaired by qualified service technicians Dirt that clogs the cooling fins of the cooler should be removed The use of an air stream or high pressure steam cleaner should be done with caution so as to not damage the delicate fins Ben
40. mmediately 20 308754 11 1 2010 Installation 6 1 System Installation Overview The LR 450 should be installed only by those who have been delegated to do so trained and who have read and understand this manual Failure to follow the instructions procedures and safety precautions in this manual may result in accidents and injuries Install use and operate this system only in full compliance with all pertinent O S H A Federal State and Local codes or requirements in addition to MMD Equipment and any company s regulations Do not modify this system except with written factory approval 6 2 Towing The Machine I Carefully inspect the machine s ball hitch drawbar and chains look for excessive wear corrosion cracked bent dented or otherwise deformed or degraded member loose nuts bolts or other fasteners Do the same on the towing vehicle s hitch and related hardware If inspection shows any worn or damaged parts DO NOT TOW the machine until repairs are made Torque Specifications N I C Hitch fasteners 150 ft Ibs Wheel lug fasteners 90 120 ft Ibs lt lt lt 2e Ix Safety chain fasteners 50 ft Ibs Chock or block the machine s wheels and raise the drawbar to the approximate level of the towing vehicle hitch Engage close and lock the coupling device Attach safety chains Attach electrical connection Attach breakaway switch Fully retract front screw jac
41. n and treat ment equipment to meet occupational safety and health administration standards Breathing Air Connect Hose 13 308754 11 1 2010 Safety 3 3 Safety and Information Decals continued STARTUP PROCEDURE EMERGENCY SHUTDOWN PROCEDURE Startup Preparation The Emergency Stop Button is to be used in situations where danger is eminent Using the emergency stop button for standard shut down WILL cause excessive wear on the drive coupling Damage to the drive coupling due to improper shut down will void the drive coupling warranty Close all service valves Verify fluid levels and refill if necessary Check battery cables ond connections for corrosion Check condition of fan belt Check all hose connections for leaks Press the AUTO button on the control panel and check for wamings or error codes Emergency Shutdown Procedure 1 Press the Emergency Stop Button on the control panel 2 Correct source of emergency situation prior to operating this machine Startup Procedure again 1 Press the RUN button on the control panel to begin the startup sequence 308805 Note The machine will cycle through a preheat cranking ond warmup period This will last approximately three minutes Machine 22227 Emergency Shutdown Procedure 2 Open service valves to begin using oir SHUTDOWN PROCEDURE Routine Shutdown Procedure 1 Close all service valves 2 Press the OFF button on the control p
42. o operating this machine again 26 308754 11 1 2010 Maintenance 8 1 Maintenance Overview This section contains instructions for performing the inspection lubrication and maintenance procedures required to ensure the system is in proper operating condition The importance of performing the maintenance described herein cannot be over emphasized A planned program of periodic inspection and maintenance will help avoid premature failure and costly repairs Keep an accurate logbook for maintenance service and operating hours The maintenance schedule intervals on this system are maximum intervals The factory recommended maintenance schedule is based on favorable operating conditions For continuous duty extreme temperature etc service more frequently Neglecting routine maintenance can result in machine failure or permanent damage This system should be maintained only by those who have been delegated to do so trained and who have read and understand this manual Failure to follow the instructions procedures and safety precautions in this manual may result in accidents and injuries 8 2 Maintenance Schedule 1 Drain liquid from separator tank More frequent draining may be required under high humidity conditions 2 Inspect lifting frame EVERY 50 HOURS OR 3 Check drawbar and two hitch bolts torque and prior to WEEKLY each move 70 ft Ibs 4 Check tire pressure 65 PSI Maximum 5 Check wheel nut torque and
43. o service any part of the equipment while in operation Never attempt to repair or modify any pressure vessel or device System contains hot oil The system must be shut off prior 2 D A N to servicing Then permit system to cool down prior to adding compressor oil or servicing the unit Do not use air from this system for breathing or food A DA N R processing Air from this system will cause severe injury or death if used for breathing or food processing The system is designed to compress air Do not attempt D G R to compress other gases Compression of other gases may create a situation where an explosion or fire may Q Do not use flammable solvents for cleaning system com T D G E R ponents as this can cause the unit to ignite or explode during operation Keep combustibles out of and away from system inlets and any associated enclosures Never disable override or remove safeties either tempo G E R rarily or permanently Do not modify systems to operate equipment at a higher DA N G E R or lower pressure than specified 10 308754 11 1 2010 Safety 3 2 Safety Precautions continued Read and understand this manual and all other safety instructions before using this equipment Failure to follow operating instructions and or failure to follow maintenance procedures and intervals could result in personal injury death and or damag
44. or recommending and consistently furnishing a suitable heavy duty lubricant must rest with the individual supplier if they choose not to use the recommended MMD Equipment rotary screw lubricant The lubricant supplier s recommendation must therefore be based upon not only the following general characteristics but also upon his own knowledge of the suitability of the recommended lubricant in helical screw type air compressors operating in the particular environment involved Mixing different types or brands of lubricants is not recom N 0 TI mended due to possibility of a dilution of additives or a reaction between additives of different types MMD Equipment Recommended Compressor Lubricant DEXRON III ATF I Specifications 1 Flash point 400 F minimum 2 Pour point 40 F 3 Contains rust and corrosion inhibitors 4 Contains foam suppressors 5 Contains oxidation stabilizer Due to environmental factors the useful life of all tended life lubricants may be shorter than quoted by N 0 TI C lubricant supplier MMD Equipment encourages user to closely monitor the lubricant condition and to participate inan oil analysis program with the supplier No lubricant however good and or expensive can replace N 0 TI CE proper maintenance and attention Select and use it wisely 32 308754 11 1 2010 Maintenance 8 8 Compressor Oil continued Adding Compressor A Verify th
45. requires a balanced coolant mixture of water and ethylene glycol base antifreeze This protects the engine cooling system from corrosion as well as freezing damage The LR 450 is shipped from the factory with a 50 50 mixture of water and ethylene glycol In tropical climates where freeze protection is not required glycol engine coolant should still be used to help prevent corrosion and pitting of cylinder liners B Mixtures Antifreeze concentration level should not exceed recommended levels To do so can cause cooling system failure 1 Amixture of 50 antifreeze and 50 water is required for temperatures above 34 2 Amixture of 60 antifreeze and 40 water is required for temperatures below 34 This provides protection to 65 3 Never exceed a 60 overall antifreeze mix C Coolant Level Before each start up when radiator is cold the coolant level should be checked When needed refill with a 50 50 solution of water and ethylene glycol DO NOT use 100 anti freeze The proper level for coolant in the system is to the bottom of the radiator fill neck and to the cold line of the recovery bottle Check the coolant level only when the engine is stopped and AWARNING the temperature is below 160 Failure to do so can cause personal injury from heated coolant spray IL Engine Radiator A Radiator Core Any sign of leakage from the engine radiator may justify a pressure test to assure its integrity Radiator leaks
46. riod This will last approximately three minutes After the warm up period is complete the compressor will switch to high speed of 2500 RPM for approximately 30 seconds then will return to a low speed of 1800 RPM IV Check system for leaks V Allow system to run until engine coolant temperature reaches 190 F VI Check for leaks again VII Open service valves to verify engine speed increases to 2500 RPM VIII Close service valves IX Press the OFF button on the control panel The control panel will ask to start the cooldown sequence X Pressthe ENTER button on the control panel This will start the cooldown sequence The cooldown sequence will last approximately three minutes DO NOT press the button two times ADANGER consecutively or during the cooldown sequence This will bypass the cooldown sequence Bypassing the cooldown sequence will cause excessive wear on the drive coupling Damage to the drive coupling due to improper shut down WILL void the drive coupling warranty XI Verify all fluid levels and refill if necessary Initial Startup testing is complete 24 308754 11 1 2010 Operation 7 1 Routine Operating Procedures The LR 450 should only be operated by those who have been delegated to do so trained and who have read and understand this manual Failure to follow the instructions procedures and safety precautions in this manual may result in accidents and injuries Operate t
47. ste CTI TT 16 Separator E E 16 Separator 16 23 Pressure Relief UM E rad RM 16 5 0 Fuel 17 2 7 Enone Air Filer oana EUER 17 5 8 Cooling 9 9 SC TNS Peto OR E EEEE EEEE T TEE 17 Enine E EAE 17 Engine Charged Air ERR FIF HER 17 Compressor OI uud eot ritiene adhi 17 5 9 Compressor pde REGE 17 2410 Conipressor CHI PIE aident 17 5 11 Compressor Oil Thermal 18 2 12 Mmmm Pr ss re VAN E 18 5 13 Blowdown Valve 18 5 14 Manual Load Unload 1 18 5 15 Discharge Pressure Ke Ol Ale 18 5 16 Digital Control REEE t E RR 18 Engine Oil Pressure Parameters nox RE re aro in 18 Engine Coolant Temperature e prote I9 Compressor Discharge Temperature Parameter erre I9 Compressor Discharge Pressure Parameter co eot tati Cepit ix 19 3 308754 11 1 2010 Contents Description of Components continued
48. t cooling fins will reduce the cooling capability of the compressor oil cooler 8 10 Compressor Oil Filter Initially the filter should be replaced after the first 50 hours of operation then every 500 hours or 6 months A dirty filter can restrict oil flow causing high oil temperature which will result in a system shutdown I Compressor Oil Filter Replacement A Verify the compressor oil system is drained B Using a strap wrench remove the oil filter and o ring C Clean o ring seating surface on the oil filter head Substitute filters may have inadequate working pressure limits resulting in filter leakage or rupture Replacement filters must be the same quality and type as the original oil filter D Apply a light film of oil to the new o ring E Hand tighten new filter until o ring is seated in o ring groove Mechanical overtightening may distort the threads or damage the filter element seal Continue tightening filter by hand an additional 1 2 to 3 4 turn Continue with Changing the Compressor steps 34 308754 11 1 2010 Maintenance 8 11 Engine Cooling System Maintenance The LR 450 s engine has a pressurized cooling system that contains a 50 50 mixture of water and ethylene glycol Maintenance of the system includes the engine coolant belt tension fan integrity and radiator Further cooling system maintenance is defined in the engine manual I Engine Coolant A Specifications This diesel engine
49. take filter with a gravity evacuator and replaceable internal element On the outlet of the engine air filter is an air filter restriction indicator This indicator serves as a maintenance tool A check filters warning will display on the control panel when the filter need to be serviced 5 8 Cooling Systems I Engine Radiator The radiator is designed to dissipate the heat load of the engine and is mounted in front of the specially selected engine fan Hot engine coolant is passed through the interior of the radiator and heat is transferred to the air that passes across the cooling fins IL Engine Charged Air Cooler The charged air cooler is designed to cool the engine intake air after it passes through a turbo charger but before the air enters the engine Cooling the air before entering the engine will optimise the power for the combustion process III Compressor Oil Cooler The compressor oil cooler is designed to dissipate the heat created during the compression of air The oil cooler is mounted adjacent to the engine radiator This works similar to the engine radiator but is designed to withstand the full compressor system working pressure 5 9 Compressor Inlet Valve The compressor inlet valve is a normally open air intake valve bolted to the compressor airend When the system is shut down this valve also acts as a check valve that prevents the air oil mixture within the compressor airend from entering the inlet tubing 5 10
50. ual or greater capacity Battery gas can explode causing acid burn to skin and blind ness Do not overcharge or jump the battery incorrectly 36 308754 11 1 2010 Troubleshooting 9 1 Troubleshooting Chart Vinespestsd No fuel low fuel or contaminated Chede euius fue Shutdown afety shutdown occurred Check control panel for cause Unable to obtain Improper engine timing Adjust engine timing 1 proper engine speed Clogged engine air filter Clean or replace immediately Damaged or loose motor mount Repair or replace Excessive Vibration Low engine speed Verify engine speed minimum of 1800 RPM Bent fan blade Repair or replace immediately Check pressure relief valve for leaks replace as Blowdown valve open ded Machine will not p aulty drive coupling Replace coupling build up pressure Compressor undersized for air Verify maximum air requirement requirement Low engine speed Check engine speed adjust if necessary Blowdown valve open Clean or replace immediately Insufficient air Check all air lines fittings and connections E Leaks in air system delivery leaks repair as necessary aulty inlet valve Repair or replace immediately aulty drive coupling Repair or replace coupling eparator tank overfilled Drain oil to proper level Check all piping lines and connections repair as Excessive Leak in compressor oil system compressor oil m consumption Oil return
Download Pdf Manuals
Related Search