Sierra Service & Maintenance: Industrial Air Solutions

Sierra Main Training
Industrial Air Solutions Service and Maintenance
SIERRA
SERVICE &
MAINTENANCE
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

INITIAL 150 HOURS
• CHANGE OIL AND FILTER

• CHECK / CLEAN CONDENSATE DRAINS
• CHECK OPERATION & RECORD ALL TEMPS /
PRESSURES

4000 HOURS
• CLEAN CRANKCASE BREATHER ASSEMBLY

• CHECK / CLEAN CONDENSATE STRAINERS
• CHECK / REPLACE AIR FILTER
• CHECK / CLEAN COOLERS
• CALIBRATE ALL TRANSDUCERS / RTD’S
• CHECK BLOWDOWN VALVE FUNCTION
• CHECK ELECTRICAL CONNECTIONS

8000 HOURS
• AS 4000 HOURS PLUS -

• CHANGE OIL AND FILTER
• INSPECT / CLEAN OIL PUMP STRAINER
• CHECK CONTACTORS
• CHECK ALL ELECTRICAL CONNECTIONS
• CHECK GRUB SCREWS ON COUPLINGS
• CHECK / ADJUST INLET VACUUM

GENERAL CHECKS
• REFER TO MOTOR DATA SECTION FOR

LUBRICATION INSTRUCTIONS
• CHECK AND RECORD MOTOR CURRENT AND

LINE VOLTAGE DURING EACH SERVICE VISIT

CARRIED OUT AT THESE INTERVALS (RUNNING HOURS)
ACTION INITIAL
WEEKLY 2000 4000 6000 8000 10000 12000 14000 16000
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 Valve
Overhaul 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

Motor Servicing
• Grease motor every 3 months for 3600 RPM
And 6 months for 1800 RPM.
• For severe duty reduce interval by one half
• Only grease motor when power has been
removed from the unit
• Remove outlet plugs
• Grease gun fitting and spring loaded outlets or
plug are arranged at each end on the motor
housing.


Motor Servicing
• Add volume of grease to each bearing per
following: (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
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 of
the motor.
• Fan motor should be greased at the
same interval as the main motor.



“B”
50-100 HP SPACER 50-100

“A” N/A ONLY
“B” N/A
“C” = .14 + - .060”
Compressor coupling aligns against
a spacer on the shaft
COMPRESSOR
MOTOR SHAFT
SHAFT
125 - 200 HP
“C” = .16 + - .080”
Motor Shaft Diameter “A” “B”

2.375” .75” .37”
2.125” 1.0” .62”
“C”
“A” IR Global Service Education Team
Sierra


Air Filter
• Replace every 4000 hours/6 months operation or as

site conditions require
• Never change filter while unit is running

Oil & Oil Filter
• Always change the oil filter whenever the
oil 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 comes
first

Gearcase Breather
• Clean gearcase breather every 4000 hours or 6
months operation, whichever occurs first
• Normal gearcase static pressure
 <.5” of water with manometer vented outside
enclosure


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

Airends
• There are no serviceable parts within the
airend so when a problem develops which
is determined to be internal to the airend,
the airend will have to be replaced

Airend
• Special tool for gear removal

• Gear Lock Nut Torque's:
 50-100
 1st Stage - 75 lb/ft
 2nd Stage - 35 lb/ft
 125-200
 1st Stage - 162 lb/ft
 2nd Stage - 75 lb/ft
• LOCTITE 222 on threads

Sierra Driven Gear Removal #1



Coolers
• Coolers may be cleaned in unit using a non
caustic cleaning solution that is non
corrosive to aluminum
• Cover air filter, main motor, 1SV and fan
motor to keep cleaning solution and rinse
from contaminating components

Shaft Seal Leaks?
• Axial movement 0.008-0.050”
• Radial movement 0.00075” (radial play)

50-100 Sierra Jackshaft Sealing With Oil Drain
Loctite ???
Loctite H
Loctite 242
Coupling End
Scavenge to
Gearcase Below oil Loctite 511
level.
125-200 Sierra Jackshaft Sealing With Oil Drain
Loctite ???
Loctite H
Loctite 242
14mm
Coupling End
Loctite 620
Loctite 511
Loctite 511
Scavenge to Gearcase Below oil level. IR Global Service Education Team

MARMON COUPLING
• UNDER NORMAL OPERATING
CONDITIONS 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 NEW
COUPLING SHOULD BE
ORDERED

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 NOT
PURGE FROM DRAIN VALVES
WHEN THE VALVE IS OPEN.

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

AIRENDS
• THERE ARE NO
SERVICEABLE PARTS
WITHIN THE AIREND SO
WHEN A PROBLEM
DEVELOPS WHICH IS
DETERMINED TO BE
INTERNAL TO THE
AIREND, THE AIREND WILL
HAVE TO BE REPLACED



Check Valve Inspection
• To be inspected annually
• Check valve kit available
• Gasket special material for high temp

Inlet Valve Service Calculator
Cycles per minute Service Hours
3 4000
2 6000
1 12000
Over 1 Minute 16000

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)

Control Valve Servicing
• Three major components
 Inlet valve
 Nothing serviceable
 Adjust to .012” unloaded
 Hydraulic cylinder
 Rebuild kit available
 Blowdown valve
 Rebuild kit available

Blowdown Valve

Blowdown Valve

Blowdown Valve

Blowdown Valve

Inlet Valve Assembly




















0.3 mm

INLET VALVE
HYDRAULIC CYLINDER COMPLETE
S37 - 75kW CPN 39862859

S90 - 150kW CPN 39862826
HYDRAULIC CYLINDER KITS
S37 - 75kW CPN 39862875

S90 - 150kW CPN 39862834

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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Sierra Main Training

Industrial Air Solutions Service and Maintenance

IR Global Service Education Team

• SUMP OIL LEVEL

IR Global Service Education Team

• CHANGE OIL AND FILTER

IR Global Service Education Team

• CLEAN CRANKCASE BREATHER ASSEMBLY

IR Global Service Education Team

• AS 4000 HOURS PLUS -

IR Global Service Education Team

• REFER TO MOTOR DATA SECTION FOR

• CHECK AND RECORD MOTOR CURRENT AND

IR Global Service Education Team

Check Sump Oil Level

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

• Neither the fan nor the fan motor have

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

50-100 HP SPACER 50-100

“C” = .16 + - .080”

Motor Shaft Diameter “A” “B”

IR Global Service Education Team

IR Global Service Education Team

• Replace every 4000 hours/6 months operation or as

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

• Special tool for gear removal

• LOCTITE 222 on threads

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

Scavenge to Gearcase Below oil level. IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

Cycles per minute Service Hours

Over 1 Minute 16000

 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)

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team

IR Global Service Education Team