Ingersoll-Rand P105WJD Operation And Maintenance Manual Download Page 1 | Manualshive

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OPERATION and MAINTENANCE

MANUAL

COMPRESSOR MODELS

This manual contains important safety information.

Do not destroy this manual.

This manual must be available to the personnel who operate and maintain this machine.

501 Sanford Ave
Mocksville, N.C. 27028

Book 22478325 (2/05)

P105WJD

CODE:

P130WJD
P160WJD
P175WJD

CODE: D

Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and

Doosan

Company

or the

products

of

either.

Revised (

10

-12)

1
2
3
...
»

Summary of Contents for P105WJD

Page 1: ...2 05 P105WJD CODE P130WJD P160WJD P175WJD CODE D Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Rand Company in this manual is historical or nominative in nature and is not meant to suggest a current affiliation between Ingersoll Rand C...

Page 2: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 3: ...arranty Information 1 16 WARRANTY REGISTRATION 1 17 Complete Machine Registration 1 17 NOISE EMISSION 3 29 Noise Emission 3 30 This section pertains only to machines distributed within the United States 3 30 Noise Emission Control Maintenance Log 3 31 Noise Emission Warranty 3 31 Introduction 3 31 GENERAL DATA 4 35 General Data 4 36 Models 4 36 COMPRESSOR 4 36 ENGINE DIESEL 4 36 FLUID CAPACITIES 4...

Page 4: ...attery 6 49 Fasteners 6 49 Radiator 6 50 Hoses 6 50 Compressor Oil Cooler 6 51 Compressor Oil 6 51 Receiver Separator Systems 6 51 Scavenge Line 6 52 Exterior Finish Care 6 52 MAINTENANCE SCHEDULE 6 54 LUBRICATION 7 55 Lubrication 7 56 Portable Compressor Fluid Chart 7 56 TROUBLE SHOOTING 8 57 Trouble Shooting 8 58 Introduction 8 58 Action Plan 8 58 Trouble Shooting Chart 8 59 ...

Page 5: ...1 Foreword ...

Page 6: ...nd approved parts list may create hazardous conditions over which Ingersoll Rand has no control Therefore Ingersoll Rand cannot be held responsible for equipment in which non approved repair parts are installed Ingersoll Rand reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products ...

Page 7: ...Foreword 3 ...

Page 8: ...Foreword 4 ...

Page 9: ...1 Drawbar Notice ...

Page 10: ...rdware box from compressor toolbox 2 Open box and remove the bag containing hardware safety chains and assembly instructions 3 Using the jack raise the front of the unit so that the legs are approximately 1 inch above the ground 4 Remove the temporary retaining bolts from both sides of the frame at the drawbar connection See Fig 1 5 Carefully lower drawbar to the Level Position 6 Install the four ...

Page 11: ...3 Section 1 Safety ...

Page 12: ...safe working pressure ratings of at least the machine safety valve rating If more than one compressor is connected to one common downstream plant effective check valves and isolation valves must be fitted and controlled by work procedures so that one machine cannot accidentally be pressurized or over pressurized by another Compressed air must not be used for a feed to any form of breathing apparat...

Page 13: ...injury or death Always attach a safety flow restrictor to each hose at the source of supply or branch line in accordance with OSHA Regulation 29CFR Section 1926 302 b Rotating fan blade can cause serious injury Do not operate without guard in place Use care to avoid contacting hot surfaces engine exhaust manifold and piping air receiver and air discharge piping etc Ether is an extremely volatile h...

Page 14: ...signs on machines shipped to international markets outside North America which point out potential hazards to the safety of you and others Read and understand thoroughly Heed warnings and follow instructions If you do not understand inform your supervisor ...

Page 15: ...Safety Operating Maintenance Manual 7 ...

Page 16: ...Operating Maintenance Manual Safety 8 ...

Page 17: ... DANGER Red Background indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING Orange Background indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION Yellow Background indicates a potentially hazardous situation which if not avoided may result in minor or moderate inj...

Page 18: ...Operating Maintenance Manual Safety 10 ...

Page 19: ...Safety Operating Maintenance Manual 11 ...

Page 20: ...ANGER WARNING or CAUTION Decal part numbers are on the bottom of each decal and are also listed in the compressor s parts manual Submit orders for Safety Decals to the Mocksville Parts Service Department The no charge order should contain only Safety Decals Help promote safety Assure that decals are present on the machines Replace decals that are not readable ...

Page 21: ...13 Section 2 WARRANTY ...

Page 22: ...y require a maintenance agreement Formal enrollment is required Ingersoll Rand will provide a new part or repaired part at its election in place of any part which is found upon its inspection to be defective in material and workmanship during the period prescribed above Such part will be repaired or replaced without charge to the initial user during normal working hours at the place of business of...

Page 23: ...ge 1 year None ENGINES Months Hours Extended Coverage Caterpillar 12 No Limit Available at dealer Cummins 24 2000 Major components 3 yrs 10 000 hours available at dealer John Deere IN COMPRESSORS IN GENERATORS AS OF 1 1 01 24 2000 5 yrs 5000 hours using JD fluids filters with 250 deductible 5 yrs 5000 hours using IR fluids and filters with 0 deductible 24 2000 2 yrs 4000 hours using IR fluids filt...

Page 24: ...times may change Consult the manufacturer s warranty policy as shipped with each new product PARTS Ingersoll Rand 6 months Hours No Limit Coverage Parts Only AIREND EXCHANGE Extended Coverage Airend 12 months 2000 hours 5 yrs 10 000 hrs requires IR oil and filters ...

Page 25: ...s changes i e change of ownership Machines shipped outside the United States require notification be made to initiate the machine warranty Fill out the Warranty Registration Form in this section keep a copy for your records and mail form to Ingersoll Rand Company Portable Compressor Division P O Box 868 Mocksville North Carolina 27028 Attn Warranty Department NOTE Completion of this form validates...

Page 26: ...Operating Maintenance Manual WARRANTY 18 ...

Page 27: ...Government municipal state county etc Quarry Shallow Oil Gas Rental rental center rental fleet etc Building Contractor Waterwell Utility Company Industrial plant use Other specify Exploration Utility Contractor Model Unit S N Engine S N Date Delivered Unit Hours Airend S N Truck S N Truck Engine S N SERVICING DISTRIBUTOR USER ACKNOWLEDGEMENT 1 The Purchaser has been instructed and or has read the ...

Page 28: ...Operating Maintenance Manual WARRANTY 20 ...

Page 29: ...29 Section 3 Noise Emission ...

Page 30: ...hereof b the air intake system or parts thereof c enclosure or parts thereof 4 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 5 Operation of the compressor with any of the enclosure doors open Compressor Noise Emission Control Information A The removal or rendering inoperative other than for the purpose of maintenance repair or replacement of any noise ...

Page 31: ...nent or system of the air compressor Defects in the design assembly or in any part component or system of the compressor which at the time of sale to the first retail purchaser caused noise emissions to exceed Federal Standards are covered by this warranty for the life of the air compressor Introduction The unit for which this Maintenance Log is provided conforms to U S E P A Regulations for Noise...

Page 32: ... adjusted at this time to insure continuous seating between gasket or acoustic material and the mating frame F Air Intake and Engine Exhaust Engine and compressor air intake and engine exhaust systems should be inspected after each 100 hours of operation for loose damaged or deteriorated components Repairs or replacements should be made before the next period of use G Cooling Systems All component...

Page 33: ...ission Operating Maintenance Manual 33 Maintenance Record For Noise Emission Control And Extended Warranty Item No Description Of Work Hourmeter Reading Maint inspect Date Location City state Work Done By Name ...

Page 34: ...Operating Maintenance Manual Noise Emission 34 ...

Page 35: ...35 Section 4 General Data ...

Page 36: ...nt 12 quarts 11 4 litres Engine Crankcase Lubricant 10 8 quarts 10 2 litres Fuel Tank 27 U S gal 103 litres UNITS MEASUREMENTS WEIGHTS Overall Length 11 5 3 5 meters Overall Height 5 2 feet 1 46 meters Overall Width 5 7 feet 1 74 meters Track Width 4 9 feet 1 49 meters Weight with fuel 2325 lbs 1054 kgf Weight less fuel 2130 lbs 966 kgf P105 P130 P160 P175 Air Delivery cfm litres sec 105 50 130 61...

Page 37: ...imary Compressor 35393685 Optional Secondary Compressor 35393651 Air Cleaner Element Engine 35393685 Optional Secondary Engine 35393651 Engine Oil Filter Element 35308030 Engine Fuel Filter Element 36534659 WARNING Modification or alteration of this machine Can result in severe injury or death Do not modify or alter without the express written consent of Ingersoll Rand Co ...

Page 38: ...Operating Maintenance Manual General Data 38 ...

Page 39: ...39 SECTION 5 OPERATION ...

Page 40: ...ed Test lights running stop and turn signals WARNING Always raise or remove jack for maximum ground clearance before towing SETTING UP ALL UNITS Position as level as possible The design of these units permits a 15 degree sidewise limit on out of level operation When the unit is to be operated out of level it is important 1 To keep the engine crankcase oil level near the high level mark with the un...

Page 41: ...om tube of jack Disconnect safety chains Crank jack to raise eye or coupler from hitch Tow vehicle can be moved UTILITY PACKAGE SET UP no running gear This unit must be located on vehicle bed to allow access for normal servicing and maintenance The air going into the inlet must be relatively free of oil dirt soot and other debris It must be no more than 10 degrees F 5 degrees C over the ambient te...

Page 42: ...8 F 120 C 7 Air Filters Restricted Needs servicing 8 Spare 9 Spare 10 Alternator Not Charging Needs attention 11 Low Fuel Level Must add fuel to operate 12 Fuel Level Gauge Indicates amount of fuel in tank 13 Engine Speed Gauge Indicates engine speed 14 Discharge Air Temp Gauge Indicates in F 82 C to 210 F 99 C 15 Engine Oil Pressure Gauge Indicates engine oil pressure 16 Engine Water Temp Gauge I...

Page 43: ...from the engine Check the compressor lubricating fluid level between bottom and midway of the sight glass on the separator tank WARNING This machine produces loud noise with doors open Extended exposure to loud noise can cause hearing loss Wear hearing protection when doors or valve s are open Close all doors to maintain a cooling air path and to avoid recirculation of hot air This will maximize t...

Page 44: ...OTICE Exercise extreme caution when using a booster battery to start To jump start Connect the ends of one booster cable to the positive terminals of each battery Then connect one end of the other cable to the negative terminal of the booster battery and the other end to the engine block NOT TO THE NEGATIVE TERMINAL OF THE WEAK BATTERY Units With Optional Diagnostics Lamps NOTICE None of the panel...

Page 45: ...losed air downstream of the valve may be trapped A vent hole in the service valve will slowly bleed air from the hose Do not disconnect hoses until all pressure has been vented NOTICE Do NOT wire around or bypass a shutdown sensor or switch Machine has shutdown and sensors as follows Low Engine oil pressure in the engine High engine coolant temperature in the engine Compressor Air Oil Temperature ...

Page 46: ...ut on air actuating cylinder A and then turn cylinder rod D until throttle arm G is forced against the governor stop After Starting Unit 4 If equipped push the SERVICE AIR button on the control panel making certain the button does not pop back out The unit should speed up and then unload and drop back to IDLE With the unit unloaded turn the adjusting screw on the pressure regulator clockwise until...

Page 47: ...SECTION 5 OPERATION Operating Maintenance Manual 47 ...

Page 48: ...Operating Maintenance Manual SECTION 5 OPERATION 48 ...

Page 49: ...47 Section 6 MAINTENANCE ...

Page 50: ...ive maintenance is the easiest and the least expensive type of maintenance Maintaining your unit and keeping it clean at all times will facilitate servicing Scheduled Maintenance The maintenance schedule is based on normal operation of the unit This page can be reproduced and used as a checklist by the service personnel In the event unusual environmental operating conditions exist the schedule sho...

Page 51: ...iagnostic lamps prior to start up During operation observe the gauges and any lamps for proper functioning Refer to Operating Controls for the normal readings Fuel Tank CLEAN fuel in the fuel tanks is vitally important and every precaution should be taken to ensure that only clean fuel is poured or pumped into the tank When filling the fuel tank on this unit by methods other than a pump and hose u...

Page 52: ... Pulling on the tubing will cause the inner sleeve to withdraw and compress thus tightening the connection The tubing can be withdrawn only while holding the sleeve against the fitting The tubing can be removed and replaced numerous times without losing its sealing ability To install the nylon tubing make a mark with tape or grease pencil approximately 7 8 inch from the end of the tubing Insert th...

Page 53: ...l and dirt from the exterior surfaces of the oil cooler core so that the entire cooling area can transmit the heat of the lubricating and cooling oil to air stream In the event foreign deposits such as sludge and lacquer accumulate in the oil cooler to the extent that its cooling efficiency is impaired a resulting high discharge air temperature is likely to occur causing shut down of the unit To c...

Page 54: ...is section 2 Thoroughly clean scavenge line any orifice and check valve 3 Assure minimum pressure valve orifice is operational 4 Run unit at rated operating pressure for 30 to 40 minutes to permit element to clear itself Exterior Finish Care This unit was painted and heat cured at the factory with a high quality thermoset polyester powder coating The following care will ensure the longest possible...

Page 55: ...nd use about 2 5 pounds of air pressure This will allow the primer to splatter causing the textured look NOTE You must be careful not to put too much primer on at one time this will effect the amount of texture that you are trying to achieve Allow the texture coat to flash for 20 minutes or until dry to touch 10 Apply any of Duponts Topcoat Finishes such as Imron or Centari according to the label ...

Page 56: ... PreCleaner Dumps C Fan Alternator Belts C Battery Connections Electrolyte C Tire Pressure and Surface C Wheel Lug Nuts C Hoses oil air intake etc C Automatic Shutdown System Test C Air Cleaner System Visual C Compressor Oil Cooler Exterior C CLEAN Engine Radiator Exterior C CLEAN Fasteners Guards C Air Cleaner Elements R Fuel Water Separator Element R Compressor Oil Filter Element R Compressor Oi...

Page 57: ...55 Section 7 LUBRICATION ...

Page 58: ...ection for details or contact your IR representative Design Operating Pressure Ambient Temperature Specification 100 psi to 300 psi 100F to 1250F 230 C to 520 C Preferred IR Pro Tec Alternate ISO Viscosity Grade 46 with rust and oxidation inhibitors designed for air compressor service 350 psi 230 C to 520 C 100 F to 1250 F 650 F to 1250 F 18 C to 52 C Preferred IR XHP 605 Alternate IR XHP405 ISO V...

Page 59: ...LUBRICATION Operating Maintenance Manual 57 ...

Page 60: ...Operating Maintenance Manual LUBRICATION 58 ...

Page 61: ...57 Section 1 Trouble Shooting ...

Page 62: ...ne 4 If the compressor will still operate is it safe to continue operating it to make further checks B Do The Simplest Things First Most troubles are simple and easily corrected For example most complaints are low capacity which may be caused by too low an engine speed or compressor over heats which may be caused by low oil level Always check the easiest and most obvious things first following thi...

Page 63: ...unctioning Relay Replace relay Blown Fuse Replace fuse Check for Short 10 Volts at Shutdown Solenoid Check battery and alternator Make repairs Engine Malfunctioning See Trouble Shooting in Engine Section Airend Malfunctioning See Table 10 Cause Corrective Action Out of Fuel Add CLEAN diesel Fuel Clogged Fuel Filters Service filters Compressor Oil Level Too Low Add corrected oil Loose Wire Connecti...

Page 64: ... Operating Conditions Move unit to cleaner environment Out of Level 15 degrees Relocate or reposition unit Ambient Temp 125 F 52 C Above spec limit Loose Wire Connection Repair or replace Broken Engine Fan Belt Replace fan belt set Malfunctioning Circuit Board Replace circuit board Complaint Corrective Action Low Oil Level Add oil Clogged Oil Filter Element s Replace element s Out of Level 15 degr...

Page 65: ...place switch Defective Sep Temp Switch Replace switch Defective Engine Temp Switch Replace switch Defective Engine Oil Pressure Switch Pull wire off Replace switch Defective Shutdown Solenoid Carefully block air inlet to stop engine Malfunctioning Relay Replace relay Defective Start Switch Pull wire off shutdown solenoid Replace defective item Wire Shorted Hot Repair short Complaint Corrective Act...

Page 66: ... adjust Defective Separator Element Install new element Engine Malfunctioning See Trouble Shooting in Engine Section Airend Malfunctioning Consult Dealer Complaint Corrective Action Dirty Fuel Filters Replace filters fuel Engine idle speed too low Raise No Load speed Rubber Mounts Loose or Damaged Tighten or replace Anti rumble valve not working Repair or Replace Drive Coupling Defective Replace c...

Page 67: ...nstall new Scavenge Tube Blocked Remove scavenge tube Clean and Replace Sep Tank Blow Down Too Quickly Allow unit to blow down automatically Defective Minimum Pressure Valve Remove valve Repair valve and replace Complaint Corrective Action Contaminated Lube Oil Drain and flush system Add new CLEAN oil Replace seal Blocked or Restricted Oil Line s Remove clean and replace line s Replace seal Malfun...

Page 68: ... Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual Malfunctioning Pressure Regulator Replace regulator Leak In Regulator Piping Repair leak s Malfunctioning Inlet Unloader Inspect valve Repair Replace Defective Separator Element Remove element Install new Defective Safety Valve Replace safety valve Ice in Regulation Lines Orifice Remove ice ...

Page 69: ...NANCE SCHEDULE 6 54 P Portable Compressor Airend Limited Optional Warranty 1 14 Portable compressor airends 1 14 Portable Compressor Fluid Chart 7 56 R Radiator 6 50 Receiver Separator Systems 6 51 S Safety Precautions 1 4 Scavenge Line 6 52 Scheduled Maintenance 6 48 SETTING UP ALL UNITS 5 40 Speed and Pressure Regulator Adjusting Instructions 5 46 Starting 5 43 Stopping 5 44 T Tires 6 49 TOWING ...

Page 70: ...WORD INDEX 9 2 Manual Name ...

Page 71: ... 2003 Ingersoll Rand Company Printed in the USA Portable Power Division Ingersoll Rand Company P O Box 868 501 Sanford Ave Mocksville N C 27028 ...

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