Ingersoll-Rand P185WIR Operating, Maintenance & Parts Manual Download Page 2

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Book: 22305593 (8/03)

QUALITY POLICY

We will supply products and services that consistently meet the requirements

of our customers and each other.

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.

Summary of Contents for P185WIR

Page 1: ...NG MAINTENANCE PARTS MANUAL COMPRESSOR MODEL P185WIR XP185WIR Revised 09 12 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of tradem...

Page 2: ...d services that consistently meet the requirements of our customers and each other CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of Califo...

Page 3: ...1 Sanford Avenue Mocksville North Carolina 27028 Declare that under our sole responsibility for manufacture and supply the product s To which this declaration relates is are in conformity with the pro...

Page 4: ...roved 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 insta...

Page 5: ...ON SECTION 3 NOISE EMISSION SECTION 4 GENERAL DATA SECTION 5 OPERATION SECTION 6 MAINTENANCE SECTION 7 LUBRICATION SECTION 8 TROUBLESHOOTING SECTION 9 ENGINE operation maintenance lubrication troubles...

Page 6: ...n 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 above the ground 4 Remove the tem...

Page 7: ...ust 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 breathin...

Page 8: ...us burns Do not open radiator while hot 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 a...

Page 9: ...WARNING Flammable liquid Air gas flow or Air discharge Look forthese signs onmachines shippedtointernationalmarkets outside NorthAmerica whichpoint out potential hazards to the safety of you and other...

Page 10: ...al Rough Service Designation Wet Location Operation WARNING Consult the operation and maintenance manual before performing any maintenance WARNING Before connecting the tow bar or when preparing to to...

Page 11: ...and Maintenance manual before operation or maintenance of this machine is undertaken XX km h Pressurized component or system Do not exceed the speed limit Pressurized vessel Do not remove the Operatin...

Page 12: ...rkets in 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 you superv...

Page 13: ...h 105 km hr Rotating fan blade Can cause serious Do not operate without guard in place WARNING injury Falling off machine Can cause serious injury Access lifting bail from inside machine or death WARN...

Page 14: ...s are present on the machines Replace decals that are not readable FREE SAFETY DECALS CAUTION This engine is equipped with an electric heater starting aid DO NOT USE ETHER ENGINE DAMAGE WILL OCCUR Hig...

Page 15: ...f twenty four 24 months from shipment to or the accumulation of 4 000 hours of service by the initial user For Air Ends the warranty against defects will include replacement of the complete Air End pr...

Page 16: ...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 an Ingersoll Rand dist...

Page 17: ...ere IN COMPRESSORS IN GENERATORS AS OF 1 1 01 24 24 2000 2000 5 yrs 5000 hours using OEM fluids filters with 250 deductible 2 yrs 4000 hours using IR fluids filters Deutz 24 2000 Available at dealer I...

Page 18: ...ranty is limited to defects in major components rotors housings gears bearings and is automatically available when the following three conditions are met 1 The original airend is returned assembled an...

Page 19: ...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...

Page 20: ...ctric water etc Utility Contractor SERVICING DISTRIBUTOR USER ACKNOWLEDGEMENT 1 The Purchaser has been instructed and or has read the manual and understands proper preventative maintenance general ope...

Page 21: ...21 Book 22305593 8 03 Ingersoll Rand Company Portable Compressor Division P O Box 868 Mocksville North Carolina 27028 Attention Warranty Department fold...

Page 22: ...her estab lishment authorized by Ingersoll Rand Company This warranty covers the following emission related parts and components Charge Air Cooling System If Equipped Fuel Injection System Intake Mani...

Page 23: ...an authorized INGERSOLL RAND Dealer will repair the heavy duty off road engine at no cost to the owner including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 1996 and later heavy dut...

Page 24: ...djustments The following is an explanation of maintenance for emission related components See the Maintenance Schedule for the specific inter val for the following items FUEL INJECTION PUMPS OR NOZZLE...

Page 25: ...the air intake system or parts thereof c enclosure or parts thereof 5 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 6 Operation of the compressor with any...

Page 26: ...e manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed built and equipped to conform at the time of sale to the first retail purchaser wi...

Page 27: ...Enclosure Panels Enclosure panels should also be inspected at 100 hour operational intervals All panels that are warped punctured torn or otherwise deformed such that their noise containment function...

Page 28: ...28 Book 22305593 8 03 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 29: ...litres Fuel Tank 27 U S gal 103 litres UNITS MEASUREMENTS WEIGHTS P XP185WIR Overall Length 11 5 feet 3 5 meters Overall Height 4 8 feet 1 46 meters Overall Width 5 7 feet 1 74 meters Track Width 4 9...

Page 30: ...LL UNITS Place the unit in an open well ventilated area 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 oper...

Page 31: ...the inlet grille 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 temperature WATER COOLED ENGINE CAUTION Do not remove pres...

Page 32: ...eceiver tank psi kPa 11 Fuel Level Gauge Indicates amount of fuel in tank Controls Standard 12 Power Switch Rotate ON to activate systems prior to Starting Rotate Off to stop engine 19 Service Air But...

Page 33: ...doors or valve s are open Close the side doors to maintain a cooling air path and to avoid recirculation of hot air This will maximize the life of the engine and compressor and protect the hearing of...

Page 34: ...is not running WARNING Since the service valve is closed air downstream of the valve may be trapped A vent hole in the service valve willslowly bleedair fromthe hose Do notdiscon nect hoses until all...

Page 35: ...actuating cylinder A and then turn cylinder rod D until throttle arm G is forced against stop L 4 If equipped push the SERVICE AIR but ton on the control panel making certain the button does not pop b...

Page 36: ...ntive maintenance is to prevent failure and consequently the need for repair Preventive maintenance is the easiest and the least expensive type of maintenance Maintaining your unit and keeping it clea...

Page 37: ...the air cleaner element manufacturer s recommendations NOTE It is recommended that replacement elements be installed in the unit The elements just removed for cleaning can be washed and stored as futu...

Page 38: ...does not use the hoses as convenient hand hold or steps Such use can cause early cover wear and hose failure Piping systems operating at less than 150 psi 1050 kPa may use a special nylon tubing The...

Page 39: ...t both from the top and from between the rollers Then rotate the bearing to repeat this operation on the next segment Keep doing this until you have the entire bearing completely filled with grease Ex...

Page 40: ...placed every twelve months or 2000 hours To replace the element proceed as follows S Ensure the tank pressure is zero S Disconnect the hose from the scavenge tube S Remove scavenge tube from tank cove...

Page 41: ...alcohol or chlorinated solvent can be used Note This may cause some dulling of the paint finish 3 If the paint has faded or chalked the use of a commercial grade non abrasive car wax may partially re...

Page 42: ...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 Ai...

Page 43: ...t 23_C to 52_C 10_F to 125_F IR Pro Tect IR XHP 605 10_F to 125_F 23_C to 52_C 65_F to 125_F IR XHP1001 Preferred Ingersoll Rand Fluids Use of these fluids with original I R filters can extend airend...

Page 44: ...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 compl...

Page 45: ...ow Oil Level Dirty Cooler Dirty Operating Conditions Loose or Broken Belts Operating Pressure Too High Malfunctioning Thermostat Defective Minimum Pressure Valve Blocked or Restricted Oil Lines Airend...

Page 46: ...rend Malfunctioning Alternator Lamp Stays On Loose or Broken Belts Loose Wire Connection Defective Battery Malfunctioning Alternator Malfunctioning Circuit Board Alternator Lamp Stays Off Loose Wire C...

Page 47: ...ine after sales support EMISSION CONTROL LABEL FUEL LUBRICANT AND COOLANT Fuel Lubricant Coolant OPERATION Check before operation Check and operation after start up Operation and care of a new engine...

Page 48: ...ly This Manual is designed to help you do this Please read this Manual carefully and follow its operating and maintenance recommendations This will ensure many years of trouble free and economical eng...

Page 49: ...pump 9 Engine oil cooler 4IRH8N 10 Engine oil filter 11 Dipstick engine oil 12 Governor lever 13 Intake manifold 14 Fuel filter 15 Fuel oil inlet 16 Fuel filter mounting with fuel priming pump 17 Fuel...

Page 50: ...m lift 15 3_ 1 ENGINE IDENTIFICATION Serial No Location The engine serial number is stamped on engine name plate on top of rocker cover See illustration on page NO TAG Confirmation of Engine Number It...

Page 51: ...e of a label required for engine emission control information along with location Engine family name as assigned by EPA and ARB identifying engine family group 3YDXL1 33M3N and this identifies 3 YDX L...

Page 52: ...el engine either may cause engine damage Handling of the Fuel Any fuel containing dust particles or water might cause engine failure Therefore the following must be observed Take care to protect the f...

Page 53: ...improper maintenance or using oil of the improper quality and or viscosity is not covered by the warranty Fig 12 A Single grade B Ambient Temperature C Multi grade COOLANT All Ingersoll Rand portable...

Page 54: ...equired before the engine oil completely flows down from the oil filler to the crankcase Wait at least ten minutes before checking the oil level NOTE Take care to avoid engine oil being splashed on th...

Page 55: ...ting the terminals start with terminal When connecting them connect the terminal last Fuel level Check the remaining fuel oil level in the fuel tank and re fuel if necessary CHECKS AND OPERATION AFTER...

Page 56: ...tank is low look for leaks at the radiator hoses and connections radiator and water pump If you find major leaks do not run the engine until these problems have been corrected If you do not findaleak...

Page 57: ...Radiator fin checking cleaning f Cooling water Cooling fan V belt checking adjusting f 1st time f 2nd after g Cooling water replacement Z or every 1 yr Cooling water path flushing maintenance F Rubbe...

Page 58: ...he engine oil filter counter clockwise using a filter wrench customer procured to remove It 5 Clean the engine oil filter mounting face 6 Moisten the new engine oil filter gasket with the engineoil an...

Page 59: ...V belt tension deflection To adjust the V belttension loosentheset boltand movethe alternator to tightenthe V belt 3 Visually check theV beltfor cracks oiliness or wear Ifany replace the V belt with n...

Page 60: ...rator assembly By unscrewing the plastic primer pump head A and stroking it up and down any air bubbles in the system willbe purgedback tothe fueltank When this has been completed the pump head must b...

Page 61: ...the engine oilevery 250hours operationfrom 2ndtime andon Replace the engine oil filter at the same time Refer to 50 hour inspection section 1 2 Checking and cleaning radiator fins Beware of dirt from...

Page 62: ...ssembly and reassembly The fuel filter separator also provides primary filtration and the element C should be changed every 500 operating hours or 6 months whichever comes first Change procedure Unscr...

Page 63: ...e opening and closing of valves Neglecting the adjustment will cause the engine to run noisily and result in poor engine performance and other damage Inspection every 2000 hours operation 1 Flushing t...

Page 64: ...l and add coolant if necessary 9 Coolant leakage check Replace any damaged or malfunctioning parts which could cause leakage 10 Radiator filler cap fitting condition The radiator cap must be installed...

Page 65: ...turn Bad cable connections Starter or starter switch failure Safety relay failure Engine stop solenoid malfunction No fuel in the fuel tank No fuel injection Clogged fuel filter element Air in the fue...

Page 66: ...een cylinders Deteriorated governor spring Incorrect valve clearance adjustment Deteriorated valve spring Engine speed stuck at high idle Engine control restriction or seizure Engine overheat Insuffic...

Page 67: ...ylinder compression leakage Injector nozzle misalignment Low cylinder compressionpressure Cylinder bore wear Insufficient air intake volume Air cleaner clogged Restricted air flow Excessive oil consum...

Page 68: ...ng in fuel Excessive white smoke Low compression pressure Injection timing incorrect Low coolant temperature Faulty turbocharger Battery over discharge Low electrolyte level Crack in battery body Natu...

Page 69: ...SECTION 11 PARTS LIST...

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