Ingersoll-Rand P250WJDU Operating & Maintenance Manual Download Page 1 | Manualshive

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OPERATING & MAINTENANCE

MANUAL

COMPRESSOR MODEL

P250WJDU

Code:

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.

Portable Power Division
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028

Book 22904767 (6/06) Rev. A

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 P250WJDU

Page 1: ...rd Ave Mocksville N C 27028 Book 22904767 6 06 Rev A 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 Ra...

Page 2: ...Book 22904767 6 06 Rev A 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: ... 26 Engine 26 COMPRESSOR 26 ENGINE DIESEL 26 FLUID CAPACITIES 26 UNITS MEASUREMENTS WEIGHTS 26 EXPENDABLE SERVICE PARTS 26 OPERATION 29 Operation 29 Control Panel 30 Diagnostics auto Shutdown Optional 30 Diagnostics auto Shutdown Standard 30 Controls Standard 30 Controls Optional 30 Utility Package Set up no running gear 31 Installation 31 Setting Up All Units 33 Compressor Oil Level 33 Before Sta...

Page 4: ...nce 39 Compressor Oil Level 39 Air Cleaner 41 Gauges 41 Fuel Tank 42 Battery 42 Fasteners 42 Radiator 42 Hoses 42 Compressor Oil Cooler 43 Compressor Oil 44 Receiver separator Systems 44 Scavenge Line 45 MAINTENANCE SCHEDULE 47 LUBRICATION 53 Lubrication 49 Portable Compressor Fluid Chart 50 TROUBLE SHOOTING 53 Trouble Shooting 53 Introduction 53 Action Plan 53 Trouble Shooting Chart 55 ...

Page 5: ...Book 22904767 6 06 Rev A 7 Foreword ...

Page 6: ...e manufacturer and wherever possible be of a type approved by Ingersoll Rand clearly rated for a pressure at least equal to the machine maximum allowable working pressure compatible with the compressor lubricant coolant accompanied with instructions for safe installation operation and maintenance Details of approved equipment are available from Ingersoll Rand Service departments The use of repair ...

Page 7: ...ay reduce the reliability of the machine The purpose of this manual is to train the operator with functions operation and basic service and maintenance requirements of the compressor During the preparation of this manual every effort was made to ensure the adequacy and accuracy of the contents Your Ingersoll Rand dealer will assist with setup and initial startup of the compressor He will also prov...

Page 8: ...10 Book 22904767 6 06 Rev A Always use Ingersoll Rand Replacement parts ...

Page 9: ...Book 22904767 6 06 Rev A 11 Safety ...

Page 10: ...nical parts In particular safety related parts such as coupling hitch drawbar components road wheels and lifting bail should be checked for total security All components which are loose damaged or unserviceable must be rectified without delay Air discharged from this machine may contain carbon monoxide or other contaminants which will cause serious injury or death Do not breathe this air This mach...

Page 11: ...ch can result in serious injury or death Always carefully vent air supply line at tool or vent valve before performing any service The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible If the discharged air is to be ultimately released into a confined space adequate ventilation must be provided W...

Page 12: ...esel fuel battery electrolyte WARNING Avoid ingestion skin contact and inhalation of fumes Should compressor lubricant come into contact with the eyes then irrigate with water for at least 5 minutes Should compressor lubricant come into contact with the skin then wash off immediately Consult a physician if large amounts of compressor lubricant are ingested Consult a physician if compressor lubrica...

Page 13: ...Do not attempt to slave start a frozen battery since this may cause it to explode Exercise extreme caution when using booster battery To jump battery connect ends of one booster cable to the positive terminal of each battery Connect one end of other cable to the negative terminal of the booster battery and other end to a ground connection away from dead battery to avoid a spark occurring near any ...

Page 14: ...ecal headings DANGER Red Background Indicates the presence of a hazard which WILL cause serious injury death or property damage if ignored WARNING Orange Background Indicates the presence of a hazard which CAN cause serious injury death or property damage if ignored CAUTION Yellow Background Indicates the presence of a hazard which WILL or can cause injury or property damage if ignored NOTICE Blue...

Page 15: ...ty Decals are available free of charge Safety decals are identified by the decal heading DANGER 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 product safety Replace decals that are ...

Page 16: ...Operating Maintenance Manual Safety 18 Book 22904767 6 06 Rev A ...

Page 17: ...Book 22904767 6 06 Rev A Noise Emission ...

Page 18: ...em or parts thereof 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 ...

Page 19: ... part component 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 Regulation...

Page 20: ...immediately to prevent subsequent damage and noise emission increase E 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 is reduced should be repaired or replaced before the next operation interval Doors access panels and hatch closures especially sh...

Page 21: ...e inspected after each 250 hours of operation Those mounts with cracks or splits in the molded rubber or with bent or broken bolts due to operation or storage in severe environments all should be replaced with equivalent parts I Engine Operation Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer J Fuels and Lubricants Use only the ...

Page 22: ...e Manual Noise Emission 24 Book 22904767 6 06 Rev A 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 23: ...Book 22904767 6 06 Rev A General Data ...

Page 24: ...g 150 psi 10 5 kgf per cm2 1030 kPa ENGINE DIESEL Manufacturer John Deere Electrical System 12 Volt FLUID CAPACITIES Compressor Lubricant 12 quarts 11 4 litres Engine Crankcase Lubricant including filters 9 quarts 8 5 litres Engine Coolant Capacity 14 4 quarts 13 6 litres Fuel Tank Diesel 28 U S gal 106 litres P250WJDU CFM litres sec 250 118 Full RPM Constant 2300 Idle RPM 1700 Engine Model 4045D ...

Page 25: ... 1116 EXPENDABLE SERVICE PARTS Compressor Oil FIlter Element Part No 36897353 Compressor Oil Separator Element Part No 39831888 Air Filter Element Part No 36876423 54415377 Engine Oil Filter Element Part No 36881696 Engine Fuel Filter Element Part No 36534659 WARNING Modification or alteration of this machine Can result in severe injury or death Do not modify or alter without the express written c...

Page 26: ...Operating Maintenance Manual General Data 28 Book 22904767 6 06 Rev A ...

Page 27: ...Book 22904767 6 06 Rev A 29 Operation ...

Page 28: ...ssure in receiver tank psi kPa 11 Fuel Level Gauge Indicates amount of fuel in tank Controls Standard 12 Power Switch Flip ON to activate systems prior to Starting Flip OFF to stop engine Controls Optional 13 Tachometer Indicates engine speed 14 Discharge Air Temp Gauge Indicates in F and C Normal operating range 185 F 85 C to 248 F 120 C 15 Engine Oil Pressure Gauge Indicates engine oil pressure ...

Page 29: ...d the compressor The cross sectional area of any ductwork must be larger by a minimum of 10 percent The addition of any power absorbing components hydraulic pumps paint mixers etc must be approved by Ingersoll Rand to maintain the warranty Units with the optional engine mounted auxiliary drive are approved for hydraulic pumps up to 15 HP CAUTION Units with the optional engine mounted auxiliary dri...

Page 30: ...Operating Maintenance Manual Operation 32 Book 22904767 6 06 Rev A ...

Page 31: ... oil if the pointer reaches the bottom of the green section NOTE The oil level gage will not read properly while the engine is running WARNING NO SMOKING SPARKS or OPEN FLAME near fuel CAUTION Do not connect the air discharge on this unit into a common header with any other unit of any description or any other source of compressed air without first making sure a check valve is used between the hea...

Page 32: ...ir path and to avoid recirculation of hot air This will maximize the life of the engine and compressor and protect the hearing of surrounding personnel Be sure no one is IN or ON the compressor unit Starting Turn the POWER switch to ON If so equipped place the Start Run Valve Switch located in the bottom right hand corner of the instrument panel to the Start Warm Up position Turn Power switch to S...

Page 33: ... located on the front of the generator control panel In Generator position the engine will maintain idle speed and the generator will give a constant voltage and frequency output for use with sensitive equipment like computers fusion welders etc No compressed air is available at the service air valves in this mode In Gen Air position voltage and frequency will vary as engine speed changes to meet ...

Page 34: ...tomatic Shutdown This unit is protected with sensors switches for high discharge air temperature high engine coolant temperature and low engine oil pressure Should any of three situations occur the unit will stop Before restarting the unit check these three areas for excessive heat and fluid level Other possible causes are listed on the Trouble Shooting Chart All units in this family of machines a...

Page 35: ... by the movement of the air cylinder piston rod D Rod D should be fully retracted and just begin to extend when the adjusting rod C is properly set 4 Lock jam nut B After Starting Unit 5 Allow unit to warm up at an engine speed greater than IDLE speed for at least five minutes Do this by loosening jam nut H on the IDLE screw L Turn the IDLE screw until the speed is properly set 6 If equipped place...

Page 36: ...w L Tighten jam nut H 10 To obtain maximum cfm at any pressure between 80 psi 550 kPa and maximum pressure rating make adjustment at the pressure regulator to obtain desired discharge pressure at FULL engine speed Lock adjusting screw and replace cover See General Data Specifications ...

Page 37: ...Book 22904767 6 06 Rev A 39 Maintenance ...

Page 38: ...t of pre operation and post operation procedures to be performed by the operating or maintenance personnel The primary function of preventive 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 clean at all times will facilitate servicing Scheduled Maintenance T...

Page 39: ...nut firmly 7 Inspect to ensure that end cap seals tightly 360 around air cleaner body In the event that the filter element must be reused immediately compressed air cleaning as follows is recommended since the element must be thoroughly dry Direct compressed air through the element in the direction opposite to the normal air flow through the element Move the nozzle up and down while rotating the e...

Page 40: ...amps must be absolutely tight Regular inspection of these connections for wear or deterioration is necessary Premature wear of both the engine and compressor is ASSURED whenever dust laden air is permitted to enter the engine s combustion chamber or compressor intake The flexible hoses used in the fuel oil and air lines on these units are primarily used for their ability to accommodate relative mo...

Page 41: ...OTICE Installing a new oil filter element when the old gasket remains on the filter head will cause an oil leak and can cause property damage 1 Lubricate the new filter gasket with the same oil being used in the machine 2 Install new filter by turning the element clockwise until gasket makes initial contact Tighten an additional 1 2 to 3 4 turn 3 Start unit and allow to build up to rated pressure ...

Page 42: ...onal separation takes place in the oil separator element which is located in the top of the tank Any oil accumulation in this separator element is continuously drained off by means of a scavenge tube which returns the accumulated oil to the system The life of the oil separator element is dependent upon the operating environment soot dust etc and should be replaced every twelve months or 2000 hours...

Page 43: ...tor element Do not replace element without first performing the following maintenance procedure 1 Check oil level Maintain as indicated earlier in this 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...

Page 44: ...to dry 8 Apply 2 medium wet coats of Duponts 222S Adhesion Promoter over the entire area to be painted with a 5 minute flash in between coats 9 To apply the texture coat use Duponts 1854S Tuffcoat Primer The proper technique to do this is to spray the Tuffcoat Primer using a pressure pot and use about 2 5 pounds of air pressure This will allow the primer to splatter causing the textured look NOTE ...

Page 45: ...Engine Oil Level C Radiator Coolant Level C Gauges Lamps C Air Cleaner Service Indicators C Fuel Tank fill at end of day C DRAIN Fuel Water Separator DRAIN C Air Cleaner Precleaner Dumps C Fan Alternator Belts C Battery Connections Electrolyte 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 ...

Page 46: ...Operating Maintenance Manual Maintenance 48 Book 22904767 6 06 Rev A ...

Page 47: ...Book 22904767 6 06 Rev A 49 Lubrication ...

Page 48: ...l warranty section for details or contact your I R 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...

Page 49: ...Book 22904767 6 06 Rev A 53 Trouble Shooting ...

Page 50: ...k has been done 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 ...

Page 51: ... at Shutdown Solenoid Check battery and alternator Make repairs Blown Fuse Replace fuse Engine Malfunctioning See Trouble Shooting in Engine Manual Airend Malfunctioning See Complaint 10 Complaint Corrective Action Low Battery Voltage Check electrolyte level Check connections 16 Volts at Shutdown Solenoid Charge battery and alternator Make repairs Blown Fuse Replace fuse Malfunctioning Start Switc...

Page 52: ... replace Malfunctioning circuit board Replace circuit board Complaint Corrective Action Low Oil Level Add oil Out of Level 15 degrees Relocate or reposition Wrong Lube Oil See Engine Oil Spec Change oil Clogged Oil Filter Element s Replace element s Engine Malfunctioning See Trouble Shooting in Engine Manual Loose Wire Connection Repair or replace Malfunctioning circuit board Replace circuit Compl...

Page 53: ...r reposition unit Low Oil Level Add oil Look for any leaks Wrong Lube Oil Check spec in this manual Dirty Cooler Clean exterior surfaces Dirty Operating Conditions Move unit to cleaner environment Clogged Oil Filter Elements Replace elements Change oil Loose or Broken Belts Tighten or replace belt set Operating Pressure Too High Reduce pressure to spec Recirculation Of Cooling Air Close side doors...

Page 54: ... Regulator Adjustment See Section 6 in this manual Malfunctioning Pressure Regulator Replace regulator Malfunctioning Inlet Unloader Butterfly Valve Inspect valve Make adjustment per Section 6 Malfunctioning Air Cylinder Replace air cylinder Defective Minimum Pressure Valve Repair or replace valve Defective Separator Element Install new element per page 45 Wrong Air Filter Element Install correct ...

Page 55: ... Malfunctioning Inlet Butterfly Valve Inspect valve fit Readjust per Section 6 Ice in Regulation Lines Orifice Apply heat to line s and or orifice Complaint Corrective Action Incorrect Stopping Procedure Read Procedure in this manual Oil Pump Drive Coupling Inspect coupling Replace if necessary Discharge Check Valve Faulty Replace Complaint Corrective Action Operating Pressure Too High Reduce pres...

Page 56: ...Operating Maintenance Manual Trouble Shooting 60 Book 22904767 6 06 Rev A ...

Page 57: ... 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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