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Operating & Maintenance Manual

MAINTENANCE

48

Maintenance

CAUTION

!

Any unauthorized modification or
failure to maintain this equipment may
make it unsafe and out of factory
warranty.

If performing more than visual
inspections, disconnect battery
cables and open manual blowdown
valve.

Use extreme care to avoid contacting
hot surfaces (engine exhaust manifold
and piping, air receiver and air
discharge piping, etc.).

Never operate this machine with any
guards removed.

Inch and metric hardware was used in
the design and assembly of this unit.
Consult the parts manual for
clarification of usage.

NOTICE

Disregard any maintenance pertaining
to components not provided on your
machine.

General

In addition to periodic inspections, many of
the components in these units require
periodic servicing to provide maximum
output and performance. Servicing may
consist 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

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 should be adjusted accordingly.

Compressor Oil Level

Check the compressor fluid level when the
machine is not operating. Maintain the fluid
level between bottom and midway of the
sight glass on the separator tank.

Air Cleaner

If this unit is equipped with the Optional
Diagnostic Panel, it has an AIR FILTERS
RESTRICTED lamp on the instrument panel,
covering both the engine and the
compressor.

This should be checked daily during
operation. If the lamp glows (red) with the
unit operating at full speed, servicing of the
cleaner element is necessary.

Also weekly squeeze the rubber valve
(precleaner dirt dump) on each air cleaner
housing to ensure that they are not clogged.

The air filters restricted sensor will
automatically reset after the main power
switch is turned to “OFF.”

To service the air cleaners on all units
proceed as follows:

1. Loosen outer wing nut and remove with

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Содержание P105WJD

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 5: ...1 Foreword ...

Страница 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 ...

Страница 7: ...Foreword 3 ...

Страница 8: ...Foreword 4 ...

Страница 9: ...1 Drawbar Notice ...

Страница 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 ...

Страница 11: ...3 Section 1 Safety ...

Страница 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...

Страница 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...

Страница 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 ...

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

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

Страница 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...

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

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

Страница 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 ...

Страница 21: ...13 Section 2 WARRANTY ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

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

Страница 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 ...

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

Страница 29: ...29 Section 3 Noise Emission ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 35: ...35 Section 4 General Data ...

Страница 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...

Страница 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 ...

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

Страница 39: ...39 SECTION 5 OPERATION ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

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

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

Страница 49: ...47 Section 6 MAINTENANCE ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 57: ...55 Section 7 LUBRICATION ...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

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

Страница 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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