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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
OPERATING & MAINTENANCE
COMPRESSOR MODEL
P250WJDU
Revised (10-12)
MANUAL
Code:
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.
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Summary of Contents for Ingersoll-Rand P250WJDU
- Page 1 This manual must be available to the personnel who operate and maintain this machine. Doosan purchased Bobcat Company from Ingersoll-Rand Company in Portable Power Division 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging P.O. Box 868 - 501 Sanford Ave to Ingersoll-Rand Company in this manual is historical or nominative Mocksville, N.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. Book 22904767 (6/06) Rev. A...
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Page 3: Table Of Contents
TABLE OF CONTENTS P250WJDU TITLE PAGE SAFETY ............. . 11 Safety . - Page 4 TABLE OF CONTENTS P250WJDU TITLE PAGE Automatic Shutdown............36 High Discharge AIR Temperature .
- Page 5 Foreword Book: 22904767 (6/06) Rev. A...
- Page 6 Details of approved equipment are available from Ingersoll-Rand Service departments. The use of repair parts other than those included within the Ingersoll-Rand 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.
- Page 7 Your Ingersoll-Rand dealer will assist with setup and initial startup of the compressor. He will also provide brief operating and service instructions and will insure that a copy of this manual is included with the machine.
- Page 8 **Always use Ingersoll-Rand Replacement parts!** Book: 22904767 (6/06) Rev. A...
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Page 9: Safety
Safety Book: 22904767 (6/06) Rev. A... -
Page 10: Safety Precautions
Operating & Maintenance Manual Safety Safety Safety Precautions General Information Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. - Page 11 Safety Operating & Maintenance Manual Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, blow gun tips, etc. well away from moving parts. Compressed Air Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.
- Page 12 Operating & Maintenance Manual Safety Materials The following substances may be produced during the operation of this machine: • brake lining dust • engine exhaust fumes WARNING Avoid inhalation Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times.
- Page 13 Safety Operating & Maintenance Manual This machine may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authorities for proper disposal of these materials. Battery A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive.
- Page 14 Operating & Maintenance Manual Safety Decals Decals are located on the machine to point out potential safety hazards. Read and follow these instructions. If you do not understand the instructions, inform your supervisor. Note that there are different decal headings: DANGER (Red Background) Indicates the presence of a hazard which WILL cause serious injury,...
- Page 15 Safety Operating & Maintenance Manual FREE SAFETY DECALS To promote communication of Safety Warnings on products manufactured by the Portable Compressor Division in Mocksville, N.C. Safety 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.
- Page 16 Operating & Maintenance Manual Safety Book: 22904767 (6/06) Rev. A...
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Page 17: Noise Emission
Noise Emission Book: 22904767 (6/06) Rev. A... -
Page 18: Compressor Noise Emission Control Information
NOTE: The above information applies only to units that are built in compliance with the U.S. Environmental Protection Agency. Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. -
Page 19: Noise Emission Control Maintenance Log
Noise Emission Operating & Maintenance Manual Noise Emission Control Maintenance Log COMPRESSOR MODEL __________________________ SERIAL NO. ___________________________________ USER UNIT NO. ________________________________ UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Engine Make & Model: ________________ __________________________________ Serial No.: _________________________ __________________________________ Purchaser or Owner: _________________ __________________________________ Address: __________________________ Date Purchased: ____________________... - Page 20 Operating & Maintenance Manual Noise Emission Maintenance Schedule Item Area Period Compressed Air Leaks As Detected Safety and Control Systems As Detected Acoustic Materials Daily Fasteners 100 hours Enclosure Panels 100 hours Air Intake & Engine Exhaust 100 hours Cooling Systems 250 hours Isolation Mounts 250 hours...
- Page 21 Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer. J. Fuels and Lubricants Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand Company and Engine Manufacturer’s Operator and Maintenance Manuals. Book: 22904767 (6/06) Rev. A...
- Page 22 Operating & Maintenance Manual Noise Emission Maintenance Record For Noise Emission Control And Extended Warranty Item Hourmeter Maint/inspect Location Work Done Description Of Work Reading Date City/state By (Name) Book: 22904767 (6/06) Rev. A...
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Page 23: General Data
General Data Book: 22904767 (6/06) Rev. A... -
Page 24: Model
Operating & Maintenance Manual General Data General Data Model: P250WJDU Rated Delivery: CFM - (litres/sec/) 250(118) Engine: Full - RPM *Constant 2300 Idle - RPM 1700 Engine Model 4045D COMPRESSOR Rated Operating Pressure ........100 psi (7.03 kgf per cm2) (700kPa) Safety Valve Setting..........150 psi (10.5 kgf per cm2) (1030 kPa) -
Page 25: Units Measurements Weights
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 consent of Ingersoll-Rand Co. Book: 22904767 (6/06) Rev. A... - Page 26 Operating & Maintenance Manual General Data Book: 22904767 (6/06) Rev. A...
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Page 27: Operation
Operation Book: 22904767 (6/06) Rev. A... -
Page 28: Control Panel
Operating & Maintenance Manual Operation Operation Control Panel 10. Compressor Discharge Pressure Gauge - Indicates pressure 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. -
Page 29: Utility Package Set-Up (No Running Gear)
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. - Page 30 Operating & Maintenance Manual Operation Book: 22904767 (6/06) Rev. A...
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Page 31: Setting - Up (All Units)
Operation Operating & Maintenance Manual WARNING Setting - Up (All Units) • Position as level as possible. The design NO SMOKING, SPARKS or OPEN of these units permits a 15 degree FLAME near fuel. sidewise limit on out-of-level operation. • When the unit is to be operated out-of- CAUTION level, it is important: 1. -
Page 32: Starting
Operating & Maintenance Manual Operation • Check the engine oil level. Maintain per Starting marks on dipstick. Turn the POWER switch to “ON”. • Check the fuel level. Add only CLEAN If so equipped, place the “Start-Run” Valve DIESEL fuel for maximum service from Switch, located in the bottom right hand the engine. -
Page 33: After Starting
Operation Operating & Maintenance Manual • In “Generator” position, the engine will maintain idle speed, and the generator will give a constant voltage CAUTION and frequency output, for use with sensitive equipment like computers, fusion welders, etc. No compressed Exercise extreme caution when using air is available at the service air a booster battery to start. -
Page 34: Units With Optional Diagnostics Lamps
Operating & Maintenance Manual Operation fluid level. Other possible causes are listed on the Trouble Shooting Chart. Units With Optional Diagnostics Lamps All units in this family of machines are protected by sensors or switches at the following locations: NOTICE 1. - Page 35 Operation Operating & Maintenance Manual P250 Speed and Pressure Regulator Adjusting Instructions The engine idle and full speed settings are After Starting Unit set and sealed at the factory, and should not be adjusted. Serious injury may result if the 5.
- Page 36 Operating & Maintenance Manual Operation speed using screw (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.
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Page 37: Maintenance
Maintenance Book: 22904767 (6/06) Rev. A... -
Page 38: General
Operating & Maintenance Manual Maintenance Maintenance for repair. Preventive maintenance is the easiest and the least expensive type of CAUTION maintenance. Maintaining your unit and keeping it clean at all times will facilitate servicing. Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory Scheduled Maintenance warranty. -
Page 39: Air Cleaner
Maintenance Operating & Maintenance Manual Air Cleaner the element must be thoroughly dry. Direct compressed air through the element in the If this unit is equipped with the Optional direction opposite to the normal air flow Diagnostic Panel, it has an AIR FILTERS through the element. -
Page 40: Fuel Tank
Operating & Maintenance Manual Maintenance start-up. During operation observe the engine cooling system hoses and all of the gauges and any lamps for proper functioning. flexible hoses used for air, oil, and fuel be Refer to Operating Controls, for the normal inspected. -
Page 41: Compressor Oil Cooler
Maintenance Operating & Maintenance Manual gasket was removed with the oil filter NOTICE element. Clean the gasket seal area on the oil filter head. The oil filter must be replaced every NOTICE 500 hours of operation or three (3) months, whichever comes first. On new or overhauled units, replace the element after the first 50 and 150 Installing a new oil filter element when... -
Page 42: Compressor Oil
Operating & Maintenance Manual Maintenance down of the unit. To correct this situation it accumulated oil to the system. will be necessary to clean it using a cleaning The life of the oil separator element is compound in accordance with the dependent upon the operating environment manufacturer’s recommendations. -
Page 43: Scavenge Line
Maintenance Operating & Maintenance Manual When replacing the element, the scavenge thoroughly cleaned and the oil changed. lines, orifice, filter, and check valve should be Scavenge Line 2. Thoroughly clean scavenge line, any orifice and check valve. 3. Assure minimum pressure valve/orifice is WARNING operational. - Page 44 Operating & Maintenance Manual Maintenance Field Repair of Texture Paint 9. To apply the texture coat, use Duponts 1854S Tuffcoat Primer. The proper 1. The sheet metal should be washed and technique to do this is to spray the clean of foreign material and then Tuffcoat Primer using a pressure pot and thoroughly dried.
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Page 45: Maintenance Schedule
Maintenance Operating & Maintenance Manual MAINTENANCE SCHEDULE These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty or wet). Daily Weekly Monthly 3 MOS. 6 MOS. 6 MOS. 250 hours 500 hours 1000 hours **Hydraulic Oil Level Compressor Oil Level Engine Oil Level Radiator Coolant Level... - Page 46 Operating & Maintenance Manual Maintenance Book: 22904767 (6/06) Rev. A...
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Page 47: Lubrication
Lubrication Book: 22904767 (6/06) Rev. A... -
Page 48: Portable Compressor Fluid Chart
IR Pro•Tec™ (-23 C to 52 Alternate: ISO Viscosity Grade 46 with rust Preferred Ingersoll-Rand Fluids - Use of and oxidation inhibitors, designed these fluids with original I-R filters can extend for air compressor service. airend warranty. Refer to operator’s manual... -
Page 49: Trouble Shooting
Trouble Shooting Book: 22904767 (6/06) Rev. A... -
Page 50: Introduction
Operating & Maintenance Manual Trouble Shooting Trouble Shooting Introduction B. Do The Simplest Things First Most troubles are simple and easily Trouble shooting for a portable air corrected. For example, most complaints are compressor is an organized study of a “low capacity”... -
Page 51: Trouble Shooting Chart
Trouble Shooting Operating & Maintenance Manual Trouble Shooting Chart Bold Headings depict the COMPLAINT - Subheadings suggest the CAUSE NOTE: Subheadings suggest sequence to follow troubleshooting. Table 1: Unit Shutdown Complaint Corrective Action Out of Fuel Add CLEAN diesel Fuel Compressor Oil Temp. - Page 52 Operating & Maintenance Manual Trouble Shooting Table 3: Engine Temperature Lamps Stays On: Complaint Corrective Action Broken Engine Fan Belt Replace fan belt set. Malfunctioning Circuit Board Replace circuit board. * Ambient Temp. >125×F (52×C) Above spec limit. Dirty Operating Conditions Move unit to cleaner environment.
- Page 53 Trouble Shooting Operating & Maintenance Manual Table 8: Alternator Lamp Stays Off: Complaint Corrective Action Bulb Burned Out Replace circuit board. Loose Wire Connection Repair or replace connector. Malfunctioning circuit board Replace circuit board. Table 9: Unit Fails To Shutdown: Complaint Corrective Action Defective Low Fuel Shutdown Switch...
- Page 54 Operating & Maintenance Manual Trouble Shooting Malfunctioning Air Cylinder Replace air cylinder and adjust per Section 6. Wrong Air Filter Element Install correct element. Defective Separator Element Install new element per page 45. Engine Malfunctioning See Trouble Shooting in Engine Manual. Airend Malfunctioning Refer to Airend Rebuild Manual.
- Page 55 Trouble Shooting Operating & Maintenance Manual Table 16: Oil Seal Leak Complaint Corrective Action Contaminated Lube Oil Drain and flush system. Add new CLEAN oil. Blocked or Restricted Oil Line(s) Remove, clean and replace line(s). Malfunctioning Seal Refer to Airend Rebuild Manual. Scored Shaft See instructions in new seal kit.
- Page 56 Operating & Maintenance Manual Trouble Shooting Book: 22904767 (6/06) Rev. A...
- Page 57 Portable Power Division Ingersoll-Rand Company P.O.Box 868 - 501 Sanford Ave. Mocksville, N.C. 27028 © 2003 Ingersoll-Rand Company, Printed in the USA...
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