Ingersoll-Rand P260WIR Operation And Maintenance Manual
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Ingersoll-Rand P260WIR Operation And Maintenance Manual

Ingersoll-Rand P260WIR Operation And Maintenance Manual

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OPERATION and MAINTENANCE
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 22442545 (04/04)
Revised (10-12)
MANUAL
COMPRESSOR MODEL
P260WIR
Code: 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.

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Summary of Contents for Ingersoll-Rand P260WIR

  • 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, P.O. Box 868 - 501 Sanford Ave service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative Mocksville, N.C.
  • Page 2 QUALITY POLICY We will supply products and services that consistently meet the require- ments 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 reproduc- tive harm.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE SAFETY ............. . 1-3 Safety .
  • Page 4 TABLE OF CONTENTS TITLE PAGE MAINTENANCE............6-47 Maintenance .

  • Page 5: Safety

    Section 1 - Safety...
  • Page 6 Operating & Maintenance Manual Safety Safety IMPORTANT NOTICE washer. Repeat for the other chain (See Sketch). This machine may have been shipped from the factory with the drawbar positioned upright. To Convert From Shipping Position to Towing Position The following tools are required: Ratchet 13mm socket to fit ratchet Torque wrench set to 68 foot pounds (9.4 kg-...

  • Page 7: Safety Precautions

    Safety Operating & Maintenance Manual If more than one compressor is connected to one common downstream plant, effective Safety Precautions check valves and isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidentally be General pressurized or over pressurized by another.
  • Page 8 Operating & Maintenance Manual Safety Connect one end of other cable to the source of supply or branch line in accordance negative (-) terminal of the booster battery with OSHA Regulation 29CFR Section and other end to a ground connection away 1926.302(b).
  • Page 9 Safety Operating & Maintenance Manual Hazardous Substance Precaution The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly. Avoid ingestion, skin contact and breathing fumes for the following substances: Antifreeze, Compressor Oil, Engine Lubricating Oil, Preservative Grease, Rust Preventative, Diesel Fuel and Battery Electrolyte.
  • Page 10 Operating & Maintenance Manual Safety Look for these 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 11 Safety Operating & Maintenance Manual...
  • Page 12 Operating & Maintenance Manual Safety...
  • Page 13 Safety Operating & Maintenance Manual Look for these signs on machines shipped to markets 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 your supervisor. DANGER DANGER (Red Background) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 14 Operating & Maintenance Manual Safety...
  • Page 15 Safety Operating & Maintenance Manual...
  • Page 16 Operating & Maintenance Manual Safety Table 1: 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.

  • Page 17: Warranty

    Section 1 - Warranty...
  • Page 18 It is the obligation of the user to provide verification that these conditions have been satisfied when submitting warranty claims. 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...
  • Page 19 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 distributor authorized to sell the type of equipment involved or other establishment authorized by Ingersoll-Rand.

  • Page 20: General Warranty Information

    2 yrs/4000 hours using IR fluids & filters Deutz 2000 Available at dealer Ingersoll-Rand 4000 5 years/10,000 hours when using genuine Ingersoll-Rand fluids and parts. Refer to operator’s manual. Kubota (North America Only) 2000 Major components 36 months/3000 hrs - parts only (Western Europe & Oceania)

  • Page 21: Warranty Registration

    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 the warranty.
  • Page 22 Operating & Maintenance Manual Warranty...
  • Page 23 Ingersoll-Rand of such use so that Ingersoll-Rand may arrange for appropriate nuclear liability protection from the owner-licensee of the facility. 4. Ingersoll-Rand reserves the right to make design changes or modifications of Ingersoll- Rand products at anytime without incurring any obligation to make similar changes or...
  • Page 24 Operating & Maintenance Manual Warranty...
  • Page 25 CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEM WARRANTY: Ingersoll-Rand Company aims to ensure that the Emission Control Systems Warranty is properly administered. In the event that you do not receive the warranty service to which you...
  • Page 26 Operating & Maintenance Manual Warranty...

  • Page 27: Noise Emission

    Section 3 - Noise Emission...

  • Page 28: This Section Pertains Only To Machines Distributed Within The United States

    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 29: 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 30 Operating & Maintenance Manual Noise Emission deformed, such that their noise containment function is reduced, should be repaired or Maintenance Schedule replaced before the next operation interval. Item Area Period Doors, access panels, and hatch closures Compressed Air Leaks As Detected especially, should be checked and adjusted Safety and Control Systems As Detected...
  • Page 31 Noise Emission Operating & Maintenance Manual 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)
  • Page 32 Operating & Maintenance Manual Noise Emission...

  • Page 33: General Data

    Section 4 - General Data...

  • Page 34: Model

    Operating & Maintenance Manual General Data General Data Model: P260AWIR Rated Delivery: CFM - (litres/sec/) 260(123) Engine (Diesel): Full - RPM (Full Load) 2300 Idle - RPM (No Load) 1700 Engine Model 4IRI8T Electrical System 12VDC COMPRESSOR Rated Operating Pressure ........100 psi (689 kPa) Safety Valve Setting..........150 psi (1034 kPa) FLUID CAPACITIES Compressor Lubricant..........12 quarts (11.4 litres)

  • Page 35: Units Measurements Weights

    Engine Fuel Filter Element........Part No. 16539462 Fuel Water Separator Element .........Part No. 54468178 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 36 Operating & Maintenance Manual General Data...

  • Page 37: Section 5- Operation

    Section 5- Operation...

  • Page 38: Before Towing

    Operating & Maintenance Manual Section 5- Operation BEFORE TOWING towing. SETTING UP (ALL UNITS) WARNING • Position as level as possible. The design of these units permits a 15 degree sidewise limit on out-of-level Failure to follow these instructions operation. CAN cause severe injury or death.
  • Page 39 Section 5- Operation Operating & Maintenance Manual UTILITY PACKAGE SET-UP (no running gear) DISCONNECT This unit must be located on vehicle bed to • Engage tow vehicle parking brake. allow access for normal servicing and maintenance. • Chock tires of compressor. The air going into the inlet must be relatively free of oil, dirt, soot and other debris.
  • Page 40 Operating & Maintenance Manual Section 5- Operation 11. Fuel Level Gauge - Indicates amount of fuel in tank. CONTROL PANEL - Diagnostics/Auto Shutdown (Standard and Optional) Controls (Standard) 12. Power Switch - Flip “ON” to activate systems prior to Starting. Flip “OFF” to stop engine.
  • Page 41 Section 5- Operation Operating & Maintenance Manual • Check the compressor lubricating oil level. The optimum oil level is with the pointer at the top of the green section on CAUTION the level gages. Add oil if the pointer reaches the bottom of the green section. Do not overfill.
  • Page 42 Operating & Maintenance Manual Section 5- Operation • Allow engine to warm up 5 to 10 cooling system can result in a loss of minutes. coolant and possible severe personal injury. • If so equipped, press the “Service Air Button”. Open air service valve(s). Units With Optional Diagnostics Lamps Cold Weather Starting...
  • Page 43 Section 5- Operation Operating & Maintenance Manual WARNING Since the service valve is closed, 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.
  • Page 44 Operating & Maintenance Manual Section 5- Operation P260 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 4.

  • Page 45: Maintenance

    Section 6 - Maintenance...

  • Page 46: 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 47: Air Cleaner

    Maintenance Operating & Maintenance Manual Air Cleaner Gauges If this unit is equipped with the Optional The instruments or gauges are essential for Diagnostic Panel, it has an AIR FILTERS safety, maximum productivity and long RESTRICTED lamp on the instrument panel, service life of the machine.

  • Page 48: Radiator

    Operating & Maintenance Manual Maintenance Radiator 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 NOTICE removed and replaced numerous times without losing its sealing ability. To install the nylon tubing, make a mark (with The use of water alone in this engine tape or grease pencil) approximately 7/8 inch...

  • Page 49: Compressor Oil Cooler

    Maintenance Operating & Maintenance Manual down of the unit. To correct this situation it NOTICE will be necessary to clean it using a cleaning compound in accordance with the manufacturer’s recommendations. Installing a new oil filter element when the old gasket remains on the filter Compressor Oil head, will cause an oil leak and can cause property damage.

  • Page 50: Scavenge Line

    Operating & Maintenance Manual Maintenance of a scavenge tube which returns the procedure: accumulated oil to the system. 1. Check oil level. Maintain as indicated The life of the oil separator element is earlier in this section. dependent upon the operating environment (soot, dust, etc.) and should be replaced 2.
  • Page 51 Maintenance Operating & Maintenance Manual 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.
  • Page 52 Operating & Maintenance Manual Maintenance MAINTENANCE SCHEDULE Daily Weekly Monthly 3 MOS. 6 MOS. 12 MOS. 250 hours 500 hours 1000 hours Compressor Oil Level Engine Oil Level Radiator Coolant Level Gauges/Lamps Air Cleaner Service Indicators Fuel Tank (fill at end of day) DRAIN Fuel Water Separator (Drain) Oil Leaks...

  • Page 53: Lubrication

    Section 7 - Lubrication...

  • Page 54: 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 55: Trouble Shooting

    Section 8 - Trouble Shooting...

  • Page 56: 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 57: Trouble Shooting Chart

    Trouble Shooting Operating & Maintenance Manual Trouble Shooting Chart Bold Headings depict the COMPLAINT - Subheadings indicate CAUSES NOTE: Subheadings suggest sequence to follow troubleshooting. Table 1: Unit Shutdown Cause Corrective Action Out of Fuel Add CLEAN diesel Fuel Compressor Oil Temp. Too High See Table 10 Engine Water Temp.
  • Page 58 Operating & Maintenance Manual Trouble Shooting Defective Engine Temp. Switch Replace Switch Defective Separator Tank Temp Switch Replace Switch Defective Low Fuel Shutdown Switch Replace Switch Defective Alternator Replace/Repair Alternator Table 3: Engine Temperature Lamps Stays On: Complaint Corrective Action Broken Engine Fan Belt Replace fan belt set.
  • Page 59 Trouble Shooting Operating & Maintenance Manual Check connectors. Clean & tighten. Recharge battery. Malfunctioning Alternator Repair or replace alternator. Shorted wire (ground) Repair short. Table 8: Alternator Lamp Stays Off: Complaint Corrective Action Bulb Burned Out Replace circuit board. Loose Wire Connection Repair or replace connector.
  • Page 60 Operating & Maintenance Manual Trouble Shooting Table 11: Engine RPM Down Complaint Corrective Action Clogged Fuel Filter Clean primary filter. Replace final filter. Drain tanks. Add CLEAN fuel. Operating Pressure Too High Reduce pressure to spec limit. Incorrect Pressure Regulator Adjustment Adjust regulator.
  • Page 61 Trouble Shooting Operating & Maintenance Manual Table 15: Excessive Oil In Air Complaint Corrective Action High Oil Level Read procedure in this manual. Out of Level > 15 degrees Relocate or reposition unit. Clogged Scavenge Orifice Remove scavenge orifice. Clean and Replace. Scavenge Tube Blocked Remove scavenge tube.
  • Page 62 Operating & Maintenance Manual Trouble Shooting...

  • Page 63: 4Ir18T Engine

    Section 9 - 4IR18T ENGINE...

  • Page 64: Contents

    Operating & Maintenance Manual 4IR18T ENGINE CONTENTS FOREWORD EXTERNAL VIEW: 4IR18T GENERAL INFORMATION: 4IR18T Main data and specifications Engine identification Ingersoll-Rand engine after sales support EMISSION CONTROL LABEL FUEL, LUBRICANT, AND COOLANT OPERATION PERIODICAL INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE TROUBLESHOOTING...

  • Page 65: Foreword

    Should your engine require servicing, please contact your nearest Ingersoll-Rand branch or distributor. All information, illustrations, and specifications contained in this manual are based on the latest product information available at the time of publication. Ingersoll-Rand reserves the right to make changes in this manual at any time without prior notice.
  • Page 66 Operating & Maintenance Manual 4IR18T ENGINE Table 1: Item Description Item Description Lifting eye Fuel filter Cooling water pump Fuel oil inlet Cooling fan Fuel filter mounting with fuel priming pump Crank shaft V-pulley Fuel priming pump V-belt Engine name plate Filler port (engine oil) Air intake port Drain plug (engine oil)
  • Page 67 4IR18T ENGINE Operating & Maintenance Manual Table 2: Engine model name 4IR18T Engine type Vertical inline water cooled diesel engine Combustion type Direct injection Aspiration Turbocharged No. of cylinders - bore x stroke 4-98x110 Engine displacement L 3.319 Compression ratio 18.1:1 Firing order 1 -3 - 4 - 2...

  • Page 68: Engine Identification

    NO TAG. Confirmation of Engine Number It is advisable to quote the engine serial number together with the machine serial number, as it is required when you contact the Ingersoll-Rand branch or distributor for repair, service or parts ordering. CAUTION Conduct confirmation of engine serial number with the engine stopped.

  • Page 69: Engine Label (For Epa) Emission Control Label

    4IR18T ENGINE Operating & Maintenance Manual Engine Label (for EPA) Emission Control Label Emission control label is attached on the “top of rocker arm cover.” The location of emission control label attached on the engine may vary depending on the engine specification.

  • Page 70: Fluid, Lubricants, And Coolant

    Ingersoll- Rand. NOTICE If any fuel other than the one specified is used, engine operation will be impaired. Engine failure or malfunction resulting from use of such improper fuel will not be warranted by Ingersoll-Rand.

  • Page 71: Water In Fuel

    4IR18T ENGINE Operating & Maintenance Manual when filling the tank. To help avoid fuel system or engine damage, please read the following: • If refueling is done from an oil drum directly, ensure that is has been Do not use diesel fuel which has been kept stationary to allow any dust, contaminated with engine oil.
  • Page 72 Operating & Maintenance Manual 4IR18T ENGINE See your authorized dealer for advise on using biocides in your area and for recommendations on which biocides you CAUTION should use. water/diesel fuel Smoke Suppressants mixture is flammable, and could be hot. To avoid The use of a smoke suppressant additive is personal injury...
  • Page 73 WARNING warranty.engine oil. Coolant Do not breathe exhaust gas because it contains carbon All Ingersoll-Rand portable compressor monoxide, which by itself engines are factory filled with a 50/50 color odor. Ethylene glycol base antifreeze/water mix. Carbon monoxide which provides protection to -33°C (-27°F).
  • Page 74 Operating & Maintenance Manual 4IR18T ENGINE Engine Oil Level Remove filler cap “yellow colored) on the • Place the engine or the machine on rocker arm cover side of engine. a level surface. Fill with engine oil up to the upper limit on the dipstick.
  • Page 75 4IR18T ENGINE Operating & Maintenance Manual will damage the electrical parts. A. Battery Cable Coolant Level Check B. Connections The coolant level must be between MAX “COLD" and MIN" marks on the reserve tank depending on the temperature of the engine. Battery Electrolyte Level Check and ensure that the level is correct.
  • Page 76 Operating & Maintenance Manual 4IR18T ENGINE Note: After start-up from cold, the engine might be noisier and the exhaust smoke color darker than when it has warmed up. CAUTION However, the condition will disappear after warm-up. highly flammable Leakage in the System hydrogen gas is released Check the following items: from the batteries, do not...
  • Page 77 OPERATION AND CARE OF A NEW MACHINE does not start to drop, turn off the Your Ingersoll-Rand engine is carefully engine and proceed as follows: tested and adjusted in the factory, however, To avoid being burned - further run-in is necessary.
  • Page 78 Liquid and Exhaust Smoke Leakage Make regular checks for lubricant, fuel, coolant and exhaust smoke leakage. Abnormal Engine Noise In the event of any abnormal engine noise, please consult your local Ingersoll-Rand branch or dealer.
  • Page 79 Rand Protec™ engine fluid wrench (customer procured) and filters. to drain the engine oil). Note: The use of genuine Ingersoll-Rand oil 3. Securely tighten the drain and filters will qualify for extended warranty plug after draining the engine coverage. Refer to Warranty Section of the oil.
  • Page 80 As the governor is precisely adjusted, most of the controls are sealed, please do not break them. Should any adjustment be necessary, contact your local Ingersoll-Rand branch or distributor. Note: Ingersoll-Rand will not accept any warranty claim on an engine with broken governor seals.
  • Page 81 4IR18T ENGINE Operating & Maintenance Manual element. Replacing Fuel Filters • Discard the old element. Replace the fuel filter at specified intervals before it is clogged with dust to adversely • Remove the old “O” ring from the affect the fuel flow. Also, replace the fuel filter bowl “D”...
  • Page 82 - As this adjustment Pump and requires specialized knowledge and skill, Fuel Valve consult your Ingersoll-Rand dealer. Rust and Nozzle. water scale will accumulate in the cooling system through many hours of operation. LW < 130...
  • Page 83 4IR18T ENGINE Operating & Maintenance Manual...
  • Page 84 Operating & Maintenance Manual 4IR18T ENGINE...
  • Page 85 4IR18T ENGINE Operating & Maintenance Manual...
  • Page 86 Operating & Maintenance Manual 4IR18T ENGINE...
  • Page 87 Section 10 - Parts Ordering...

  • Page 88: General

    How To Order Always insist on genuine Ingersoll-Rand Company parts for your compressor. Always specify the model and serial number of the unit.
  • Page 89 WARRANTY REGISTRATION ....1-19 Ingersoll-Rand Preferred Fluids ... . . 7-56 WATER COOLED ENGINE ....5-41 Isolation Mounts .
  • Page 90 WORD INDEX Manual-Name 11 - 2...
  • Page 91 © 2004 Ingersoll-Rand Company, Printed in the USA...

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