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This manual contains important safety information and must be made
available to personnel who operate and maintain this machine.
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.
C.C.N. : 22488183 GB
DATE
: AUGUST 2004
Revised (10-12)
OPERATING, MAINTENANCE,
PARTS MANUAL
COMPRESSOR MODEL
9/235
9/235
SERIAL No :
814000
–>
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Summary of Contents for Ingersoll-Rand 9/235
- Page 1 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...
- Page 2 Wigan WN2 4EZ United Kingdom Declare that, under our sole responsibility for manufacture and supply, the product(s) 9/235 to which this declaration relates, is (are) in conformity with the provisions of the above directives using the following principal standards EN29001 : EN292, EN60204–1, EN1012–1, PN8NTC2, EN50081, EN50082 Issued at Mocksville on 15–4–2004...
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Page 3: Table Of Contents
Commissioning Italy Compressor Mounting Norway Prior to starting Netherlands Starting Portugal Stopping Sweden Emergency stopping Finland Re–starting F.H.R.G. Fixed height running gear Monitoring during operation V.H.R.G. Variable height running gear Decommissioning ENGINE INSTRUCTION MANUAL MAINTENANCE FAULT FINDING PARTS ORDERING 9/235... -
Page 4: Foreword
The company accepts no responsibility for errors in translation of of unapproved usage are also given, however Ingersoll–Rand cannot this manual from the original English version. anticipate every application or work situation that may arise. 2004 IF IN DOUBT CONSULT SUPERVISION © COPYRIGHT INGERSOLL–RAND COMPANY 9/235... - Page 5 Ingersoll–Rand Engines – The earlier of twenty—four (24) EXPRESSED OR IMPLIED, (EXCEPT THAT OF TITLE), AND months from shipment to or the accumulation of 4,000 hours of THERE ARE NO WARRANTIES OF MERCHANTABILITY OR OF service. FITNESS FORA PARTICULAR PURPOSE. 9/235...
- Page 6 Hours Coverage No Limit Parts Only Ingersoll–Rand AIREND EXCHANGE Months Hours Extended Coverage Airend 2000 2 yrs/4000 hrs – available from IR. Note: Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with each new product. 9/235...
- Page 7 XHP505 Compressor Fluids are available from your local Ingersoll–Rand branch or distributor. For units operating within the USA & Canada, call the Mocksville Product Support Department on 1–800–633–5206 XHP650/900/1070 will continue to use XHP505 and will have the extended warranty when above conditions are met. 9/235...
- Page 8 Caterpillar, Cummins and Perkins do not require a separate registration form but they stipulate that any new engine should be registered with their local dealer to initiate warranty. You MUST provide proof of the “in–service” date when requesting engine warranty repairs. 9/235...
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Page 9: Warranty
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 modifications on previously sold units. 9/235... - Page 10 WARNING – Pressure control. WARNING – Corrosion risk. WARNING – Air/gas flow or Air discharge. WARNING – Maintain correct tyre pressure. WARNING – Pressurised vessel. WARNING – Hot and harmful exhaust gas. (Refer to the GENERAL INFORMATION section of this manual). 9/235...
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Page 11: Decals
Do not remove the Operating and Maintenance Do not operate the machine without the guard Do not stack. manual and manual holder from this machine. being fitted. 9/235... - Page 12 Read the Operation and Maintenance manual When parking use prop stand, handrake and Compressor oil filling before operation or maintenance of this wheel chocks. machine is undertaken. Diesel fuel Rough Service Designation. Parking brake. No open flame. Wet Location Operation. 9/235...
- Page 13 DECALS Replace any cracked protective shield. Oil drain. Engine Oil Fuel level/point Pressure control Malfunction Battery charging condition Low pressure High pressure High compressor temperature Engine malfunction Compressor malfunction Engine high temperature Low engine oil pressure 9/235...
- Page 14 Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). 9/235...
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Page 15: Safety
Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water. After setting, fully tighten each joint by hand and then tighten further to the next pin. Refit the pin. 9/235... - Page 16 Ensure that the effective cable length is as short as possible, whilst still allowing enough slackness for the trailer to articulate without the handbrake being applied. 9/235...
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Page 17: General Information
Maximum oil system temperature. 120_C (248_F) (*Machine only :– at maximum load in open site conditions) C) EPA Noise 76 dB(A) ENGINE WHEELS AND TYRES 9/235 Number of wheels. Type/model. Ingersoll–Rand 6IRC8A Tyre size. 7.50 – 16 LT Number of cylinders. -
Page 18: Operating Instructions
It is necessary to isolate the compressor package from the carrier base with a flexible mounting system. Such a system must also prevent detachment of the package from the carrier base in the event the isolators fail. Contact Ingersoll–Rand representative for flexible mounting kits. 9/235... -
Page 19: Prior To Starting
9/235... - Page 20 10. Voltmeter – Indicates charging system voltage. 5. Service Air Switch – After warm–up, PUSH. Provides full air pressure at the service outlet. 11. Spare– Used for optional accessories. 6. Engine Speed Gauge – Indicates engine speed. (RPM) 12. Spare– Used for optional accessories. 9/235...
- Page 21 8. DIAGNOSTICS AUTO SHUTDOWN. 3. High Engine Coolant Temp: Fault indicator lamp. Indicates 9. LAMP TEST – WITH ENGINE OFF, TURN POWER SWITCH TO “OFF”, THEN TO “ON”. ALL LAMPS SHOULD LIGHT. shutdown due to high engine water temperature. 9/235...
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Page 22: Emergency Stopping
At this point in the operation of the machine it is safe to apply full load dismantled, it is important to ensure that all hazard risks are either to the engine. eliminated or notified to the recipient of the machine. In particular:– 9/235... - Page 23 Do not dispose of any pressure vessel that is not clearly marked Do not dispose of a complete machine without documentation with its relevant data plate information or rendered unusable by drilling, relating to instructions for its use. cutting etc. 9/235...
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Page 24: Engine Instruction Manual
Coolant OPERATION Check before operation Check and operation after start– up Operation and care of a new engine PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance COLD WEATHER OPERATION MAINTENANCE SCHEDULE TROUBLESHOOTING 9/235... - Page 25 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. The pictures contained within are for guidance only and might not reflect the physical characteristics of each individual engine covered 9/235...
- Page 26 (16) Coolant heater port. (7) Engine dataplate. (17) Lubricating oil cooler. (8) Fuel injection pump (18) Lubricating oil filter. (9) Fuel drain line. (19) Turbocharger oil drain. (10) Intake manifold. (20) Coolant filter. (21) Starter motor (22) Turbocharger exhaust outlet. 9/235...
- Page 27 Ingersoll–Rand branch or distributor for repair, service or parts ordering. CAUTION: Conduct confirmation of engine serial number with the engine stopped. To avoid being injured, do not check it, while the engine is still hot. 9/235...
- Page 28 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 fuel from ingress of dust particles or water when filling the fuel tank. 9/235...
- Page 29 Refer to fig 5. Fig. 5 A. (Single – grade) B. Ambient Temperature C. (Multi – grade) COOLANT All Ingersoll–Rand portable compressor engines are factory filled with a 50/50 Ethylene glycol base antifreeze/water mix. which provides protection to –33_C (–27_F) 9/235...
- Page 30 The battery cables must be tightened securely. Never reverse “+” and “–” terminals when reconnecting Fan and Belt Check cables after disconnection. Even a short period of reverse connection The engine is fitted with an automatic belt tensioner will damage the electrical parts. 9/235...
- Page 31 Cover the radiator cap with a thick cloth and loosen the cap slowly to reduce the pressure, then When disconnecting the terminals, start with “–” terminal. When connecting them, connect the “–” terminal last. remove the cap. 9/235...
- Page 32 LONG TERM STORAGE If the equipment is to be out of operation for an extended period, it should be started at least once per week and run on load for about 15 minutes after it has reached normal operating temperature. 9/235...
- Page 33 Clean skin and nails thoroughly using soap and water –not Fig. 10 mineral oil, fuels, or solvents. Launder or discard clothing, shoes, or rags containing used engine oil. A Cartridge Discard used engine oil and other oils properly. 9/235...
- Page 34 When the cooling system circuit is contaminated with water scales or sludge particles, cooling efficiency will be lowered. Periodically clean the circuit interior with a suitable cleaner. Clean the cooling system circuit every 1000 operating hours or 12 months, whichever comes first. 9/235...
- Page 35 ‘A’ should be changed every 500 operating hours or 6 months, A Normal whichever comes first. B Clogged Change procedure: C Indicator Disconnect fuel sensor (where fitted). Loosen drain plug B and empty fuel into suitable container D Red signal 9/235...
- Page 36 SERVICE AND MAINTENANCE Please refer to the engine maintenance schedule. For continued trouble free engine operation throughout its life, the service procedures marked with an asterisk (*) need to be carried out by a skilled and trained technician. 9/235...
- Page 37 COLD STARTING When operating in cold ambient conditions, or when starting from cold. If the engine does not start at the first attempt, allow the battery to recover for at least 30 seconds. Observe the following procedures: 9/235...
- Page 38 Note: 1. After every 1500 hours of operation, the service intervals should be repeated in accordance with this check and maintenance schedule. 2. When servicing on the asterisked (*) items is necessary, consult your local Ingersoll–Rand branch or distributor. 9/235...
- Page 39 Clean at intervals of 1000 hours or 12 months, whichever comes first. cleaning Radiator filling cap Check radiator pressure cap periodically for proper operation. Consult your local Ingersoll–Rand branch or function check distributor. Battery electrolyte level Replenish with distilled water if necessary. check 9/235...
- Page 40 Check and clean the breather tube daily during cold weather. Check according to the equipment ventilation valve cleaning specifications. Perform the adjustment, cleaning, repair or replacement every 1500 hours. (This is a recommended maintenance item L). Consult your local Ingersoll–Rand branch or distributor. 9/235...
- Page 41 Incorrect preheating operation. Glow plug malfunction. Fuel is injected but engine does not Incorrect injection timing. fire. cylinder compression pressure. Engine stop solenoid not fully returned. Engine fires but stalls immediately. Air in the fuel system. Incorrect low idle speed adjustment. 9/235...
- Page 42 Restricted coolant flow (high concentration of antifreeze, etc.) Low oil pressure Lack of oil Oil leakage High oil consumption Wrong oil Wrong type and viscocity. High coolant temperature. Over heat. Clogged filter and strainer. Worn bearings and oil pump. Faulty relief valve. 9/235...
- Page 43 Faulty valve stem seal. Damaged seal / Damaged turbocharger seal Oil leakage Loose joints/gaskets. Improper installation of filter and piping. Fuel leakage Damaged seals. Excessive fuel consumption Improper component installation or tightening. Excessive injection volume. Injection pump defective. Excessive mechanical loads 9/235...
- Page 44 Injection timing incorrect. Low coolant temperature Faulty turbocharger Battery overdischarge Low electrolyte level Crack in battery body. Natural consumption. Charging failure Loose or damaged belt. Faulty alternator. Damaged wiring or contact failure. Excessive electrical loads Insufficient battery capacity for the application. 9/235...
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Page 45: Maintenance
(2) or as defined by local or national legislation =Replace = Check (adjust, clean or replace as necessary) = Test =check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 9/235... - Page 46 (2) or as defined by local or national legislation =Replace = Check (adjust, clean or replace as necessary) = Test =check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 9/235...
- Page 47 (e.g. pressurised components, electrically live components, removed panels, covers and guards, Ensure that maintenance personnel are adequately trained, extreme temperatures, inflow and outflow of air, intermittently moving competent and have read the Maintenance Manuals. parts, safety valve discharge etc.). 9/235...
- Page 48 Do not use gasket sealant since this will affect electrical relieved of all air pressure. (Refer to STOPPING THE UNIT in the conductance. OPERATING INSTRUCTIONS section of this manual). 9/235...
- Page 49 Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion. VENTILATION The retaining clamp should be kept tight enough to prevent the Always check that the air inlets and outlets are clear of debris etc. battery from moving. 9/235...
- Page 50 Refer to the Engine operators’ manual/section for engine oil specifications RUNNING GEAR WHEEL BEARINGS Wheel bearings should be packed with grease every 6 months. The Refer to the Engine section of this manual. type of grease used should conform to specification MIL–G–10924. 9/235...
- Page 51 5 gal. 55 gal. 220 gal. Preferred Fluids (3.8 Litre) (19.0 Litre) (208.2Litre) (836 litre) Preferred: IR Pro–Tect 36899698 36899706 36899714 36899722 IR XHP605 – 22252076 22252050 22252068 IR XHP1001 – 35612738 35300516 – XHP405 – 22252126 22252100 22252118 9/235...
- Page 52 E. Inlet Unloader normal operating discharge pressure. Close the service valve. The engine will slow to idle speed. CAUTION: Never allow the idle pressure to exceed maximum allowable pressure on the pressure gauge, otherwise the safety valve will operate. 9/235...
- Page 53 13 inch 60–70 1/2” lug nuts 13 inch 80–90 1/2” lug nuts 15 inch 105–115 1/2” lug nuts 16 inch 105–115 1/2” lug nuts 16.5 inch 105–115 5/8” lug nuts 16 inch 190–210 5/8” lug nuts 17.5 inch 190–210 9/235...
- Page 54 Wheel Nut / Bolt Size Torque Moment (Nm) Torque Moment (ft–lb) 66 ± 4 M12 x 1.5 90± 5 110 ± 4 M14 x 1.5 150± 5 133 ± 4 M16 x 1.5 180± 5 155 ± 4 M18 x 1.5 210± 5 9/235...
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Page 55: Fault Finding
Refer to SPEED Check the fan drive. PRESSURE REGULATION Water present in fuel Check water ADJUSTMENT in the system. separator and clean if MAINTENANCE section required. of this manual. Faulty relay. Check the relays and replace if necessary. 9/235... - Page 56 Inlet valve set Refer to SPEED AND incorrectly. PRESSURE REGULATION ADJUSTMENT in the MAINTENANCE section of this manual. Loose pipe/hose Check pipe/hose connections. connections. Faulty safety valve. Check relieving pressure. Replace the safety valve if faulty. DO ATTEMPT REPAIR. 9/235...
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Page 57: Parts Ordering
Afterwards, service sets of exterior decals and current production total number of parts used in the machine. Where no quantity is safety warning decals are available. Contact the Product Support specified the quantity is assumed to be one. Group at Mocksville for your particular needs and availability. 9/235... - Page 58 CLAIM must be processed through the Customer Service Department. can be received by the Company, the additional charges will be If returned without a Warranty MRR (Material Return Request) honored by the Purchaser. Number, no warranty claim will be considered. 9/235...
- Page 59 Ingersoll–Rand European Sales Ltd Swan Lane, Hindley Green Emergency order telephone # +44 (0) 777 617 0921 Wigan WN2 4 EZ United Kingdom Fax: +44 (0) 1942 523 417 Office hours: Monday – Friday 8:00 a.m. to 4:30 p.m. (GMT) 9/235...
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