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COMPRESSOR MODELS CODE: E 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...
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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.
The use of repair parts other than those included within the approved parts list may create hazardous conditions over which Ingersoll-Rand has no control. Therefore, Portable Power cannot be held responsible for equipment in which non-approved repair parts are installed.
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Foreword Operating & Maintenance Manual This machine should not be used: A. For direct or indirect human consumption of the compressed air. B. Outside the ambient temperature range specified in the general data section of this manual. C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists.
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.
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.
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.
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.
Operating & Maintenance Manual Safety Transport When loading or transporting machines ensure that the specified lifting and tie down points are used. When loading or transporting machines ensure that the towing vehicle, its size, weight, towing hitch and electrical supply are all suitable to provide safe and stable towing at speeds either, up to the legal maximum for the country in which it is being towed or, as specified for the machine model if lower than the legal maximum.
Safety Operating & Maintenance Manual 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,...
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Operating & Maintenance Manual Safety FREE SAFETY DECALS To promote communication of Safety Warnings on products manufactured by the Portable Power Division in Statesville, 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.
Operating & Maintenance Manual Noise Emission 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:_____________________ __________________________________ The Noise Control Act of 1972 (86 Stat.
Noise Emission Operating & Maintenance Manual Introduction The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air Compressors. The purpose of this book is to provide (1) the Maintenance Performance Schedule for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when.
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: 22846471 (3-09-07) Rev. B...
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Noise Emission Operating & Maintenance Manual Table 1: MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK OR HOURMETER MAINT/ LOCATION WORK DONE COMMENTS READING INSPECT DATE CITY/STATE BY (NAME) Book: 22846471 (3-09-07) Rev. B...
Operating & Maintenance Manual Operating Instructions Operating Instructions Commissioning Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the instructions given below in PRIOR TO STARTING. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.
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Operating Instructions Operating & Maintenance Manual WARNING 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 accidently be pressurised/over pressurised by another.
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Operating & Maintenance Manual Operating Instructions CAUTION Use only a No. 2–D diesel fuel oil with a minimum octane number of 45 and a sulphur content not greater than 0,5%. CAUTION When refuelling:- • switch off the engine. • do not smoke. •...
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Operating Instructions Operating & Maintenance Manual When starting or operating the machine in temperatures below or approaching 0°C (32°F), ensure that the operation of the regulation system, the unloader valve, the safety valve, and the engine are not impaired by ice or snow, and that all inlet and outlet pipes and ducts are clear of ice and snow.
Operating & Maintenance Manual Operating Instructions Operating Controls and Instruments The operating controls and instruments are arranged on the control panel as shown above. A description of each panel device is as follows: 1. Panel Light: Illuminates the instrument control panel controlled by Switch 14. 2.
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Operating Instructions Operating & Maintenance Manual 20. Discharge Air Pressure Gage: Indicates pressure in receiver tank, normally from 0 psi(kPa) to the rated pressure of the machine. 21. Engine Tachometer: Indicates engine speed in RPM from 0 when stopped to full speed.
Operating & Maintenance Manual Operating Instructions Wedge Diagnostic Display Codes 1. High Compressor Temp: Fault indicator lamp. Indicates shutdown due to high compressor temperature. 2. Low Engine Oil Pressure: Fault indicator lamp. Indicates shutdown due to low engine oil pressure. 3.
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Operating Instructions Operating & Maintenance Manual 7. Restricted Air Filter: Alarm indicator lamp. Indicates engine/compressor air inlet filters need service. 8. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to high pressure in “IQ” air filters (if equipped). 9.
Operating & Maintenance Manual Operating Instructions CATERPILLAR C-9 Engine Diagnostic and Event Flash Codes Displayed Code Definition 5 volt sensor DC power supply short to + batt 5 volt sensor DC power supply short to ground 8 volt DC supply short to + batt 8 volt DC supply short to ground Engine oil pressure open/short to + batt Engine oil pressure short to ground...
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Operating Instructions Operating & Maintenance Manual Displayed Code Definition Engine timing calibration required Low engine oil pressure WARNING Low engine oil pressure derate Low engine oil pressure shutdown Air inlet heater relay open/current below normal Air inlet heater relay grounded/current above normal System voltage intermittent/erratic/high/low Check programmable parameters J1939 Data Link Communications...
Operating & Maintenance Manual Operating Instructions Starting the Machine Ensure emergency stop button is reset. WARNING Under no circumstances should volatile fluids such as ether be used for starting this machine. All normal starting functions are incorporated in the key operated switch. Turn the keyswitch to (position 1);...
Operating Instructions Operating & Maintenance Manual NOTE: In order to allow the machine to start at a reduced load, a valve, which is operated by a service air switch located on the instrument panel, is incorporated in the regulation system. (The valve automatically returns to the start position when the machine is switched off and air pressure relieved from the system).
Operating & Maintenance Manual Operating Instructions CAUTION Never allow the machine to stand idle with pressure in the system. Emergency Stopping In the event that the unit has to be stopped in an emergency, PRESS THE EMERGENCY STOP SWITCH ON THE FRONT OF THE MACHINE. If the unit is not fitted with an emergency stop switch, rotate the start switch to the (0) off position.
Operating Instructions Operating & Maintenance Manual Decommissioning When the machine is to be permanently decommissioned or dismantled, it is important to ensure that all hazard risks are either eliminated or notified to the recipient of the machine. In particular:- • Do not destroy batteries or components containing asbestos without containing the materials safely.
Maintenance Operating & Maintenance Manual Routine Maintenance This section refers to the various components which require periodic maintenance and replacement. The SERVICE MAINTENANCE INTERVAL CHART indicates the various components’ descriptions and the intervals when maintenance has to take place. Oil capacities, etc., can be found in the GENERAL INFORMATION section of this manual.
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Operating & Maintenance Manual Maintenance Prior to opening or removing panels or covers to work inside a machine, ensure that:- • anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts. •...
Maintenance Operating & Maintenance Manual Protective Shutdown System Refer to the Wedge diagnostic display codes table for a listing of shutdown conditions. Low Engine Fuel Level Switch At three month intervals, test the low engine fuel level switch circuit as follows: •...
Operating & Maintenance Manual Maintenance Compressor Oil Filter Refer to the MAINTENANCE INTERVAL CHART in this section for the recommended servicing intervals. Removal WARNING Do not remove the filter(s) without first making sure that the machine is stopped and the system has been completely relieved of all air pressure. (Refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual).
Maintenance Operating & Maintenance Manual Compressor Oil Separator Element Refer to the SERVICE MAINTENANCE INTERVAL CHART in this section for service intervals. Removal WARNING Do not remove the filter(s) without first making sure that the machine is stopped and the system has been completely relieved of all air pressure. (Refer to STOPPING THE UNIT in the OPERATING INSTRUCTIONS section of this manual).
Operating & Maintenance Manual Maintenance CAUTION Start the machine (refer to PRIOR TO STARTING and STARTING THE UNIT in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the machine is put back into service. Compressor Oil Cooler & Engine Radiator Air Charge Cooler When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator, the efficiency is impaired.
Maintenance Operating & Maintenance Manual Air Filter Element The air filter should be inspected regularly (refer to the SERVICE MAINTENANCE INTERVAL CHART) and the element replaced when the restriction indicator lamp illuminates. The dust collector box(es)should be cleaned daily (more frequently in dusty operating conditions) and not allowed to become more than half full.
Operating & Maintenance Manual Maintenance Ventilation Always check that the air inlets and outlets are clear of debris etc. CAUTION NEVER clean by blowing air inwards. Cooling Fan Drive Periodically check that the fan mounting bolt in the fan hub has not loosened. If, for any reason, it becomes necessary to remove the fan or re-tighten the fan mounting bolt, apply a good grade of commercially available thread locking compound to the bolt threads and tighten to the torque value shown in the TORQUE SETTING TABLE later in this section.
Maintenance Operating & Maintenance Manual Electrical System WARNING Always disconnect battery cables before performing maintenance or service. Inspect the safety shutdown system switches and the instrument panel relay contacts for evidence of arcing and pitting. Clean where necessary. Check the mechanical action of the components. Check the security of electrical terminals on the switches and relays i.e.
Operating & Maintenance Manual Maintenance Running Gear/Wheels Check the wheel nut torque 20 miles (30 kilometres) after refitting the wheels. Refer to the TORQUE SETTING TABLE later in this section. The bolts securing the running gear to the chassis should be checked periodically for tightness (refer to the SERVICE/MAINTENANCE CHART for frequency) and re-tightened where necessary.
CAUTION Some oil mixtures are incompatible and result in the formation of varnishes, shellacs or lacquers which may be insoluble. NOTE: Always specify INGERSOLL-RAND Pro-Tec oil for use at all ambient temperatures above -23°C. For extended warranty use only IR fluids. Refer to portable compressor fluids chart.
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Operating & Maintenance Manual Maintenance SPEED and PRESSURE REGULATION ADJUSTMENT XHP,SHP Regulation pressure Air cylinder Pressure transducer transducer Butterfly valve Start/Run solenoid Minimum pressure valve Mini compressor Pressure regulator Separator tank Unloader Solenoid Panel pressure guage Auto blowdown valve Relief valve Manual blowdown valve HR2 Airend Orifice...
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Maintenance Operating & Maintenance Manual bracket ‘C’ to the main bracket ‘J’. (continued on next page). Allow the cylinder to return to its extended position and reconnect the ballast spring ‘A’. CAUTION Ensure all components are aligned and move freely. Start engine: Note receiver pressure.
Operating & Maintenance Manual Maintenance Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change. NOTE: Fluids listed as “preferred”...
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Maintenance Operating & Maintenance Manual Recommended Ingersoll-Rand Fluids - Use of these fluids with original IR filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your IR representative. Ingersoll-Rand 1 gal. 5 gal. 5 gal.
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**Always use Ingersoll-Rand Replacement parts!**...
Operating & Maintenance Manual Machine Systems General Information and Operational Theory General The mid-range machine has an electronic monitor and control system to provide discharge air pressure control and engine and package monitor functions. The system uses the WEDGE controller to perform these functions. The electrical system connects all the necessary switches, sensors and transducers to the WEDGE controller in order for it to perform the monitor and control functions.
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Machine Systems Operating & Maintenance Manual A PWM (Pulse Width Modulated) throttle is used to communicate with the CAT engine. The WEDGE controller receives diagnostic and run time data from the engine over the J1939 CAN network. A PWM throttle interface is used with the engine. Figure 2-2 shows the connections between the WEDGE controller and the engine controller.
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Operating & Maintenance Manual Machine Systems Electronic Engine The mid-range machine contains an emissions certified diesel engine. In order to meet the emissions requirements, the engine has an electronic control system. The control system handles all monitor, alarm and control functions for the engine. The WEDGE controller communicates with the engine controller over the J1939 CAN network.
Operating & Maintenance Manual Fault Finding Fault Finding FAULT CAUSE REMEDY No reaction from Emergency stop Reset emergency stop button. instrument panel actuated. when key turned to Batteries not connected. Connect batteries. (I) position. Fuse at starter motor Replace fuse. ‘blown’.
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Fault Finding Operating & Maintenance Manual FAULT CAUSE REMEDY Engine starts but Electrical fault. Test the electrical circuits. will not run or Low engine oil pressure. Check the oil level and oil filter(s). engine shuts down prematurely. Safety shut-down Check the safety shut-down switches. system in operation.
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Dirty or blocked oil Clean the oil cooler fins. cooler. Incorrect grade of oil. Use Ingersoll-Rand recommended oil. Defective by-pass valve. Check the operation of the element and replace if necessary. Recirculation of cooling Move the machine to avoid recirculation.
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Fault Finding Operating & Maintenance Manual FAULT CAUSE REMEDY Safety valve Operating pressure too Check the setting and operation of the operates. high. regulator valve piping. Incorrect setting of the Adjust the regulator. regulator. Faulty regulator. Replace the regulator. Inlet valve set Refer to SPEED AND PRESSURE incorrectly.
Options Operating & Maintenance Manual IQ System - General The IQ System is a complete, self-contained system which provides cooler, cleaner air than from a standard portable compressor. The system utilizes an integral aftercooler, high-efficiency filtration, and a patented condensate disposal system to provide the cool, clean air.
TCU to further close the louvers if the compressed air temperature falls to approximately 36°F (2°C) or lower. There are no user selectable or serviceable components in the TCU. Contact Ingersoll-Rand Service if any abnormal operation of the freeze protection control system occurs.
Options Operating & Maintenance Manual • Remove and replace the filter element, being careful not to damage outer wrap. Verify the part number of new element vs. old element, as the two IQ filters are of different media. Safety CAUTION The compressor regulation system is adjusted to maintain regulated pressure at the separator tank.
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