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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.
501 Sanford Ave
Mocksville, N.C. 27028
Revised (10-12)
Book 22478325 (2/05)
MANUAL
COMPRESSOR MODELS
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 Company and Doosan Company or the products of
either.
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Summary of Contents for Ingersoll-Rand P105WJD
- 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 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging...
- 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS TITLE PAGE FOREWORD ............1-1 Foreword. - Page 4 TABLE OF CONTENTS TITLE PAGE MAINTENANCE ............6-47 Maintenance .
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Page 5: Foreword
Foreword... - 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 Foreword...
- Page 8 Foreword...
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Page 9: Drawbar Notice
Drawbar Notice... -
Page 10: Drawbar Notice - This Machine May Have Been Shipped From The Factory With The Drawbar Positioned Upright. To Convert From Shipping Position To Towing Position
Drawbar Notice Drawbar Notice - 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 and 13mm socket to fit ratchet Torque wrench set to 68 foot pounds (9.4 kg-meters) 16mm socket to fit torque wrench 5 inch extension for torque wrench Hardware included: (4) 12mm bolts with pre-applied thread lock, (2) 8mm Taptite... -
Page 11: Safety
Section 1 - Safety... -
Page 12: Safety Precautions
Operating & Maintenance Manual Safety Safety Precautions General one common downstream plant, effective check valves and isolation valves must be Ensure that the operator reads and fitted and controlled by work procedures, so understands the decals and consults the that one machine cannot accidentally be manuals before maintenance or operation. - Page 13 Safety Operating & Maintenance Manual ends of one booster cable to the positive (+) Ether is an extremely volatile, highly terminal of each battery. Connect one end of flammable gas. USE SPARINGLY! DO NOT other cable to the negative (-) terminal of the use ETHER if unit has GLOW Plug starting booster battery and other end to a ground aid.
- Page 14 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 15 Safety Operating & Maintenance Manual...
- Page 16 Operating & Maintenance Manual Safety...
- Page 17 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 18 Operating & Maintenance Manual Safety...
- Page 19 Safety Operating & Maintenance Manual...
- Page 20 Operating & Maintenance Manual Safety Table 1: FREE SAFETY DECALS 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.
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Page 21: Warranty
Section 2 - WARRANTY... - Page 22 Oil-Free airends are fee-based and may 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.
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Page 23: General Warranty Information
Deutz (Model 2011) 2000 Major components 3 yrs/3000 hours 2000 Major components 3 yrs/3000 hours Deutz (Model 2012) Ingersoll-Rand 4000 5 years/10,000 hours requires IR Fluids and Filters. Kubota (North America Only) 2000 Major components 36 months/3000 hrs - PARTS ONLY THROUGH DEALERS ONLY. - Page 24 Operating & Maintenance Manual WARRANTY PARTS Ingersoll-Rand 6 months Hours - No Limit Coverage - Parts Only AIREND EXCHANGE - Extended Coverage 12 months 2000 hours 5 yrs/10,000 hrs requires IR oil and filters. Airend Note: Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with each new product.
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Page 25: 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 26 Operating & Maintenance Manual WARRANTY...
- Page 27 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 28 Operating & Maintenance Manual WARRANTY...
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Page 29: Noise Emission
Section 3 - Noise Emission... -
Page 30: 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 31: 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 32 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 33 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 34 Operating & Maintenance Manual Noise Emission...
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Page 35: General Data
Section 4 - General Data... -
Page 36: Models
Operating & Maintenance Manual General Data General Data Models: P105 P130 P160 P175 Air Delivery (cfm (litres/sec) 105 (50) 130 (61) 160 (76) 175 (83) Engine Speed - RPM (Full Load) 2000 2000 2250 2400 Engine Speed - RPM (No Load) 2000 2000 1700... -
Page 37: Expendable Service Parts
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. - Page 38 Operating & Maintenance Manual General Data...
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Page 39: Section 5 - Operation
SECTION 5 - OPERATION... -
Page 40: 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 Failure to follow these instructions degree sidewise limit on out-of-level CAN cause severe injury or death. - Page 41 SECTION 5 - OPERATION Operating & Maintenance Manual DISCONNECT • Engage tow vehicle parking brake. • Chock tires of compressor. • Set the vehicle parking brake. Chock wheels of unit. • Standing to the side, remove pin from tube of jack. •...
- Page 42 Operating & Maintenance Manual SECTION 5 - OPERATION 11. Low Fuel Level - Must add fuel to operate. CONTROL PANEL - Diagnostics/Auto Shutdown (Standard and Optional) 12. Fuel Level Gauge - Indicates amount of fuel in tank. 13. Engine Speed Gauge - Indicates engine speed.
- Page 43 SECTION 5 - OPERATION Operating & Maintenance Manual WARNING Before Starting • Open service valve(s) to ensure pressure This machine produces loud noise is relieved in receiver-separator system. with doors open. Extended exposure Close valve(s) in order to build up full air to loud noise can cause hearing loss.
- Page 44 Operating & Maintenance Manual SECTION 5 - OPERATION to the negative (-) terminal of the booster battery and NOTICE the other end to the engine block. NEGATIVE (-) TERMINAL OF THE WEAK BATTERY. Do not operate the starter motor for more than 10 Units With Optional Diagnostics seconds without allowing Lamps...
- Page 45 SECTION 5 - OPERATION Operating & Maintenance Manual the engine. Close air service valves. • Allow the unit to run at idle for 3 to 5 Compressor Air/Oil Temperature: minutes reduce engine temperatures. • At the airend outlet. • Turn Power Switch to “OFF” position. •...
- Page 46 Operating & Maintenance Manual SECTION 5 - OPERATION 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 47 SECTION 5 - OPERATION Operating & Maintenance Manual...
- Page 48 Operating & Maintenance Manual SECTION 5 - OPERATION...
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Page 49: Maintenance
Section 6 - MAINTENANCE... -
Page 50: 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 51: Gauges
MAINTENANCE Operating & Maintenance Manual cover. Remove Element. Battery 2. Inspect air cleaner housing for any Keep the battery posts-to-cable connections condition that might cause a leak and clean, tight and lightly coated with a grease. correct as necessary. Also the electrolyte level in each cell should 3. -
Page 52: Radiator
Operating & Maintenance Manual MAINTENANCE Radiator design. Features are as follows: Pulling on the tubing will cause the inner sleeve to withdraw and compress, thus NOTICE tightening the connection. The tubing can be withdrawn only while holding the sleeve against the fitting. The tubing can be The use of water alone in this engine removed and replaced numerous times can result in major engine failure. -
Page 53: Compressor Oil Cooler
MAINTENANCE Operating & Maintenance Manual 3. Inspect the oil filter head to be sure the In the event foreign deposits, such as sludge gasket was removed with the oil filter and lacquer, accumulate in the oil cooler to element. Clean the gasket seal area on the extent that its cooling efficiency is the oil filter head. -
Page 54: Scavenge Line
Operating & Maintenance Manual MAINTENANCE Additional separation takes place in the oil 4. Run unit at rated operating pressure for separator element which is located in the top 30 to 40 minutes to permit element to of the tank. clear itself. Any oil accumulation in this separator element is continuously drained off by means Exterior Finish Care... - Page 55 MAINTENANCE Operating & Maintenance Manual 8. Apply 2 medium - wet coats of Duponts NOTE: You must be careful not to put too 222S Adhesion Promoter over the entire much primer on at one time, this will effect area to be painted, with a 5 minute flash the amount of texture that you are trying to in between coats.
- Page 56 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...
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Page 57: Lubrication
Section 7 - LUBRICATION... -
Page 58: 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 59 LUBRICATION Operating & Maintenance Manual...
- Page 60 Operating & Maintenance Manual LUBRICATION...
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Page 61: Trouble Shooting
Section 1 - Trouble Shooting... -
Page 62: Introduction
Operating & Maintenance Manual Trouble Shooting Trouble Shooting B. Do The Simplest Things First Most troubles are simple and easily corrected. For example, most complaints are Introduction “low capacity” which may be caused by too low an engine speed or “compressor over- Trouble shooting for a portable air heats”... -
Page 63: 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 Level Too Low Add correct oil Compressor Oil Temp. - Page 64 Operating & Maintenance Manual Trouble Shooting Defective Shutdown Solenoid Replace solenoid. Defective Engine Temp. Switch Replace Switch Defective Separator Tank Temp Switch Replace Switch Defective Low Fuel Shutdown Switch Replace Switch Malfunctioning Relay Replace relay. Engine Malfunctioning See Trouble Shooting in Engine Section. Airend Malfunctioning See Table 10.
- Page 65 Trouble Shooting Operating & Maintenance Manual Table 7: Alternator Lamp Stays On: Complaint Corrective Action Low Battery Voltage Check electrolyte level. Add if necessary. Loose or Broken Belts Tighten or replace belt set. Check connectors. Clean & tighten. Recharge battery. Malfunctioning Alternator Repair or replace alternator.
- Page 66 Operating & Maintenance Manual Trouble Shooting Defective Minimum Pressure Valve Repair or replace valve. Malfunctioning Fan Check fan belt tension. Tighten or replace belt set. Blocked or Restricted Oil Lines Clean by flushing or replace. Airend Malfunctioning See Tables 11, 12, 13, 15, 16 or 18. Table 11: Engine RPM Down Complaint Corrective Action...
- Page 67 Trouble Shooting Operating & Maintenance Manual Table 14: Short Air Cleaner Life Complaint Corrective Action Inadequate Element Cleaning Install new element. Dirty Operating Conditions Move unit to cleaner environment. Incorrect Stopping Procedure Read procedure in this manual. Wrong Air Filter Element Install proper element.
- Page 68 Operating & Maintenance Manual Trouble Shooting Table 19: Safety Valve Relieves Complaint Corrective Action Operating Pressure Too High Reduce pressure to spec limit. Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual. Malfunctioning Pressure Regulator Replace regulator. Leak In Regulator Piping Repair leak(s).
- Page 69 Hoses ....... . . 6-50 Ingersoll-Rand Preferred Fluids ... . . 7-56 Lubrication .
- Page 70 WORD INDEX Manual-Name 9 - 2...
- Page 71 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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Questions and answers
what kind of oil is used in a IR160 compressor with a John Deere motor?
The Ingersoll-Rand IR160 compressor with a John Deere motor uses IR Pro•Tec™ as the preferred compressor oil. An alternative is ISO Viscosity Grade 46 oil with rust and oxidation inhibitors, designed for air compressor service.
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