Ingersoll-Rand P185WJD Operation And Maintenance Manual
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Ingersoll-Rand P185WJD Operation And Maintenance Manual

Ingersoll-Rand P185WJD 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.
501 Sanford Ave
Mocksville, N.C. 27028
Book 22610380 (4/05)
Revised (10-12)
MANUAL
COMPRESSOR MODELS
P185WJD
XP185WJD
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
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 P185WJD

  • 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Manual-Name TITLE PAGE FOREWORD ............1-1 Foreword.
  • Page 4 TABLE OF CONTENTS Manual-Name TITLE PAGE MAINTENANCE ............6-47 Maintenance .

  • 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: Drawbar Notice

    Drawbar Notice...

  • Page 9: 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 10: Safety

    Section 1 - Safety...

  • Page 11: 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 12 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 13 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 14 Safety Operating & Maintenance Manual...
  • Page 15 Operating & Maintenance Manual Safety...
  • Page 16 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 17 Operating & Maintenance Manual Safety...
  • Page 18 Safety Operating & Maintenance Manual...
  • Page 19 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.

  • Page 20: Warranty

    Section 2 - WARRANTY...
  • Page 21 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.

  • Page 22: 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 23 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.

  • Page 24: 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 25 Operating & Maintenance Manual WARRANTY...
  • Page 26 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 27 Operating & Maintenance Manual WARRANTY...

  • Page 28: Noise Emission

    Section 3 - Noise Emission...

  • Page 29: 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 30: 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 31 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 32 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 33 Operating & Maintenance Manual Noise Emission...

  • Page 34: General Data

    Section 4 - General Data...

  • Page 35: Models

    Operating & Maintenance Manual General Data General Data Models: Unit Model P185 XP185 Air Delivery (cfm (litres/sec) 185 (87) 185 (87) Engine Speed - RPM (Full Load) 2500 2500 Engine Speed - RPM (No Load) 1700 1700 COMPRESSOR Rated Operating Pressure - psi (kPa).......100 psi (689) Safety Valve Setting - psi (kPa) ........150 psi (1034) Net Weight (less fuel) pounds........2265 ENGINE (DIESEL)

  • Page 36: Tire Size

    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 37 Operating & Maintenance Manual General Data...

  • Page 38: Section 5 - Operation

    SECTION 5 - OPERATION...

  • Page 39: 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 40 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 41 Operating & Maintenance Manual SECTION 5 - OPERATION 12. Power Switch - Rotate “ON” to activate system prior to starting. CONTROL PANEL - Diagnostics/Auto Rotate “OFF” to stop engine. Shutdown (Standard and Optional) (Standard) 13. Engine Speed Gauge - Indicates engine speed.
  • Page 42 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 43 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 44 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 45 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 46 SECTION 5 - OPERATION Operating & Maintenance Manual...
  • Page 47 Operating & Maintenance Manual SECTION 5 - OPERATION...

  • Page 48: Maintenance

    Section 6 - MAINTENANCE...

  • Page 49: 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 50 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 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: Lubrication

    Section 7 - LUBRICATION...

  • Page 57: 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 58 LUBRICATION Operating & Maintenance Manual...
  • Page 59 Operating & Maintenance Manual LUBRICATION...

  • Page 60: Trouble Shooting

    Section 1 - Trouble Shooting...

  • Page 61: 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 62: 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 63 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 64 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 65 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 66 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 67 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 68 Hoses ....... . . 6-50 Ingersoll-Rand Preferred Fluids ... . . 7-56 Lubrication .
  • Page 69 WORD INDEX Manual-Name 9 - 2...
  • Page 70 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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