Ingersoll-Rand P185AWIR, Operation And Maintenance Manual

Page 1: ...ville N C 27028 Book 22442560 05 04 Revised 10 12 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks service marks logos o...

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 reproduc tive harm...

Page 3: ...s only to machines distributed within the United States 3 30 Compressor Noise Emission Control Information 3 30 Noise Emission Control Maintenance Log 3 31 Noise Emission Warranty 3 31 Introduction 3...

Page 4: ...neral 6 48 Scheduled Maintenance 6 48 Compressor Oil Level 6 48 Air Cleaner 6 48 Gauges 6 49 Fuel Tank 6 49 Battery 6 49 Fasteners 6 49 Radiator 6 49 Hoses 6 49 Compressor Oil Filters 6 50 Compressor...

Page 5: ...ondition 9 76 Battery Cable Connection 9 76 Battery Electrolyte Level 9 76 Fuel Level 9 77 CHECKS and OPERATION AFTER START UP 9 77 Leakage in the System 9 77 Checking Coolant Level 9 78 OPERATION AND...

Page 6: ...1 4...

Page 7: ...3 FOREWORD...

Page 8: ...4...

Page 9: ...d 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...

Page 10: ...6...

Page 11: ...7 DRAWBAR NOTICE...

Page 12: ...Operating Maintenance Manual 8...

Page 13: ...ardware box from compressor toolbox 2 Open box and remove the bag containing hardware safety chains and assembly instructions 3 Using the jack raise the front of the unit so that the legs are approxim...

Page 14: ...Operating Maintenance Manual 10...

Page 15: ...11 Section 1 Safety...

Page 16: ...safe working pressure ratings of at least the machine safety valve rating If more than one compressor is connected to one common downstream plant effective check valves and isolation valves must be fi...

Page 17: ...injury or death Always attach a safety flow restrictor to each hose at the source of supply or branch line in accordance with OSHA Regulation 29CFR Section 1926 302 b Rotating fan blade can cause seri...

Page 18: ...igns 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 instru...

Page 19: ...Safety Operating Maintenance Manual 15...

Page 20: ...Operating Maintenance Manual Safety 16...

Page 21: ...DANGER Red Background indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING Orange Background indicates a potentially hazardous situa...

Page 22: ...Operating Maintenance Manual Safety 18...

Page 23: ...Safety Operating Maintenance Manual 19...

Page 24: ...NGER WARNING or CAUTION Decal part numbers are on the bottom of each decal and are also listed in the compressor s parts manual Submit orders for Safety Decals to the Mocksville Parts Service Departme...

Page 25: ...21 Section 2 WARRANTY...

Page 26: ...quired Ingersoll Rand engines will be free of defects in material and workmanship for a period of the earlier of twenty four months from shipment to or the accumulation of 4 000 hours of service by th...

Page 27: ...ement Ingersoll Rand Company warrants initial owner and each subsequent owner that the engine is designed built and equipped so as to conform with applicable regulations for its warranty period Fuel I...

Page 28: ...e ENGINES Months Hours Extended Coverage Caterpillar 12 No Limit Available at dealer Cummins 24 2000 Major components 3 yrs 10 000 hours available at dealer John Deere IN COMPRESSORS IN GENERATORS AS...

Page 29: ...changes i e change of ownership 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...

Page 30: ...Operating Maintenance Manual WARRANTY 26...

Page 31: ...tc Government municipal state county etc Quarry Shallow Oil Gas Rental rental center rental fleet etc Building Contractor Waterwell Utility Company Industrial plant use Other specify Exploration Utili...

Page 32: ...Operating Maintenance Manual WARRANTY 28...

Page 33: ...29 Section 3 NOISE EMISSION...

Page 34: ...ereof b the air intake system or parts thereof c enclosure or parts thereof 4 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 5 Operation of the compressor...

Page 35: ...ent or system of the air compressor Defects in the design assembly or in any part component or system of the compressor which at the time of sale to the first retail purchaser caused noise emissions t...

Page 36: ...prevent subsequent damage and noise emission increase E Enclosure Panels Enclosure panels should also be inspected at 100 hour operational intervals All panels that are warped punctured torn or other...

Page 37: ...after each 250 hours of operation Those mounts with cracks or splits in the molded rubber or with bent or broken bolts due to operation or storage in severe environments all should be replaced with eq...

Page 38: ...Maintenance Manual NOISE EMISSION 34 Maintenance Record For Noise Emission Control And Extended Warranty Item No Description Of Work Hourmeter Reading Maint inspect Date Location City state Work Done...

Page 39: ...35 Section 4 GENERAL DATA...

Page 40: ...Length 11 5 3 5 meters Overall Height 5 2 feet 1 46 meters Overall Width 5 7 feet 1 74 meters Track Width 4 9 feet 1 49 meters Weight with fuel 2325 lbs 1054 kgf Weight less fuel 2130 lbs 966 kgf UNI...

Page 41: ...Element Compressor Part No 35393685 Air Cleaner Element Engine Part No 35393685 Engine Oil Filter Element Part No 22226351 Engine Fuel Filter Element Part No 22226369 Fuel Water Separator Element Par...

Page 42: ...Operating Maintenance Manual GENERAL DATA 38...

Page 43: ...39 SECTION 5 OPERATION...

Page 44: ...lights running stop and turn signals WARNING Always raise or remove jack for maximum ground clearance before towing SETTING UP ALL UNITS Position as level as possible The design of these units permit...

Page 45: ...m tube of jack Disconnect safety chains Crank jack to raise eye or coupler from hitch Tow vehicle can be moved UTILITY PACKAGE SET UP no running gear This unit must be located on vehicle bed to allow...

Page 46: ...F 120 C 7 Air Filters Restricted Needs servicing 8 Spare 9 Spare 10 Alternator Not Charging Needs attention 11 Low Fuel Level Must add fuel to operate 12 Fuel Level Gauge Indicates amount of fuel in...

Page 47: ...rom the engine Check the compressor lubricating fluid level between bottom and midway of the sight glass on the separator tank WARNING This machine produces loud noise with doors open Extended exposur...

Page 48: ...TICE Exercise extreme caution when using a booster battery to start To jump start Connect the ends of one booster cable to the positive terminals of each battery Then connect one end of the other cabl...

Page 49: ...osed 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 NOTICE Do NOT wire aroun...

Page 50: ...t on air actuating cylinder A and then turn cylinder rod D until throttle arm G is forced against the governor stop After Starting Unit 4 If equipped push the SERVICE AIR button on the control panel m...

Page 51: ...47 Section 6 MAINTENANCE...

Page 52: ...ve maintenance is the easiest and the least expensive type of maintenance Maintaining your unit and keeping it clean at all times will facilitate servicing Scheduled Maintenance The maintenance schedu...

Page 53: ...e fuel tanks is vitally important and every precaution should be taken to ensure that only clean fuel is poured or pumped into the tank When filling the fuel tank on this unit by methods other than a...

Page 54: ...0 25 inch O D tubing This will ensure that tubing is fully engaged in the sealing mechanism Compressor Oil Filters The oil filter must be replaced every 500 hours of operation or six 6 months whicheve...

Page 55: ...es first Refer to warranty section about extended warranty Receiver Separator Systems WARNING High pressure air can cause severe injury or death from hot oil and flying parts Always relieve pressure b...

Page 56: ...cured at the factory with a high quality thermoset polyester powder coating The following care will ensure the longest possible life from this finish 1 If necessary to remove dust pollen etc from hou...

Page 57: ...o splatter causing the textured look NOTE You must be careful not to put too much primer on at one time this will effect the amount of texture that you are trying to achieve Allow the texture coat to...

Page 58: ...trolyte C Tire Pressure and Surface C Wheel Lug Nuts C Hoses oil air intake etc C Automatic Shutdown System Test C Air Cleaner System Visual C Compressor Oil Cooler Exterior C CLEAN Engine Radiator Ex...

Page 59: ...55 Section 7 LUBRICATION...

Page 60: ...ction for details or contact your IR representative Design Operating Pressure Ambient Temperature Specification 100 psi to 300 psi 100F to 1250F 230 C to 520 C Preferred IR Pro Tec Alternate ISO Visco...

Page 61: ...57 Section 8 Trouble Shooting...

Page 62: ...e 4 If the compressor will still operate is it safe to continue operating it to make further checks B Do The Simplest Things First Most troubles are simple and easily corrected For example most compla...

Page 63: ...nctioning Relay Replace relay Blown Fuse Replace fuse Check for Short 10 Volts at Shutdown Solenoid Check battery and alternator Make repairs Engine Malfunctioning See Trouble Shooting in Engine Secti...

Page 64: ...Operating Conditions Move unit to cleaner environment Out of Level 15 degrees Relocate or reposition unit Ambient Temp 125 F 52 C Above spec limit Loose Wire Connection Repair or replace Broken Engine...

Page 65: ...lace switch Defective Sep Temp Switch Replace switch Defective Engine Temp Switch Replace switch Defective Engine Oil Pressure Switch Pull wire off Replace switch Defective Shutdown Solenoid Carefully...

Page 66: ...adjust Defective Separator Element Install new element Engine Malfunctioning See Trouble Shooting in Engine Section Airend Malfunctioning Consult Dealer Complaint Corrective Action Dirty Fuel Filters...

Page 67: ...stall new Scavenge Tube Blocked Remove scavenge tube Clean and Replace Sep Tank Blow Down Too Quickly Allow unit to blow down automatically Defective Minimum Pressure Valve Remove valve Repair valve a...

Page 68: ...Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual Malfunctioning Pressure Regulator Replace regulator Leak In Regulator Piping Repair leak s Malfunctioning Inlet Unloader Inspe...

Page 69: ...65 Section 9 4IRI8N 4IRI8T ENGINE...

Page 70: ...you operate and maintain it correctly This section is designed to help you do this Please read this section carefully and follow the operating and maintenance recommendations This will ensure many yea...

Page 71: ...l priming pump 4 Crank shaft V pulley 17 Fuel priming pump 5 V belt 18 Engine name plate 6 Filler port engine oil 19 Air intake port 7 Drain plug engine oil 20 Flywheel 8 Fuel injection pump 21 Flywhe...

Page 72: ...4 2 Exhaust emission control system Fuel injection nozzles fuel injector pump Governor Mechanical type Injection nozzles Hole type Specified fuel Diesel fuel ISO 8217 DMA BS2869 A1 A2 Starter V kW 12...

Page 73: ...service or parts ordering INGERSOLL RAND ENGINE AFTER SERVICE Contact your Ingersoll Rand dealer for periodical inspection and maintenance Ingersoll Rand parts are identical with those used in the en...

Page 74: ...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 The following is t...

Page 75: ...requirements Table 3 Applicable Standard Recommendation Fuel Requirements The fuel injection pump injector or other parts of the fuel system and engine can be damaged if you use an fuel or fuel additi...

Page 76: ...t been winterized Check with the fuel supplier to be sure you get the properly blended fuel NOTICE Do not use home heating oil or gasoline in your diesel engine Either may cause engine damage Handling...

Page 77: ...uel lines fuel filters or injector They can also cause fuel system corrosion If fungus or bacteria has caused fuel system problems you should have your authorized dealer correct these problems Then us...

Page 78: ...y important Without LLC cooling performance will decrease due to scale and rust in the cooling water line Without LLC cooling water will freeze and expand to break the cooling line Be sure to use the...

Page 79: ...s A certain period of time is required before the engine oil completely flows down from the oil filler to the crankcase Wait at least ten minutes before checking the oil level Note Take care to avoid...

Page 80: ...loosened cable connection will result in hard engine starting or insufficient battery charge The battery cables must be tightened securely Never reverse and terminals when reconnecting cables after d...

Page 81: ...ten to the engine and if any abnormal noise is heard check to determine the cause Check the fuel combustion condition by observing the exhaust smoke color The exhaust smoke color after engine warm up...

Page 82: ...e engine shows any sign of abnormalities Engine Oil Pressure The engine oil pressure is monitored by a switch that will stop the engine if the pressure falls below a pre set value Coolant Temperature...

Page 83: ...engine parts Under some conditions the ethylene glycol in engine coolant is combustible If the engine coolant level in the reserve tank is at the correct level but there is still an indication of an...

Page 84: ...ustomer procured to drain the engine oil 3 Securely tighten the drain plug after draining the engine oil 4 Turn the engine oil filter counter clockwise using a filter wrench customer procured to remov...

Page 85: ...n evacuated tighten the drain valve E and follow the fuel system air bleeding procedure below Fuel System Air Bleeding The entry of air into the fuel system will cause difficult engine starting or eng...

Page 86: ...her to 1 2 at a turn using a filter wrench Tightening torque 11 8 15 6N m 1 2 1 6kgf m Applicable Fuel Filter Part No 22226369 4 Bleed the fuel system Refer to Inspection at 50 hours IMPORTANT Use gen...

Page 87: ...ng of valves Neglecting the adjustment will cause the engine to run noisily and result in poor engine performance and other damage Inspection Every 2000 Hours of Operation Flushing the cooling system...

Page 88: ...I8T ENGINE 84 Table 4 Check Fuel Valve Nozzle and clean Adjust cleaning and repair of Fuel Injection Pump and Fuel Valve Nozzle 1500 hours of use and at 1500 hour intervals thereafter 3000 hours of us...

Page 89: ...e stop solenoid not fully returned Engine fires but stalls immediately Air in the fuel system Incorrect low idle speed adjustment Cause Corrective Action Unstable Low Idling Crack in injection pipe In...

Page 90: ...oolant Temperature Overheat Clogged Filter and Strainer Clean and or replace Worn Bearings and Oil Pump Replace Faulty Relief Valve Replace Cause Corrective Action Incorrect Injection Timing Too far a...

Page 91: ...ng Cause Corrective Action Excessive Injection Volume Injection pump defective Cause Corrective Action Excessive Black Smoke Clogged air cleaner Damaged injector nozzle Wrong injector nozzle Injection...

Page 92: ...tance Precaution 1 13 Hoses 6 49 I Ingersoll Rand Preferred Fluids 7 56 Isolation Mounts 3 33 L Lubrication 7 56 M Maintenance 6 48 MAINTENANCE SCHEDULE 6 54 N Noise Emission 3 30 P Portable Compresso...