Ingersoll-Rand P250WJD Operation And Maintenance Manual

OPERATION and MAINTENANCE

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 his torical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand C

ompany and Doosan

Company or the products of

e

ith

er.

Revised (10-12)

MANUAL

COMPRESSOR MODEL

P250WJD

Code: C

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 22478341 (01-15-07) Rev A

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.

TABLE OF CONTENTS

TITLE PAGE

FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3

DRAWBAR NOTICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Drawbar Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

This section pertains only to machines distribute d with in the United States. . . . . . . . . . . . . . . . . . . 3-20

Noise Emission Control Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

General Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Engine (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Fluid Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Units Measurements Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Expendable Service Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Before Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

1 - 1

TABLE OF CONTENTS

TITLE PAGE

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

Compressor Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Receiver-Separator Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

Exterior Finish Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

Trouble Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Action Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Trouble Shooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

1 - 2

FOREWORD

22478341 (1-15-07) Rev A 3

Manual-Name FOREWORD

Nothing contained in this document is intended to extend any promise, warranty or
representation, expressed or implied, regarding the Ingersoll Rand products described herein .
Any such warranties or other terms and conditions of sale of products shall be in accordance
with the standard terms and conditions of sale for such products, which are available upon
request.

This manual contains instructions and technical data to cover all routine operation and
scheduled maintenance tasks by operation and maintenance staff. Major overhauls are
outside the scope of this manual and should be referred to an authorized Ingersoll Rand
service department.

Machine models represented in this manual may be used in various locations worldwide.
Machines sold and shipped into European common market countries requires that the
machine display the EC Mark and conform to various directives. In such cases, the design
specification of this machine has been certified as complying with EC directives. Any
modification to any part is absolutely prohibited and would result in the CE certification and
marking being rendered invalid. A declaration of that conformity follows:

All components, accessories, pipes and connectors added to the compressed air system
should be:

• of good quality, procured from a reputable manufacturer and, wherever possible, be
of a type approved by Ingersoll Rand.

• clearly rated for a pressure at least equal to the machine maximum allowable working
pressure.

• compatible with the compressor lubricant/coolant.

• accompanied with instructions for safe installation, operation and maintenance.

Details of approved equipment are available from Ingersoll Rand Service departments. The
use of repair parts other than those included within the Ingersoll Ra nd 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.

Ingersoll Rand reserves the right to make changes and improvements to products without
notice and without incurring any obligation to make such changes or add such improvements
to products sold previously.

The intended uses of this machine are outlined below and examples of unapproved usage are
also given. However, Ingersoll Rand cannot anticipate every application or work situation that
may arise. If in doubt, consult supervision.

This machine has been designed and supplied for above ground operation to be used for
compression of normal ambient air containing no additional gases, vapors or particles within
the ambient temperature range specified in the general data section of this 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.

4 22478341 (1-15-07) Rev A

FOREWORD Manual-Name

C. When an actual or forese eable risk of hazardou s levels of fla mmable g ases or

vapors exists.
D. With other than Ingersoll Rand approved components.
E. With guards, or controls or switches missing or disabled.
F. For storage or transportation of materials inside or on the enclosure.

This company accepts no responsibility for errors in translation of this manual from the original
English version.

You as the customer are expected to provide certain service and maintenance items. Your
Ingersoll Rand dealer will provide all other more detailed service and maintenance items on a
special preventive maintenance schedule for each machine. It is very important that the
minimum service and maintenance requirements explained in this manual be performed at the
required intervals. Exceeding these intervals may reduce the reliability of the machine.

The purpose of this manual is to train the operator with functions, operation, and basic service
and maintenance requirements of the compressor. During the preparation of this manual,
every effort was made to ensure the adequacy and accuracy of the contents.

Your Ingersoll Rand dealer will assist with setup and initial startup of t he comp ressor. He will
also provide brief operating and service instructions and will insure that a copy of this manual
is included with the machine. Before starting the compressor, this manual and instructions
should be carefully read to obtain a thorough knowledge of the duties to be performed. Please
take pride in the compressor, keep it clean, and in good mechanical condition.

To enable proper maintenance records, Ingersoll Rand provides a Noise Emission Control
Maintenance Log Book (PCD Form 685) with each compressor shipped from the factory. This
Log Book contains a recommended schedule and space so that the serviceman can note what
service and maintenance was done, by whom, where, and when.

22478341 (1-15-07) Rev A 5

**Always use Ingersoll Rand Replacement parts!**

6 22478341 (1-15-07) Rev A

DRAWBAR NOTICE

22478341 (1-15-07) Rev A 7

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

bolts, (2) Washers, (2) Safety Chains

1. Remove hardware 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 approximately 1 inch
above the ground.

4. Remove the temporary retaining bolts from both sides of the frame at the drawbar
connection (See Fig. 1).

5. Carefully lower drawbar to the Level Position.

6. Install the four bolts (with pre-applied thread lock) to the four points inside the
enclosure and torque to 68 ft. lbs. (9.4kg-m) (See Fig.2).

7. Install safety chains by sliding the second link of one chain into the slot in drawbar
plate. Fasten chain to plate using taptite and washer. Repeat for other chain.

8 22478341 (1-15-07) Rev A

SAFETY

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Operating & Maintenance Manual SAFETY

Safety Precautions

General

Ensure that the operator reads and
understands the decals and consults the
manuals before maintenance or operation.

Ensure that the Operation and Maintenance
manual, and manual holder if equipped, are
not removed permanently from the machine.

Ensure that maintenance personnel are
adequately trained, competent and have
read the manuals.

Make sure that all protective covers are in
place and that the canopy/doors are closed
during operation.

The specification of this machine is such that
the machine is not suitable for use in
flammable gas risk areas. If such an
application is required then all local
regulations, codes of practice and site rules
must be observed.

To ensure that machine can operate in a safe
and reliable manner, additional equipment
such as gas detection, exhaust spark
arrestors, and intake (shut-off) valves may be
required, dependent on local regulations or
the degree of risk involved.

Air discharged from this machine may
contain carbon monoxide or other
contaminants which will cause serious injury
or death. Do not breathe this 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.

Ensure that the machine is operating at the
rated pressure and that the rated pressure is
known to all relevant personnel.

All air pressure equipment installed in or
connected to the machine must have 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
fitted and controlled by work procedures, so
that one machine cannot accidentally be
pressurized or over pressurized by another.

Compressed air must not be used for a feed
to any form of breathing apparatus or mask.

The discharged air contains a very small
percentage of compressor lubricating oil and
care should be taken to ensure that
downstream equipment is compatible.

If the discharged air is to be ultimately
released into a confined space, adequate
ventilation must be provided.

When using compressed air, always use
appropriate personal protective equipment.

All pressure containing parts, especially
flexible hoses and their couplings, must be
regularly inspected, be free from defects and
be replaced according to the Manual
instructions.

Avoid bodily contact with compressed air.
The safety valve located in the separator

tank must be checked periodically for correct
operation.

Never operate unit without first observing all
safety warnings and carefully reading the
operation and maintenance manual shipped
from the factory with this machine.

Never operate the engine of this machine
inside a building without adequate
ventilation.

Avoid breathing exhaust fumes when
working on or near the machine. Do not alter
or modify this machine.

A battery contains sulfuric acid and can give
off gases which are corrosive and potentially
explosive. Avoid contact with skin, eyes and
clothing. In case of contact, flush area
immediately with water.

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SAFETY Operating & Maintenance Manual

Exercise extreme caution when using
booster battery. To jump battery, connect
ends of one booster cable to the positive (+)
terminal of each battery. Connect one end of
other cable to the negative (-) terminal of the
booster battery and other end to a ground
connection away from dead battery (to avoid
a spark occurring near any explosive gases
that may be present). After starting unit,
always disconnect cables in reverse order.

High Pressure Air can cause serious injury or
death. Relieve pressure before removing
filler plugs/caps, fittings or covers.

Air pressure can remain trapped in air supply
line which can result in serious injury or
death.

Always carefully vent air supply line at tool or
vent valve before performing any service.

This machine produces loud noise with doors
open or service valve vented. Extended
exposure to loud noise can cause hearing
loss. Always wear hearing protection when
doors are open or service valve is vented.

Never inspect or service unit without first
disconnecting battery cable(s) to prevent
accidental starting.

Use care to avoid contacting hot surfaces
(engine exhaust manifold and piping, air
receiver and air discharge piping, etc.).

Ether is an extremely volatile, highly
flammable gas. USE SPARINGLY! DO NOT
use ETHER if unit has GLOW Plug starting
aid. Engine damage will result.

Never allow the unit to sit stopped with the
pressure in receiver-separator system. As a
precaution, open manual blowdown valve.

Never operate unit with guards, covers or
screens removed. Keep hands, hair,
clothing, tools, blow gun tips, etc. well away
from moving parts.

Make sure wheels, tires and tow bar
connectors are in safe operating condition
and tow bar is properly connected before
towing.

Whenever the machine is stopped, air will
flow back into the compressor system from
devices or systems downstream of the
machine unless the service valve is closed.
Install a check valve at the machine service
valve to prevent reverse flow in the event of
an unexpected shutdown when the service
valve is open. Stop machine to add fuel.

Do not remove the pressure cap from a HOT
radiator. Allow radiator to cool down before
removing pressure cap.

Do not use petroleum products (solvents or
fuels) under high pressure as this can
penetrate the skin and result in serious
illness.

Wear eye protection while cleaning unit with
compressed air to prevent debris from
injuring eye(s).

Disconnected air hoses whip and can cause
serious 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 serious injury.

Do not operate without guard in place.

Hazardous Substance Precaution

The following substances are used in the
manufacture of this machine and may be
hazardous to health if used incorrectly.

Avoid ingestion, skin contact and breathing
fumes for the following substances:

Antifreeze, Compressor Oil, Engine
Lubricating Oil, Preservative Grease, Rust
Preventative, Diesel Fuel and Battery
Electrolyte.

:

22478341 (1-15-07) Rev A 11

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.

12 22478341 (1-15-07) Rev A

SAFETY Operating & Maintenance Manual

22478341 (1-15-07) Rev A 13

Operating & Maintenance Manual SAFETY

14 22478341 (1-15-07) Rev A

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

WARNING (Orange Background) indicates a potentially hazardous

situation which, if not avoided, could

result in death or serious injury.

!

WARNING

result in death or serious injury.

!

CAUTION

CAUTION (Yellow Background) indicates a potentially hazardous

situation which, if not avoided, may

result in minor or moderate injury.

NOTICE

NOTICE (Blue Background) indicates important set-up, operating or

maintenance information.

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Operating & Maintenance Manual SAFETY

16 22478341 (1-15-07) Rev A