Ingersoll-Rand P250WJD Operation And Maintenance Manual

Ingersoll-Rand P250WJD is a powerful and versatile compressor designed to meet the demands of a wide range of applications. With its robust construction and reliable performance, the P250WJD is ideal for use in construction, mining, and other industries where compressed air is essential. Its compact size and easy-to-use controls make it a great choice for both professional contractors and do-it-yourselfers.

PDF

Document

OPERATION and MAINTENANCE

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.

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.

501 Sanford Ave

Mocksville, N.C. 27028

Book 22478341 (01-15-07) Rev A

Revised (

-12)

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.

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 distributed within 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

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 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.

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.

22478341 (1-15-07) Rev A

FOREWORD Manual-Name

C. When an actual or foreseeable risk of hazardous levels of flammable gases 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 the compressor. 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.

22478341 (1-15-07) Rev A

SAFETY

22478341 (1-15-07) Rev A 9

Operating & Maintenance Manual

Safety Precautions

SAFETY

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.

22478341 (1-15-07) Rev A

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.

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.

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.

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 result in death or serious injury.

WARNING

WARNING (Orange Background) indicates a potentially hazardous situation which, if not avoided, could 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.

22478341 (1-15-07) Rev A 15

Operating & Maintenance Manual SAFETY

16 22478341 (1-15-07) Rev A

SAFETY Operating & Maintenance Manual

22478341 (1-15-07) Rev A 17

Operating & Maintenance Manual SAFETY

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. Submit orders for Safety Decals to the Mocksville Parts

Service Department. The no charge order should contain only Safety Decals. Help promote safety! Assure that decals are present on the machines. Replace decals that are not readable.

18 22478341 (1-15-07) Rev A

NOISE EMISSION

22478341 (1-15-07) Rev A 19

Operating & Maintenance Manual

Noise Emission

NOISE EMISSION

This section pertains only to machines distributed within the United

States.

WARNING

Tampering with Noise Control System Prohibited

Federal law prohibits the following acts or the causing thereof:

1. The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or

2. the use of the compressor after such device or element of design has been removed or rendered inoperative by any person.

Among those acts included in the prohibition against tampering are these:

3. Removal or rendering inoperative any of the following: a.the engine exhaust system or parts thereof 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 with any of the enclosure doors open.

Compressor Noise Emission Control Information

A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of design incorporated into this compressor in compliance with noise control act;

B. The use of this compressor after such device or element of design has been removed or rendered inoperative.

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.

The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor.

22478341 (1-15-07) Rev A

NOISE EMISSION Operating & Maintenance Manual

Noise Emission Control Maintenance Log

COMPRESSOR MODEL __________________________

SERIAL NO. ___________________________________

USER UNIT NO. ________________________________

UNIT IDENTIFICATION

Engine Make & Model: ________________

Serial No.: _________________________

Purchaser or Owner: _________________

Address: __________________________

DEALER OR DISTRIBUTOR FROM

WHOM PURCHASED:

__________________________________

Date Purchased: ____________________

The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations, specifically the following acts or the causing thereof:

(1) the removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the compressor after such device or element of design has been removed or rendered inoperative by any person.

Noise Emission Warranty

The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built and equipped to conform at the time of sale to the first retail purchaser, with all applicable U.S. EPA Noise Control Regulations.

This warranty is not limited to any particular part, component, 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 to exceed

Federal Standards are covered by this warranty for the life of the air compressor.

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. The Maintenance Schedule and detailed instructions on the maintenance items are given on following page.

22478341 (1-15-07) Rev A 21

Operating & Maintenance Manual NOISE EMISSION

Maintenance Schedule

Item

Area Period

Compressed Air Leaks

Safety and Control Systems

Acoustic Materials

Fasteners

Enclosure Panels

Air Intake & Engine Exhaust

Cooling Systems

Isolation Mounts

Engine Operation

Fuels & Lubricants

As Detected

Daily

100 hours

250 hours

See Operator’s Manual

A. Compressed Air Leaks

Correct all compressed air leaks during the first shutdown period after discovery. If severe enough to cause serious noise problems and efficiency loss, shut down immediately and correct the leak(s).

B. Safety and Control Systems

Repair or replace all safety and control systems or circuits as malfunction occurs. No compressor should be operated with either system bypassed, disabled, or nonfunctional.

C. Acoustic Materials

In daily inspections, observe these materials. Maintain all acoustic material as nearly as possible in its original condition. Repair or replace all sections that have: 1) sustained damage,

2) have partially separated from panels to which they were attached, 3) are missing, or have otherwise deteriorated due to severe operating or storage conditions.

D. Fasteners

All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be inspected for looseness after each 100 hours of operation. They should be retightened, repaired, or if missing, replaced immediately to 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 otherwise deformed, such that their noise containment function is reduced, should be repaired or replaced before the next operation interval. Doors, access panels, and hatch closures especially, should be checked and adjusted at this time to insure continuous seating between gasket or acoustic material and the mating frame.

F. Air Intake and Engine Exhaust

Engine and compressor air intake and engine exhaust systems should be inspected after each

100 hours of operation for loose, damaged, or deteriorated components. Repairs or replacements should be made before the next period of use.

22478341 (1-15-07) Rev A

NOISE EMISSION Operating & Maintenance Manual

G. Cooling Systems

All components of the cooling system for engine water and compressor oil should be inspected every 250 hours of use. Any discrepancies found should be corrected before placing the unit back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at all times during operation.

H. Isolation Mounts

Engine/airend isolation mounts should be inspected 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 equivalent parts.

I. Engine Operation

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.

22478341 (1-15-07) Rev A 23

Operating & Maintenance Manual NOISE EMISSION

Item

No.

Maintenance Record For Noise Emission Control And Extended Warranty

Description Of Work

Hourmeter

Reading

Maint/inspect

Date

Location

City/state

Work Done

By (Name)

24 22478341 (1-15-07) Rev A

GENERAL DATA

22478341 (1-15-07) Rev A 25

Operating & Maintenance Manual

General Data

Models:

Unit Model

Air Delivery (cfm (litres/sec)

Engine Speed - RPM (Full Load)

Engine Speed - RPM (No Load)

P250

250

2300

1700

Compressor

Rated Operating Pressure - psi (kPa).......................100 psi (689)

Safety Valve Setting - psi (kPa) ................................150 psi (1034)

Net Weight (less fuel) pounds...................................2510

Engine (Diesel)

Manufacturer.............................................................John Deere

Model ........................................................................4045D

Electrical System ......................................................12 VDC

Fluid Capacities

Compressor Lubricant...............................................12 quarts (11.4 litres)

Engine Crankcase Lubricant.....................................10.8 quarts (10.2 litres)

Fuel Tank .................................................................29 U.S. gal. (110 litres)

Units Measurements Weights

Overall Length...........................................................11.5 (3.5 meters)

Overall Height ...........................................................4.8 feet (1.46 meters)

Overall Width ............................................................5.7 feet (1.74 meters)

Track Width...............................................................4.9 feet (1.49 meters)

Running Gear

Tire Size....................................................................P215/75RX15

Inflation Pressure (cold) ............................................35 psi

Towing Speed (maximum) ........................................65 mph (105 km/hr)

GENERAL DATA

22478341 (1-15-07) Rev A

GENERAL DATA Operating & Maintenance Manual

Expendable Service Parts

Compressor Oil Filter Element ..................................36897353

Compressor Oil Separator Element ..........................39831888

Air Cleaner Element Primary (Compressor) .............54415377

Air Cleaner Element (Engine) ...................................35393685

Engine Oil Filter Element .........................................36881696

Engine Fuel Filter Element........................................36534659

Fuel Water Separator Element .................................54468178

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.

CAUTION

Any departure from the specifications may make this equipment unsafe.

22478341 (1-15-07) Rev A 27

**Always use Ingersoll Rand Replacement parts!**

28 22478341 (1-15-07) Rev A

OPERATION

22478341 (1-15-07) Rev A 29

Operating & Maintenance Manual

Before Towing

towing.

OPERATION

WARNING

Failure to follow these instructions

CAN cause severe injury or death.

• Assure tow vehicle has towing capacity for weight of this unit as stated on general data decal.

• Position the tow vehicle to align its hitch with the pintle eye or coupler of the compressor.

• Engage the parking brake and chock the tires of the tow vehicle.

• Stand to the side and ensure pin is

FULLY inserted (secure) in tube of jack. .

• Crank jack to seat pintle eye or coupler onto hitch. Latch and lock hitch. Cross safety chain(s) under drawbar. Attach to vehicle

• Crank jack to raise pad off the ground. Pull pin from tube of jack.

• Fold jack handle down and forward.

Swing up jack tube and FULLY insert pin in tube.

• Remove tire chocks.

• Test brakes, if so equipped.

• Test lights (running, stop, and turn signals).

WARNING

Always raise (or remove) jack for maximum ground clearance before

Setting Up (All Units)

• Position as level as possible. The design of these units permits a 15 degree sidewise limit on out-of-level operation.

• When the unit is to be operated outof-level, it is important:

1. To keep the engine crankcase oil level near the high level mark (with the unit level).

2. To have the compressor oil level gauge show no more than mid-scale. Do not overfill either the engine crankcase or the compressor lubricating oil system.

3. The side doors must be closed to maintain a cooling air path and to avoid recirculation hot air.

Towing

WARNING

Failure to follow these instructions

CAN cause severe injury or death.

• Ensure that tires, wheels and running gear are in good condition and secure.

• Ensure that tires are inflated to 35 psi.

• Do not tow this unit in excess of 65 mph.

• Use a tow vehicle whose towing capacity is greater than the gross weight of this unit.

22478341 (1-15-07) Rev A

OPERATION

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.

• 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 access for normal servicing and maintenance.

The air going into the inlet must be relatively free of oil, dirt, soot and other debris. It must be no more than 10 degrees F. (5 degrees C) over the ambient temperature.

CONTROL PANEL - Diagnostics/Auto

Shutdown (Standard and Optional)

Instruments & Controls (Optional)

High Engine Temperature - Coolant above 220°F (104°C).

Operating & Maintenance Manual

Low Engine Oil Pressure - 12 psi or less.

High Compressor Temperature -

248°F (120°C)

Air Filters Restricted - Needs servicing.

Spare

Alternator Not Charging - Needs attention.

Low Fuel Level - Must add fuel to operate.

Hourmeter Records running time for maintenance.

(Standard)

10.

Compressor Discharge Pressure

Gauge - Indicates pressure in receiver tank, psi (kPa).

(Standard)

11.

Fuel Level Gauge - Indicates amount of fuel in tank.

12.

Power Switch - Rotate “ON” to activate system prior to starting.

Rotate “OFF” to stop engine.

(Standard)

13.

Engine Speed Gauge - Indicates engine speed.

14.

Discharge Air Temp. Gauge -

Indicates in °F (82°C) to 210°F

(99°C).

15.

Engine Oil Pressure Gauge -

Indicates engine oil pressure.

16.

Engine Water Temp. Gauge -

Indicates coolant temperature, with normal operating range from 180°F

(82°C) to 210°F (99°C).

17.

Voltmeter - Indicates battery condition.

18.

Ether Inject Button - Injects a measured shot. USE SPARINGLY.

22478341 (1-15-07) Rev A 31

Operating & Maintenance Manual OPERATION

19.

Service Air Button - After warm-up,

PUSH. Provides full air pressure at the service outlet. Indicates engine speed.

20.

Spare

21.

Spare

Note: 9, 10 and 12 are standard.

Before Starting

• Open service valve(s) to ensure pressure is relieved in receiver-separator system.

Close valve(s) in order to build up full air pressure and ensure proper oil circulation.

• Check battery for proper connections and condition.

• Check engine coolant level.

level between bottom and midway of the sight glass on the separator tank.

WARNING

This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss.

Wear hearing protection when doors or valve (s) are open.

• Close all doors to maintain a cooling air path and to avoid recirculation of hot air.

This will maximize the life of the engine and compressor and protect the hearing of surrounding personnel.

• Be sure no one is IN or ON the compressor unit.

WARNING

Do not remove pressure cap from a HOT radiator. Allow radiator to cool down before removing pressure cap. Use extreme care when removing a pressure cap from a liquid cooling system for the engine. The sudden release of pressure from a heated cooling system can result in a loss of coolant and possible severe personal injury.

• Check the engine oil level. Maintain per marks on dipstick.

• Check the fuel level. Add only CLEAN

DIESEL fuel for maximum service from the engine.

• Check the compressor lubricating fluid

WARNING

Unrestricted air flow from a hose will result in a whipping motion of the hose which can cause severe injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure in case of hose failure or other sudden pressure release. Reference: OSHA regulation

29 CFR Section 1926.302 (b).

Starting

• Turn the POWER switch to “ON”.

• Turn Power switch to “START” position to crank engine. Hold switch in “START” position for approximately 5 seconds after engine starts.

22478341 (1-15-07) Rev A

OPERATION Operating & Maintenance Manual

NOTICE

Do not operate the starter motor for more than 10 seconds without allowing at least 30 seconds cooling time between start attempts.

Release Power Switch (it will automatically move to the “ON” position) when the engine starts and sustains running.

• Allow engine to warm up 5 to 10 minutes.

• If so equipped, press the “Service Air

Button”. Open air service valve(s).

Cold Weather Starting

a. Turn power switch to the glow plug position and hold 10 seconds. Then turn to start.

NOTICE

Engine is equipped with glow plugs for cold starting aid. Do not use ETHER/ starting fluid. Engine damage can occur.

NOTICE

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 cable to the negative (-) terminal of the booster battery and the other end to the engine block. NOT TO THE

NEGATIVE (-) TERMINAL

OF THE WEAK BATTERY.

Units With Optional Diagnostics

Lamps

NOTICE

None of the panel lamps should be glowing when machine is operating. If they are, shut unit down and refer to Trouble

Shooting Section.

Stopping

NOTICE

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.

Close air service valves.

• Allow the unit to run at idle for 3 to 5 minutes to reduce the engine temperatures.

• Turn Power Switch to “OFF” position.

22478341 (1-15-07) Rev A 33

Operating & Maintenance Manual

• When the engine stops, automatic blowdown valve should relieve system air pressure. If automatic blow-down valve malfunction is suspected, open manual blowdown valve.

• Never allow unit to sit under pressure when engine is not running.

OPERATION

UNITS WITH DIAGNOSTIC LAMPS

In a shutdown situation, the function of the panel lamps is to indicate what specific failure caused the unit to shut down. These lamps will remain illuminated until the Power

Switch is turned “OFF”.

WARNING

Since the service valve is closed, 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 around or bypass a shutdown sensor or switch.

Machine has shutdown and sensors as follows:

• Low Engine oil pressure, in the engine.

• High engine coolant temperature, in the engine.

Compressor Air/Oil Temperature:

• At the airend outlet.

• In separator tank.

22478341 (1-15-07) Rev A

OPERATION Operating & Maintenance Manual

Speed and Pressure Regulator Adjusting Instructions

The engine idle and full speed settings are set and sealed at the factory, and should not be adjusted. Serious injury may result if the full speed is increased. Removal of the seals without authorization could affect the warranty. If speed settings are lost due to engine fuel pump service or other repairs, the speed settings can be reset as follows:

Before Starting

1. At the Pressure Regulator (on service pipe near receiver tank), remove the cover to expose the adjusting screw.

Loosen the jam nut and turn screw counterclockwise until tension is no longer felt at the screw. Then, turn screw clockwise one full turn.

2. Close service valve(s).

3. Inspect throttle arm (G) on engine governor to see the arm is resting against the governor stop. Loosen jam nut 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, making certain the button does not pop back out.

The unit should speed up and then unload (and drop back to IDLE). With the unit unloaded, turn the adjusting screw on the pressure regulator clockwise until the discharge pressure gauge indicates

125-130 psi. Tighten the pressure regulator jam nut. Replace cover.

5. With the service valve closed, adjust

IDLE speed (*). Adjust speed using adjusting rod (D). Tighten jam nut (H).

6. Open the service valve and adjust the discharge pressure to 100 psi (700 kPa).

Now turn adjusting rod (C) until the proper engine FULL speed setting (*) is reached. Tighten jam nuts (B & J).

7. To obtain maximum CFM at any pressure between 80 psi (550kPa) and maximum pressure rating (*), make adjustment at the pressure regulator to obtain desired discharge pressure at FULL engine speed. Lock adjusting screw and replace cover.

* See General Data Specifications.

22478341 (1-15-07) Rev A 35

**Always use Ingersoll Rand Replacement parts!**

36 22478341 (1-15-07) Rev A

MAINTENANCE

22478341 (1-15-07) Rev A 37

Operating & Maintenance Manual

Maintenance

CAUTION

Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty.

If performing more than visual inspections, disconnect battery cables and open manual blowdown valve.

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

Never operate this machine with any guards removed.

Inch and metric hardware was used in the design and assembly of this unit.

Consult the parts manual for clarification of usage.

for repair. Preventive 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 schedule is based on normal operation of the unit. This page can be reproduced and used as a checklist by the service personnel. In the event unusual environmental operating conditions exist, the schedule should be adjusted accordingly.

Compressor Oil Level

Check the compressor fluid level when the machine is not operating. Maintain the fluid level between bottom and midway of the sight glass on the separator tank.

Air Cleaner

NOTICE

Disregard any maintenance pertaining to components not provided on your machine.

General

In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and post-operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need

If this unit is equipped with the Optional

Diagnostic Panel, it has an AIR FILTERS

RESTRICTED lamp on the instrument panel, covering both the engine and the compressor.

This should be checked daily during operation. If the lamp glows (red) with the unit operating at full speed, servicing of the cleaner element is necessary.

Also weekly squeeze the rubber valve

(precleaner dirt dump) on each air cleaner housing to ensure that they are not clogged.

The air filters restricted sensor will automatically reset after the main power switch is turned to “OFF.”

To service the air cleaners on all units proceed as follows:

1. Loosen outer wing nut and remove with

22478341 (1-15-07) Rev A

MAINTENANCE Operating & Maintenance Manual

cover. Remove Element.

2. Inspect air cleaner housing for any condition that might cause a leak and correct as necessary.

3. Wipe inside of air cleaner housing with a clean, damp cloth to remove any dirt accumulation, especially in the area where the element seals against the housing.

4. Install new elements in the reverse order to the above. Tighten wing nut firmly.

5. Inspect to ensure that end cap seals tightly 360° around air cleaner body.

In addition, the air cleaner system (housing and piping) should be inspected every month for any leakage paths or inlet obstructions.

Make sure the air cleaner mounting bolts and clamps are tight. Check the air cleaner housing for dents or damage which could lead to a leak. Inspect the air transfer tubing from the air cleaner to the compressor and the engine for leaks.

Make sure that all clamps and flange joints are tight.

Battery

Keep the battery posts-to-cable connections clean, tight and lightly coated with a grease.

Also the electrolyte level in each cell should cover the top of the plates. If necessary, topup with clean distilled water.

Tires

A weekly inspection is recommended. Tires that have cuts or cracks or little tread should be repaired or replaced. Monthly check the wheel lug nuts for tightness.

Fasteners

Visually check entire unit in regard to bolts, nuts and screws being properly secured.

Spot check several capscrews and nuts for proper torque. If any are found loose, a more thorough inspection must be made. Take corrective action.

Gauges

The instruments or gauges are essential for safety, maximum productivity and long service life of the machine. Inspect the gauges and test any diagnostic lamps prior to start-up. During operation observe the gauges and any lamps for proper functioning.

Refer to Operating Controls, for the normal readings.

Wheel Torque Chart

M12 bolts

13” wheel

1/2” lug nuts

13” wheel

15” wheel

16” wheel

16.5” wheel

5/8” lug nuts

16” wheel

17.5” wheel

Torque (ft-Lbs)

60-70

80-90

105-115

190-210

Fuel Tank

CLEAN fuel in the 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 pump and hose, use a

CLEAN non-metallic funnel.

22478341 (1-15-07) Rev A 39

Operating & Maintenance Manual

Radiator

NOTICE

The use of water alone in this engine can result in major engine failure.

Refer to engine section for coolant recommendation.

Hoses

Each month it is recommended that all of the intake lines to and from the air cleaners, the engine cooling system hoses and all of the flexible hoses used for air, oil, and fuel be inspected.

To ensure freedom from air leaks, all rubber hose joints and the screw-type hose clamps must be absolutely tight. Regular inspection of these connections for wear or deterioration is necessary.

Premature wear of both the engine and compressor is ASSURED whenever dustladen air is permitted to enter the engine’s combustion chamber or compressor intake.

The flexible hoses used in the fuel, oil and air lines on these units are primarily used for their ability to accommodate relative movement between components. It is important they be periodically inspected for wear and deterioration. It is also important the operator does not use the hoses as convenient hand hold or steps. Such use can cause early cover wear and hose failure.

Pulling on the tubing will cause the inner sleeve to withdraw and compress, thus tightening the connection. The tubing can be withdrawn only while holding the sleeve against the fitting. The tubing can be removed and replaced numerous times without losing its sealing ability.

To install the nylon tubing, make a mark (with tape or grease pencil) approximately 7/8 inch from the end of the tubing. Insert the tubing into the sleeve and “push-in” past the first resistance to the bottom. The mark should be approximately 1/16 inch from the sleeve, for the 3/8 inch O.D. tubing; 1/8 inch for the 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, whichever comes first.

To service oil filters it will first be necessary to shut the unit down. Wipe off any external dirt and oil from the exterior of the filter to minimize any contamination from entering the lubrication system. Proceed as follows:

WARNING

High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system.

1. Open the service air valve(s) to ensure that system is relieved of all pressure.

Close the valve(s).

NOTICE

Some of the airlines are nylon tubing.

The associated fittings are “push-in” design. Features are as follows:

2. Turn the spin-on filter element counterclockwise to remove it from the filter housing. Inspect the filter.

22478341 (1-15-07) Rev A

MAINTENANCE Operating & Maintenance Manual

3. Inspect the oil filter head to be sure the gasket was removed with the oil filter element. Clean the gasket seal area on the oil filter head.

NOTICE

Installing a new oil filter element when the old gasket remains on the filter head, will cause an oil leak and can cause property damage.

4. Lubricate the new filter gasket with the same oil being used in the machine.

5. Install new filter by turning the element clockwise until gasket makes initial contact.

Tighten an additional 1/2 to 3/

4 turn.

6. Start unit and allow to build up to rated pressure. Check for leaks before placing unit back into service.

In the event foreign deposits, such as sludge and lacquer, accumulate in the oil cooler to the extent that its cooling efficiency is impaired, a resulting high discharge air temperature is likely to occur, causing shut down of the unit. To correct this situation it will be necessary to clean it using a cleaning compound in accordance with the manufacturer’s recommendations.

Compressor Oil

The lubricating and cooling oil must be replaced every 500 hours of operation or six

(6) months, whichever comes first. Refer to warranty section about extended warranty.

Receiver-Separator Systems

Compressor Oil Cooler

The compressor lubricating and cooling oil is cooled by means of the fin and tube-type oil cooler, located beside the radiator. The lubricating and cooling oil, flowing internally through the core section, is cooled by the air stream from the cooling fan flowing past the core section. When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler, its efficiency is impaired.

Each month it is recommended that the oil cooler be cleaned by directing compressed air which contains a nonflammable, noncaustic safety solvent through the core of the oil cooler. This should remove the accumulation of grease, oil and dirt from the exterior surfaces of the oil cooler core so that the entire cooling area can transmit the heat of the lubricating and cooling oil to air stream.

WARNING

High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system.

• Open service valve at end of machine.

• Ensure pressure is relieved, with BOTH:

— Discharge air pressure gauge reads zero (0).

— No air discharging from service valve.

Remove plug in bottom of separator tank to drain compressor oil.

When adding oil, remove and replace (make tight) plug on side of separator tank.

In the compressor lubricating and cooling system, separation of the oil from the compressed air takes place in the receiverseparator tank. As the compressed air enters the tank, the change in velocity and direction drop out most of the oil from the air.

22478341 (1-15-07) Rev A 41

Operating & Maintenance Manual

Additional separation takes place in the oil separator element which is located in the top of the tank.

Any oil accumulation in this separator element is continuously drained off by means of a scavenge tube which returns the accumulated oil to the system.

The life of the oil separator element is dependent upon the operating environment

(soot, dust, etc.) and should be replaced every twelve months or 1000 hours.

Scavenge Line

WARNING

High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system.

The scavenge line originates at the receiverseparator tank cover and terminates at the compressor air-end near the oil filter element. An orifice check valve is located on the scavenge tube.

Once a year or every 1000 hours of operation, whichever comes first, replace the separator element and clean the scavenge orifice/check valve.

NOTE: Excessive oil carry-over may be caused by an oil-logged separator element.

Do not replace element without first performing the following maintenance procedure:

1. Check oil level. Maintain as indicated earlier in this section.

2. Thoroughly clean scavenge line, any orifice and check valve.

3. Assure minimum pressure valve/orifice is operational.

4. Run unit at rated operating pressure for

30 to 40 minutes to permit element to clear itself.

Exterior Finish Care

This unit was painted and heat 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 housing, wash with water and soap or dish washing liquid detergent. Do not scrub with a rough cloth, pad, etc.

2. If grease removal is needed, a fast evaporating alcohol or chlorinated solvent can be used. Note: This may cause some dulling of the paint finish.

3. If the paint has faded or chalked, the use of a commercial grade, non-abrasive car wax may partially restore the color and gloss.

Field Repair of Texture Paint

1. The sheet metal should be washed and clean of foreign material and then thoroughly dried.

2. Clean and remove all grease and wax from the area to be painted using

Duponts 3900S Cleaner prior to sanding.

3. Use 320 grit sanding paper to repair any scratches or defects necessary.

4. Scuff sand the entire area to be painted with a red scotch brite pad.

5. Wipe the area clean using Duponts

3900S.

6. Blow and tack the area to be painted.

7. Apply a smooth coat of Duponts 1854S

Tuffcoat Primer to all bare metal areas and allow to dry.

22478341 (1-15-07) Rev A

MAINTENANCE Operating & Maintenance Manual

8. Apply 2 medium - wet coats of Duponts

222S Adhesion Promoter over the entire area to be painted, with a 5 minute flash in between coats.

9. To apply the texture coat, use Duponts

1854S Tuffcoat Primer. The proper technique to do this is to spray the

Tuffcoat Primer using a pressure pot and use about 2-5 pounds of air pressure.

This will allow the primer to 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 flash for 20 minutes or until dry to touch.

10. Apply any of Duponts Topcoat Finishes such as Imron™ or Centari™ according to the label instructions.

NOTE: To re-topcoat the textured surfaces when sheet metal repairs are not necessary, follow steps 1, 2, 4, 5, 6, 8 and 10.

22478341 (1-15-07) Rev A 43

Operating & Maintenance Manual

MAINTENANCE SCHEDULE

Compressor Oil Level

Engine Oil Level

Radiator Coolant Level

Gauges/Lamps

Air Cleaner Service Indicators

Fuel Tank (fill at end of day)

Fuel Water Separator (Drain)

Oil Leaks

Fuel Leaks

Drain Water From Fuel Filters

Coolant Leaks

Radiator Filler Cap

Air Cleaner PreCleaner Dumps

Fan/Alternator Belts

Battery Connections/Electrolyte

Tire Pressure and Surface

Wheel Lug Nuts

Hoses (oil, air, intake, etc)

Automatic Shutdown System Test

Air Cleaner System Visual

Compressor Oil Cooler Exterior

Engine Radiator Exterior

Fasteners, Guards

Air Cleaner Elements

Fuel/Water Separator Element

Compressor Oil Filter Element

Compressor Oil

Engine Oil Change (initial change @ 50 hrs)

Engine Oil Filter (initial change @ 50 hrs)

Wheels (bearings, seals, etc)

Engine Coolant Test

Fuel Filter Element

Shutdown Switch Settings

Scavenge Orifice & related parts

Test

Oil Separator Element

Lights (running, brake, & turn)

Pintle Eye Bolts

Daily Weekly Monthly 3 MOS.

6 MOS.

12 MOS.

250 hours 500 hours 1000 hours

DRAIN

CLEAN

R -non IR fluids

R non IR fluids

CLEAN

CBT

R=replace, C=check (adjust if necessary) CBT = check before towing.

* Applies only when using IR Protec™ Engine Fluid

22478341 (1-15-07) Rev A

LUBRICATION

22478341 (1-15-07) Rev A 45

Operating & Maintenance Manual

Lubrication

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” are required for extended warranty.

Compressor oil carryover (oil consumption) may be greater with the use of alternative fluids.

Design

Operating

Pressure

Ambient

Temperature

Specification

100 psi to

300 psi

-10

F to 125

(-23

C to 52

Preferred:

IR Pro•Tec™

Alternate:

ISO Viscosity Grade 46 with rust and oxidation inhibitors, designed for air compressor service.

350 psi

(-23

C to 52

-10

F to 125

Preferred:

IR XHP 605

Alternate:

IR XHP405

ISO Viscosity Grade 68 Group 3 or 5 with rust and oxidation inhibitors designed for air compressor service.

F to 125

(-18°C to 52°C)

Preferred:

XHP605

IR XHP1001

Preferred Ingersoll Rand Fluids - Use of these fluids with original I-R filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your IR representative.

Ingersoll Rand

Preferred Fluids

Preferred:

IR Pro-Tec™

IR XHP605

IR XHP1001

XHP405

Engine Oil

1 gal. (3.8 Litre)

36899698

54480918

5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Litre)

36899706

22252076

35612738

22252126

36875938

36899714

22252050

35300516

22252100

36866903

36899722

22252068

22252118

22478341 (1-15-07) Rev A

TROUBLE SHOOTING

22478341 (1-15-07) Rev A 47

Operating & Maintenance TROUBLE SHOOTING

Trouble Shooting

Introduction

Trouble shooting for a portable air compressor is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The trouble shooting chart that follows includes some of the problems that an operator may encounter during the operation of a portable compressor.

The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the answers for correction of the problems. The chart does give those problems that are most apt to occur. To use the trouble shooting chart:

A. Find the “complaint” depicted as a bold heading.

B. Follow down that column to find the potential cause or causes. The causes are listed in order (1,2,3 etc.) to suggest an order to follow in trouble shooting.

B. Do the Simplest Things First

Most troubles are simple and easily corrected. For example, most complaints are

“low capacity” which may be caused by too low an engine speed or “compressor over- heats” which may be caused by low oil level.

Always check the easiest and most obvious things first; following this simple rule will save time and trouble.

NOTE: For trouble shooting electrical problems, refer to the Wiring Diagram

Schematic found in Parts List Section.

C. Double Check Before Disassembly

The source of most compressor troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a compressor can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly. Check again to be sure an easy solution to the problem has not been overlooked.

Action Plan

A. Think Before Acting

Study the problem thoroughly and ask yourself these questions:

1. What were the warning signals that preceded the trouble?

2. Has a similar trouble occurred before?

3. What previous maintenance work has been done?

4. If the compressor will still operate, is it safe to continue operating it to make further checks?

D. Find and Correct Basic Cause

After a mechanical failure has been corrected, be sure to locate and correct the cause of the trouble so the same failure will not be repeated. A complaint of “premature breakdown” may be corrected by repairing any improper wiring connections, but something caused the defective wiring. The cause may be excessive vibration.

22478341 (1-15-07) Rev A

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

Out of Fuel

Compressor Oil Level Too Low

Compressor Oil Temp. Too High

Engine Water Temp. Too High

Loose Wire Connection

Low Fuel Level Shutdown Switch

Defective Discharge Air Temp. Switch

Defective Engine Oil Pressure Switch

Broken Engine Fan Belt

Engine Oil Pressure Too Low

Defective Shutdown Solenoid

Malfunctioning Relay

Blown Fuse

* < 10 Volts at Shutdown Solenoid

Engine Malfunctioning

Airend Malfunctioning

Corrective Action

Add CLEAN diesel Fuel

Add correct oil

See Table 10

Check coolant level. If necessary, Add.

Wiggle wires at switches & connector blocks. Make repairs.

Replace switch.

Replace fan belt.

See Table 3 and Table 4.

Replace solenoid.

Replace relay.

Replace fuse/Check for Short.

Check battery and alternator. Make repairs.

See Trouble Shooting in Engine Section.

See Table 10.

Table 2: Won’t Start/Run:

Cause

Out of Fuel

Clogged Fuel Filters

Compressor Oil Level Too Low

Loose Wire Connection

Low Battery Voltage

* <10 Volts at Shutdown Solenoid

Defective Alternator

Out of Fuel

Engine Water Temp. Too High

Malfunctioning Start Switch

Defective D2 Diode

Blown Fuse

Engine Oil Pressure Too Low

Compressor Oil Temp. Too High

Defective Discharge Air Temp. Switch

Defective Engine Oil Pressure Switch

Defective Shutdown Solenoid

Defective Engine Temp. Switch

Corrective Action

Add CLEAN diesel Fuel

Service filters.

Add corrected oil

Repair or replace connection.

Check electrolyte level. Check connections.

Charge battery and alternator. Make repairs.

Replace/Repair Alternator

Add CLEAN fuel.

Check fluid level. If necessary, Add.

Replace switch.

Replace D2 Diode.

Replace fuse/Check for Short.

See Table 3 and Table 4.

See Table 10.

Replace switch.

Replace solenoid.

Replace Switch

22478341 (1-15-07) Rev A 49

Operating & Maintenance Manual TROUBLE SHOOTING

Defective Separator Tank Temp Switch Replace Switch

Defective Low Fuel Shutdown Switch Replace Switch

Malfunctioning Relay

Engine Malfunctioning

Airend Malfunctioning

Replace relay.

See Trouble Shooting in Engine Section.

See Table 10.

Table 3: Engine Temperature Lamps Stays On:

Complaint

Dirty Cooler

Operating Pressure Too High

Recirculation of Cooling Air

Dirty Operating Conditions

* Out of Level >15 degrees

* Ambient Temp. >125×F (52×C)

Loose Wire Connection

Broken Engine Fan Belt

Malfunctioning Circuit Board

Corrective Action

Clean exterior of cooler.

Reduce pressure to spec.

Close side doors.

Move unit to cleaner environment.

Relocate or reposition unit.

Above spec limit.

Repair or replace.

Replace fan belt set.

Replace circuit board.

Table 4: Engine Oil Pressure Lamp Stays On:

Complaint

Low Oil Level

Clogged Oil Filter Element(s)

Out of Level >15 degrees

Loose Wire Connection.

Wrong Lube Oil

Malfunctioning circuit board

Engine Malfunctioning

Corrective Action

Add oil.

Replace element(s).

Relocate or reposition.

Repair or replace.

See Engine Oil Spec. Change oil.

Replace circuit.

See Trouble Shooting in Engine Section.

Table 5: Engine Temperature Lamps Stays Off:

Complaint

Bulb Burned Out

Shorted Wire (Hot)

Malfunctioning circuit board

Corrective Action

Replace circuit board.

Repair short.

Replace circuit board.

Table 6: Engine Oil Pressure Lamp Stays Off:

Complaint

Bulb Burned Out

Shorted Wire (Hot)

Malfunctioning circuit board

Corrective Action

Replace circuit board.

Repair short.

Replace circuit board.

22478341 (1-15-07) Rev A

TROUBLE SHOOTING Operating & Maintenance Manual

Complaint

Low Battery Voltage

Loose or Broken Belts

Malfunctioning Alternator

Shorted wire (ground)

Table 7: Alternator Lamp Stays On:

Corrective Action

Check electrolyte level. Add if necessary.

Tighten or replace belt set.

Check connectors. Clean & tighten.

Recharge battery.

Repair or replace alternator.

Repair short.

Complaint

Bulb Burned Out

Loose Wire Connection

Malfunctioning circuit board

Table 8: Alternator Lamp Stays Off:

Corrective Action

Replace circuit board.

Repair or replace connector.

Replace circuit board.

Table 9: Unit Fails To Shutdown:

Complaint

Defective Low Fuel Shutdown Switch

Corrective Action

Pull wire off shutdown solenoid. Replace switch.

Defective Discharge Air Temperature Switch Pull wire off. Replace switch.

Defective Sep. Temp. Switch Replace switch.

Defective Engine Temp. Switch

Defective Engine Oil Pressure Switch

Defective Shutdown Solenoid

Malfunctioning Relay

Defective Start Switch

Wire Shorted Hot

Replace switch.

Pull wire off. Replace switch.

Carefully block air inlet to stop engine.

Replace relay.

Pull wire off shutdown solenoid. Replace defective item.

Repair short.

Table 10: Excessive Compressor Oil Temperature:

Complaint

Dirty Cooler

Low Oil Level

Clogged Oil Filter Elements

Operating Pressure Too High

Dirty Operating Conditions

Ambient Temp. > 125°F (52°C)

Out of Level > 15 degrees

Wrong Lube Oil

Recirculation Of Cooling Air

Malfunctioning Thermostat

Loose or Broken Belts

Defective Oil Cooler Relief Valve

Defective Minimum Pressure Valve

Malfunctioning Fan

Blocked or Restricted Oil Lines

Airend Malfunctioning

Corrective Action

Clean exterior surfaces.

Add oil. Look for any leaks.

Replace elements. Change oil.

Reduce pressure to spec.

Move unit to cleaner environment.

Above spec limit.

Relocate or reposition unit.

Check spec in this manual.

Close side doors. Replace belly pan.

Replace thermostat in bypass valve.

Tighten or replace belt set.

Replace valve.

Repair or replace valve.

Check fan belt tension. Tighten or replace belt set.

Clean by flushing or replace.

See Tables 11, 12, 13, 15, 16 or 18.

22478341 (1-15-07) Rev A 51

Operating & Maintenance Manual TROUBLE SHOOTING

Complaint

Clogged Fuel Filter

Dirty Air Filter

Operating Pressure Too High

Incorrect Pressure Regulator Adjustment

Incorrect Linkage Adjustment

Wrong Air Filter Element

Malfunctioning Pressure Regulator

Malfunctioning Air Cylinder

Defective Separator Element

Engine Malfunctioning

Airend Malfunctioning

Table 11: Engine RPM Down

Corrective Action

Clean primary filter. Replace final filter. Drain tanks.

Add CLEAN fuel.

Clean or replace elements.

Reduce pressure to spec limit.

Adjust regulator.

Adjust linkage.

Install correct element.

Replace regulator.

Replace air cylinder and adjust.

Install new element.

See Trouble Shooting in Engine Section.

Consult Dealer.

Table 12: Excessive Vibration

Complaint

Dirty Fuel/Filters

Engine idle speed too low.

Rubber Mounts, Loose or Damaged

Anti-rumble valve not working.

Drive Coupling Defective

Defective Fan

Engine Malfunctioning

Airend Malfunctioning

Corrective Action

Replace filters/fuel.

Raise “No Load” speed.

Tighten or replace.

Repair or Replace.

Replace coupling.

Replace fan.

See Trouble Shooting in Engine Section.

See Table 15 and 17.

Table 13: Low CFM

Complaint

Engine RPM too Low

Malfunctioning Air Cylinder

Incorrect Linkage Adjustment

Malfunctioning Inlet Unloader

Dirty Air Filter

Incorrect Pressure Regulator Adjustment

Malfunctioning Pressure Regulator

Wrong Air Filter Element

Defective Separator Element

Defective Minimum Pressure Valve

Corrective Action

Adjust RPM

Replace air cylinder.

Adjust linkage.

Inspect valve.

Clean or replace elements.

Adjust linkage.

Replace regulator.

Install correct element.

Install new element.

Repair or replace valve.

Complaint

Inadequate Element Cleaning

Dirty Operating Conditions

Incorrect Stopping Procedure

Wrong Air Filter Element

Table 14: Short Air Cleaner Life

Corrective Action

Install new element.

Move unit to cleaner environment.

Read procedure in this manual.

Install proper element.

22478341 (1-15-07) Rev A

TROUBLE SHOOTING Operating & Maintenance Manual

Table 15: Excessive Oil In Air

Complaint

High Oil Level

Clogged Scavenge Orifice

Incorrect Oil

Defective Scavenge Check Valve

Out of Level > 15 degrees

Defective Separator Element

Scavenge Tube Blocked

Sep. Tank Blow Down Too Quickly

Defective Minimum Pressure Valve

Corrective Action

Read procedure in this manual.

Remove scavenge orifice. Clean and Replace.

Replace by spec. in this manual.

Remove check valve. Replace with new valve.

Relocate or reposition unit.

Remove element. Install new.

Remove scavenge tube. Clean and Replace.

Allow unit to blow down automatically.

Remove valve. Repair valve and replace.

Complaint

Contaminated Lube Oil

Blocked or Restricted Oil Line(s)

Malfunctioning Seal

Scored Shaft

Table 16: Oil Seal Leak

Corrective Action

Drain and flush system. Add new CLEAN oil.

Replace seal.

Remove, clean and replace line(s). Replace seal.

Consult dealer. Replace seal.

See instructions in new seal kit.

Table 17: Will Not Unload

Complaint

Incorrect Pressure Regulator Adjustment

Leak in Regulator Piping

Malfunctioning Pressure Regulator

Malfunctioning Inlet Valve Unloader

Defective Separator Element

Ice in Regulation Lines/Orifice

Corrective Action

Adjust regulator.

Find and repair leak(s).

Replace regulator.

Inspect valve. Repair/Replace.

Remove element. Install new.

Apply heat to line(s) and or orifice.

Complaint

Incorrect Stopping Procedure

Malfunctioning Unloader

Table 18: Oil In Air Cleaner

Corrective Action

Read Procedure in this manual.

Repair/Replace.

Table 19: Safety Valve Relieves

Complaint

Operating Pressure Too High

Incorrect Pressure Regulator Adjustment

Malfunctioning Pressure Regulator

Leak In Regulator Piping

Malfunctioning Inlet Unloader

Defective Separator Element

Defective Safety Valve

Ice in Regulation Lines/Orifice

Corrective Action

Reduce pressure to spec limit.

Refer to Section 6 in this manual.

Replace regulator.

Repair leak(s).

Inspect valve. Repair/Replace.

Remove element. Install new.

Replace safety valve.

Remove ice.

22478341 (1-15-07) Rev A 53

**Always use Ingersoll Rand Replacement parts!**

54 22478341 (1-15-07) Rev A

Ingersoll Rand Company

P.O.Box 868 - 501 Sanford Ave.

Mocksville, N.C. 27028

©

2007 Ingersoll Rand Company, Printed in the USA

Hi! I've gone through the Ingersoll-Rand P250WJD Compressor Operation and Maintenance Manual. I can assist you with questions regarding its operation (including towing instructions), maintenance schedules, troubleshooting (with the provided charts), and safety precautions. Let me know what you need!

Show related prompts

Assistant typing

Assistant is out of keyboard. Please, try again later.

Key features

Powerful diesel engine provides ample power for demanding applications.
Compact size and easy-to-use controls make it ideal for both professional contractors and do-it-yourselfers.
Durable construction ensures long-lasting performance in harsh environments.

Frequently asked questions

The P250WJD has a 10-gallon fuel tank and a 4-gallon compressor oil tank.

The P250WJD requires regular maintenance, including checking the compressor oil level, air cleaner, gauges, fuel tank, battery, and radiator.

OPERATION and MAINTENANCE

MANUAL

COMPRESSOR MODEL

P250WJD

Code: C

Revised (

-12)

CALIFORNIA

Proposition 65 Warning

TABLE OF CONTENTS

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

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

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

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

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

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

TABLE OF CONTENTS

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

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

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

FOREWORD

Manual-Name FOREWORD

FOREWORD Manual-Name

DRAWBAR NOTICE

DRAWBAR NOTICE

Drawbar Notice

SAFETY

Operating & Maintenance Manual

Safety Precautions

SAFETY

General

SAFETY Operating & Maintenance Manual

Hazardous Substance Precaution

Operating & Maintenance Manual SAFETY

SAFETY Operating & Maintenance Manual

Operating & Maintenance Manual SAFETY

SAFETY Operating & Maintenance Manual

WARNING

CAUTION

Operating & Maintenance Manual SAFETY

SAFETY Operating & Maintenance Manual

Operating & Maintenance Manual SAFETY

FREE SAFETY DECALS

NOISE EMISSION

Operating & Maintenance Manual

Noise Emission

NOISE EMISSION

This section pertains only to machines distributed within the United

States.

WARNING

Compressor Noise Emission Control Information

NOISE EMISSION Operating & Maintenance Manual

Noise Emission Control Maintenance Log

Noise Emission Warranty

Introduction

Operating & Maintenance Manual NOISE EMISSION

A. Compressed Air Leaks

B. Safety and Control Systems

C. Acoustic Materials

D. Fasteners

E. Enclosure Panels

F. Air Intake and Engine Exhaust

NOISE EMISSION Operating & Maintenance Manual

G. Cooling Systems

H. Isolation Mounts

I. Engine Operation

J. Fuels and Lubricants

Operating & Maintenance Manual NOISE EMISSION

GENERAL DATA

Operating & Maintenance Manual

General Data

Models:

Compressor

Engine (Diesel)

Fluid Capacities

Units Measurements Weights

Running Gear

GENERAL DATA

GENERAL DATA Operating & Maintenance Manual

Expendable Service Parts