OPERATING, MAINTENANCE,

PARTS MANUAL

COMPRESSOR MODELS
P130WJDU
P175WJDU
P185WJDU

Code: A

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.

Portable Air Compressor Division

P.O. Box 868 -- 501 Sanford Ave
Mocksville, N.C. 27028
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.
Book 22478358 (7/02) Revised (10-12) (1)
 QUALITY POLICY
We will supply products and services that consistently meet the requirements
of our customers and each other.

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.

Book 22478358 (7/02) (2)

 Foreword
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:

Declaration of Conformity
WITH EC DIRECTIVE
98/37/EC

Ingersoll--Rand Company We Ingersoll--Rand Company Limited

Portable Compressor Division Standard Products Division
P.O. Box 868 Represented In EC By: Swan Lane
501 Sanford Avenue Hindley Green
Mocksville, North Carolina 27028 Wigan WN2 4EZ
United Kingdom

Declare that, under our sole responsibility for manufacture and supply, the product(s)
HP1300WCU VHP825WCU XHP900WCAT VHP750WCAT XHP1070CAT
XP1400WCU HP935WCU XHP650WCAT VHP850WCAT NXP1300WCU
P1600WCU XP1050WCU XHP750WCAT HP900WCAT
XP900WCU HP825WCU XHP825WCAT XP1000WCAT
To which this declaration relates, is (are) in conformity with the provisions of the above
directives using the following principal standards

EN1012-- 1, EN29001, EN202, EN60204-- 1

PN8NTC2, EN 50081, EN50082

Issued at Mocksville on 1--1--95 Issued at Hindley Green on 1--1--95

________________________________ ________________________________
Ric Lunsford H. Seddon, Q.A. Manager
Manager of Quality Control

Book 22478358 (7/02) (3)

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.

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

S of good quality, procured from a reputable manufacturer and, wherever possible, be of a type
approved by Ingersoll--Rand.
S clearly rated for a pressure at least equal to the machine maximum allowable working pressure.
S compatible with the compressor lubricant/coolant.
S 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.

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.

Book 22478358 (7/02) (4)

 TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . SAFETY

SECTION 2 . . . . . . . . . . . . . . . WARRANTY/REGISTRATION

SECTION 3 . . . . . . . . . . . . . . . NOISE EMISSION

SECTION 4 . . . . . . . . . . . . . . . GENERAL DATA

SECTION 5 . . . . . . . . . . . . . . . OPERATION

SECTION 6 . . . . . . . . . . . . . . . MAINTENANCE

SECTION 7 . . . . . . . . . . . . . . . LUBRICATION

SECTION 8 . . . . . . . . . . . . . . . TROUBLESHOOTING

Book 22478358 (7/02) (5)

 SECTION 1-- SAFETY
SAFETY PRECAUTIONS If more than one compressor is connected to one com-
mon downstream plant, effective check valves and
General Information
isolation valves must be fitted and controlled by work
Ensure that the operator reads and understands the procedures, so that one machine cannot accidentally
decals and consults the manuals before maintenance be pressurized or over pressurized by another.
or operation.
Compressed air must not be used for a feed to any
Ensure that the Operation and Maintenance manual, form of breathing apparatus or mask.
and the manual holder if equipped, are not removed
The discharged air contains a very small percentage
permanently from the machine.
of compressor lubricating oil and care should be taken
Ensure that maintenance personnel are adequately to ensure that downstream equipment is compatible.
trained, competent and have read the manuals.
If the discharged air is to be ultimately released into a
Make sure that all protective covers are in place and confined space, adequate ventilation must be pro-
that the canopy/doors are closed during operation. vided.

The specification of this machine is such that the ma- When using compressed air, always use appropriate
chine is not suitable for use in flammable gas risk personal protective equipment.
areas. If such an application is required then all local
regulations, codes of practice and site rules must be All pressure containing parts, especially flexible hoses
observed. To ensure that the machine can operate in and their couplings, must be regularly inspected, be
a safe and reliable manner, additional equipment such free from defects and be replaced according to the
as gas detection, exhaust spark arrestors, and intake Manual instructions.
(shut--off) valves may be required, dependent on local
Avoid bodily contact with compressed air.
regulations or the degree of risk involved.
The safety valve located in the separator tank must be
Air discharged from this machine may contain carbon checked periodically for correct operation.
monoxide or other contaminants which will cause seri-
ous injury or death. Do not breathe this air. Never operate unit without first observing all safety
warnings and carefully reading the operation and
Compressed air can be dangerous if incorrectly han-
maintenance manual shipped from the factory with
dled. Before doing any work on the unit, ensure that all
this machine.
pressure is vented from the system and that the ma-
chine cannot be started accidentally. Never operate the engine of this machine inside a
building without adequate ventilation. Avoid breathing
Ensure that the machine is operating at the rated pres- exhaust fumes when working on or near the machine.
sure and that the rated pressure is known to all rele- Do not alter or modify this machine.
vant personnel.
A battery contains sulfuric acid and can give off gases
All air pressure equipment installed in or connected to which are corrosive and potentially explosive. Avoid
the machine must have safe working pressure ratings contact with skin, eyes and clothing. In case of con-
of at least the machine safety valve rating. tact, flush area immediately with water.

Book 22478358 (7/02) (6)

Exercise extreme caution when using booster battery. to each hose at the source of supply or branch line in
To jump battery, connect ends of one booster cable to accordance with OSHA Regulation 29CFR Section
the positive (+) terminal of each battery. Connect one 1926.302(b).
end of other cable to the negative (--) terminal of the
Hot pressurized fluid can cause serious burns. Do not
booster battery and other end to a ground connection open radiator while hot.
away from dead battery (to avoid a spark occurring
Rotating fan blade can cause serious injury. Do not
near any explosive gases that may be present). After
operate without guard in place.
starting unit, always disconnect cables in reverse or-
der. Use care to avoid contacting hot surfaces (engine
exhaust manifold and piping, air receiver and air
Never operate unit without first observing all safety
discharge piping, etc.).
warnings and carefully reading the operation and
maintenance manual shipped from the factory with
Ether is an extremely volatile, highly flammable gas.
this machine.
USE SPARINGLY! Do NOT use ETHER if unit has
This machine may include such materials as oil, diesel GLOW Plug starting aid. Engine damage will result.
fuel, antifreeze, brake fluid, oil/air filters and batteries
which may require proper disposal when performing Never allow the unit to sit stopped with pressure in the
maintenance and service tasks. Contact local authori- receiver--separator system. As a precaution, open the
ties for proper disposal of these materials.
manual blowdown valve.
A battery contains sulfuric acid and can give off gases
which are corrosive and potentially explosive. Avoid Never operate unit with guards, covers or screens
contact with skin, eyes and clothing. In case of con- removed. Keep hands, hair, clothing, tools, blow gun
tact, flush area immediately with water. tips, etc. well away from moving parts.
High Pressure Air can cause serious injury or death. Make sure wheels, tires and tow bar connectors are in
Relieve pressure before removing filler plugs/caps, fit- safe operating condition and tow bar is properly
tings or covers. connected before towing.

Air pressure can remain trapped in air supply line Whenever the machine is stopped, air will flow back
which can result in serious injury or death. Always into the compressor system from devices or systems
carefully vent air supply line at tool or vent valve before downstream of the machine unless the service valve
performing any service. is closed. Install a check valve at the machine service
valve to prevent reverse flow in the event of an
This machine produces loud noise with the doors open unexpected shutdown when the service valve is open.
or service valve vented. Extended exposure to loud
noise can cause hearing loss. Always wear hearing Hazardous Substance Precaution
protection when doors are open or service valve is
vented. The following substances are used in the manufacture
of this machine and may be hazardous to health if
Never inspect or service unit without first disconnect- used incorrectly. Precaution: Avoid ingestion, skin
ing battery cable(s) to prevent accidental starting. contact and breathing fumes for the following
Do not remove the pressure cap from a HOT radiator. substances: Antifreeze, Compressor Oil, Engine
Allow radiator to cool down before removing pressure Lubricating Oil, Preservative Grease, Rust
cap. Preventative, Diesel Fuel and Battery Electrolyte.

Do not use petroleum products (solvents or fuels) un- The following substances may be produced during the
der high pressure as this can penetrate the skin and operation of this machine and may be hazardous to
result in serious illness. wear eye protection while health: Avoid build--up of Engine Exhaust Fumes in
cleaning unit with compressed air to prevent debris confined spaces.
from injuring eye(s). Avoid breathing Exhaust Fumes.
Disconnected air hoses whip and can cause serious Avoid breathing Brake Lining Dust during mainte-
injury or death. Always attach a safety flow restrictor nance.

Book 22478358 (7/02) (7)

SAFETY LABELS
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 you supervisor.

Corrosion risk Hot Surface

Lifting point

WARNING: Electrical shock risk. Parking Brake No open flame

Diesel Fuel.
No open flame.
Do not operate the machine Lifting point
without guard being fitted.

WARNING -- Flammable liquid. When parking use prop stand,

handbrake and wheel chocks. Air/gas flow or Air discharge.

WARNING -- Hot and harmful exhaust gas. Tie down point Do not breathe the compressed
air from this machine.

Book 22478358 (7/02) (8)

 Read the Operation and Maintenance
manual before operation or maintenance
of this machine is undertaken.
X,X BAR

WARNING -- Maintain correct tire pressure.

(Refer to the GENERAL INFORMATION section
of this manual).

WARNING: Consult the operation

and maintenance manual before
performing any maintenance.

Rough Service Designation

Wet Location Operation

Do not stack

Replace any cracked

Do not use fork lift truck from this side protective shield.

On (power).

Off (power).
Do not operate with the doors or enclosure
open.

WARNING -- Before connecting the tow bar or

when preparing to tow, consult the operation
and maintenance manual. Emergency stop.

Book 22478358 (7/02) (9)

 Oil Drain

XX
km/h

WARNING -- Do not undertake any

Do not exceed the speed limit. maintenance on this machine until the
electrical supply is disconnected and the air
pressure is totally relieved.

Read the Operation and Maintenance manual

0_C before operation or maintenance of this
machine is undertaken

Do not remove the Operating and

WARNING -- For operating temperature below Maintenance manual and manual holder from
0_C, consult the operation and maintenance this machine.
manual.

Pressurized vessel. Use fork lift truck from this side only. Pressurized component or system.

Book 22478358 (7/02) (10)

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 you supervisor.

Indicates the presence of a hazard which WILL cause

! serious injury, death or property damage, if ignored.

(Red Background)

Indicates the presence of a hazard which CAN

! cause serious injury, death or property damage,

if ignored.
(Orange Background)

Indicates the presence of a hazard which WILL or

can cause injury or property damage, if ignored.

(Yellow Background)

Indicates important set--up, operating or maintenance

information.

(Blue Background)
WARNING
DANGER

Trapped air pressure. Can cause serious

injury or death.
Air discharged from this machine can
Close service valve and operate tool to vent
contain carbon monoxide or other
trapped air before performing any service.
contaminants which will cause serious
injury or death. Do not breathe this air.

WARNING
WARNING

High pressure air. Can cause serious

Hot pressurized fluid. injury or death.
Can cause serious burns. Relieve pressure before removing filler
Do not open radiator while hot. plugs/caps, fittings or covers.

Book 22478358 (7/02) (11)

 WARNING WARNING
Improper operation of this equipment. Modification or alteration of this machine.
CAN cause serious injury or death. CAN cause serious injury or death.
Read Operator’s Manual supplied with this Do NOT alter or modify this machine without the
machine before operation or servicing. express written consent of the manufacturer.

WARNING
Collapsing jack stand. Excessive towing speed.
Will cause serious injury. Can cause serious injury or death.
Do NOT exceed 65 mph (104 km/hr)
Insert locking pin
completely.

For Highway Towable Units

WARNING WARNING

Excessive Towing Speed. CAN

cause serious injury or death.
Rotating Fan Blade. CAN cause seri-
ous injury. Do NOT Tow on Highway.
Do NOT operate with guard removed. Do NOT exceed 20 mph (32 km/h)
For Non--Highway Towable Machines

WARNING WARNING

Falling off machine. CAN cause serious Door under pressure CAN cause serious
injury or death. injury.
Use both hands to open door when machine
Access Lifting Bail from inside machine. is running.

Book 22478358 (7/02) (12)

 WARNING WARNING

Disconnected Air Hoses Whip. CAN

cause serious injury or death. Combustible Gas. CAN cause serious
When using air tools attach safety device burns, blindness or death.
(OSHA Valve) at source of air supply for Keep sparks and open flames away
each tool. from batteries.

FREE SAFETY DECALS!

To promote communication of Safety Warnings on
products manufactured by the Portable Compressor
Division in Mocksville, N.C., 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 product safety! Assure that
decals are present on the machines. Replace decals that
are not readable.

Book 22478358 (7/02) (13)

 SECTION 2 -- Warranty
Ingersoll--Rand, through its distributor, warrants that each item of equipment manufactured by it and delivered
hereunder to the initial user will be free of defects in material and workmanship for a period of three (3) months from
initial operation or six (6) months from the date of shipment to the initial user, whichever occurs first.

With respect to the following types of equipment, the warranty period enumerated below will apply in lieu of the
foregoing warranty period.

A. Aftercoolers -- The earlier of nine (9) months from date of shipment to or six (6) months from start up by
initial user.

B. Portable Compressors, Portable Generator Sets (GENSET) 8KW, 11KW, 20KVA thru 575KVA, Porta-
ble Light Towers and Air Dryers -- The earlier of twelve (12) months from shipment to or the accumulation of
2,000 hours of service by the initial user.
3.5KW thru 7.0KW and 10KW– The earlier of twelve (12) months from shipment to or the accumulation of
2,000 hours of service by the initial user, whichever occurs first. Ingersoll--Rand will provide a new part or
repaired part, at it’s election, in place of any part which is found to be defective in material or workmanship
during the period described above. Labor cost to replace the part is the responsibility of the user.

C. Portable Compressor Air Ends -- The earlier of twenty--four (24) months from shipment to or the accumulation
of 4,000 hours of service by the initial user. For Air Ends, the warranty against defects will include replace-
ment of the complete Air End, provided the original Air End is returned assembled and unopened.

C.1 Portable Compressor Airend Limited Optional Warranty -- The earlier of sixty (60) months from shipment
to or the accumulation of 10,000 hours of service. The optional warranty is limited to defects in rotors, hous-
ings, bearings and gears and provided all the following conditions are met:
1. The original air end is returned assembled and unopened.
2. Continued use of genuine Ingersoll--Rand parts, fluids, oil and filters.
3. Maintenance is performed at prescribed intervals.
Oil--Free airends are fee--based and may require a maintenance agreement. Formal enrollment is
required.

D. Genset Generators 8KW, 11KW, 20KVA thru 575KVA -- The earlier of twenty--four (24) months from ship-
ment to or the accumulation of 4,000 hours of service by the initial user.
3.5KW thru 7.0KW and 10KW -- The earlier of twelve (12) months from shipment to or the accumula-
tion of 2,000 hours of service.

E. Portable Light Tower Generators-- The earlier of twelve (12) months from shipment to or the accumulation
of 2,000 hours of service by the initial user. Light Source model only, the earlier of twenty--four (24) months
from shipment to or the accumulation of 4,000 hours of service.

F. Ingersoll--Rand Engines -- The earlier of twenty--four (24) months from shipment to or the accumulation of
4,000 hours of service.

Book 22478358 (7/02) (14)

G. Ingersoll--Rand Platinum Drive Train Warranty (Optional) – Platinum drive train pertains to the Ingersoll--
Rand Engine and Airend combination. The earlier of sixty (60) months from shipment to, or the accumulation
of 10,000 hours of service. The starter, alternator, fuel injection system and all electrical components are
excluded from the extended warranty. The airend seal and drive coupling are included in the warranty (airend
drive belts are not included). The optional warranty is automatically available when meeting the following
conditions:

1. The original airend is returned assembled and unopened.

2. Continued use of genuine Ingersoll--Rand parts, fluids, oil and filters.
3. Maintenance is performed at prescribed intervals.

It is the obligation of the user to provide verification that these conditions have been satisfied when submitting
warranty claims.

F. Spare Parts– Six (6) months from date of shipment.

Ingersoll--Rand will provide a new part or repaired part, at its election, in place of any part which is found upon
its inspection to be defective in material and workmanship during the period prescribed above. Such part will
be repaired or replaced without charge to the initial user during normal working hours at the place of business
of an Ingersoll--Rand distributor authorized to sell the type of equipment involved or other establishment au-
thorized by Ingersoll--Rand. User must present proof of purchase at the time of exercising warranty.

The above warrantees do not apply to failures occurring as a result of abuse; misuse, negligent repairs, corrosion,
erosion and normal wear and tear, alterations or modifications made to the product without express written consent
of Ingersoll--Rand; or failure to follow the recommended operating practices and maintenance procedures as pro-
vided in the product’s operating and maintenance publications.

Accessories or equipment furnished by Ingersoll--Rand, but manufactured by others, including, but not limited to,
engines, tires, batteries, engine electrical equipment, hydraulic transmissions, carriers, shall carry whatever war-
ranty the manufacturers have conveyed to Ingersoll--Rand and which can be passed on to the initial user.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT OF
TITLE),AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.

Book 22478358 (7/02) (15)

 GENERAL WARRANTY INFORMATION
GENERAL WARRANTY Extended Coverage

Portable Compressor Package 1 year/2000 hours

Airend 2 years/4000 hours 5 years/10,000 hours Limited warranty, major components

(refer to operator’s manual).

Portable Genset 8KW, 11KW, 20KVA Package 1 year/2000 hours None

thru 575KVA

Generator 2 years/4000 hours None

Portable Genset 3.5KW thru 7.0KW Package 1 year/2000 hours PARTS ONLY None
and 10KW

Generator 1 year/2000 hours PARTS ONLY None

Light Tower Package 1 year/2000 hours

Generator 1 year/2000 hours 2 years/4000 hours, for Lightsource

introduced 8/16/99.

ENGINES

Caterpillar Months Hours Extended Coverage

12 No Limit Available at dealer

Cummins 24 2000 Major components 3 yrs/10,000 hours -- available at dealer

John Deere
(IN COMPRESSORS) 24 2000 5 yrs/5000 hours using OEM fluids & filters with $250 deductible.
2 yrs/4000 hours using IR fluids & filters
(IN GENERATORS AS OF 1/1/01) 24 2000

Deutz 24 2000 Available at dealer

Ingersoll--Rand 24 4000 5 years/10,000 hours when using genuine Ingersoll--Rand fluids

and parts. Refer to operator’s manual.

Kubota (North America Only) 24 2000 Major components 36 months/3000 hrs -- parts only
(Western Europe & Oceania) 24 2000 None
(Central & South America, Asia, Middle 12 1000 None
East & Africa)

Mitsubishi 24 2000 2 years/4000 hours using IR fluids and filters

Volvo 24 2000 2 years/4000 hours using IR fluids and filters

Honda 12 unlimited None

Vanguard 24 unlimited None

PARTS

Months Hours Coverage

Ingersoll--Rand 6 No Limit Parts Only

AIREND EXCHANGE

Months Hours Extended Coverage

Airend 12 2000 hours 2 years/4000 hours -- available
from IR.

Note: Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with each new product.

Book 22478358 (7/02) (16)

 Extended Limited Airend Warranty
Ingersoll--Rand Portable Compressor Division is pleased to announce the availability of extended limited airend
warranty. Announcement of the extended warranty coincides with the introduction of PROSTECt Compressor
Fluid. PROSTECt Compressor Fluid is an amber colored fluid specially formulated for Portable Compressors and
is being provided as the factory filled fluid for all machines except ! XHP650/900/1070 models.
All machines have the standard airend warranty -- The earlier of 24 months from shipment to, or the accumulation
of 4000 hours of service.
The warranty against defects will include replacement of the complete airend, provided the original airend is re-
turned assembled and unopened.
The optional limited warranty is the earlier of 60 months from shipment to, or the accumulation of 10,000 hours
of service. The optional warranty is limited to defects in major components (rotors, housings, gears, bearings),
and is automatically available when the following three conditions are met:
1. The original airend is returned assembled and unopened.
2. Submissions of proof that Ingersoll--Rand fluid, filters and separators have been
used. Refer to the Operation and Parts manual for the correct fluids, filters and separator
elements required.
3. Submission of proof that maintenance intervals have been followed.

WARRANTY TIME *BARE AIREND * * AIREND COMPONENTS

STANDARD 2 yrs/4000 hrs 100% parts and labor 100% parts and labor

OPTIONAL 5 yrs/10,000 hrs 100% parts and labor 0%

* Bare Airend -- pertains to major airend parts (rotors, housings, gears and bearings).
** Airend Components -- pertains to auxiliary attachments to the bare airend (drive coupling, seals, pumps, valves,
tubes, hoses, fittings and filter housing).

PROSTECt and XHP505 Compressor Fluids are available from the Mocksville
Product Support department by calling 1-- 800-- 633-- 5206.

! XHP650/900/1070 will continue to use XHP505 and will have the extended warranty when above conditions are
met.

Book 22478358 (7/02) (17)

 WARRANTY REGISTRATION

Complete Machine Registration

Machines shipped to locations within the United States do not require a warranty registration
unless the machine status changes (i.e. change of ownership).

Machines shipped outside the United States require notification be made to initiate the
machine warranty.

Fill out the Warranty Registration Form in this section, keep a copy for your records and
mail form to:

Ingersoll--Rand Company
Portable Compressor Division
P.O. Box 868
Mocksville, North Carolina 27028
Attn: Warranty Department

Note: Completion of this form validates the warranty.

Book 22478358 (7/02) (18)

Selling Distributor Servicing Distributor WARRANTY REGISTRATION
Name Name Owner/User Name
Address Address Address
City City City
County County County
State State State
Zip Code Zip Code Zip Code
Telephone Telephone Telephone

Complete the Applicable Blocks

Owner/User Type of Business (check one only)

Construction--Heavy Asphalt Contractor Coal Mining Other Mining

(highway, excavation, etc.)

Construction--Light Government Quarry Shallow Oil & Gas

(carpentry, plumbing, pools, (municipal, state,
mason, etc.) county, etc.)

Rental Building Contractor Waterwell Utility Company

(rental center, rental fleet, etc.) (gas, electric, water, etc.)

Industrial (plant use) Other Exploration Utility Contractor

specify __________

Model Unit S/N Engine S/N Date Delivered

Unit--Hours Airend S/N Truck S/N Truck Engine S/N

SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT

1. The Purchaser has been instructed and/or has read the manual and understands proper preventative
maintenance, general operation and safety precautions.
2. The warranty and limitation of liability has been reviewed and understood by the owner/user.
3. In the event that this unit is to be used within a nuclear facility, the owner/user shall notify Ingersoll--Rand of such
use so that Ingersoll--Rand may arrange for appropriate nuclear liability protection from the owner--licensee of the
facility.
4. Ingersoll--Rand reserves the right to make design changes or modifications of Ingersoll--Rand products at anytime
without incurring any obligation to make similar changes or modifications on previously sold units.

Book 22478358 (7/02) (19)

 Attention: Warranty Department

Mocksville, North Carolina 27028

P.O. Box 868
Portable Compressor Division
Ingersoll- Rand Company

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
fold

Book 22478358 (7/02) (20)

 SECTION 3 -- 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 re-
placement, 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:

4. 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

5. Removal of any of the following:

a. fan shroud
b. vibration mounts
c. sound absorption material

6. 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 the 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.

Book 22478358 (7/02) (21)

 NOISE EMISSION CONTROL
MAINTENANCE LOG

COMPRESSOR MODEL

SERIAL NO.

USER UNIT NO.

UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM

Engine Make & Model: WHOM PURCHASED:

Serial No.:

Purchaser or Owner:

Address: 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 re-
placement, 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 de-
sign, 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.

Book 22478358 (7/02) (22)

 MAINTENANCE SCHEDULE
ITEM AREA PERIOD
A. Compressed Air Leaks As Detected
B. Safety and Control Systems As Detected
C. Acoustic Materials Daily
D. Fasteners 100 hours
E. Enclosure Panels 100 hours
F. Air Intake & Engine Exhaust 100 hours
G. Cooling Systems 250 hours
H. Isolation Mounts 250 hours
I. Engine Operation See Operator’s Manual
J. Fuels & Lubricants See Operator’s Manual

F. Air Intake and Engine Exhaust

A. Compressed Air Leaks Engine and compressor air intake and engine exhaust
systems should be inspected after each 100 hours of
Correct all compressed air leaks during the first shut-
operation for loose, damaged, or deteriorated compo-
down period after discovery. If severe enough to cause
nents. Repairs or replacements should be made be-
serious noise problems and efficiency loss, shut down
fore the next period of use.
immediately and correct the leak(s).

B. Safety and Control Systems G. Cooling Systems

Repair or replace all safety and control systems or cir- All components of the cooling system for engine water
cuits as malfunction occurs. No compressor should be and compressor oil should be inspected every 250
operated with either system bypassed, disabled, or hours of use. Any discrepancies found should be cor-
nonfunctional. rected before placing the unit back in operation. Unre-
stricted airflow over the radiator and oil cooler must be
C. Acoustic Materials maintained at all times during operation.

In daily inspections, observe these materials. Maintain H. Isolation Mounts

all acoustic material as nearly as possible in its original
condition. Repair or replace all sections that have: 1) Engine/airend isolation mounts should be inspected
sustained damage, 2) have partially separated from after each 250 hours of operation. Those mounts with
panels to which they were attached, 3) are missing, or cracks or splits in the molded rubber, or with bent or
have otherwise deteriorated due to severe operating broken bolts due to operation or storage in severe en-
or storage conditions. vironments, all should be replaced with equivalent
parts.
D. Fasteners
I. Engine Operation
All fasteners such as hinges, nuts, bolts, clamps,
screws, rivets, and latches should be inspected for Inspect and maintain engine condition and operation
looseness after each 100 hours of operation. They as recommended in the manuals supplied by the en-
should be retightened, repaired, or if missing, replaced gine manufacturer.
immediately to prevent subsequent damage and noise
emission increase. J. Fuels and Lubricants
E. Enclosure Panels Use only the types and grades of fuels and lubricants
recommended in the Ingersoll--Rand Company and
Enclosure panels should also be inspected at 100 hour Engine Manufacturer’s Operator and Maintenance
operational intervals. All panels that are warped, punc- Manuals.
tured, torn, or otherwise deformed, such that their
noise containment function is reduced, should be re-
paired 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 mate-
rial and the mating frame.

Book 22478358 (7/02) (23)

 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY
ITEM NO. DESCRIPTION OF WORK HOURMETER MAINT/ LOCATION CITY/ WORK DONE BY
READING INSPECT DATE STATE (NAME)

Book 22478358 (7/02) (24)

 SECTION 4 -- GENERAL DATA
MODEL:

P--( )--W--JD--U 130 175 185

Rated Delivery:
CFM-- (litres/sec/) 130 (61) 175 (83) 185 (87)

Engine:
Full -- RPM 2000 2350 2500
*Constant
Idle -- RPM 2000 1700 1700
Engine Model -- 3029 3029 4045

COMPRESSOR
Rated Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 psi (7.03 kgf per cm2) (700kPa)
Safety Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 psi (10.5 kgf per cm2) (1030 kPa)

ENGINE (DIESEL)
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt

FLUID CAPACITIES P185 P130 -- P175

Compressor Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 quarts (11.4 litres) 12 quarts (11.4 litres)
Engine Crankcase Lubricant (including filters) . . . . . . . . 9 quarts ( 8.5 litres) 6.3 quarts (6.0 litres)
Engine Coolant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4 quarts (13.6 litres) 11.6 quarts (11 litres)
Fuel Tank (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 U.S gal. (106 litres) 28 U.S gal. (106 litres)

UNITS MEASUREMENTS
WEIGHTS . . . . . . . . . . . . . . . .
Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.3 (2165)
Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.3 (1327)
Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3 (845)
P185 P130 -- P175
Net Weight (less fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2265 (1027) . . . . . . . . . 2020 lbs. (916 kg)
Gross Weight (all fluids) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2460 (1116) . . . . . . . . . . 2216 lbs. (1005 kg)

EXPENDABLE SERVICE PARTS P185 P100--P175

Compressor Oil FIlter Element . . . . . . . . . . . . . . . . . . . . . Part No. 35296920 P/N 35296920
Compressor Oil Separator Element . . . . . . . . . . . . . . . . . Part No. 36845303 P/N 36845303
Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 35291970 P/N 35291970
Engine Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 35308030 P/N 35308030
Engine Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 35389527 P/N 35389527

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.

Book 22478358 (7/02) (25)

 SECTION 5 -- OPERATION
CONTROL PANEL
10. Compressor Discharge Pressure Gauge --
14 15 Indicates pressure in receiver tank, psi (kPa).
10
13 11. Fuel Level Gauge --
16 17
Indicates amount of fuel in tank.
7 8 CONTROLS (Standard)
12. Power Switch -- Flip “ON” to activate systems
1 3 5 9 11 prior to Starting. Flip “OFF” to stop engine.
2 4 6 19. Service Air Button -- After warm--up, PUSH.
12 Provides full air pressure at the service outlet.
Indicates engine speed.
18 19 20 21
CONTROLS (Optional)

13. Engine Speed Gauge -- Indicates engine speed.

14. Discharge Air Temp. Gauge --

DIAGNOSTICS/AUTO SHUTDOWN (optional) Indicates in _F and _C. Normal operating

range: 185_F/85_C to 248_F/120_C.
1. High Engine Temperature --
15. Engine Oil Pressure Gauge --
Coolant above 220_F (104_C) or more.
Indicates engine oil pressure.
2. Low Engine Oil Pressure -- 12 psi or less
16. Engine Water Temp. Gauge --
3. High Compressor Temperature --
Indicates coolant temperature, with normal
248_F (120_C). operating range from 180_F (82_C) to 210_F
4. Air Filters Restricted -- Needs Servicing. (99_C.

5. Spare 17. Voltmeter --

6. Spare Indicates battery condition.

DIAGNOSTICS/AUTO SHUTDOWN (standard) 18. Ether Inject Button --

7. Alternator Not Charging -- Needs attention Injects a measured shot. USE SPARINGLY.
(Not on WIR Models)
8. Low Fuel Level -- Must add fuel to operate.
20. Spare
9. Hourmeter --
Records running time for maintenance. 21. Spare

Begin with Serial Number 326650

Book 22478358 (7/02) (26)

UTILITY PACKAGE SET--UP
(no running gear)
INSTALLATION
The unit must be secured to a vehicle bed using mounting holes provided, to prevent unwanted motion of the unit while
running or transporting. See Figure X for mounting holes provided in base.
The air going into the inlet grilles 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.
The inlet and outlet grilles must not be restricted. See Figure Y for recommended clearance around the compressor. The
cross--sectional area of any ductwork must be larger by a minimum of 10 percent.
The addition of any power--absorbing components (hydraulic pumps, paint mixers, etc.) must be approved by
Ingersoll--Rand to maintain the warranty. Units with the optional engine--mounted auxiliary drive are approved for hydraulic
pumps up to 15 HP.
CAUTION: Units with the optional engine mounted auxiliary drive and/or 4.5 kw generator can potentially overload the
engine if the combination of air, hydraulic power and electrical power exceeds the Horsepower capability of the engine. This
can lead to damage to the engine. Refer to Figure Z for the maximum HP available for the auxiliary drive.
High loading/continuous operation requires engine oil changes at 1/2 normal interval.

Mounting Holes
.88I
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ---- -- -- -- -- -- mounting holes
| |
| 77.24I |
| | outside dimension
32.85I 1.56I| 29.73I
| of base
| |
| |
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ---- -- -- -- -- -- --

1.38I
80I

Figure X

Cooling Air Clearance Dimensions minimum clearances for

cooling air exhaust.
Do Not Block
12I
48I
2I
minimum clearance
for cooling air inlets cooling air inlets
Do Not Block
-- -- -- --
-- -- 8I
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
cooling air inlet
Do Not Block

cooling air inlets

Do Not Block both ends Figure Y

Book 22478358 (7/02) (27)

 Figure Z

Book 22478358 (7/02) (28)

 removing a pressure cap from a liquid cooling
system for the engine. The sudden release of
SETTING -- UP (ALL UNITS) pressure from a heated cooling system can result
• Position as level as possible. The design of these in a loss of coolant and possible severe personal
units permits a 15 degree sidewise limit on injury.
out--of--level operation.
• When the unit is to be operated out--of--level, it is WARNING
important:
NO SMOKING, SPARKS or OPEN FLAME near
(1) To keep the engine crankcase oil level near the high
fuel.
level mark (with the unit level).
(2) To have the compressor oil level gauge show no CAUTION
more than mid--scale. Do not overfill either the engine
crankcase or the compressor lubricating oil system.
Do not connect the air discharge on this unit into
(3) The side doors must be closed to maintain a a common header with any other unit of any
cooling air path and to avoid recirculation hot air. description, or any other source of compressed
air, without first making sure a check valve is used
COMPRESSOR OIL LEVEL between the header and the unit. If this unit is
The oil level should be checked before the unit is connected with another unit, a safety hazard
started. Always check the oil level while the unit is could occur.
level, the engine off, and there is zero pressure in the
separator tank. The optimum oil level is with the WARNING
pointer at the top of the green section on the level
gage. Add oil if the pointer reaches the bottom of the
green section. Unrestricted air flow from a hose will result in a
whipping motion of the hose which can cause
Note: The oil level gage will not read properly while the severe injury or death. A safety device must be
engine is running. 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).
OPTIMUM OIL LEVEL
YELLOW - TOO HIGH (EITHER SIDE) BEFORE STARTING:
S All checks should be made while the unit is level.

• Open service valve (s) to ensure pressure is relieved

GREEN - OK
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 the engine oil level. Maintain per marks on
RED
TOO LOW dipstick.
• Check the fuel level. Add only CLEAN DIESEL fuel
ADD OIL LEVEL for maximum service from the engine.
(EITHER SIDE)
• Check the compressor lubricating oil level. The
optimum oil level is with the pointer at the top of the
green section on the level gages. Add oil if the pointer
CAUTION reaches the bottom of the green section. Do not
overfill.
Check the coolant level in the radiator and overflow
Do not remove pressure cap from a HOT radiator. bottle.
Allow radiator to cool down before removing
pressure cap. Use extreme care when

Book 22478358 (7/02) (29)

The coolant must cover the tubes in the top tank If equipped with the optional cold starting aid
(approximately 1 inch high on a clean measuring rod (ETHER), operate the valve once or twice ONLY while
stuck down filler neck). The coolant in the overflow the engine is cranking.
bottle should be above the “COLD” mark for cold
engine (<120_F). CAUTION
A fuel level gauge reading can be obtained without
Ether is an extremely volatile, highly flammable
starting the unit, by turning the power switch to “ON”.
Afterwards, turn the switch to “OFF”. gas. Use sparingly! If too much is injected, the
uncontrolled explosion may result in costly dam-
Check the fuel level. Use Clean DIESEL fuel for age to the engine.
maximum service from the engine.

WARNING CAUTION

This machine produces loud noise with doors Exercise extreme caution when using a booster
open. Extended exposure to loud noise can battery to start. To jump start: Connect the ends
cause hearing loss. Wear hearing protection of one booster cable to the positive (+) terminals
when doors or valve (s) are open. of each battery. Then connect one end of the other
cable to the negative (--) terminal of the booster
• Close all doors to maintain a cooling air path and to battery and the other end to the engine block. NOT
avoid recirculation of hot air. This will maximize the life TO THE NEGATIVE (--) TERMINAL OF THE WEAK
of the engine and compressor and protect the hearing BATTERY.
of surrounding personnel.
• Be sure no one is IN or ON the compressor unit.
AFTER STARTING:
STARTING a. Reduce engine speed to IDLE.
Turn the POWER switch to “ON”. b. Disconnect the negative (--) cable from the engine

If so equipped, place the “Start--Run” Valve Switch, block first, then from the booster battery.
located in the bottom right hand corner of the c. Disconnect positive (+) cable from both batteries.
instrument panel, to the “Start/Warm--Up” position.
Turn Power switch to “START” position to crank
engine. Hold switch in “START” position for CAUTION
approximately 5 seconds after engine starts.

NOTICE Do not remove pressure cap from a HOT radiator.

Allow radiator to cool down before removing
Do not operate the starter motor for more than 10
pressure cap. Use extreme care when removing a
seconds without allowing at least 30 seconds
pressure cap from a liquid cooling system for the
cooling time between start attempts. engine. The sudden release of pressure from a
heated cooling system can result in a loss of
Release Power Switch (it will automatically move to
coolant and possible severe personal injury.
the “ON” position) when the engine starts and sustains
running.
Allow engine to warm up 5 to 10 minutes.
If so equipped, place the “Start--Run” Valve Switch in
the “AIR” position.
Cold Weather Starting:
If so equipped, place the Start--Run valve switch,
located in the bottom right hand corner of the
instrument panel, to the “START/WARM--UP”
position.
Open manual blowdown valve, if so equipped, and
press ether inject button. Use Ether sparingly. Close
manual blowdown valve after engine is running.

Book 22478358 (7/02) (30)

 compressed air is available at the service air valves in
this mode.
Hose Reel Operation
To Unwind Hose
1. Disconnect end of hose from docking port at bottom
right--hand corner of compressor.
2. Release reel lock pin on left--hand side of reel by S In “Gen/Air” position, voltage and frequency will vary
pulling and rotating pin toward cradle and releasing it. as engine speed changes to meet air demands, and
3. Pull hose to unwind. should only be used for lights and hand tools.
4. Re--engage reel lock pin into reel. S In “Air” position, the generator provides no electrical
power.

To Retract Hose 1. Start compressor with the Start--Run Switch

1. Release reel lock pin on left--hand side of reel, by located in the bottom right corner of the instrument
pulling and rotating pin toward cradle and releasing it. panel) in the “Start/Warm--up” position.

2. Push and hold in “Reel Rewind” button at bottom

right--hand corner of compressor. 2. Close all service air valves.

3. Place the start--run switch in the “Run” position.

WARNING: Keep Hands AWAY from Hose Reel
while controlling hose.
4. Place the generator control switch in either
“Generator” or “Gen/Air” position. The red light on the
3. Secure end of hose into docking port. front of the generator control panel should glow, and
the voltage meter should read 120 Volts AC.
4. Reengage reel lock pin into reel.
5. Plug electric tools or lights into the receptacles on
To Swing Hose Reel Away from Compressor Door the front of the generator control panel.

1. Disconnect end of hose from docking port at bottom

right--hand corner of compressor.
2. Release latch on right--side of hose reel frame.
3. Swing hose reel out, away from compressor door.

CAUTION: Hose Reel Must Be Returned To It’s

Latched Position Before Moving Vehicle.

OPERATION OF OPTIONAL GENERATOR

This unit will operate in three modes, depending on the
position of the generator control switch (located on the
front of the generator control panel).
S In “Generator” position, the engine will maintain idle
speed, and the generator will give a constant voltage
and frequency output, for use with sensitive
equipment like computers, fusion welders, etc. No

Book 22478358 (7/02) (31)

Units with Diagnostic Lamps: AUTOMATIC SHUTDOWN
In a shutdown situation, the function of the panel This unit is protected with sensors (switches) for high
lamps is to indicate what specific failure caused the discharge air temperature, high engine coolant
unit to shut down.These lamps will remain illuminated
temperature and low engine oil pressure.
until the Power Switch is turned “OFF”.
Should any of three situations occur, the unit will stop.
Before restarting the unit, check these three areas for
UNITS WITH OPTIONAL DIAGNOSTICS LAMPS excessive heat and fluid level. Other possible causes
NOTICE are listed on the Trouble Shooting Chart.
All units in this family of machines are protected by
None of the panel lamps should be glowing when ma-
sensors or switches at the following locations:
chine is operating. If they are, shut unit down and refer
to Trouble Shooting Section. (1) Low engine oil pressure, in the engine.
(2) High engine coolant temperature, in the engine.

STOPPING High Discharge AIR Temperature

(3) At the airend outlet.
Close air service valve.
(4) In separator tank.
Allow the unit to run at idle for 3 to 5 minutes to reduce
the engine temperatures.
Turn Power Switch to “OFF” position.
When the engine stops, automatic blowdown valve
should relieve system air pressure. If automatic blow- NOTICE
down valve malfunction is suspected, open manual
blowdown valve. Do NOT wire around or bypass a shutdown
sensor or switch.
Never allow unit to sit under pressure when engine is
not running.

WARNING DANGER
Even after pressure is relieved from the receiver--
Since the service valve is closed, air downstream
of the valve may be trapped. A vent hole in the ser- separator system, any air supply line from the
vice valve will slowly bleed air from the hose. Do compressor to a tool or a machine could remain
not disconnect hoses until all pressure has been under pressure and cause very serious personal
vented.
injury or death. After the compressor stops, care-
fully open a valve at any tool or machine to ex-
haust the pressure in any line prior to removal or
servicing.

Book 22478358 (7/02) (32)

 P130WJDU Speed and Pressure Regulator Adjusting Instructions

Normally, speed and pressure regulation requires no adjusting, but if proper adjustment is lost, proceed
as follows. Refer to the General Data table for proper engine speeds.

Before Starting
1. Remove regulator valve cover (A), (if equipped) on valve (B) to expose adjusting screw (C).
Loosen jam nut (D) on adjusting screw (C) and turn screw counterclockwise until tension is no
longer felt on screw. Now, turn screw clockwise one full turn.

2. Close service valve(s).

After Starting Unit

3. Allow unit to warm up at least five minutes, then if equipped, place the Start--Run Valve Switch in
the “AIR” position to obtain full service air pressure.

4. With Service Air Valve closed, turn the adjusting screw (C) clockwise until the discharge pressure
reaches 120 psi (range =20psi). Tighten jam nut (D).

5. Replace regulator valve cover (A), if equipped.

6. To select any pressure range fro 85 to 100 psi, change adjusting screw (C) to obtain a “closed”
service valve pressure that is 20 psi greater than the desired “working” service pressure. Always
lock and protect pressure setting of adjusting screw (C) with jam nut (D) and regulator valve cover
(A).

Book 22478358 (7/02) (33)

 P175 - 185 Speed and Pressure Regulator Adjusting Instructions

6. If equipped, place the Start--Run Valve

Switch to the “AIR” position. The unit
The engine idle and full speed settings are set and
sealed at the factory, and should not be adjusted. should speed up and then unload (and
Serious injury may result if the full speed is drop back to IDLE). With the unit un-
increased. Removal of the seals without loaded, turn the adjusting screw on the
authorization could affect the warranty. If speed pressure regulator clockwise until the dis-
settings are lost due to engine fuel pump service charge pressure gauge indicates
or other repairs, the speed settings can be reset
as follows: 125--130 psi. Tighten the pressure regula-
tor jam nut. Replace cover.
Before Starting
1. At the Pressure Regulator (on service pipe 7. Open the service valve and adjust the dis-
near receiver tank), remove the cover to charge pressure to 100 psi (700 kPa).
expose the adjusting screw. Loosen the Now turn adjusting rod (C) until the proper
jam nut and turn screw counterclockwise engine FULL speed setting (*) is reached.
until tension is no longer felt at the screw.
Then, turn screw clockwise one full turn. 8. If necessary, loosen jam nut (J) on FULL
speed screw (K) and turn screw until it hits
2. Close service valve(s). a stop. Recheck the FULL speed setting
and reset if required. Tighten jam nuts (J)
3. At air cylinder (A), loosen jam nut (B) on
and (H).
adjusting rod (C). Turn rod (C) until it just
touches the piston inside of the cylinder. 9. Close the service valve and recheck IDLE
This is determined by the movement of speed (*). If necessary, adjust speed us-
the air cylinder piston rod (D). Rod (D) ing screw (L). Tighten jam nut (H).
should be fully retracted and just begin to
extend when the adjusting rod (C) is prop- 10. To obtain maximum cfm at any pressure
erly set. between 80 psi (550 kPa) and maximum
pressure rating (*), make adjustment at
4. Lock jam nut (B). the pressure regulator to obtain desired
discharge pressure at FULL engine
After Starting Unit
speed. Lock adjusting screw and replace
5. Allow unit to warm up at an engine speed cover.
greater than IDLE speed (*) for at least five
minutes. Do this by loosening jam nut (H) on * See General Data Specifications.
the IDLE screw (L). Turn the IDLE screw until
the speed is properly set (*).

Book 22478358 (7/02) (34)

 SECTION 6 -- MAINTENANCE
COMPRESSOR OIL LEVEL
CAUTION
The oil level should be checked before the unit is
started. Always check the oil level while the unit is
Any unauthorized modification or failure to maintain level, the engine off, and there is zero pressure in the
this equipment may make it unsafe and out of factory separator tank. The optimum oil level is with the
warranty. pointer at the top of the green section on the level
gage. Add oil if the pointer reaches the bottom of the
If performing more than visual inspections, disconnect green section.
battery cables and open manual blowdown valve.
Note: The oil level gage will not read properly while the
Use extreme care to avoid contacting hot surfaces engine is running.
(engine exhaust manifold and piping, air receiver and
air discharge piping, etc.).

Never operate this machine with any guards removed.

OPTIMUM OIL LEVEL
YELLOW - TOO HIGH
(EITHER SIDE)
Inch and metric hardware was used in the design and
assembly of this unit. Consult the parts manual for
clarification of usage.
GREEN - OK

Notice: Disregard any maintenance pertaining to

components not provided on your machine.

RED
TOO LOW
GENERAL
ADD OIL LEVEL
(EITHER SIDE)
In addition to periodic inspections, many of the
components in these units require periodic servicing
to provide maximum output and performance.
AIR CLEANER
Servicing may consist of pre--operation and If this unit is equipped with the Optional Diagnostic
post--operation procedures to be performed by the Panel, it has an AIR FILTERS RESTRICTED lamp on
operating or maintenance personnel. The primary the instrument panel, covering both the engine and
function of preventive maintenance is to prevent the compressor.
failure, and consequently, the need for repair. This should be checked daily during operation. If the
Preventive maintenance is the easiest and the least lamp glows (red) with the unit operating at full speed,
expensive type of maintenance. Maintaining your unit servicing of the cleaner element is necessary.
and keeping it clean at all times will facilitate servicing.
Also weekly squeeze the rubber valve (precleaner dirt
dump) on each air cleaner housing to ensure that they
are not clogged.
SCHEDULED MAINTENANCE The air filters restricted sensor will automatically reset
after the main power switch is turned to “OFF.”
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.

Book 22478358 (7/02) (35)

 NOTE: To prevent damage to the element, never
To service the air cleaners on all units proceed as fol- exceed a maximum air pressure of 100 psi (700
lows: kPa).

1. Loosen outer wing nut and remove with cover.

In the event the element is contaminated with dry dirt,
Remove Element.
oil or greasy dirt deposits, and a new element is not
2. Inspect air cleaner housing for any condition available, cleaning can be accomplished by washing,
that might cause a leak and correct as using the air cleaner element manufacturer’s recom-
necessary. mendations.

3. Wipe inside of air cleaner housing with a clean,

damp cloth to remove any dirt accumulation, NOTE: It is recommended that replacement ele-
especially in the area where the element seals ments be installed in the unit. The elements just
against the housing. removed for cleaning can be washed and stored
as future replacement elements.
4. Inspect element by placing a bright light inside
and rotating slowly. If any holes or tears are
found in the paper, discard this element. If no In addition, the air cleaner system (housing and
ruptures are found, the element can be piping) should be inspected every month for any
cleaned. leakage paths or inlet obstructions. Make sure the air
cleaner mounting bolts and clamps are tight. Check
5. If a new air filter element is to be used check it
closely for shipping damage. 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.
6. Install cleaned or new elements in the reverse
Make sure that all clamps and flange joints are tight.
order to the above. Tighten wing nut firmly.

GAUGES
7. Inspect to ensure that the end cap seals tightly
The instruments or gauges are essential for safety,
360 degrees around the air cleaner body.
maximum productivity and long service life of the
In the event that the filter element must be reused machine. Inspect the gauges and test any diagnostic
immediately, compressed air cleaning (as follows) is lamps prior to start--up. During operation observe the
recommended since the element must be thoroughly gauges and any lamps for proper functioning. Refer to
dry. Direct compressed air through the element in the Operating Controls, for the normal readings.
direction opposite to the normal air flow through the
element.

Move the nozzle up and down while rotating the

element. Be sure to keep the nozzle at least one inch
(25.4 mm) from the pleated paper.

Book 22478358 (7/02) (36)

FUEL TANK Premature wear of both the engine and compressor is
CLEAN fuel in the fuel tanks is vitally important and ASSURED whenever dust--laden air is permitted to
every precaution should be taken to ensure that only enter the engine’s combustion chamber or the
compressor intake.
clean fuel is poured or pumped into the tank.
The flexible hoses used in the fuel, oil and air lines on
When filling the fuel tank on this unit, by methods other these units are primarily used for their ability to
than a pump and hose, use a CLEAN non--metallic accommodate relative movement between
funnel. 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.
BATTERY
Keep the battery posts--to--cable connections clean,
NOTICE
tight and lightly coated with a grease. Also the
electrolyte level in each cell should cover the top of the Piping systems operating at less than 150 psi
plates. If necessary, top--up with clean distilled water. (1050 kPa) may use a special nylon tubing. The
associated fittings are also of a special “push--in”
design. If so, features are as follows:

Pulling on the tubing will cause the inner sleeve to

FASTENERS withdraw and compress, thus tightening the
Visually check entire unit in regard to bolts, nuts and connection. The tubing can be withdrawn only while
screws being properly secured. Spot check several holding the sleeve against the fitting. The tubing can
capscrews and nuts for proper torque. If any are found be removed and replaced numerous times without
loose, a more thorough inspection must be made. losing its sealing ability.
Take corrective action.

To install the nylon tubing, make a mark (with tape or

grease pencil) approximately 7/8 inch from the end of
RADIATOR the tubing. Insert the tubing into the sleeve and
NOTICE “push--in” past the first resistance to the bottom. The
mark should be approximately 1/16 inch from the
The use of water alone in this engine can result in
sleeve, for the 3/8 inch O.D. tubing; 1/8 inch for the
major engine failure.
0.25 inch O.D. tubing. This will ensure that the tubing
is fully engaged in the sealing mechanism.
HOSES
Each month it is recommended that all of the intake NOTICE
lines to and from the air cleaners, the engine cooling The oil filter must be replaced every 500 hours of
system hoses and all of the flexible hoses used for air, operation or three (3) months, whichever comes
oil, and fuel be inspected.
first. On new or overhauled units, replace the ele-
To ensure freedom from air leaks, all rubber hose ment after the first 50 and 150 hours of operation;
joints and the screw--type hose clamps must be thereafter, service the oil filter every 500 hours.
absolutely tight. Regular inspection of these
connections for wear or deterioration is necessary. To service the 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:

Book 22478358 (7/02) (37)

 COMPRESSOR OIL COOLER
WARNING
The compressor lubricating and cooling oil is cooled by

High pressure air can cause severe injury or death means of the fin and tube--type oil cooler, located
from hot oil and flying parts. Always relieve beside the radiator. The lubricating and cooling oil,
pressure before removing caps, plugs, covers or flowing internally through the core section, is cooled by
other parts from pressurized air system. the air stream from the cooling fan flowing past the
1. Open the service air valve(s) to ensure that core section. When grease, oil and dirt accumulate on
system is relieved of all pressure. Close the the exterior surfaces of the oil cooler, its efficiency is
valve(s).
impaired.
2. Turn the spin--on filter element counterclockwise Each month it is recommended that the oil cooler be
to remove it from the filter housing. Inspect the filter.
cleaned by directing compressed air which contains a
nonflammable, non--caustic safety solvent through
NOTICE the core of the oil cooler. This should remove the
If there is any indication of formation of varnishes,
accumulation of grease, oil and dirt from the exterior
shellacs or lacquers on the oil filter element, it is a
surfaces of the oil cooler core so that the entire cooling
warning the compressor lubricating oil has im-
area can transmit the heat of the lubricating and
proper characteristics and should be immediately
changed. cooling oil to the air stream.

3. Inspect the oil filter head to be sure the gasket was In the event foreign deposits, such as sludge and lac-
removed with the oil filter element. Clean the gasket quer, accumulate in the oil cooler to the extent that its
seal area on the oil filter head. cooling efficiency is impaired, a resulting high dis-
charge air temperature is likely to occur, causing shut
down of the unit. To correct this situation it will be nec-
essary to clean it using a cleaning compound in accor-
NOTICE dance with the manufacturer’s recommendations.
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

1. Lubricate the new filter gasket with the same oil

being used in the machine.

2. Install new filter by turning element clockwise until

gasket makes initial contact. Tighten an additional 1/2
to 3/4 turn.

3. Start unit and allow to build up to rated pressure.

Check for leaks before placing unit back into service.

Book 22478358 (7/02) (38)

COMPRESSOR OIL
The lubricating and cooling oil must be replaced every
500 hours of operation or six (6) months, whichever
comes first.

RECEIVER--SEPARATOR SYSTEMS

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.

S Open service valve at end of machine.

S Ensure pressure is relieved, with BOTH:

-- Discharge air pressure gauge reads zero (0).
-- No air discharging from service valve.

When draining oil, remove plug from the separator

tank drain fitting.

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 receiver--separator tank. As the
compressed air enters the tank, the change in velocity
and direction drop out most of the oil from the air.

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.

Book 22478358 (7/02) (39)

 S Place a straightedge across top of element and mea-
The life of the oil separator element is dependent upon sure from bottom of straightedge to bottom of ele-
the operating environment (soot, dust, etc.) and ment (See Fig. 4.1).
should be replaced every twelve months or 2000
hours. To replace the element proceed as follows: S Replace scavenge tube in cover (cover is still off of
tank).
S Ensure the tank pressure is zero.
S Measure from bottom of cover to end of scavenge
S Disconnect the hose from the scavenge tube. tube. Measurement should be from 1/8” to 1/4” less
than the element measurement. If not, cut to size.
S Remove scavenge tube from tank cover. S Remove scavenge tube.

S Disconnect service line from cover. S Reposition cover (use care not to damage gaskets).

S Remove cover mounting screws.

S Replace cover mounting screws: tighten in a criss-
S Remove cover and element. cross pattern.

S Remove any gasket material left on cover or tank. S Reconnect service line. Replace scavenge tube.
Reconnect hose.
S Install new element.
S Close service valve. Start unit and look for leaks.
NOTICE
When replacing the element, the scavenge lines,
Do not remove staples from the element/gasket orifice, filter, and check valve should be thoroughly
connection. cleaned and the oil changed.

cut line
if necessary

Book 22478358 (7/02) (40)

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

High pressure air can cause severe injury or death Field Repair of Texture Paint
from hot oil and flying parts. Always relieve
pressure before removing caps, plugs, covers or
1. The sheet metal should be washed and
other parts from pressurized air system.
clean of foreign material and then
thoroughly dried.
The scavenge line originates at the receiver--separa-
tor tank cover and terminates at the compressor air- 2. Clean and remove all grease and wax from
end near the oil filter element. An orifice check valve the area to be painted using Duponts 3900S
is located on the scavenge tube. Cleaner prior to sanding.
Once a year or every 1000 hours of operation,
whichever comes first, replace the separator element 3. Use 320 grit sanding paper to repair any
and clean the scavenge orifice/check valve. scratches or defects necessary.

NOTE: Excessive oil carry--over may be caused by 4. Scuff sand the entire area to be painted with
an oil--logged separator element. Do not replace a red scotch brite pad.
element without first performing the following
maintenance procedure: 5. Wipe the area clean using Duponts 3900S.
1. Check oil level. Maintain as indicated earlier in
this section. 6. Blow and tack the area to be painted.

7. Apply a smooth coat of Duponts 1854S

2. Thoroughly clean scavenge line, any orifice
Tuffcoat Primer to all bare metal areas and
and check valve.
allow to dry.
3. Assure minimum pressure valve/orifice is op-
8. Apply 2 medium -- wet coats of Duponts
erational.
222S Adhesion Promoter over the entire
area to be painted, with a 5 minute flash in
4. Run unit at rated operating pressure for 30 to 40
between coats.
minutes to permit element to clear itself.
9. To apply the texture coat, use Duponts
EXTERIOR FINISH CARE 1854S Tuffcoat Primer. The proper
This unit was painted and heat cured at the factory technique to do this is to spray the Tuffcoat
with a high quality, thermoset polyester powder coat- Primer using a pressure pot and use about
ing. The following care will ensure the longest possible 2--5 pounds of air pressure. This will allow
life from this finish. the primer to splatter causing the textured
look. Note: you must be careful not to put
1. If necessary to remove dust, pollen, etc. from too much primer on at one time, this will
housing, wash with water and soap or dish effect the amount of texture that you are
washing liquid detergent. Do not scrub with a trying to achieve. Allow the texture coat to
rough cloth, pad, etc. flash for 20 minutes or until dry to touch.

2. If grease removal is needed, a fast evaporating 10. Apply any of Duponts Topcoat Finishes
alcohol or chlorinated solvent can be used. Note: such as Imront or Centarit according to
This may cause some dulling of the paint finish. 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.

Book 22478358 (7/02) (41)

 MAINTENANCE SCHEDULE
These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty or wet).

Daily Weekly Monthly 3 MOS . 6 MOS. 12 MOS.

SMALL UNITS (P100-- P600) 250 hours 500 hours 1000 hours
LARGE UNITS (HP600-- P1600) 500 hours 1000 hours 2000 hours
**Hydraulic Oil Level C R
Compressor Oil Level C
Engine Oil Level C
**Radiator Coolant Level C
Gauges/Lamps C
Air Cleaner Service Indicators C
Fuel Tank (fill at end of day) C DRAIN
**Fuel/Water Separator DRAIN C
Air Cleaner Precleaner Dumps C
Fan/Alternator Belts C
Battery Connections/Electrolyte C
**Tire Pressure and Surface C
**Wheel Lug Nuts C
Hoses (oil, air, intake, etc.) C
Automatic Shutdown System Test C
Air Cleaner System Visual C
Compressor Oil Cooler Exterior C CLEAN
**Engine Radiator Exterior C CLEAN
Fasteners, Guards C
Air Cleaner Elements WI
** Fuel/Water Separator Element R
*Compressor Oil Filter Element B A
*Compressor Oil R
**Wheels (bearings, seals, etc) C C
Engine Coolant Test C R
Shutdown Switch Settings Test C
Scavenge Orifice & related parts CLEAN
Oil Separator Element R
**Lights (running, brake, & turn) CBT
**Pintle Eye Bolts CBT
Engine (oil changes, oil & fuel filters, etc) R

**Disregard if not appropriate for this particular machine.

*NXP Units -- consult manual

R=replace, C=check (adjust if necessary), WI=OR when indicated, CBT = check before towing.

A = Small Units

B = Large Units

Refer to specific sections of the operator’s manual for more information.

Book 22478358 (7/02) (42)

 SECTION 7 -- LUBRICATION

GENERAL INFORMATION

Lubrication is an essential part of preventive mainte- If the unit has been operated for the time/ hours men-
nance, affecting to a great extent the useful life of the tioned above, it should be completely drained of oil. If
unit. Different lubricants are needed and some compo- the unit has been operated under adverse conditions,
nents in the unit require more frequent lubrication than or after long periods in storage, an earlier change peri-
others. Therefore, it is important that the instructions od may be necessary as oil deteriorates with time as
regarding types of lubricants and the frequency of their well as by operating conditions.
application be explicitly followed. Periodic lubrication
of the moving parts reduces to a minimum the possibil-
ity of mechanical failures. WARNING
The Preventive Maintenance Schedule shows those
High pressure air can cause severe injury or death
items requiring regular service and the interval in
from hot oil and flying parts. Always relieve pres-
which they should be performed. A regular service
sure before removing caps, plugs, covers or other
program should be developed to include all items and
parts from pressurized air system. Ensure the fol-
fluids. These intervals are based on average
lowing conditions are met:
operating conditions. In the event of extremely severe
(hot, cold, dusty or wet) operating conditions, more
frequent lubrication than specified may be necessary. -- Discharge air pressure gauge reads zero (0).
Details concerning lubrication of the running gear are -- No air discharging from an “open” manual
in Maintenance Section. blowdown valve.

All filters and filter elements for air and compressor lu- An oil change is good insurance against the accumula-
bricant must be obtained through Ingersoll--Rand to tion of dirt, sludge, or oxidized oil products.
assure the proper size and filtration for the compres-
sor. Completely drain the receiver-- separator, piping, and
oil cooler. If the oil is drained immediately after the unit
has been run for some time, most of the sediment will
COMPRESSOR OIL CHANGE be in suspension and, therefore, will drain more readi-
ly. However, the fluid will be hot and care must be tak-
These units are normally furnished with an initial sup- en to avoid contact with the skin or eyes.
ply of oil sufficient to allow operation of the unit for ap-
proximately 6 months or 1000 hours, whichever
comes first. If a unit has been completely drained of all After the unit has been completely drained of all old oil,
oil, it must be refilled with new oil before it is placed in close the drain valve. Add oil in the specified quantity
operation. Refer to specifications in Lubrication Table. at the filler plug. Tighten the filler plug and run the ma-
chine to circulate the oil. Check the oil level WHEN
NOTICE RUNNING AT FULL LOAD. If not near the middle of
the sight tube, stop the unit and make corrections. DO
Some oil types are incompatible when mixed and re-
NOT OVERFILL.
sult in the formation of varnishes, shellacs, or lacquers
which may be insoluble. Such deposits can cause se-
rious troubles including clogging of the filters. Where NOTICE
possible, do NOT mix oils of different types and avoid Ingersoll--Rand provides compressor oil specifically
mixing different brands. A type or brand change is formulated for Portable Compressors and requires the
best made at the time of a complete oil drain and refill. use of these fluids in order to obtain extended limited
airend warranty.

Book 22478358 (7/02) (43)

Portable Compressor Fluid Chart

Refer to these charts for correct compressor fluid RATED OPERATING PRESSURE
required. Note that the selection of fluid is dependent on
the design operating pressure of the machine and the 100 - 300 PSI 350 PSI
125_F
ambient temperature expected to be encountered 50_C
before the next oil change.
40_C 104_F IR IR
Note: Fluids listed as “preferred” are required for XHP605 XHP 1001
extended warranty. IR
30_C 86_F XHP405

Compressor oil carryover (oil consumption) may

be greater with the use of alternative fluids. IR
20_C 65_F
PRO-- TECt

Design Operating Ambient Specification

Pressure 10_C 50_F
Temperature

Preferred: 0_C 32_F

100 psi to 300 psi --10_F to 125_F IR Pro-- Tect
(--23_C to 52_C)
Alternate: - 10_C 14_F
ISO Viscosity Grade 46
with rust and oxidation 10_F
inhibitors, designed for - 20_C
air compressor service. - 10_F
- 30_C - 22_F
Preferred: Consult Factory Consult Factory
350 psi (--23_C to 52_C) IR XHP 605
--10_F to 125_F - 40_C - 40_F
Alternate:
IR XHP405
ISO Viscosity Grade 68
Group 3 or 5 with rust
and oxidation inhibitors
designed for air compres-
sor service. Preferred Ingersoll--Rand Fluids -- Use of these fluids with
Preferred: original I--R filters can extend airend warranty. Refer to
65_F to 125_F XHP605 operator’s manual warranty section for details or contact
(--18_C to 52_C) IR XHP1001 your I--R representative.

Ingersoll--Rand 1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. 220 gal. (836 litre)
Preferred Fluids (208.2Litre)
Preferred:
IR Pro--Tect 36899698 36899706 36899714 36899722
IR XHP605 -- 22252076 22252050 22252068
IR XHP1001 -- 35612738 35300516 --
XHP405 -- 22252126 22252100 22252118
Engine Oil 54480918 36875938 36866903

Book 22478358 (7/02) (44)

 SECTION 8 -- Trouble Shooting
INTRODUCTION B. Do The Simplest Things First
Trouble shooting for a portable air compressor
is an organized study of a particular problem or Most troubles are simple and easily corrected. For
example, most complaints are “low capacity” which may
series of problems and a planned method of
be caused by too low an engine speed or “compressor
procedure for investigation and correction. over-- heats” which may be caused by low oil level.
The trouble shooting chart that follows
includes some of the problems that an Always check the easiest and most obvious things first;
operator may encounter during the operation following this simple rule will save time and trouble.
of a portable compressor.

The chart does not attempt to list all of the Note: For trouble shooting electrical problems, refer to
troubles that may occur, nor does it attempt to the Wiring Diagram Schematic found in Parts List
give all of the answers for correction of the Section.
problems. The chart does give those
problems that are most apt to occur. To use the
trouble shooting chart:
C. Double Check Before Disassembly
A. Find the “complaint” depicted as a bold The source of most compressor troubles can be traced
heading. not to one component alone, but to the relationship of one
component with another. Too often, a compressor can be
B. Follow down that column to find the po- partially disassembled in search of the cause of a certain
tential cause or causes. The causes are trouble and all evidence is destroyed during disassembly.
listed in order (1,2,3 etc.) to suggest an Check again to be sure an easy solution to the problem
order to follow in trouble shooting. has not been overlooked.

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
ACTION PLAN failure will not be repeated. A complaint of “premature
breakdown” may be corrected by repairing any improper
A. Think Before Acting wiring connections, but something caused the defective
wiring. The cause may be excessive vibration.
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?

Book 22478358 (7/02) (45)

 TROUBLE SHOOTING CHART
Bold Headings depict the COMPLAINT -- Subheadings suggest the CAUSE
Note: Subheadings suggest sequence to follow troubleshooting.

1. Unit Shutdown: Corrective Action

Out of Fuel Add CLEAN diesel Fuel
Compressor Oil Temp. Too High See Complaint 10
Engine Water Temp. Too High Check coolant level. If necessary, Add.
Engine Oil Pressure Too Low See Complaint 3 and Complaint 4.
Broken Engine Fan Belt Replace fan belt.
Loose Wire Connection Wiggle wires at switches & connector blocks. Make repairs.
Low Fuel Level Shutdown Switch Replace switch.
Defective Discharge Air Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Replace switch.
Defective Shutdown Solenoid Replace solenoid.
Malfunctioning Relay Replace relay.
* < 16 Volts at Shutdown Solenoid Check battery and alternator. Make repairs.
Blown Fuse Replace fuse.
Engine Malfunctioning See Trouble Shooting in Engine Manual.
Airend Malfunctioning See Complaint 10.

2. Won’t Start/Run:
Low Battery Voltage Check electrolyte level. Check connections.
* <16 Volts at Shutdown Solenoid Charge battery and alternator. Make repairs.
Blown Fuse Replace fuse.
Malfunctioning Start Switch Replace switch.
Defective Safety Bypass Switch Replace switch.
Clogged Fuel Filters Service filters. See Engine Operator’s Manual.
Out of Fuel Add CLEAN fuel.
Compressor Oil Temp. Too High See Complaint 10.
Engine Water Temp. Too High Check fluid level. If necessary, Add.
Engine Oil Pressure Too Low See Complaint 3 and Complaint 4.
Loose Wire Connection Repair or replace connection.
Defective Discharge Air Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Replace switch.
Defective Shutdown Solenoid Replace solenoid.
Malfunctioning Relay Replace relay.
Engine Malfunctioning See Trouble Shooting in Engine Manual.
Airend Malfunctioning See Complaint 10.

3. Engine Temperature Lamps Stays On:

Broken Engine Fan Belt Replace fan belt set.
Malfunctioning Circuit Board Replace circuit board.
* Ambient Temp. >125_F (52_C) Above spec limit.
Dirty Operating Conditions Move unit to cleaner environment.
Dirty Cooler Clean exterior of cooler.
* Out of Level >15 degrees Relocate or reposition unit.
Operating Pressure Too High Reduce pressure to spec.
Recirculation of Cooling Air Close side doors.
Loose Wire Connection Repair or replace.
Malfunctioning circuit board. Replace circuit board.

* : > = greater than, < = less than

Book 22478358 (7/02) (46)

4. Engine Oil Pressure Lamp Stays On: Corrective Action
Low Oil Level Add oil.
Out of Level >15 degrees Relocate or reposition.
Wrong Lube Oil See Engine Oil Spec. Change oil.
Clogged Oil Filter Element(s) Replace element(s).
Engine Malfunctioning See Trouble Shooting in Engine Manual.
Loose Wire Connection. Repair or replace.
Malfunctioning circuit board Replace circuit.

5. Engine Temperature Lamps Stays Off:

Bulb Burned Out Replace circuit board.
Malfunctioning circuit board Replace circuit board.

6. Engine Oil Pressure Lamp Stays Off:

Bulb Burned Out Replace circuit board.
Malfunctioning circuit board Replace circuit board.

7. Alternator Lamp Stays On:

Loose or Broken Belts Tighten or replace belt set.
Loose Wire Connection Repair or replace connection.
Low Battery Voltage Check electrolyte level. Add if necessary.
Check connectors. Clean & tighten.
Recharge battery.
Malfunctioning Alternator Repair or replace alternator.
Malfunctioning circuit board Replace circuit board.

8. Alternator Lamp Stays Off:

Bulb Burned Out Replace circuit board.
Loose Wire Connection Repair or replace connector.
Malfunctioning circuit board Replace circuit board.

9. Unit Fails To Shutdown:

Defective Low Fuel Shutdown Switch Pull wire off shutdown solenoid. Replace switch.
Defective Discharge Air Temperature Switch Pull wire off. Replace switch.
Defective Engine Oil Pressure Switch Pull wire off. Replace switch.
Defective Shutdown Solenoid Carefully block air inlet to stop engine.
Malfunctioning Relay Replace solenoid.
Defective Safety Bypass Switch Pull wire off shutdown solenoid. Replace relay.
Pull wire off shutdown solenoid. Replace defective
item.

Book 22478358 (7/02) (47)

 10. Excessive Compressor Oil Temperature: Corrective Action
Ambient Temp. > 125_F (52_C) Above spec limit.
Out of Level > 15 degrees Relocate or reposition unit.
Low Oil Level Add oil. Look for any leaks.
Wrong Lube Oil Check spec in this manual.
Dirty Cooler Clean exterior surfaces.
Dirty Operating Conditions Move unit to cleaner environment.
Clogged Oil Filter Elements Replace elements. Change oil.
Loose or Broken Belts Tighten or replace belt set.
Operating Pressure Too High Reduce pressure to spec.
Recirculation Of Cooling Air Close side doors. Replace belly pan.
Malfunctioning Thermostat Replace thermostat in bypass valve.
Malfunctioning Fan Check fan belt tension. Tighten or replace belt set.
Defective Oil Cooler Relief Valve Replace valve.
Defective Minimum Pressure Valve Repair or replace valve.
Blocked or Restricted Oil Lines Clean by flushing or replace.
Airend Malfunctioning See Complaint 11, 12, 13, 15, 16 or 18.

11. Engine RPM Down:

Clogged Fuel Filter Clean primary filter. Replace final filter. Drain tanks.
Add CLEAN fuel.
Operating Pressure Too High Reduce pressure to spec limit.
Incorrect Pressure Regulator Adjustment See Section 6 in this manual.
Malfunctioning Pressure Regulator Replace regulator.
Incorrect Linkage Adjustment See Section 6 in this manual.
Dirty Air Filter Clean or replace elements.
Malfunctioning Air Cylinder Replace air cylinder and adjust per Section 6.
Wrong Air Filter Element Install correct element.
Defective Separator Element Install new element per page 21.
Engine Malfunctioning See Trouble Shooting in Engine Manual.
Airend Malfunctioning Refer to Airend Rebuild Manual.

12. Excessive Vibration:

Rubber Mounts, Loose or Damaged Tighten or replace.
Defective Fan Replace fan.
Drive Coupling Defective Replace coupling.
Engine Malfunctioning See Trouble Shooting in Engine Manual.
Airend Malfunctioning See Complaint 15 and 17.
Anti--rumble valve not working. Repair or Replace.
Engine idle speed too low. Raise “No Load” speed per Section 6.

13. Low CFM:

Dirty Air Filter Clean or replace elements.
Incorrect Linkage Adjustment See Section 6 in this manual.
Incorrect Pressure Regulator Adjustment See Section 6 in this manual.
Malfunctioning Pressure Regulator Replace regulator.
Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve. Make adjustment per Section 6.
Malfunctioning Air Cylinder Replace air cylinder.
Defective Minimum Pressure Valve Repair or replace valve.
Defective Separator Element Install new element per Page 21.
Wrong Air Filter Element Install correct element.

Book 22478358 (7/02) (48)

14. Short Air Cleaner Life: Corrective Action
Dirty Operating Conditions Move unit to cleaner environment.
Inadequate Element Cleaning Install new element.
Incorrect Stopping Procedure Read procedure in this manual.
Wrong Air Filter Element Install proper element.
Oil Pump Drive Coupling Inspect coupling. If necessary, replace coupling.

15. Excessive Oil In Air:

High Oil Level Read procedure in this manual.
Out of Level > 15 degrees Relocate or reposition unit.
Clogged Scavenge Orifice Remove scavenge orifice. Clean and Replace.
Scavenge Tube Blocked Remove scavenge tube. Clean and Replace.
Defective Scavenge Check Valve Remove check valve. Replace with new valve.
Sep. Tank Blow Down Too Quickly Allow unit to blow down automatically.
Defective Minimum Pressure Valve Remove valve. Repair valve and replace.

16. Oil Seal Leak:

Contaminated Lube Oil Drain and flush system. Add new CLEAN oil.
Blocked or Restricted Oil Line(s) Remove, clean and replace line(s).
Malfunctioning Seal Refer to Airend Rebuild Manual.
Scored Shaft See instructions in new seal kit.

17. Will Not Unload:

Leak in Regulator Piping Find and repair leak(s).
Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual.
Malfunctioning Pressure Regulator Replace regulator.
Malfunctioning Inlet Butterfly Valve Inspect valve fit. Readjust per Section 6.
Ice in Regulation Lines/Orifice Apply heat to line(s) and or orifice.

18. Oil In Air Cleaner:

Incorrect Stopping Procedure Read Procedure in this manual.
Oil Pump Drive Coupling Inspect coupling. Replace if necessary.
Discharge Check Valve Faulty Replace.

19. Safety Valve Relieves:

Operating Pressure Too High Reduce pressure to spec limit.
Leak In Regulator Piping Repair leak(s).
Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual.
Malfunctioning Pressure Regulator Replace regulator.
Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve fit. Readjust per Section 6.
Defective Safety Valve Replace safety valve.
Defective Separator Element Remove element. Install new.
Ice in Regulation Lines/Orifice Apply heat to lines and/or orifice.

Book 22478358 (7/02) (49)