Ingersoll-Rand 9/235 HA IR Operating instructions

Ingersoll land
OPERATING and MAINTENANCE,
MANUAL
COMPRESSOR MODEL
9/235
HA IR
Code C:
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.
<fjj) Ingersoll.and
Portable Power
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
www.portablepower.irco.com
Book 22364079 (3/04)
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.
Revised (09-12)

TABLE OF CONTENTS
TITLE PAGE
FOREWORD .
SECTION 1 - SAFETY .
SAFETY PRECAUTIONS .
General Information .
Hazardous Substance Precaution .
SAFETY LABELS .
SECTION 2 - WARRANTY .
WARRANTy .
Warranty Information .
GENERAL WARRANTY INFORMATION .
WARRANTY REGiSTRATION .
Complete Machine Registration .
SECTION - 3 GENERAL DATA .
GENERAL DATA .
SPECIFICATIONS .
SECTION 4 - OPERATING INSTRUCTIONS .
OPERATING INSTRUCTIONS .
COMMISSIONING .
COMPRESSOR MOUNTING .
PRIOR TO STARTING .
STARTING .
STOPPiNG .
EMERGENCY STOPPING .
RE-STARTING .
MONITORING DURING OPERATION .
DECOMMISSIONING .

TABLE OF CONTENTS
TITLE PAGE
SECTION 5 - MAINTENANCE .
GENERAL .
SCHEDULED MAINTENANCE .
COMPRESSOR OIL LEVEL .
COMPRESSOR OIL .
AIR CLEANER .
GAUGES .
FUEL TANK .
BATTERy .
COMPRESSOR OIL, HYDRAULIC OIL and FUEL COOLERS .
RADIATOR .
HOSES .
COMPRESSOR OIL FILTERS .
FASTENERS .
COMPRESSOR and HYDRAULIC OIL .
ENGINE COOLING FAN DRIVE .
AIR COOLING FAN DRIVE .
FINISH CARE .
EXTERIOR FINISH CARE .
FIELD REPAIR
of TEXTURE PAINT .
MAINTENANCE SCHEDULE .
SECTION 6 - LUBRICATION .
LUBRICATION .
SECTION 7 - FAULT FINDING .
Fault Finding Chart .
SECTION 8 - PARTS ORDERING .
PARTS ORDERING .
GENERAL .
DESCRIPTION .
FASTENERS .
MARKINGS AND DECALS .
HOW TO USE PARTS LIST .
HOW TO ORDER .
TERMS AND CONDITIONS ON PARTS ORDERS .
AIREND EXCHANGE PROGRAM .
SECTION 9 - PARTS LIST .

FOREWORD
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Book 22364079 (3/04)

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2
FOREWORD
Nothing contained in this document is intended to extend any promise, warranty or representation,
expressed or implied, regarding the Ingersoll-Rand products described herein. Any such warranties or
other terms and conditions
of sale of products shall be in accordance with the standard terms and
conditions
of sale for such products, which are available upon request.
This manual contains instructions and technical data to cover all routine operation and scheduled
maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope
of this
manual and should be referred to an authorized Ingersoll-Rand service department.
All components, accessories, pipes and connectors added to the compressed air system should be:
of good quality, procured from areputable manufacturerand, wherever possible, be of atype
approved by Ingersoll-Rand.
clearly rated for apressure at least equal to the machine maximum allowable working
pressure.
compatible with the compressor lubricant/coolant.
accompanied with instructions for safe installation, operation and maintenance.
Details
of approved equipment are available from Ingersoll-Rand Service departments. The use of
repair parts other than those included within the Ingersoll-Rand approved parts list may create
hazardous conditions over which Ingersoll-Rand has
no control. Therefore, Ingersoll-Rand cannot be
held responsible for equipment
in which non-approved repair parts are installed.
Ingersoll-Rand reserves the right to make changes and improvements to products without notice and
without incurring any obligation to make such changes
or add such improvements to products sold
previously.
The intended uses
of this machine are outlined below and examples of unapproved usage are also
given. However, Ingersoll-Rand cannot anticipate every application
or work situation that may arise. If
in doubt, consult supervision.
This machine has been designed and supplied for above ground operation to be used for compression
of normal ambientaircontaining noadditional gases, vapors or particleswithin the ambienttemperature
range specified
in the general data section of this manual.
This machine should not be used:
1. For direct or indirect human consumption of the compressed air.
B. Outside the ambient temperature range of minus 20°F to 115°F.
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 22035593 (8/03)

SECTION 1 - SAFETY
Book 22364079 (3/04)

2
Operating and Maintenance
SAFETY PRECAUTIONS
General Information
Ensure that the operator reads and understands
the decals and consults the manuals before
maintenance
or operation.
Ensure that the Operation and Maintenance
manual, and the manual holder if equipped, are
not removed permanently from the machine.
Ensure that maintenance personnel are
adequatelytrained, competentand have read the
manuals.
Make sure that all protective covers are in place
and that the canopy/doors are closed during
operation.
The specification
of this machine is such that the
machine is not suitable for use
in flammable gas
risk areas. Ifsuch an application is required then
all local regulations, codes
of practice and site
rules must be observed.
To ensure that the
machine can operate
in asafe and reliable
manner, additional equipment such as gas
detection, exhaust spark arrestors, and intake
(shut-off) valves may be required, dependent on
local regulations or the degree
of risk involved.
Air discharged from this machine may contain
carbon monoxide or other contaminants which
will cause serious injury
or death. Do not breathe
this air.
Compressed air can be dangerous ifincorrectly
handled. Before doing any work on the unit,
ensurethatall pressure is vented from the system
and that the machine cannot be started
accidentally.
Ensure that the machine is operating atthe rated
pressure and that the rated pressure is known to
all relevant personnel.
All air pressure equipment installed
in or
connected to the machine must have safe
working pressure ratings
of at least the machine
safety valve rating.
Ifmore than one compressor is connected to one
common downstream plant, effective check
SECTION 1 - SAFETY
valves and isolation valves must be fitted and
controlled by work procedures, so that one
machine cannot accidentally be pressurized or
over pressurized by another.
Compressed air must not be used for afeed to
any form
of breathing apparatus or mask.
The discharged air contains avery small
percentage ofcompressorlubricating oil and care
should be taken to ensure that downstream
equipment
is compatible.
Ifthe discharged air is to be ultimately released
into aconfined space, adequate ventilation must
be provided.
When using compressed air, always use
appropriate personal protective equipment.
All pressure containing parts, especially flexible
hoses and their couplings, must be regularly
inspected, be free from defects and be replaced
according to the Manual instructions.
Avoid bodily contact with compressed air.
Never operate unit without first observing all
safety warnings and carefully reading the
operation and maintenance manual shipped from
the factory with this machine.
Neveroperate the engine
of this machine inside a
building without adequate ventilation. Avoid
breathing exhaust fumes when working on
or
near the machine. Do not alter or modify this
machine.
Abattery contains sulfuric acid and can give off
gases which are corrosive and potentially
explosive. Avoid contact with skin, eyes and
clothing.
In case of contact, flush area
immediately with water.
Exercise extreme caution when using booster
battery. Tojump battery, connect ends of one
booster cable to the positive (+) terminal
of each
battery. Connect one end
of other cable to the
negative (-) terminal
of the booster battery and
otherend to aground connection awayfrom dead
battery (to avoid aspark occurring nearany
explosive gases that may be present). After
starting unit, always disconnectcables
in reverse
order.
Book 22364079 (3/04)

SECTION 1 - SAFETY
Never operate unit without first observing all
safety warnings and carefully reading the
operation and maintenance manual shipped from
the factory with this machine.
This machine may include such materials as oil,
diesel fuel, antifreeze, brake fluid, oil/air filters
and batteries which may require proper disposal
when performing maintenance and service tasks.
Contact local authorities for proper disposal
of
these materials.
High Pressure Air can cause serious injury or
death. Relieve pressure before removing filler
plugs/caps, fittings
or covers.
Air pressure can remain trapped
in air supply line
which can result in serious injury ordeath. Always
carefully vent air supply line at tool or vent valve
before performing any service.
This machine produces loud noise with the doors
open orservice valve vented. Extended exposure
to loud noise can cause hearing loss. Always
wear hearing protection when doors are open or
service valve is vented.
Never inspect or service unit without first
,disconnecting battery cable(s) to prevent
accidental starting.
Do not remove the pressure cap from aHOT
radiator. Allow radiator to cool down before
removing pressure cap.
Do not use petroleum products (solvents or fuels)
under high pressure as this can penetrate the
skin and result in serious illness. wear eye
protection while cleaning unitwith compressed air
to prevent debris from injuring eye(s).
Disconnected air hoses whip and can cause
serious injury or death. Always attach asafety
flow restrictor to each hose at the source
of
supply or branch line in accordance with OSHA
Regulation 29CFR Section 1926.302(b).
Hotpressurized fluid can cause serious burns. Do
not open radiator while hot.
Rotating fan blade can cause serious injury. Do
not operate without guard
in place.
Use care to avoid contacting hotsurfaces (engine
Book 22364079 (3/04)
Operating and Maintenance
exhaust manifold and piping, air receiver and air
discharge piping, etc.).
Ether is an extremely volatile, highly flammable
gas. USE SPARINGLY! Do NOT use ETHER if
unit has GLOWPlug starting aid. Engine damage
will result.
Never allow the unit to sit stopped with pressure
in the receiver-separator system. As a
precaution, open the manual blowdown valve.
Neveroperate unitwith guards, covers orscreens
removed. Keep hands, hair, clothing, tools, blow
gun tips, etc. well away from moving parts.
Make sure wheels, tires and tow bar connectors
are
in safe operating condition and tow bar is
properly connected before towing.
Whenever the machine is stopped, air will flow
back into the compressor system from devices or
systems downstream of the machine unless the
servicevalve isclosed. Install acheckvalve atthe
machine service valve to prevent reverse flow
in
the event of an unexpected shutdown when the
service valve is open.
Hazardous Substance
Precaution
The following substances are used in the
manufacture
of this machine and may be
hazardous to health ifused incorrectly.
Precaution: Avoid ingestion, skin contact and
breathing fumes for the following substances:
Antifreeze, Compressor Oil, Engine Lubricating
Oil, Preservative Grease, Rust Preventative,
Diesel Fuel and Battery Electrolyte.
The following substances may be produced
during the operation of this machine and may be
hazardous to health:
Avoid build-up of Engine Exhaust Fumes in
confined spaces.
Avoid breathing Exhaust Fumes.
Avoid breathing Brake Lining Dust during
maintenance.
3

Operating and Maintenance
SAFETY LABELS
SECTION 1 - SAFETY
Look for these signs on machines shipped to international markets outside North America,
which point out potential hazards to the safety of you and others. Read and understand
thoroughly. Heed warnings and follow instructions. If you do not understand, inform you
supervisor.
Corrosion risk
WARNING: electrical shock risk.
Diesel Fuel.
No open flame.
WARNING -Flammableliquid.
HotSurface
Parking Brake
Do not operetethemachlne
without guard being fitted.
When parking us. prop stand,
handbrake and wheel chocks.
•
UftJng point
No open flame
•
UftIng point
Alr/lasflow orAir discharge.
4
WARNING -Hot and harmful exhaust gas. Tie down point
Do not breathe the compressed
air frOm this maoblne.
Book 22364079 (3/04)

SECTION 1 - SAFETY Operating and Maintenance
Read the Operation and Maintenance
manual before operation or maintenance
of·this machine Is undertaken.
WARNING: Consultthe operation
and maintenance manual before
performing any maintenance.
WARNING -Maintain correct tire .pressure.
(Refer to theGENERALINFOFlMATlON section
of this manual) ~
a1,5m. ~ if IP54+ £
Rough Service Deslgnallon
Wet Location Operation
Do notstack
Do not use fork 11ft truck from lhlsslde @
~
Replace any cracked
p.rotectivi .hl.I~~:
~. ;'.
Do not operate with the door, or enolosure
open.
WARNING - Before connecting the tow bar or
whenp'.perlng to tow, consult the operation
an:d IRIlnt_nce manual.
Book 22364079 (3/04)
On tower).
o
Off to • .,).
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5

Operating and Maintenance SECTION 1 - SAFETY
~
D
011 Drain
Do not exceed the speed limit.,
WARNING - For operating temperature below
O°C, consult the operation and maintenance
manual.
WARNING - Do not undertake any
maintenance on ·thls machln.until the
electrl~1 supply Is disconnected and the air
pressure Istotally relieved.
"Read the Operation and Malntenanoemanual
befOre. operation .. or maintenance of this
machine. undertaken
Do not remove the Operating and Maintenance
manuallnd mlnual holde, from "Ie machine.
6
Pressurized vessel.
Use fork 11ft truck from this side only. Pressurized component or system.
Book 22364079 (3/04)

SECTION 1 - SAFETY Operating and Maintenance
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.
ADANGER
(Red Background)
Indicates the presence of ahazard which WILL cause serious injury,
death or property damage, if ignored.
(Orange Background)
Indicates the presence of ahazard which CAN cause serious injury, death or property
damage,
if ignored.
(Yellow Background)
Indicates the presence of ahazard which WILL orcan cause injuryor propertydamage,
if ignored.
NOTICE
(Blue Background)
NOTE: Indicates important set-up, operating or maintenance information.
Book 22364079 (3/04) 7

Operating and Maintenance SECTION 1 - SAFETY
~WARNING
& WARNING
Trapped alrprt8.ure.
Cancau •• serious
Injury or death.
Close service valve and
operate taotto vent
tr~ped· air before
perfOrming any.· service.
lhWARI
11 DANGER
Discharted air can contain carbon
monoxide oroth. contamlnams.
Wlilcau ••• lrIoullnJury or death.
Do not breathe this air.
Hot pr8IIUI1Hd fluid. f-
Cln oau •• AriOUI
bums.
00 not openrad
while hot.
High preasur •• ,.
Cancau .... rIoul
Injury ordeath.
Relieve preuurebefore
removing fiDerplup/caps.
fittings orcovera ..
8Book 22364079 (3/04)

SECTION 1 - SAFETY
& WARNING
Improperoperatlonof·thla equlRment.
Can c.use serious Injury or death.
Read O~rator's Manual supplied with
this m,aChine before operation or
servioing.
Modification oralteration of this machine.
Can caul. serious InJury or death.
Do notalter or modify this machine
without the ~xpress written consent of
the manufactUrer ..
LtWARNING
Rotating fan blad••
Can cause serioul . ."",.~~-....
Injury.
Do not operate without
guard in place.
LhWARNING
Door under pressure.
Can cause serious Injury.
Use both hands ·to open door
when machine is running ..
DO NOT WELD.
ELECTRONIC DAMAGE
WILL OCCUR.
This engine is equipped with an
eleclron·lc engine controller and
other electron.1e components ..
Book 22364079 (3/04)
Operating and Maintenance
LtWARNING
Falling off machine ..
can cause serious InJury ~
or death. f
Access liftinp bail from
inside machine.
Disconnected air ho ... Whip.
Caneauee •• dous .... tt.
InjUry or duth. r>p.
~
When using air tools
attach·~ device
(OSHA vaNe) at source of
air supply for each· tool.
LhWARNING
Combustible gas.
C8n cause serious bu
blindn ... or death.
Keep ,parksand open
flames away from batteries.
9

Operating and Maintenance
CAUTION
SECTION 1 - SAFETY
& WARNING
DO NOT USE ETHER.
ENGINE DAM.AGE WILL OCCUR"
This engine is equipped with an
electric heater starting aid.
High pressureal,.
Can causeserloue
Injury or death.
Relieve pressure before
removing fiUer plugS/caps,
fittings or covers.
ii: .• ,: .O .•...... ~,.. .... ~ ..... ~ ... ,,:,J;>~...... ...
r
USE DIESEL
FUEL ONLY
NOTICE
COOlANT Fill INSTRUCTIONS
Adding:
Remove radiator cap. Top offat radiator. Use
same antj""freeze mixture as in radiator.
'i . Replacing:
With system cool, remove radiator cap. Drain
coolant and close drain. /4tr.diator. reftO system.
Replace radiator cap. Run for 30 minutes .. · Stop
and allowtocootN. radiator, add coolant as
necessary to reach "Coler level.
10
FREE SAFETY DeCALSI
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 decalsareid:entified 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 safetyl Assure that
decals are present on the machines. Replace decals that
are not readable.
Book 22364079 (3/04)

SECTION 2 - WARRANTY
Book 22364079 (3/04)

Operating and Maintenance
WARRANTY
Warranty Information
SECTION 2 - WARRANTY
12
Ingersoll-Rand, through its distributor, warrants that each item
of equipment manufactured by it and
delivered hereunderto the initial userwill be free
of defects in material and workmanship for aperiod of
the earlier of twelve (12) months from shipment to or the accumulation of 2000 hours of service by the
initial user.
Portable compressor airends will be free
of defects in material and workmanship for aperiod of the
earlier
of twenty four monthsfrom shipment to orthe accumulation of 4000 hours of service by the initial
user. Thewarranty against defectswill include replacement
of the complete airend, provided the original
airend is returned assembled and unopened.
Portable compressor Airend Limited Optional Warranty -The earlier ofsixty (60) months from shipment
to or the accumulation
of 10,000 hours of service. The optional warranty is limited to defects in rotors,
housings, bearings, and gears and provided all the followint 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 amaintenance
agreement. Formal
enrollment is required.
Ingersoll-Rand will provide anew 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 authorized by Ingersoll-Rand. User must present proof
of purchase at
the time
of exercising warranty.
The above warranty does notapply to failures occurring as aresult
of abuse; misuse, negligent repairs,
corrosion, erosion and normal wear and tear, alterations or modifications made to the product without
expresswritten consent
of Ingersoll-Rand; orfailure to follow the recommended operating practices and
maintenance procedures as provided
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 whateverwarranty 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 APARTICULAR PURPOSE.
Book 22364079 (3/04)

SECTION 2 - WARRANTY Operating and Maintenance
GENERAL WARRANTY INFORMATION
GENERAL WARRANTY
Portable 'Compressor
. ,;,;,;. ..... ;,
.:. -
J-\Irena
....
1year/2000 hrs
2yrs/4000 hrs
Extended Coverage
5yrs/10,000 hrs
Limited warranty, major
components (refer to operator's
manual).
.
~l7)ftllilllle.·.c:$ertsl!t •. 8KW,
1 .••••• 1 ••• KW ••••• ••· •• a.s ••• .A •. · .•• tb.· ... I.I·. ··515.~ •••...••.•. · ... i .. ii .. ' .. /> i .. ".' ..
./'/'" .
1year/2000 hrs
2yrs/4000 hrs
None
None
1yr/2000 hrs (parts only) None
1yrs/2000
~rs (parts only) None
1year/2000 hrs
1year/2000 hrs 2years/4000 hours, for
Lightsource introduced 8/16/99.
CATERPILLAR
Months Hours Extended Coverage
12 unlimited Available at dealer
CUMMINS 24 2000 Major components 3yrs/10,000 hrs
Available at dealer
JOHN DEERE (in compressors) 24 2000 5yrs/5000 hrs using OEM fluids
and filters with $250 deductible
(in generators as of 1/1/01) 24 2000 2yrs/4000 hrs using IR fluids and filters
DEUTZ 24 2000 Available at dealer
Book 22364079 (3/04)

Operating and Maintenance SECTION 2 - WARRANTY
INGERSOLL-RAND 24 4000 5yrs/1 0,000 hrs when using genuine
Ingersoll-Rand fluids and parts. Refer to
operator's manual.
KUBOTA (North America only) 24 2000 Major components 36 mo/3000 hrs (parts
(Western Europe &Oceania) 24 2000 only)
(Central &South America, Asia, Middle East 12 1000 None
&Africa) None
MITSUBISHI 24 2000 2yrs/4000 hrs using IR fluids &filters
VOLVO 24 2000 2yrs/4000 hrs using IR fluids &filters
HONDA 12 unlimited None
VANGUARD 24 unlimited None
Ingersoll-Rand Months Hours Coverage
6No Limit Parts Only
Airend Months Hours Extended Coverage
12 2000 hours 2yrs/4000 hrs -available from IR.
14
Note: Actual warranty times may change. Consult the manufacturer's warranty policy as shipped with
each new product.
Book 22364079 (3/04)

SECTION 2 - WARRANTY
WARRANTY REGISTRATION
Complete Machine Registration
Operating and Maintenance
Machines shipped to locations within the United States do not require awarranty
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 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 22364079 (3/04)