Ingersoll Rand P100WD & P125WD

INGERSOLL-RAND®AIR COMPRESSORS Portable Compressor Division P.O. Box 868 Mocksville, N.C. 27028 COMPRESSOR MODEL P100WD P125WD Book P/N 35389816 (April, 1995) Code:E .257386.-257425 © Book 35389816 (4/95) ( 1) !-Rand Co. 1 QUALITY POLICY We will supply products and services that consistently meet the requirements of our customers and each other. Book 35389816 (4/95) (2) TABLE OF CONTENTS SECTION SAFETY SECTION WARRANTY SECTION WARRANTY REGISTRATION SECTION OPERATION SECTION GENERAL DATA SECTION MAINTENANCE/LUBRICATION SECTION PARTS ORDERING SECTION ENGINE INFORMATION SECTION PARTS LIST SECTION PARTS REFERENCE Book 35389816 (4/95) (3) SECTION 1 . If you do not understand. (Yellow Background) Indicates important set-up. if ignored. death or property damage. death or property damage. inform your supervisor. operating_ or maintenance information. (Blue Background) Book 35389816 (4/95) (4) . if ignored. Heed warnings and follow instructions. (Orange Background) Indicates the presence of a hazard which WILL or can cause injury or property damage.SAFETY I' I Look for these signs which point out potential hazards to the safety of you and others. if ignored. Read and understand thoroughly. ~ (Red Background) Indicates the presence of a hazard which CAN cause severe injury. Indicates the presence of a hazard which WILL cause injury. Safety decals are identified by the decal heading: DANGER -WARNING or CAUTION. DANGER I I CAUTION~ Never operate the engine of this machine Inside a building without adequate ventilation. Avoid breathing exhaust fumes when working on or near the machine. eyes and clothing.Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. Avoid contact with skin.C. Do not breathe this air.. Air discharged from this machine may contain carbon monoxide or other contaminants which will cause severe Injury or death. Submit orders for Safety Decals to the Mocksville Parts Service Department. flush area Immediately with water. !wARNING I A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive. Decal part numbers are on the bottom of each decal and are also listed In the · compressor's parts manual. Replace decals that are not readable. Exercise extreme caution when using booster battery. N. Help promote product safety! Assure that decals are present on the machines. To jump battery. always disconnect cables In reverse order. The no charge order should contain only Safety Decals. In case of contact. Safety Decals are available free of charge. connect ends of one booster cable to the positive (+) terminal of each battery. After starting unit. Book 35389816 (4/95) (5) . FREE SAFETY DECALS! To promote communication of Safety Warnings on products manufactured by the Portable Compressor Division in Mocksville. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). 302(b). !wARNING I Never run unit with guards. Relieve pressure before removing filler plugs/caps. Always wear hearing protection when doors are open or service valve Is vented. Always attach a safetyflowrestrlctor to each hose "at the source of supply or branch line" In accordance with OSHA Regulation 29CFR Section 1826. Never Inspect or service unit without first disconnecting battery cable(s) to prevent accidental starting. Can cause severe Injury or death.IWARNING I IWARNING I This machine produces loud noise with the doors open or service valve vented. fittings or covers. well away from moving parts. Air pressure can remain trapped In air supply line which can result In serious Injury or death. etc. tools. I I Disconnected Air Hoses Whip. Keep hands. blow gun tips. High pressure air. Extended exposure to loud noise can cause hearing loss. Can cause severe Injury or death. jwARNINGI Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result In serious Illness. covers or screens removed. -hair. Book 35389816 (4/95) (6) . Wear eye unit with protection while cleaning compressed air to prevent debris from Injuring eye(s). Always carefully vent air supply line at tool or vent valve before performing any service. clothing. Never allow the unit to sit stopped with pressure In the receiver-separator system. open the service valve. or any other source of compressed air. I CAUTION~ Do not connect the air discharge on this unit onto a common header with any other unit of any description. Ether Is an extremely volatile. Book 35389816 (4/95) (7) Always make sure wheels. Rotating fan blade. air receiver and air discharge piping. Can cause severe Injury. USE SPARINGLYIIf too much Is Injected. Will cause severe Insert locking pin completely. Can cause severe burns. highly flammable gas. a safety hazard could occur. without first making sure a check-valve Is used between the header and the unit. tires and tow bar connectors are In safe operating condition and tow bar Is properly connected before towing.). .Collapsing jack stand. Do not open radiator while hot. As a precaution. Hot pressurized fluid. It may result In costly damage to the engine. etc. If this unit Is connected with another unit. Do not operate without guard In I CAUTION~ IWARNING I Use extreme care to avoid contacting hot surtaces (engine exhaust manifold and piping. fan shroud b. Removal or rendering inoperative any of the following: a. 2. 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. Book 35389816 (4/95) (8) . the engine exhaust system or parts thereof b. repair. vibration mounts c. enclosure or parts thereof Removal of any of the following: a. Among those acts included in the prohibition against tampering are these: 1. other than for purposes of maintenance.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. 3. the air intake system or parts thereof c. or replacement. sound absorption material Operation of the compressor with any of the enclosure doors open. or (2) the use of the compressor after such device or element of design has been removed or rendered inoperative by any person. A void ingestion. skin contact and breathing fumes. The following substances may be produced during the operation of this machine and may be hazardous to health. A void ingestion. A void ingestion.& Hazardous Substance Precaution The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly. Book 35389816 (4/95) (9) . SUBSTANCE PRECAUTION Compressor Oil Engine Lubricating Oil Preservative Grease Rust Preventative Diesel Fuel Battery Electrolyte A void ingestion. skin contact and breathing fumes. A void breathing during maintenance. SUBSTANCE PRECAUTION Engine Exhaust Fumes Engine Exhaust Fumes Brake Lining Dust Avoid breathing. skin contact and breathing fumes. A void ingestion. skin contact and breathing fumes. skin contact and breathing fumes. skin contact and breathing fumes. A void ingestion. Avoid build-up of fumes in confined spaces. Insert locking pin completely.A ~ This dacal naar radiator cap.''· f ~2. 1 . rn1s dflCdl no:Jr sofllicc valve. PRESENCE OF A HAZARD WHICH WILL OR CAN CAUSE MINOR INJURY OR PROPERTY Do not breathe this air.~=" Trapped air pressure. blindness or death. Can cause severe InJury or death. WARNING . WARNING .) Combustible gas. ~ ' ([c ( :•. This decal rlNtr control pancf. Tflfs doctJI near battery.302(b). performing any service. ~ ('</]~ Hot pressurized fluid. Do NOT exceed 50 mph (80 km/ph. Excessive towing speed. WARNING &. tool to vent trapped air before removing filler plugs/caps. Do not open radiator while hot. DANGER DANGER IS USED TO INDICATE THE PRESENCE OF A HA2ARO WHICH WILL CAUSE SEVERE INJURY OR DEATH IFrne WARNING IS IGNORED.. Attach safety flow restrictor to each hose . This docal near seNic. Can cause severe InJury. &. Modification or alteration of this machine..~.. &. Do not operate without guard in place.~' ~ -8- Disconnected air hoses whip. can cause severe injury or death. Keep sparks and open flame away from batteries. Can cause severe bums. CAUTION IS USED TO INDICATE THE Will cause severe Injury or death. &.. Can cause severe Injury.. . WARNING &. DAMAGE IF THE WARNING IS IGNORED. . Do not alter or modify this machine without the express written consent of the manufacturer.\ ~. WARNING / Collapsing Jackstand. Can cause severe Injury or death. This decal near Jan. WARNING Improper operation of this equipment Can cause severe InJury or death.OJ g "'""' "' "' ~ INGERSOll-RAND® Ol ~ "' PORTABLE COMPRESSOR SAFETY CARD AIR COMPRESSORS L1ii.. Read Operator's Manual supplied with this machine before operation or service. Can result in severe InJury or death.o j . High pressure air. Can cause severe Injury or death. This decaf near receiver tank. / ' This decal on drawbar. WARNING - &. WARNING Discharge Air can contain carbon monoxide or &.7 l!!g'].at the source of supply or branch line" in accordance with OSHA Regulation 29CFR Section Close service valve and operate Relieve pressure before 1926. Ct~n cause severe burns. &. ~ ~ ~ ~..'·. &CAUTION contaminants.:-~. This decaf near SoflliCC outlet. Rotating fan blade.w. ~ . &WARNING WARNING IS USED TO INDICATE THE PRESENCE OF A HAZARD WHICH CAN CAUSE SEVERE INJURY OR DEATH IF THE WARNING IS IGNORED. ~~ !\'-. the warranty against defects will include replacement of the complete Air End.WARRANTY Ingersoll-Rand. Drill Mountings and Klemm Rotary Heads. upright and walk behinds) and Rotary Drills. Milling Machines. Ingersoll-Rand may elect to Issue full or partial credit toward the purchase of a new part.The earlier of six (6) months from initial operation or nine (9) months from date of shipment to the initial user.000 hours of service by. whichever first occurs. Aftercoolers. or the accumulation of 1000 hours of service by. Spare Parts (excluding downhill drills). the warranty period enumerated will apply in lieu of the foregoing warranty period.The earlier of twenty-four (24) months from shipment to. or accumulation of 1000 hours of service by. Pedestrian Compactors (Including baseplates.SECTION 2. With respect to the following types of equipment. Book 35389816 (4/95) (11) .Three (3) months from date of shipment. Downhole Drills . For Air Ends. or the accumulation of 2.The earlier of twelve (12) months from shipment to. Pavers. GENSET Generators and Paving Breakers. warrants that each item of equipment manufactured by it and delivered hereunder to the initial user to 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. the initial user. Portable Generator Sets (GENSET). the initial user.The earlier of twelve {12) months from shipment to. through its distributor. Forklifts and Self-Propelled Compactors. Portable Light Towers and Abrasive Blasting Equipment. or the accumulation of 4000 hours of service by.In lieu of the repair or replacement of defective parts. Jackhammers.The earlier of (6) months from shipment to. provided the original Air End is returned assembled and unopened. The extent of credit issued will be determined by pro rating against the normal service life of the part in question. All Compressor Air Ends. Portable Compressors. the initial user. the initial user. User must present proof of purchase and date at the time of exercising warranty. autonomous company or authorized distributor must first contact the Parts Service Department at the factory at which your portable air compressor was manufactured for an airend exchange number. its suppliers{s) and its distributors shall in no event be liable to the user. indemnity. AIREND EXCHANGE PROGRAM Your Ingersoll-Rand Company Construction Equipment Group Sales Offices and authorized distributors as well as lngersolf-Rand International autonomous companies and authorized distributors now have an airend exchange program to benefit portable compressor users. or failure of. warranty.Warrantv Ingersoll-Rand will provide a new part or repaired part. erosion and normal wear and tear. Such part will be repaired or replaced without charge to the initial user during normal working hours at the place of business of an lngersolf-Rand distributor authorized to sell the type of equipment involved or other establishment authorized by lngersolf-Rand. but manufactured by others. misuse. On the airend exchange program the exchange price is determined by the age and condition of the airend and may be classified by one of the following categories. at its election. or any defects in. The warranty on an exchange or factory rebuilt airend is 365 days. interest. corrosion. loss by reason of shutdown or non-operation. shall carry whatever warranty the manufacturers have conveyed to Ingersoll-Rand and which can be passed on to the initial user. tires. indirect. This warranty Is In lieu of all other warranties (except of title). strict liability or otherwise. Ingersoll-Rand. lost goodwill. The airend must be tagged with this preassigned number and returned to the factory prepaid. installation. special or punitive damages Note: Airends being returned to the factory in connection with a WARRANTY CLAIM must be processed through the Customer Service Department. or malfunction of the equipment under this sale whether based upon loss of use. indemnity. alterations or modification made to the product without express written consent of Ingersoll-Rand. including. but not limited to. impairment of other goods. This warranty does not apply to failures occurring as a result of abuse. any successors in interest or any beneficiary or assignee relating to this sale for any consequential. with no excluded parts. warranty. Accessories or equipment furnished by lngersolfRand. no warranty claim will be considered. batteries. delivery. The remedies of the user set forth under the provisions of warranty outlined above are exclusive and the total liability of lngersolf-Rand or its distributors with respect to this sale. hydraulic transmissions. Category "A": The airend must not be over two years old and must have reusable rotor housing{s) and rotor{s). Book 35389816 {4/95) (12) . engine electrical equipment. Limitation of Liabilitv arising out of this sale or any breach thereof. and there are no warranties of merchantablllty or of fitness for a particular purpose. lost profits or revenue. incidental. otherwise the exchange agreement may be cancelled. strict liability or otherwise shall not exceed the purchase price of the unit of equipment upon which such liability is based. engines. Your nearest sales office. negligence. or failure to follow the recommended operating practices and maintenance publications. Category "C": The airend must be over five years old. negligent repairs. expressed or implied. cost of purchase of replacement power or claims of users or customers of the user for service interruption whether or not such loss or damage is based on contract. increased expenses of operation of the equipment. The airend must be intact. negligence. repair or technical direction covered by or furnished under this sale whether based on contract. If returned without a Warranty MRR {Material Return Request) Number. carriers. Category "B": The airend must be between two and five years old and returned with two or more reusable major castings. work stoppage. in place of any part which is found upon its inspection to be defective in material and workmanship during the period prescribed above. 5-6 KW) PRODUCT WARRANTY ENGINE WARRANTY Kubota 24 2000 major components 25-36 mo/3000 hrs PARTS WARRANTY A/REND EXCHANGE WARRANTY Book 35389816 (4/95) (13) . 1 yr/2000 hrs (parts & hrs (2.General Warranty Information 2 (20--50 KW) hrs. e. North Carolina 27028 Attn: Warranty Department Note: Completion of this form validates the warranty. Machines shipped to locations within the United States do not require a warranty registration unless the machine status changes (i. Must present Proof of Purchase whenever engine warranty service is required.SECTION 3 . change of ownership). Box 868 Mocksville. 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. Book 35389816 (4/95) (14) .WARRANTY REGISTRATION Complete Machine Registration Machines shipped outside the United States require notification be made to initiate the machine warranty. Engine Registration: No engine registration required.O. excavation. general operation and safety precautions 2. etc.. etc.. The warranty and limitation olliability (see reverse side) has been reviewed and understood by the owner/user.....) CJ Government (municipal...) CJ Construction-Light (carpentry.- 0 Exploration 0 Utility Contractor Model Unit-Hours Unrr SIN Air End SIN Engine SiN Truck SIN Date Delv'd Truck Engine SIN SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT 1.) 0 Quarry :1 Shallow Oil & Gas 0 Rental (rental center.) o Building Contractor 0 Waterwell 0 Utility Company (gas. plumbing. 4. electric. etc.) 0 Industrial (plant use) C Other specily . etc... In the event that this unh is to be used wrrhin a nuclear faciley. Owner/User --------------------------------------- Date----------~---------------- I hereby certify that the above is accurate and complete Distributor/1-R Rep. etc. state..INGERSOLL-RAND® Warranty Registration Form AIR COMPRESSORS WARRANTY REGISTRA110N SERVICING Q!SJB!Bl!TOB SELliNG O!SIB!B\JTOB Name ______________________ Name --------------------- Owner/User Name ------------Address------------------- Address ------------------- Address------------------- Chy _ _ _ _ _ _ _ _ _ __ Chy ___________________ County -------------------Slate _____________________ County ____________________ City ---------------------County ___________________ Stale ------------------- State .. water... county. 3. mason. the owner/user shall notify fngersoii·Rand of such use so that Ingersoll-Rand may arrange for appropriate nuclear Iiabilhy protection from the owner-licensee of the facilny. rentallleet... The Purchaser has been instructed and/or has read the manual and understands proper preventative maintenance. I hereby acknowledge acceptance of above and the conditions on reverse side.- Zip Code ------------------ Zip Code ------------------ Zip Code ----------------- Telephone ------------------- Telephone------------------- Telephone------------------- COMPLETE THE APPLICABLE BLOCKS Owner/User Type of Business (check only one) CJ Construction-Heavy ~ ~ Asphalt Contractor 0 Coal Mining :·.. lngersoii·Rand reserves the right to make design changes or modifications to Ingersoll-Rand products at anytime wnhout incurring any obligation to make similar changes or modifications on previously sold unhs.. pools. Other Mining (Highway.... ---------------------------------.Date------------------------COMPLETION OF THIS FORM VALIDATES THE WARRANTY X-4051-C ... wawpedea AlueJJI!!M :uotwamt BZOLZ I!!U!JOJI!!:J 1./0d iuedwoo puel:J-J/OSJB6UJ PfOJ ./IJON '81/fiiSJf:JOfN 898XOS 'O"d UOfS!II/0 JOSS8JdWO:J 9Jql!!l. As jack tube swings down. -Stand to the side and ensure pin is FULLY inserted (secure) in tube of jack. Attach to vehicle. SETTING . . The design of these units permits a 15 degree sidewise limit on out--<>f-level operation. well-ventilated area. Cross safety chain(s) under drawbar. FULLY insert pin in the tube. The air going into the inlet grille must be relatively free of oil. It must be no more than 10 degrees F.Ensure that tires are inflated to 32 psi (220kPa). SPARKS or OPEN FLAME near fuel. . Pull pin from tube of jack. Failure to follow these Instructions could result In very serious personal Injury or death. OIL COOLED ENGINE I CAUTION~ Do not remove oil coolant hose or connections while engine Is running. soot and other debris.OPERATION BEFORE TOWING IwARNING I . it is important: (1) to keep the engine crankcase oil level near the high level mark (with the unit level). Position as level as possible. and (2) to have the compressor oil level gauge show no more than mid-scale (with the unit running at full load). remove pin from tube of jack. DISCONNECT . Latch and lock hitch. Swing up jack tube and FULLY insert pin in tube. dirt. Crank jack to raise eye or coupler from hitch.SECTION 4 . -Disconnect safety chains. . Book 35389816 (4/95) (15) I NO SMOKING. I CAUTION~ . -Crank jack to raise pad off the ground. •When the unit is to be operated out--<>f-level. -Standing to the side. -Set the vehicle parl<ing brake. Chock wheels of unit. Tow vehicle can be moved. Fold jack handle down and forward. (5 degrees C) over the ambient temperature.Do not tow this unit in excess of 50 mph (80 km/hr).UP (ALL UNITS) • Place the unit in an open. Crank jack to seat pintle eye or coupler onto hitch. UTILITY PACKAGE SET-UP (no running gear) The unit must be located on vehicle bed to allow access for normal servicing and maintenance. wheels and running gear are in good condition and secure. TOWING IwARNING I IwARNING Failure to follow these Instructions could result In very serious personal Injury or death. -Ensure that tires.Engage the parl<ing brake and chock the wheels of the tow vehicle.Position the tow vehicle to align its hitch with the pintle eye or coupler of the compressor. Do not overtill either the engine crankcase or the compressor lubricating oil system.Use a tow vehicle whose towing capacity is greater than the gross weight of this unit. etc. Control Panel D~al00§@:111~G:J@. Pr6Stige SeriBS. 0 ~ .l. C! ~ "i\0 CD '"(!)- ~AM ®0 ~-~ ® ® 0 0-- 0 ®0 0 0 -0- ~"" ~~0.. s~ ~-~ ~~- r::!l \'C(.'NI!I'e'i ~= <:> ~~ 0 -~ 0 <ll=-,%] ~=~~ ~ = 8 ~·-~~ ~ = 'f( ®·= _,...,._,.,_@o ·- ~~ ~===-~· 0 0 ·- 36525830 Operating Controls/Instruments (Standard) Diagnostics/Auto Shutdown Lamps (Optional) 1. 6. Master Switch (start)- Rotate to "ON"; observe any lit Diagnostic Lamps. See Lamp Test Instructions. Rotate to"START' to crank engine; release when engine sustains firing. Glows when compressor discharge air temperature exceeds 248°F (120°C)±. 7. 2. Service Air Button- Push After Warm-up (Optional) A wo-way valve that provides full air pressure at the service outlet. 3. Otherwise, lights in gauges are controlled by theMaster Switch (1). Low Engine 011 Pressure - Glows when engine oil pressure drops below 2.5 psi (17 kPa)±. 8. High Engine Temperature - Glows when engine coolant temperature is excessive. Oil cooled Engine: 266° F (130° C). 9. Light Switch (Option, for Gauges)- High Compressor Temperature- Low Fuel Level (Optional)- Glows when less than 1 gallon in tank. 10. Alternator Not Charging Indicates alternator or drive belt failure. 4. Air Discharge Pressure Gauge - 11. Air Filters Restricted (Optional)- Indicates pressure in receiver tank, normally from 0 psi (kPa) to the rated pressure of the machine. 5. Indicates the air filters need servicing. 12. Any Special Option Hourmeter- OPTIONAL GAUGES Records running time for maintenance. Engine Oil Pressure Engine Temperature Compressor Temp. Book 35389816 (4/95) (16) Not Shown Tachometer Voltmeter Fuel Level BEFORE STARTING WARNING I CAUTION~ Do not connect the air discharge on this unit Into a common header with any other unit of any description, or any other source of compressed air, without first making sure a check valve Is used between the header and the unit. If this unit Is connected with another unit, a safety hazard could occur. • Close the side doors to maintain a cooling air path and to avoid recirculation of hot air. This will maximize the life of the engine and compressor and protect the hearing of surrounding personnel. • Be sure no one Is IN or ON the compressor unit. IWARNING I Unrestricted air flow from a hose will result In a whipping motion of the hose which can cause severe injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure In case of hose failure or other sudden pressure release. Reference: OSHA regulation 29 CFR Section 1926.302 (b). Before Starting: • Open service valve {s) to ensure pressure is relieved in receiver-separator system. Close valve {s) in order to build up full air pressure and ensure proper oil circulation. • Check battery for proper connections and condition. • Check the engine oil level. Maintain per marks on dipstick. • Check the fuel level. Add only CLEAN DIESEL fuel for maximum service from the engine. • Check the compressor lubricating oil level. The proper oil level is mid-way on the sight gauge. Add oil if the level falls to the bottom of the sight gauge. Do not overfill. Book 35389816 {4/95) This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve (s) are open. (17) I CAUTION~ Exercise extreme caution when using a booster battery to start. To jump start: Connect the ends of one booster cable to the positive (+) terminals of each battery. Then coonect one end of the other cable to the negative (-) terminal of the booster battery and the other end to the engine block. NOT TO THE NEGATIVE (-) TERMINAL OF THE WEAK BATTERY. After Starting: a. Reduce engine speed to IDLE. b. Disconnect the negative (-) cable from the engine block first, then from the booster battery. c. Disconnect positive {+) cable from both batteries. OIL-COOLED DiESEL ENGINE I CAUTION~ Do not remove oil coolant hoses or connections while engine Is running. UNITS WITH OPTIONAL DIAGNOSTICS LAMPS STARTING 1. NOTICE Turn the POWER switch to "ON". 2. Turn power switch to "START' position to crank engine. None of the panel lamps should be glowing when machine is operating. If they are, shut unit down and refer to Trouble Shooting Section. NOTICE Do not operate the starter motor for more than 10 seconds without allowing at least 30 sec· STOPPING Close air service valve. onds cooling time between start attempts. Allow the unit to run at idle for 3 to 5 minutes to reduce the engine temperatures. Cold Weather Starting: Turn Power Switch to "OFF" position. Open manual blowdown valve, if so equipped, and press ether inject button. Use ether sparingly. Close manual blowdown valve after engine is running. When the engine stops, automatic blowdown valve should relieve system air pressure. If automatic blowdown valve malfunction is suspected, open manual blowdown valve if so equipped. Never allow unit to sit under pressure when engine is not running. I CAUTION~ NOTICE Ether Is an extremely volatile, highly flammable gas. Use sparingly! If too much Is Injected, the uncontrolled explosion may result In costly damage to the engine. 3. Release POWER SWITCH when the engine starts and sustains running. I Do NOT wire around or bypass a shutdown sensor or switch. All units in this family of machines are protected by sensors or switches at the following locations: (1) Low engine oil pressure, in the engine. High Discharge AIR Temperature 4. Allow engine to warm up 5 to 10 minutes (2} At the airend outlet. 5. If so equipped, press Service Air Button. Open air service valve(s). Note: If equipped with the optional cold starting aid (ether), operate the valve once or twice ONLY while the engine is cranking. • Rotate the Master Switch to "ON". Book 35389816 (4/95) (18) (3) In separator tank. Units with Diagnostic Lamps: In a shutdown situation, the function of the panel lamps is to indicate what specific failure caused the unit to shut down.These lamps will remain illumi· nated until the Power Switch is turned "OFF". Removal of the seals without authorization could affect the warranty. and should not be adjusted. turn the pressure regulator screw (B) until speed lever (G) just begins to move. Tighten jam nut (H). Replace bolt (E) and tighten. Replace cover. Turn adjusting screw (J) to the specified speed. push the SERVICE AIR button on the control panel. Tighten jam nut (D). Book 35389816 (4/95) " 6. Pull engine speed lever (G) toward air cylinder (Full Load Position). 4. 3. Turn screw (B) counterclockwise until tension is no longer felt at the screw. make adjustment at the pressure regulator to obtain desired discharge pressure at FULL engine speed. If equipped. If necessary.Speed and Pressure Regulation The engine idle and full speed settings are set and sealed at the factory. making certain the button does not pop back out. DISCHARGE PRESSURE GAGE PRESSURE REGULATOR A B [)==t:(~=ro UNLOADER CHECKVALVE ORIFICE At the Pressure Regulator (on service pipe near receiver tank). With the discharge pressure at 100 psi. turn the adjusting screw on the pressure regulator clockwise until the discharge pressure gauge indicates 120--122 psi (827-841 kPa). To set the idle or NO LOAD speed. Close service valve(s). Loosen the jam nut (A). TO SEPARATOR TANK (F). If speed settings are lost due to engine fuel pump service or other repairs. adjust pressure regulator screw (B) clockwise to increase pressure. 8. 10. tum screw clockwise one full turn. (19) . With the unit unloaded. at full engine speed. The engine should speed up and then slow down. Remove bolt (E) and disconnect rod end bearing (F). 2. The unit should speed up and then unload (and drop back to IDLE). Then. loosen jam nut (H) on the side of engine. Close the service valve and recheck IDLE speed. 7. Lock adjusting screw and replace cover. To obtain maximum ctm at any pressure between 80 psi (552 kPa) and maximum pressure rating (*}. loosen lock nut (D). The engine will slow down. remove the cover to expose the adjusting screw. 5. Tighten the pressure regulator jam nut. While still maintaining 100 psi. 9. On Air Cylinder rod (C). Adjust rod end bearing to line up with hole in lever. AIRCVUNDER 36611896 Open the service valve and adjust the discharge pressure to 100 psi (689 kPa). the speed settings can be reset as follows: Before Starting 1. adjust the engine speed to the FULL load RPM by loosening lock nut (D) against rod end bearing After Starting Unit Allow unit to warm up at an engine speed greater than IDLE speed for at least five minutes. but to the relationship of one component with another. Too often. be sure to locate and correct the cause of the trouble so the same failure will not be repeated. 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. The chart does not attempt to list all of the troubles that may occur. c. B. but something caused the defective wiring. Find the "complainf' depicted as a bold heading. Note: For trouble shooting electrical problems. shooting chart that follows includes some of the problems that an operator may encounter during the operation Always check the easiest and most obvious things first. For series of problems and a planned method of example. refer to the Wiring Diagram Schematic. The cause may be excessive vibration. a compressor can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly. most complaints are "low capacity" which may procedure for investigation and correction. Find And Correct Basic Cause ACTION PLAN A. Double Check Before Disassembly problems that are most apt to occur. Think Before Acting After a mechanical failure has been corrected. The causes are The source of most compressor troubles can be traced not to one component alone. be caused by too low an engine speed or "compressor The trouble over. Follow down that column to find the potential cause or causes. listed in order (1 . following this simple rule will save time and trouble.3 etc. Check again to be sure an easy solution to the problem has not been overlooked. Study the problem thoroughly and ask yourself these questions: (1) What were the warning signals that preceded the trouble? (2) (3) Has a similar trouble occurred before? What previous maintenance work has been done? (4) If the compressor will still operate. A complaint of "premature breakdown" may be corrected by repairing any improper wiring connections.2. of a portable compressor.heats" which may be caused by low oil level.) to suggest an order to follow in trouble shooting. D. nor does it attempt to give all of the answers for correction of the The chart does give those problems. To use the trouble shooting chart: A. is it safe to continue operating it to make further checks? Book 35389816 (4/95) (20) .Trouble Shooting INTRODUCTION B. TROUBLE SHOOTING CHART Bold Headings depict the COMPLAINT. Tank Blown Down Too Quickly Defective Minimum Pressure Valve Engine RPM Low: Wlll Not Unload: Leaks in Regulator Piping Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Malfunctioning Inlet Unloader/Butterfly Valve Ice in Regulation Lines/Orifice Clogged Fuel Filter Operating Pressure Too High Incorrect Pressure Regulator Adjustment Dirty Air Filter Malfunctioning Speed Control Cylinder Defective Separator Element Ice In Regulation Lines/Orifice Engine Malfunctioning Airend Malfunctioning Excessive VIbration: Low Engine RPM Rubber Mounts Damaged Out of Balance Fan Engine Malfunctioning Airend Malfunctioning Ollln Air Cleaner: Incorrect Stopping Procedure LowCFM: Safety Valve Relieves: Leaks In Regulator Piping Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Malfunctioning Inlet Unloader/Butterfly Valve Defective Separator Element Ice in Regulation Lines/Orifice Defective Safety Valve Book 35389816 (4/95) (21) Low Engine RPM Dirty Air Filter Incorrect Linkage Adjustment Incorrect Pressure Regulator Adjustment Malfunctioning Inlet Unloader/Butterfly Valve Malfunctioning Speed Control Cylinder Defective Minimum Pressure Valve Defective Separator Element .Subheadings depict the CAUSE Note: Subheadings suggest order to follow in cause of troubleshooting. Excessive Compressor Oil Temperature: Short Air Cleaner Life: Ambient Temperature Too High Out of Level > 15 degrees Low Oil Level Dirty Cooler Dirty Operating Conditions Loose or Broken Belts Operating Pressure Too High Malfunctioning Thermostat Defective Minimum Pressure Valve Blocked or Restricted Oil Lines Airend Malfunctioning Dirty Operating Conditions Inadequate Element Cleaning Defective Service Indicator Incorrect Stopping Procedure Wrong Air Filter Element Excessive Ollln Air: High Oil Level Out of Level > 15 degrees Clogged Scavenge Orifice Scavenge Tube Blocked Defective Scavenge Check Valve Sep. Too High Engine Oil Pressure Too Low Loose Wire Connection Defective Switches Malfunctioning Relay Engine Malfunctioning Airend Malfunctioning Engine Temperature Lamps Stays On: Unit Falls To Shutdown: Broken Engine Fan Belt Malfunctioning Circuit Board Defective Engine Belt Break Switch Ambient Temperature Too High Dirty Operating Conditions Dirty Cooler Out of Level > 15 degrees Operating Pressure Too High Defective Switches Defective Shutdown Solenoid Malfunctioning Relay Defective Start Switch Alternator Lamp Stays On: Loose or Broken Belts Loose Wire Connection Defective Battery Malfunctioning Alternator Malfunctioning Circuit Board Engine 011 Pressure Lamp Stays On: Low Oil Level Out of Level >15 degrees Wrong Lube Oil Engine Malfunctioning Alternator Lamp Stays Off: Loose Wire Connection Malfunctioning Circuit Board Engine Temperature Lamps Stays Off: Bulb Burned Out Loose Wire Connection Malfunctioning Circuit Board Defective Engine Belt Break Switch Engine 011 Pressure Lamp Stays Off: Bulb Burned Out Malfunctioning Circuit Board Defective Engine Oil Pressure Switch Engine Malfunctioning Book 35389816 (4/95) (22) . Too High Engine Water Temp.Unit Shutdown: Won't Start/Run: Out of Fuel Compressor Oil Temp. Too High Engine Oil Pressure Too Low Broken Engine Fan Belt Loose Wire Connection Defective Switches Defective Shutdown Solenoid Malfunctioning Relay Blown Fuse Engine Malfunctioning Airend Malfunctioning Low Battery Voltage Blown Fuse Malfunctioning Start Switch Clogged Fuel Filters Out of Fuel Compressor Oil Temp. ..... .... . . ..... ... . .. ..... .. ... P185/80R x 13 Inflation Pressure (Cold) . 10 quarts (9.........60 meters) Net Weight (less fuel} pounds (kg) ...... . ... ..... . . ... ... ....... P125WD Air Delivery. ......... .. ..... .. .psi (kPa) .... ..... .... . . . ... ... ....... .... . ... ................. . .... ... ................ ... ..... ........ . . ..... ... . ... . ...... ............... . ...... ..... ..... . 10 quarts (9.....psi (kpa) .... ...... . . . 35291970 Book 35389816 (4/95) (23) . .... .. ... .......... ... .. ..s. ..... . ... ... ....... . .. ........ . .. .... . .......... .... ....... ......... .... ... ..2 feet (1.51itres) Engine Lube (including cooler) ............. ... .... .. . 2300 2800 ..... ..... . ....... .. ... ..... ..... . ... ......... . ...... . ....... . . ....... . ... .. ...... ... F3M1011F Electrical System .. .... .......... ....6 u.... . .. P100WD ........... .... ...... .. ........ . .... 50 mph (80 km/hr) CAUTION: Any departure from the specifications may make this equipment unsafe. .. ... .......... 100 {689) Safety Valve Setting..... ..44 meters) Overall Width .. . ..... ..... .... ............ . ...... .. ... .. .. . ....RPM (Full Load} .. . 36845303 Air Cleaner Element (compressor) ... 1830 pounds (830 kg) RUNNING GEAR 1ire Size .. 11.. ... ... .... . . ... .......... . . ..... (63 litres) UNITS MEASUREMENTS/WEIGHTS Overall Length .... . ..... .. .... ........ . ... . . .. ... ....... . . ... .. .. 4...SECTION 5... ......7 feet (1. .. .. . .. . ........ ...... ..... . . ... .... .. .. . 32 psi {220 kPa) Towing Speed (Maximum) ....... . . ... ... .... .... .. . ... ..... .. ..... . ........ ...... ...... . . .. 150 (1034) ENGINE (Diesel) Manufacturer . ... .. .. . ..... . . ... .. . ..... . . .. . .. ... ... .. ............. . . ... ....... ....GENERAL DATA Unit Model: .60 meters) Overall Height .......... .. .. .. 12 VDC FLUID CAPACITIES Compressor Lubricant . 35291970 Air Cleaner Element (engine) . ..... .. .. 5..RPM (No Load} .. 35296920 Compressor Oil Separator Element ... . .. ... ... .. .... ... ..... .. ... . ... . ..... .... EXPENDABLE SERVICE PARTS Compressor Oil Filter Element .. .. . .. ... .... .... ...... . .. ... ... KHD/Deu1z Model .. .. . ........... . .... .. . .... . ... . . ... ......... .. .... . . .. ...... ....... . 16.elm (litres/sec) ... ......... .. 125 (59) Engine Speed... . . ...... ..... ..... .... 100 (47) . .. ... ....... .. ............. ....... . .. .............. .... ... ........ ....... .. .. ... 2000 2000 COMPRESSOR Rated Operating Pressure. .5 litres) Fuel Tank . .... .. ... gal... ........8 feet (3...... .... ... covering both the engine and the compressor. To service the air cleaners on all units proceed as Servicing may consist of pre-operation and post--{)peration procedures to be performed by the operating or maintenance follows: personnel. In addition to periodic inspections. Maintaining your unit and keeping it clean at all times will facilitate servicing. Loosen outer wing nut and remove with cover. A totally filled sight tube in which the level is not visible indicates an over-full condition and requires that oil be drained. discard this element." performance. etc. especially in the area where the element seals against the housing. If the lamp glows (red) with the unit operating at full speed. the element can be cleaned. damp cloth to remove any dirt accumulation.). Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping. the schedule should be adjusted accordingly. make appropriate corrections (Add or Drain). air receiver and air discharge piping. 3. and consequently. Inspect air cleaner housing for any condition that might cause a leak and correct as necessary. See the decal beside the sight tube. The primary function of preventive 1. Preventive maintenance is the easiest and the least expensive type of maintenance. This should be checked daily during operation. started.MAINTENANCE COMPRESSOR OIL LEVEL I CAUTION~ The oil level should be checked before the unit is Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty. SCHEDULED MAINTENANCE The maintenance schedule is based on normal operation of the unit. many of the The air filters restricted sensor will automatically re- components in these units require periodic servicing to provide maximum output and set after the main power switch is turned to "OFF. Notice: Disregard any maintenance pertaining to components not provided on your machine. Inspect element by placing a bright light inside and rotating slowly. Wipe inside of air cleaner housing with a clean. Consult the parts manual for clarification of usage. If any holes or tears are found in the paper. Remove Element. Also weekly squeeze the rubber valve (precleaner dirt dump) on each air cleaner housing to ensure GENERAL that they are not clogged. If performing more than visual inspections. In the event unusual environmental operating conditions exist.SECTION 6 . If no ruptures are found. AIR CLEANER If this unit is equipped with the Optional Diagnostic Panel. Inch and metric hardware was used in the design and assembly of this unit. The optimum operating level is midway of the sight tube on the side of the receiver tank. 4. maintenance is to prevent failure. it has an AIR FILTERS RESTRICTED lamp on the instrument panel. This page can be reproduced and used as a checklist by the service personnel. disconnect battery cables and open manual blowdown valve. Never operate this machine with any guards removed. servicing of the cleaner element is necessary. If the oil level is not in the "OK" range. Book 35389816 (4/95) (24) . the need for repair. 2. Check the air cleaner housing for dents or damage which could lead to a leak.4 mm) from the pleated paper. When filling the fuel tank on this unit. and a new element is the electroly1e level in each cell should cover the top not available. never exceed a maximum air pressure of 100 psi (700 kPa). Refer to Operating Controls. tightness. oil or greasy dirt deposits. only clean fuel is poured or pumped into the tank. Inspect the gauges and test any diagnostic lamps prior to start-up. using the air cleaner element manufactur- distilled water. The elements just removed for cleaning can be washed and A weekly inspection is recommended. In addition. maximum productivity and long service life of the machine. During operation observe the gauges and any lamps for proper functioning. Tires that have cuts or cracks or little tread should be repaired or replaced. Monthly check the wheel lug nuts for stored as future replacement elements. Also dirt. Install cleaned or new elements in the reverse order to the above. by methods other than a pump and hose. 6.5. If necessary. Book 35389816 (4/95) (25) . NOTE: To prevent damage to the element. 7. the air cleaner system (housing and piping) should be inspected every month for any leakage paths or inlet obstructions. er's recommendations. Move the nozzle up and down while rotating the element. Be sure to keep the nozzle at least one inch (25. Make sure that all clamps and flange joints are tight. washing. for the normal readings. Make sure the air cleaner mounting bolts and clamps are tight. In the event that the filter element must be reused immediately. If a new air filter element is to be used check it closely for shipping damage. top-up with clean TIRES NOTE: It Is recommended that replacement efe· ments be Installed In the unit. Tighten wing nut firmly. Inspect to ensure that the end cap seals tightly 360 degrees around the air cleaner body. cleaning can be accomplished by of the plates. Inspect the air transfer tubing from the air cleaner to the compressor and the engine for leaks. Direct compressed air through the element in the direction opposite to the normal air FUEL TANK CLEAN fuel in the fuel tanks is vitally important and every precaution should be taken to ensure that flow through the element. compressed air cleaning (as follows) is recommended since the element must be thoroughly dry. use a CLEAN non-metallic funnel. GAUGES The instruments or gauges are essential for safety. tight and lightly coated with a grease. BATIERY Keep the battery posts-to-cable connections In the event the element is contaminated with dry clean. through the core of the oil cooler. such as sludge and lacquer. non-<:austic safety solvent The flexible hoses used in the fuel. In the event foreign deposits. oil and dirt from the exterior suriaces of the oil cooler core so that the entire cooling area can transmit the heat of the lubricating and cooling oil to the air stream. • To install the nylon tubing. replace the element after the first 50 and 150 hours of operation. It is also important the operator does not use the hoses as convenient hand hold or steps. When grease. Book 35389816 (4/95) (26) Piping systems operating at less than 150 psi (1 050 kPa) may use a special nylon tubing. HOSES Each month it is recommended that all of the intake lines to and from the air cleaners. and fuel be inspected. It is important they be periodically inspected for wear and deterioration. Insert the tubing into the sleeve and "push-in" past the first resistance to the bottom. the engine cooling system hoses and all of the flexible hoses used for air. is cooled by the air stream from the cooling fan flowing past the core section. Such use can cause early cover wear and hose failure. features are as follows: Pulling on the tubing will cause the inner sleeve to withdraw and compress. Regular inspection of these connections for wear or deterioration is necessary. The tubing can be withdrawn only while holding the sleeve against the fitting. all rubber hose joints and the screw-type hose clamps must be absolutely tight. On new or overhauled units. The mark should be approximately 1/16 inch from the sleeve. service the oil fll· ter every 500 hours. thus tightening the connection. To correct this situation it will be necessary to clean it using a cleaning compound in accordance with the manufacturer's recommendations.D. oil and dirt accumulate on the exterior suriaces of the oil cooler. thereafter. To ensure freedom from air leaks. tubing. If so. a resulting high discharge air temperature is likely to occur. its efficiency is impaired. located below the radiator. 1/8 inch for the 0. make a mark (with tape or grease pencil) approximately 7/8 inch from the end of the tubing. Each month it is recommended that the oil cooler be cleaned by directing compressed air which contains a nonflammable. The lubricating and cooling oil. for the 3/8 inchD. oil. Premature wear of both the engine and compressor is ASSURED whenever dust-laden air is permitted to enter the engine's combustion chamber or the compressor intake. Proceed as follows: . The engine oil cooler is located above the compressor oil cooler and functions the same as the compressor oil cooler. causing shut down of the unit. Wipe off any external dirt and oil from the exterior of the filter to minimize any contamination from entering the lubrication system.COMPRESSOR OIL COOLER The compressor lubricating and cooling oil is cooled by means of the fin and tube-type oil cooler. NOTICE The oil filter must be replaced every 500 hours of operation or six (6) months. The tubing can be removed and replaced numerous times without losing its sealing ability. This will ensure that the tubing is fully engaged in the sealing mechanism.25 inch O. accumulate in the oil cooler to the extent that its cooling efficiency is impaired. ENGINE OIL COOLER The engine in this machine is oil cooled. whichever comes first. To service the oil filters it will first be necessary to shutthe unit down. tubing. This should NOTICE remove the accumulation of grease. flowing internally through the core section. oil and air lines on these units are primarily used for their ability to accommodate relative movement between components. The associated fittings are also of a special "push-In" design.D. FASTENERS Visually check entire unit in regard to bolts. a more thorough inspection must be made. Check for leaks before placing unit back into service. 5. Turn the spi~n filter element counterclockwise to remove it from the filter housing. Repack wheel bearings. Open the service air valve(s) to ensure that system is relieved of all pressure. Take corrective action. covers or other parts from pressurized air system. nuts and screws being properly secured. Always relieve pressure before removing caps. grease seals and axle spindles should be inspected for damage (corrosion. Start unit and allow to build up to rated pressure. Inspect the filter. Replace any damaged or worn parts. Spot check several capscrews and nuts for proper torque. plugs. 3. 6. · Use a wheel bearing grease conforming to specification MIL--G--10924 and suitable for all ambient temperatures. RUNNING GEAR Every month or 500 miles. shellacs or lacquers on the oil filter ele· ment. Book 35389816 (4/95) (27) . If any are found loose. etc. Every six months the wheel bearings. Inspect the oil filter head to be sure the gasket was removed with the oil filler element. will cause an oil leak and can cause property damage. 1. Install new filler by turning element clockwise until gasket makes initial contact. Installing a new oil filter element when the old gasket remains on the filter head.) or excessive wear.I wARNING I NOTICE High pressure air can cause severe Injury or death from hot oil and flying parts. Grease can be replaced in a wheel bearing using a special fixture or by hand as follows. whichever comes first. Clean the gasket seal area on the oil filter head. It Is a warning the compressor lubricating oil has Improper characteristics and should be Immediately changed. NOTICE If there Is any Indication of formation of var· nlshes.95 lbs. Close the valve(s).-ft. Lubricate the new filter gasket with the same oil being used in the machine. place a light coat of grease on the bearing cups which are pressed in the hub. 2. 4. Before installing bearing. COMPRESSOR OIL The lubricating and cooling oil must be replaced every 500 hours of operation or six (6) months. tighten the wheel lug nuts to 85 . llghten an additional! /2 to 3/4 turn. Push a segment of the wider end of the bearing down into the outer edge of the grease pile closest to the thumb. 6. covers or other parts from pressurized air system. There should be no evidence of looseness (free play) at the bearing. Loosen nut until the first nut castellation lines up with cotter pin hole in spindle. When draining oil. the top and bottom and rock. • Open service valve at end of machine. Grasp the tire at • Ensure pressure Is relieved. In the compressor lubricating and cooling system. Then rotate the bearing to repeat this operation on the next segment. 1. the following procedure must be followed to ensure a correct bearing adjustment of 0. Excessive grease In the hub or grease cap serves no purpose due to the fact that there Is no way to force the grease Into the bearing. RECEIVER-sEPARATOR SYSTEMS nut to approximately 15 lbs. As the compressed air enters the tank. Keep lifting and pushing the bearing down into the edge of the grease pile until grease oozes out both from the top and from between the rollers. Insert cotter pin.Place a spoonful of grease in the palm of one hand and take the bearing in the other hand. separation of the oil from the compressed air takes place in the receiver~eparator tank. 3.001 to . Book 35389816 (4/95) (28) . remove plug from bottom of separator tank. 2. . When adding oil. NOTICE If bearing adjustment is required or the hub has been removed for any reason. Additional separation takes place in the oil separator element which is located in the top of the tank.-ft. remove and replace (make tight) plug on side of separator tank. Keep doing this until you have the entire bearing completely filled with grease. 4. Do 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. Loosen nut to remove preload torque. the change in velocity and direction drop out most of the oil from the air. Finger tighten nut until just snug. Nut should be free to move with only restraint being the cotter pin.012 free play. with BOTH: -Discharge air pressure gauge reads zero (0). not rotate hub. Ensure a definite but minimal amount of free play by rocking the tire. While rotating hub slowly to seat the bearings.No air discharging from service valve. plugs. The manufacturer's standard procedure Is to thoroughly pack the Inner and outer bearing with grease and then to apply only a very small amount of grease Into the grease cap. in and out. Always relieve pressure before removing caps. tighten spindle !wARNING I High pressure air can cause severe Injury or death from hot off and flying parts. Reconnect hose. • Replace cover mounting screws: tighten in a crisscross pat1ern.The life of the oil separator element is dependent upon the operating environment (soot. NOTICE Do not remove staples from the element/gasket connection. 4. • Install new element. • Disconnect the hose from the scavenge tube.. the scavenge lines.. cut to size.. filter. To replace the element proceed as follows: • Ensure the tank pressure is zero. • Remove cover and element. • Reconnect service line. • Remove scavenge tube from tank cover. • Replace scavenge tube in cover (cover is still off of tank).l ** u J I .1 ). • Measure from bot1om of cover to end of scavenge tube. Start unit and look for leaks. • Disconnect service line from cover. • Remove cover mounting screws. If not.. • Remove any gasket material left on cover or tank.. Replace scavenge tube. orifice. • Close service valve. • Remove scavenge tube. dust. etc.) and should be replaced every twelve months or 2000 hours.. When replacing the element. TANK TOP-- 'i ' l I SHOULD BE 1/B" TO 1/4"--1!._ SHORTERTHAN ELEMENT MEASUREMENT L _____j--01---.- . • Place a straightedge across top of element and measure from bot1om of straightedge to bot1om of element (See Fig._SCAVENGE TUBE .cut line If necessary (29) . and check valve should be thoroughly cleaned and the oil changed.SEPARATOR TANK Book 35389816 (4/95) c. Measurement should be from 1/8" to 1/4" less than the element measurement. • Reposition cover (use care not to damage gaskets). any orifice and check valve. Change rag when soiled. Do not scrub with a rough cloth. moisture or any other form of surface contamination. etc. etc. thermoset polyester powder coating. lint. wash with water and soap or dish washing liquid detergent. Check oil level. 2. 2. DO NOT USE WATER BORNE OR LATEX PRODUCTS. Before applying paint: Inspect to Insure that area Is free of all dirt. Do not replace element without first performing the following maintenance procedure: 1. The following care will ensure the longest possible life from this finish. 4. Always relieve pressure before removing caps. Note: This may cause some dulling of the paint finish. grease. Book 35389816 (4/95) (30) To touch-up or paint over and retain the superior fin· ish requires the following: 1. This unit was painted and heat cured at the factory with a high quality. Run unit at rated operating pressure for 30 to 40 minutes to permit element to clear Itself. 2. plugs. 3. the use of a commercial grade. a fast evaporating alcohol or chlorinated solvent can be used. replace the separator element and clean the scavenge orifice/check valve. An orifice check valve is located on the scavenge tube. automotive-type. If grease removal Is needed. The scavenge line originates at the receiver-separator tank cover and terminates at the compressor airend near the oil filter element.EXTERIOR FINISH CARE SCAVENGE LINE jwARNINGI High pressure air can cause severe injury or death from hot oil and flying parts. 4. Remove all sanding dust with alco· hoi using clean. coat area with a solvent based. The area to be painted should be finish sanded with 320 grit paper. If the paint has faded or chalked. high quality liquid paint that will adhere to powder coatings. pollen. whichever comes first. from housing. allow 30 days before washing with anything but clean water. nonabrasive car wax may partially re· store the color and gloss. Once a year or every 1000 hours of operation. Thoroughly clean scavenge line. pad. NOTICE Excessive oil carry-over may be caused by an oil-logged separator element. covers or other parts from pressurized air system. 1. . fibers. If necessary to remove dust. Remove any lint and other loose contamlna· tion with atitomobll9-iJrade tack rag(s}. If possible. Assure minimum pressure valve/or!· flee Is operational. lint free rag(s}. 3. Maintain as Indicated earlier In this section. 3. ETC.INTAKE. ETC. c c c c c CLEAN c CLEAN FASTENERS AIR CLEANER ELEMENTS c WI R 'FUEL/WATER SEPARATOR ELEMENT COMPRESSOR OIL FILTER ELEMENT R COMPRESSOR OIL R c c 'WHEELS (BEARINGS. 2000 HRS DRAIN AIR CLEANER PRECLEANER DUMPS TIRE PRESSURE AND SURFACE MO.) AUTOMATIC SHUTDOWN SYSTEM TEST AIR CLEANER SYSTEM COMPRESSOR OIL COOLER ENGINE RADIATOR/OIL COOLER VISUAL EXTERIOR EXTERIOR 6MO.) 'ENGINE COOLANT TEST SHUTDOWN SWITCH SETTINGS TEST R c SCAVENGER ORIFICE & RELATED PARTS CLEAN R OIL SEPARATOR ELEMENT ENGINE (OIL CHANGES. WI=OR when Indicated. 3MO. SEALS. these time periods should be reduced.PREVENTIVE MAINTENANCE SCHEDULE If operating In extreme environments (very hot.) REFER TO ENGINE OPERATOR•s MANUAL *Disregard If not appropriate for this particular machine. Unit _ _ _ _ __ Ingersoll-Rand 36509966 Date: _ _ _ __ Hours _ _ _ _ __ Book 35389816 (4/95) R=Replace Serviceman _ _ _ __ (31) . dusty or wet). FILTERS. Dally COMPRESSOR OIL LEVEL c ENGINE OIL LEVEL c c c c 'RADIATOR COOLANT LEVEL GAUGES/LAMPS 'AIR CLEANER SERVICE INDICATORS FUEL TANK (FILL AT END OF DAY) 'FUEL/WATER SEPARATOR DRAIN c c Wkly c FAN ALTERNATOR BELTS c BATTERYCON c c SIELECTROLVTE 'WHEEL LUG NUTS HOSES (OIL. cold. C=Check (and adjust or replace If necessary). 500 HRS 1000 HRS 12MO.AIR. ETC. Reg.LUBRICATION FLUIDS AND LUBRICANTS TABLE ITEM FLUID Compressor Models: Lubrlcan VHP-(200+ psi) HP-(150 psi) XP-(125 psi) P-(100 pslj AMBIENT TEMP. API CC -40°F to 125 ° F 0 -10°F to 125°F (-40°C to 52°C) XHP (300 psi) -10°F to 125°F (-23°C to 52°C) -10°Fto 100°F (-23°C to 38°C) 70°F to 125°F (21 °C to 52°C) XHP (350 psi) Engine: SPECIFICATION 1-R PIN 35382472 Synthetic Fluid • Dexron® II ATF • 1-R XHP 505 Synthetic or Equivalent • 1-RXHP 505 Synthetic or Equivalent •1-R XHP 1001 Synthetic or Equivalent • 011 •Coolan • Fuel Running Gear •wheel Bearings • Other • Hydraulic Brakes Grease Grease Fluid All All All MIL-G-10924 Multi-Purpose Dot 3 or4 DEXRON®. (-23°C to 52°C) • Dexron ® or Dexron ® II ATF • MIL-L-46152 SAE 10W. Book 35389816 (4/95) (32) .M. T. of General Motors Corp. Book 35389816 (4/95) (33) ..ADDRESS: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ DATE P U R C H A S E D : .58-1 ).. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations.... This warranty is not limited to any particular part..S.. : .SERIAL N O .....- The Noise Control Act of 1972 (86 Stat. _ _ _ _ _ _ _ _ __ UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: ENGINE MAKE & M O D E L : . or system of the compressor which...... or replacement. with all applicable U. or system of the air compressor. _ _ _ _ _ _ _ _ _ __ USER UNIT NO. built and equipped to conform at the time of sale to the first retail purchaser.. 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. EPA Noise Control Regulations.. or in any part. other than for purposes of maintenance...PURCHASER OR O W N E R : . 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. repair. assembly. 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. Defects in the design... component... specifically the following acts or the causing thereof: (1) The removal or rendering inoperative by any persons....NOISE EMISSION CONTROL MAINTENANCE LOG COMPRESSOR MODEL _ _ _ _ _ __ SERIAL NO... (40CFR204.. component............ A. The purpose of this book is to provide (1) the Maintenance Performance Schedule below for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done. Detailed instructions on the maintenance items below are given on the following page. ACOUSTIC MATERIALS DAILY D. COMPRESSED AIR LEAKS AS DETECTED B. by whom. SAFETY AND CONTROL SYSTEMS AS DETECTED c.P. ISOLATION MOUNTS 250 HOURS I. COOLING SYSTEMS 250 HOURS H. E. Regulations for Noise Emissions. FUELS & LUBRICANTS SEE OPERATOR'S MANUAL Book 35389816 {4/95) (34) . ENCLOSURE PANELS 100 HOURS F.S. AIR INTAKE & ENGINE EXHAUST 100 HOURS G. where and when. ENGINE OPERATION SEE OPERATOR'S MANUAL J. applicable to Portable Air Compressors. MAINTENANCE SCHEDULE ITEM PERIOD AREA A. FASTENERS 100 HOURS E.INTRODUCTION The unit for which this Maintenance Log is provided conforms to U. hours of use. All components of the cooling systems for engine water and compressor oil should be inspected every 250. all should be replaced with equivalent parts. or otherwise deformed. bolts. or have otherwise deteriorated due to severe operating or storage conditions. Book 35389816 (4/95) (35) . Engine and compressor air intake and engine exhaust systems should be inspected after each 100 hours of operation for loose. 2) have partially separated from panels to which they were attached. C. Unrestricted airflow over the radiator and oil cooler must be maintained at all times during operation. or nonfunctional. or with bent or broken bolts due to operation or storage in severe environments. disabled. AIR INTAKE AND ENGINE EXHAUST Correct all compressed air leaks during the first shutdown period after discovery.A. COMPRESSED AIR LEAKS F. ISOLATION MOUNTS In daily inspections observe these materials. 3) are missing. Doors.if missingreplaced immediately to prevent subsequent damage and noise emission increase. screws. punctured. Repairs or replacements should be made before the next period of use. They should be retightened. Maintain all acoustic material as nearly as possible in its original condition. should be repaired or replaced before the next operation interval. damaged. ENGINE OPERATION All fasteners such as hinges. or deteriorated components. Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer. and latches should be inspected for loosenes& after each 100 hours of operation. FASTENERS I. rivets. FUELS AND LUBRICANTS Enclosure panels should also be inspected at 100hour operational intervals. All panels that are warped. ENCLOSURE PANELS J. shut down immediately and correct the leak(s). such that their noise containment function is reduced. Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand Company and Engine Manufacturer's Operator and Maintenance Manuals. or. Any discrepancies found should be corrected before placing the unit back in operation. D. Those mounts with cracks or splits in the molded rubber. and hatch closures especially. nuts. SAFETY AND CONTROL SYSTEMS G. repaired. torn. access panels. No compressor should be operated with either system bypassed. If severe enough to cause serious noise problems and efficiency loss. B. COOLING SYSTEMS Repair or replace all safety and control systems or circuits as malfunction occurs. should be checked and adjusted at this time to insure continuous sealing between gasket or acoustic material and the mating frame. ACOUSTIC MATERIALS H. E. Engine/airend isolation mounts should be inspected after each 250 hours of operation. Repair or replace all sections that have: 1) sustained damage. clamps. MAINTENANCE RECORD FOR NOISE EMISSION CONTROL ITEM NO. HOURMETER READING DESCRIPTION OF WORK OR COMMENTS MAINTANSPECT DATE - Book 35389816 (4/95) (36) - LOCATION CITY/STATE WORK DONE BY(NAME) . This covers the standard models and the more popular options that are available. The descriptive modifier may be followed by words or abbreviations such as upper. inner. MARKINGS AND DECALS NOTICE DESCRIPTION The illustrated parts breakdown illustrates and lists the various assemblies.SECTION 7 PARTS ORDERING GENERAL of parts used in the machine. the description of the part and the quantity of parts required are shown on each illustration or on adjacent page. In the disassembly and reassembly of parts. rear. Special order parts may not be included in this manual. size and description. Each description of a part is based upon the "noun first" method. FASTENERS Both SAE!inch and ISO/metric hardware have been used in the design and assembly of these units. extreme care must be taken to avoid damaging threads by the use of wrong fasteners. always consider the drawbar end of the unit as the front. In order to clarify the proper usage and for exact replacement parts. listed in the parts breakdown. Any fastener that has not been identified by both part number and size is a specially engineered part that must be ordered by part number to obtain the exact replacement part. the identifying noun or item name is always the first part of the description. For the greatest protection always insist on genuine Ingersoll-Rand Company parts for your compressor. has been prepared as an aid in locating those parts which may be required In the maintenance of the unit. RH.e. lower. A series of illustrations show each part distinctly and in location relative to the other parts in the assembly. All of the compressor parts. This will enable a customer to obtain fasteners locally rather than ordering from the factory. The part number. i. LH. Ingersoll-Rand Company service facilities and parts are available worldwide. immediately order replacements from the factory. In Canada our customers are serviced by the Canadian Ingersoll-Rand Company. . Contact the Mocksville Parts Department with the unit serial number for assistance with these special parts. all standard fasteners have been identified by part number. Standing at the rear of the unit facing the drawbar (front) will determine the right and left sides. Part numbers for original individual decals and their mounting locations are shown within Parts List Section. NOTICE Ingersoll-Rand Company can bear no responsibility for Injury or damages resulting directly from the use of non-approved repair parts. the front or to either side of the unit. Limited. Where no quantity is specified the quantity is assumed to be one. are manufactured with the same precision as the original equipment. when they are essential. etc. The quantities specified are the number of parts used per one assembly and are not necessarily the total number Book 35389816 (4/95) In referring to the rear.. These are available as long as a particular model is in production. front. The noun name is generally followed by a single descriptive modifier. subassemblies and detailed parts which make up this particular machine. (37) Do not paint over safety warnings or Instructional decals. This publication. There are IngersollRand Company Construction Equipment Group Sales Offices and authorized distributors located in the principal cities of the United States. outer. which contains an illustrated parts breakdown. There are also Ingersoll-Rand International autonomous companies and authorized distributors located in the principal cities throughout the free world. These parts are identified in tables that will be found at the rear of the parts illustrations. If safety warning decals become Illegible. sale. strikes. Always specify the part number. The Company's liability under this warranty shall be limited to the repair or replacement of any part which was defective at the time of shipment provided Purchaser notifies the Company of any such defect promptly upon discovery. Warranty: The Company warrants that parts manufactured by it will be as specified and will be free from defects in materials and workmanship. d. fires. but in no event later than three (3) months from the date of shipment of such part by the Company. it is expressly understood and agreed that the terms and conditions of such order form shall not apply unless expressly agreed to by Ingersoll-Rand Company ("Company'') in writing. or any other cause beyond the Company's reasonable control.O. however. the additional charges will be honored by the Purchaser. riot. point of shipment. Locate the desired part on the illustration by visual identification and make note of part number and description. Delivery: Shipping dates are approximate. locate the area or system of the compressor in which the desired part is used and find illustration page number. embargo. autonomous company or authorized distributor. Always specify the model number of the unit as shown on the general data decal attached to the unit. (The serial number on the unit is also permanently stamped in the metal of the frame side rail. as well as the description of the part. with complete information. Contact the Product Support Group at Mocksville for your particular needs and availability. Acceptance: Acceptance of an offer is expressly limited to the exact terms contained herein. Warranties applicable to material and equipment supplied by the Company but wholly manufactured by others shall be limited to the warranties extended to the Company by the manufacturer which are able to be conveyed to the Purchaser. b.) c. The Company shall not be responsible for costs of transportation. Always specify the serial number of the unit. exactly as it is given on the parts list illustration. Always specify the quantity of parts required. floods. war. b. In the event parts are being returned to your nearest sales office. The serial number of the unit will be found stamped on a plate attached to the unit. e. Always specify the number of the parts list publication. service sets of exterior decals and current production safety warning decals are available. removal or installation. THIS IS IMPORTANT. it is important to include the serial number of the unit from which the parts were removed. HOW TO ORDER The satisfactory ordering of parts by a purchaser is greatly dependent upon the proper use of all available information.B. delay or default on the part of the Company's vendors. such as exclusive use of shipping facilities. acts of Government. you will enable them to fill your order correctly and to avoid any unnecessary delays. Taxes: Any tax or other governmental charge now or hereafter levied upon the production. No additional or contrary terms will be binding upon the Company unless expressly agreed to in writing. HOW TO USE PARTS LIST a. for inspection or repair. c. The Company will use best efforts to ship by the dates specified. Book 35389816 (4/95) (38) . or parts.TERMS AND CONDITIONS ON PARTS ORDERS Afterwards. transportation shortages. In order that all avoidable errors may be eliminated. the following instructions are offered as a guide to the purchaser when ordering replacement parts: a. The only exception to the previous statement is the extended warranty as it applies to the special airend exchange program. autonomous company or authorized distributor. Repairs and replacements shall be made by the Company F. use or shipment of material and equipment ordered or sold is not included in the Company's price and will be charged to and paid for by the Purchaser. Should Purchaser request special shipping instruction. If purchaser's order form is used for acceptance of an offer. the Company shall not be liable for any delay or failure in the estimated delivery or shipment of material and equipment or for any · damages suffered by reason thereof. including air freight when common carrier has been quoted and before change order to purchase order can be received by the Company. By supplying your nearest sales office. Turn to Parts List Section. Shipping dates shall be extended for delays due to acts of God. acts of Purchaser. 35389816 . . Operation Manual FM 1011F DEUTZ SERVICE A KHD DEU"'"Z . · facturer for resultant damage. o Unauthorized engine modifications will · invalidate any liability claims against the manu. This will enable you to avoid accidents. The manufacturer will not assume responsibility for any damage resulting therefrom. e The relevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be observed. Adherence to legislation on pollution cannot be guaranteed under such conditions. Manipulations of the injection and regulating system may also influence the pertormance of the engine. The risks involved are to be borne solely by the user. . preserve the manufacturer's warranty and maintain the engine in peak operating condition. The engine should only be operated by personnel trained in its use and the hazards involved. Any use exceeding that scope is considered to be contrary to the intended purpose. maintenance and servicing. o Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for operation. 0 This engine has been built exclusively for the application specified in the scope of supplyas described by the equipment manufacturerand is to be used only for the intended purpose.e Please read and observe the information given in this Operation Manual. and its emissions. Operation Manual FM 1011 F Engine Serial Number IIIIIIII Please enter the engine serial number here. This number should be quoted when inquiring about Customer Service, Repairs or Spare Parts (see Section 2.1) All rights reserved. Technical modifications required to improve our engines are reserved with regard to specification data and other technical information contained in this Oper-ation Manual. No part of this Manual may be reproduced in any form or by any means without our written approval. Foreword Dear Customer, Liquid-cooled DEUTZ engines are designed for a large number of applications. Consequently, a wide range of variants are offered to meet the requirements of specific cases. Your engine is appropriately equipped for the installation concerned, which means that not all of the components described in this Operation Manual are necessarily mounted to your engine. We have endeavored to highlight any differences so that you will be able to locate the operating and maintenance instructions relevant to your engine quickly and easily. Please read this Manual before starting your engine, and always observe the operating and maintenance instructions. We are available to help with any additional inquiries. Sincerely, DEUTZ SERVICE INTERNATIONAL GmbH • Index 1 2 General Engine Description 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.2 2.2.1 2.2.2 2.3 2.3.1 2.4 2.4.1 Model Rating Plate Rating Plate Location Engine Serial Number Cylinder Numbering Fuel Delivery Lock Engine Illustrations Service side Service side Lube Oil Circuit Lube Oil Circuit Schematic Fuel System Fuel System Schematic 3 Engine Operation Commissioning 3.1 Adding Engine Oil 3.1.1 Initial Engine Oil Fill-Up for 3.1.2 BF4M 1011 Series Filling Oil Bath Air Cleaner 3.1.3 Adding Fuel 3.1.4 3.1.5 Other Preparations Additional Maintenance Work 3.1.6 3.2 Starting 3.2.1 Electric Starting Monitoring Systems 3.3 3.3.1 Engine Oil Pressure 3.3.2 Coolant Temperature 3.4 Stopping 3.4.1 Mechanical Shutdown Electrical Shutdown (Ignition Key) 3.4.2 3.5.1 Winter Operation 3.5 Operating Conditions 3.5.2 High Ambient Temperature, 4 Operating Media 4.1 Lube Oil 4.1.1 Quality Grade 4.1.2 Viscosity 4.2 Fuel Operating Media 4.2.1 Quality Grade 4.2.2 Winter-Grade Fuel 5 Routine Maintenance 6 Service and Maintenance 5.1 5.2 6.1 6.1.1 6.1.2 6.1.3 6.2 6.2.1 6.2.2 6.3 6.3.1 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.5 6.5.1 6.5.2 Maintenance Schedule Maintenance Chart Lubrication System Oil Change Intervals Changing Engine Oil Changing Oil filter Fuel System Changing Fuel Filter Fuel Pump Cooling System Cleaning Intervals Combustion Air Cleaner Cleaning Intervals Emptying Cyclone Type Precleaner Cleaning Oil Bath Air Cleaner Dry Type Air Cleaner Belt Drives Checking V-Belts Tensioning Alternator Belts 6.5.3 Changing Alternator Belts Checking Toothed Belts 6.5.4 6.6 Adjustments 6.6.1 Checking I Adjusting Valve Clearances 6.6.1.1 Valve Clearance 6.7 Accessories 6.7.1 Battery 6.7.1.1 Checking Battery and Cable Connectors 6.7.1.2 Checking Electrolyle Level 6.7.1.3 Checking Specific Gravity of Electrolyle 6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle Ether Starting System 6.7.4 6.7.4.1 Changing the Fluid Container 7 Troubleshooting 7.1 Diagnosis Chart 8 Engine Preservation 9 Technical Specifications D D D 8.1 Preservation 8.1.1 Preserving Engine 8.1.2 Removing Engine Preservations 9.1 9.2 9.3 Engine Specifications and Settings Torque Wrench Settings Tools 10 Deutz D n D . high reliability and lowfuelconsumption. & All safety instructions in this Manual are designated by the accompanying symbol. Safety Asbestos thattheengine continues to meet your requirements. Service and Maintenance DEUTZ SERVICE INTERNATIONAL GmbH Sound service and maintenance practices will ensure Recommended service intervals must be observed and service and maintenance work carried out conscientiously. D . Never fHI the fuel tank while the engine is running. Special care should be taken under abnormally demanding operating conditions. The resulting know-how. When carrying out maintenance and repair work. Please follow them carefully. coupled with stringent quality standards. be sure to refit any panels and guards that may have been removed. General safety and accident prevention regulations laid down by Jaw must also be observed. please [ ) use appropriate spare parts. Our trained specialists will carry out repairs quickly and professionally. Ensure that the engine cannot be accidentally started ·accidents may otherwise occur -. The seals and gaskets used in this engine are asbestos~free. using only genuine spare parts. guarantee their long service life. A table of DEUTZ SERVICE INTERNATIONAL GmbH contact numbers is given at the end of this Operation Manual. The attention of operating personnel should be drawn to these safety instructions. When the work is complete.General DEUTZ Diesel Engines are the product of many years of research and development. Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Observe industrial safety regulations when running the engine in an enclosed space or underground. Genuine spare parts from DEUTZ SERVICE INTERNATIONAL GmbH are always manufactured to the highest technical standards. Beware of Running Engine Shut the engine down before carrying out maintenance or repair work. It goes without saying that the highest standards for environmental protection are met. . Engine Description 2.3 2.2 2.1 2.4 Model Engine Illustrations Lube Oil Circuit Schematic Fuel System Schematic . 5 Fuel Delivery Lock 2.1 Rating Plate f) 26 332 0 Cylinders are numbered consecutively. with locking paint on model: torque balancer. with plastic protective cap on model: without torque balancer Adjustments to the regulator are to be carried out only by authorized DEUTZ SERVICE specialists. The rating plate C is attached to the ventilation hood. The manufacturer shall not be held liable for damages resulting from adjustments made to the regulator by the operator.1. The lock screws are protected ln order to prevent this: 1.1.1. the engine serial number B and the performance data are stamped on the rating plate. 2.1 Model 2. The model and engine serial number must be given when ordering spare parts.4 Cylinder Numbering 2. beginning at the flywheel end.2 Rating Plate Location 2.Engine Description 2.3 Engine Serial Number The model A.1. .1. 2. The engine serial number D is stamped on the crankcase as well as the rating plate. 2.2 Engine Illustrations 2.Engine Description 2.1 Service side 13 6 . 1 Fuel System Schematic 4 3 Oil sump Intake manifold Oil pump Main oil duct Oil-cooled cylinder Cylinder head cooling neck Oil duct for rocker arm lubrication Rocker arm Oil manifold for the thermostat Intake to external engine oil cooler Return from external engine oil cooler Thermostat housing with slide thermostat Oil duct to oil filter Oilfilter Oil ductto the cam. con-rod and crank shaft bearing Injection jet for cooling the pistons Oil return via crankcase to the oil sump 2 5 26 437 0 .3.3 Lube Oil Circuit 2.Engine Description 2.4 Fuel System 2.4.1 Lube Oil Circuit Schematic 9 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 8 11 D 16 17 14 17 18 16 2 3 4 26 430 0 2. 3 3.2 3.5 Commissioning Starting Monitoring Systems Stopping Operating Conditions .Engine Operation 3.1 3.4 3. 3 Filling Oil Bath Air Cleaner II I ~ I ~ FUEL 24 980 2 Fill oil cup 1 ofthe oil bath air cleaner with oil up to the arrow. depending on the ambient temperature.1 Adding Engine Oil 3. ~collector 80 543 0 Use only commercial-grade diesel fuel.1. Never fill the fuel tank while the engine is running. see 9.1. two minutes. Pour lube oil into the oil filler neck (arrow).1. For fuel grade.1.Engine Operation 3.1 For oil grade and viscosity. engines are delivered empty of oil.2. A 3.max" marking on the engine dipstick. For oil grade and viscosity. For oil quantities. o Start the engine and le4ve it to run for approx. As a rule. . Keep the filler cap area clean and do not spill fuel.1 3. see 4.2 Initial Engine Oil Fiii·Up Fill in the engine oil in two phases as follows: Phase 1 o Fill the oil sump with initial quantity of oil. see 4.4 Adding Fuel Do not fill the precleaner dust (if fitted) with oil. e Switch off the engine and wait for approx. see 4. Use summer or winter~grade fuel. one minute. Phase 2 0 Fill in oil up to the .1.1 Commissioning 3. 5 Other Preparations Gl Check battery and cableconnections.5 e 3.2 D . see 6.1.1.6 Additional Maintenance Work Breaking in During the break-in phase ·about 200 operating hours • check the oil level twice a day. see 6.1 Gl Transport hooks e The following maintenance should be carried out after 50 operating hours: Remove if fitted (see 6. After the engine is broken in. 7. see 6.2 During and after trial run .1.6.1.Check the oil level. top up oil.1. Check the V-belts and retension as necessary e Check valve clearance and adjust as necessary.1 e Check theengine for leaks Gl Check the engine mount and adjust as necessary. Gl Change lube oil. see 6. see 9.Check the engine for leaks After the engine has been turned off .1/2 Retension V-belts. checking once a day will be sufficient.1 Commissioning 3.7. see 3. see 6.3). e Trial run After the engine has been prepared.2 If necessary. let it run for about 10 minutes without load.Engine Operation 3. 1 Electric Starting Starting without Cold-Start Aid Before starting. . After repair work: Check that all guards have been replaced and that all tools have been removed from theengine.Position 0 = no operating voltage. . If the engine does not catch after two attempts. Move cut·out handle 2 into operating position. hold for approx.1). The switch must not be moved to position H when the engine is switched off and the ignition is switched on. do not use any other starter substance (e.Pilot lights come on. Push the key in and turn it further clockwise against spring pressure. . make sure that nobody is standing in the immediate vicinity of the engine or driven machine. Preheat lamp comes on. . .Engine Operation 3. . . . e Push key in and turn further clockwise against spring pressure.2. 411 Insert key.Position 3 = start Release key as soon as engine fires. disengage the clutch to separate the engine from any driven parts. If the engine does not catch.g.Position 2 = no function. e To assist acceleration at lowertemperatures and to avoid white fumes. Turn key clockwise. wait a minute then try Insert key.Position 3 = start. . e Turn key clockwise.2 Starting 3.Position 1 =operating voltage. 0 Release key as soon as engine fires. Pilot lights go out. briefly hold the arctic switch in switch position H. e 25 963 0 o Starting fluid is injected automatically in switch position A. as tong as the starter is operated. .Position 0 = no operating voltage. . A D 25 746 2 0 8 e Where possible.Pilot lights come on. with Cold·Start Aid .Glow Plugs with Cold·Start Aid . . injection with start pilot).Position 3 = start. . . • Turn key clockwise. e Push key in and turn further clockwise against spring pressure. refer to the Diagnosis Chart (see 7.Pilot lights go out. • e e e Do not actuate the starter for more than 20 seconds. again.Position 1 =operating voltage. . Move speed control lever 1 into idle position.Pilot lights go out. 1 minute. Doing so could result in an accident. e Release key as soon as engine fires. When starting with glow plugs.Position 2 = Preheat.Position 2 =no function . .Pilot lights come on. .Position 0 = no operating voltage.Ether Starting System 25 746 2 25 746 2 Insert key.Position 1 =operating voltage. 3.3.1). 3. Turn it off and establish the cause from the Diagnosis Chart (see 7.Engine Operation 3.1 Engine Oil Pressure Oil Pressure Pilot Light Oil Pressure Indicator 25 i52 1 0 The oil pressure pilot light comes on with operating voltage on and engine off. D . e The oil pressure pilot light should go out when the engine is running. Oil Pressure Gauge 25 754 0 e The pointer must remain in the green sector over the entire operating range. It should rarely enter the yellow-green sector.2 Coolant Temperature Gauge Pointer 24 985 0 e The coolant temperature gauge pointer should remain in the green sector most of the time.3 Monitoring Systems 3. e The pointer must indicate the minimum oil pressure (see 9.1 ). If the pointer enters the orange sector. the engine is overheating. see 6. The charge pilot light and the oil pressure pilot light will come on when the engine stops. to a stop.Efficient cold starting requires a healthy battery. see 6. .7.1. see 4. see 3.2.Use winter-grade diesel fuel for operation below 0 •c.1. remove the battery and store in awarm place).5.2. This not only lowers the starting limit temperature. .2 Electrical Shutdown (Ignition Key) D 25 746 2 e Move speed control lever 1 to low idle. (To do so. 41 Turn key counterclockwise (to Position 0) and remove.At temperatures near or below freezing point.The starting limittemperaturecan be lowered by 4-5 •c by heating the battery up to about +20 •c. use glow plugs it necessary.1 Winter Operation e Lube Oil Viscosity . t.2.Selectthe oil viscosity (SAE grade) according to the ambient temperature when the engine is started. . e Operate shutdown lever 2 untilthe engine comes e Turn key counterclockwise (to Position 0) and remove.Engine Operation 3.Increase oil changetrequencywhen operating below -10 •c.1. The pilot lights will go out.5 Operating Conditions 3.4.Adjustthe oil level in the oit bath airc/eaner(if fitted) to suit the ambient temperature.4 Stopping 3. * l . e Battery .2 0 Additional Maintenance Work . 3.4.1 Mechanical Shutdown 3. CD Cold-Start Aids . The pilot lights will go out. e 0/esel Fuel . see 4. but provides easier starting at tern peratures normally not requiring astarting aid.1.Orain the sludge from the fuel tank once a week. 3. D . the engine can be used at altitudes up to 1000 meters and temperatures up to 30'C.2 High Ambient Temperature. askyou rengine or equipment supplier whether the engine has been derated in the interests of reliability. the density of the airtends to decrease. engine power. Otherwise contact DEUTZ SERVICE. in extreme cases.5 Operating Conditions Engine Operation 3. the starting behavior. it will be necessary to reduce the injected fuel quantity and thus. If the engine is to operate under more severe conditions (at higher altitudes or temperatures). Ill If you have any doubts about engine operation underthese or similar conditions. the exhaust gas quality and. High Altitude Ill As the altitude and ambienttemperature rise. which affects the maximum power output of the engine.5. service life and exhaust gas quality (smoke). Under transient conditions. . 1 Lube Oil 4.2 Fuel 0 .Operating Media 4. I ""'.also reduce fuel consumption...1 Lube Oil 4.5 •14 -10 • -15 5 ...1 ·10 I Ii I _t ~ ~ ~ ~~ ~ ~ ~ 5 ~ . Diesel fuel containing additives (Super diesel) is often on sale as well. Aooroved API Oils: Naturally aspirated engines: CCISE CCISF Aonroved CCMC Oils: Naturally aspirated engines: ·c •F 86 • •30 ~ 77 68 -t20 -1-~ 59 50 ~ ..... Oil changes dictated by the seasons can be avoided by using multi-grade lube oils. 'k i'- .1. 60% -----+- ~ In most cases.1. Winter diesel fuel I -20.t -40 0 0 4.. winter· grade fuel (suitable down to -15 'C) should be used.. for use down to ·20 oc. -31 40- .j__ .. Multi-grade oilsparticularly light-flowing oils . If the sulfur content is higher than 0.... the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site..4 8 Attemperatures below -15 'C to -20 'G..... In common use are specifications named after the API (American Petroleum Institute) and CCMC (Committee of Common Market Automobile Constructors).2.2 Viscosity lube oils are differentiated according to their performance and quality class. The following fuel specifications I standards are approved: 41 DIN 51 601 (Feb. cold starting may be affected but the engine will not be damaged. Inquire at the nearest service representative. In order to keep wear to a minimum.• 0 0 -4 -20 ~ ~ '5 ·1~ -22 .. A Mix in tank only..2. Fill with the appropriate amount of kerosene first. up to 60% kerosene can be added (see diagram). see 9.1 Quality Grade 4...1.. clogging the fuel system and reducing engine efficiency.. oil change intervals should be reduced. If the ambient temperature is less than 0 °C.. do not exceed application limits for extended periods of time.1 Quality Grade 4. see 6. Waxing may occur at low temperatures.13 -25 -22 -301 .._ .0 -30 0 • ~~"'.1.2 Winter-Grade Fuel Use commercially available diesel fuel with less than 0.1 Oil capacities. (This fuel is usually available from filling stations well in advance of the cold months).5%... then add the diesel fuel . Optimum operating behavior will be attained if you take the accompanying oil viscosity diagram as a guide.. 1-0 and 2-D It CEN EN 590 or DIN EN 590 C1 NATO Code F-54 and F-75 •32 0 •23 . "'"r-. The relevant percentages are given in the adjacent diagram._. SUm~er diesel fuel r-.1. As the viscosity of the lube oil is dependent on temperature.5% sulfur content. 1986) 41 BS 2869: A1 and A2 (With A2...Operating Media 4. adequate resistance to cold can be obtained by adding a flow improver (additive). kerosene should be added to the diesel fuel. Suoer diesel fuel .. .~~ 30 40 "'" ~ r-.....t to •c M 10 20 L_____.2 Fuel 4.... 50 -·'"90 ol k.• ..to 4 .. see 6. If summer-grade diesel fuel must be used at temperatures below 0 °C... Should the temperature fall temporarily below the limits of the SAE grade selected. take note of the sulfur content) 41 ASTM 0 975·88.o 32 04 I 23 14 D Oil change intervals. 1 Maintenance Schedule 5.Routine Maintenance 5.3 Maintenance Record .2 Maintenance Chart 5. 1. ask your engine or equipment supp lie r for a fresh supply of labels.3 6.6.1 6.Routine Maintenance 100H chack Operating Hours (OH') every once "'~ 5.1.2 6. If necessary.2.7.5.and dry type air cleaners 314151 Battery and cable connectors Cooling system (depending on engine use) 31 61 Engine oil (depending on engine use) 4161 Oil filter cartridge (depending on oil change interval) 61 Fuel filler cartridge Valve clearance (adjust if necessary) Engine mounts (retighten if necessary) V-belts (retension if necessary) Toothed belts 71 Injection valves Fuel pump I strainer 5J 6. 1011 0297 49n IQJ Stop the engine before carrying out any maintenance work.1.1 9.2 6.4 6.1.4 6.5 6.1 6. .1 Maintenance Schedule clean after 50 21 or daily • • • • ••• • • I 125 250 500 750 11000 2000 3000 Operation •• • • • est • • • • 6) • • • 1) recommended maximum 2) commissioning new or reconditioned engine 3) clean if needed 4) Oil quality API·CO or CCMC~D4 + 05 Oil level in engine/separate container • • • • • • • • • see Section change • •• • • • Engine leaks Oil bath.2 Maintenance Chart The maintenance chart shown here is supplied as a self-adhesive label with each engine.3.2.1 7) change every 5 years or 4500 OH with sprocket 5.1 6.1 6. Routine work should be carried out according to the schedule in 5.2 5) change if required 6) for oil change intervals. ft should be affixed where it can be seen clearly on the engine or driven equipment.1. Check that this is the case. see 6. Date Signature I Stamp . OH Date Signature I Stamp DH 2875 3000 3125 3250 3375 3500 3625 3750 3875 4000 4125 4250 4375 4500 4625 4750 4875 5000 5125 5250 5375 5500 5625 5750 Duly completed maintenance jobs can be recorded and signed off in the above chart.Routine Maintenance 5.3 Maintenance Record OH Datum Signature I Stamp OH so· - 125 250 375 500 625 750 875 1000 1125 1250 1375 1500 1625 1750 1875 2000 2115 2250 2375 2500 2625 2750 Date Sionature 1Stamo *after commissioning of new and reconditioned engines Duly completed maintenance jobs can be recorded and signed off in the above chart. Date Signature I Stamp .Routine Maintenance OH Datum 5.3 Maintenance Record OH Signature I Stamp 5875 6000 6125 6250 6375 6500 6625 6750 6875 7000 7125 7250 7375 7500 7625 7750 7825 8000 8125 8250 8375 8500 8625 8750 Duly completed maintenance jobs can be recorded and signed off in the above chart. 3 6.4 6.6 6.2 6.5 6.1 6. 7 Lubrication System Fuel System Cooling System Combustion Air Cleaner Belt Drives Adjustments Accessories .Service and Maintenance 6. For grade/viscosity. 3J SHPD lube oils can be used. Oils with only a Cclassification (e. 80'C).5% by weight. 411 Turn the engine off. Be careful when draining hot oil • danger of scalds! Do notlet used oil run into the soil but catch it in a container ready for proper disposal. emergency pumps. • Turn the engine off. API classification 11 Lube oils having bolh aC. sweeping machines. 411 Check oil level. winter operation equipment. cranes. These are the equivalent of 05 grade. CD Allow the engine to warm up . Heavy-duty oil usage.g.1. the oil should be changed cc 1) CD/CE!CF-4 1) CCMC classific'ation 04 D5(SH PO) 2) 500 750 250 375 Normal oil usage. rail-run vehicles II The table refers to the following conditions: . Change the oil with the engine off but still warm (lube oil temperature approx.: at least once a year.g. 411 Fill with lube oil . electrical units. ships.g.: Combine harvesters. Checking Oil Level OIL ~ ?• II II I[ ~~MAX ~<}-MIN 25729 26022 0 e Ensure that the engine or vehicle is on a level surface. 80 °G.1 .1.8% by mass.For quantity. undergro Wintequipment.Lube oil temperature approx. 6.and an Sclassification (e. contact your service representative.1 Oil Change Intervals lube oil intervals in OH Installed Engines Pressure charged engines 411 The oil change intervals are dependent on the Lube oil quality engine application and the quality of the lube oil. emergency power generating units. pumps.Continuous ambient temperatures down to -10 'C (+14 'F). e 411 Fit oil drain plug with new gasket and tighten firmly (for torque. see 9.2 Changing Engine Oil. II If the sulfur content is > 0. 0. e Drain oil.1. see 4. e. . •·In the case of fuels containing more than 1% sulfur. the intervals between oil changes should be halved. . top up with oil as far as the upper bar. Road vehicles.g.1 Lubrication System 6. tractors. . • If the engine runs fewer hours during the year than stated in the table.5 to 1% or the oc continuous ambient temperature below -10 (+14 'F). Unscrew drain plug. CD/SE) can be used. construction machinery. CE) generally perform very well in diesel engines and are to be preferred. e.For diesel fuel: sulfur content max. 0 Start engine and run at low idle for about 2 minutes.2).If necessary.Service and Maintenance 6. e Place oil tray under the engine. see 9. industrial trucks. 21 05 grade oil with sulfate ash content> 1. e Clean any dirt from the filter carrier rim.1 Lubrication System 6. 0 Catch any dripping oil.. The fuel system does not need to be bled.Service and Maintenance 6. .. 8 Screw in the nei'J cartridge finger tight against the gasket. see 3. turn. gasket of the new fuel filter cartridge.&.2 Fuel System 6. . Keep naked flames away when working on the fuel system. 0 Check oil level. e Tighten the oil filter cartridge with another half· 0 Lightly oil the rubber gasket of the new oil filter cartridge. 0 Check for leaks.3 Changing Oil filter 258-80 0 e Undo the filter cartridge using acommercial tool and spin off.1. 6. 0 Undo fuel filter cartridge with commercial tool and spin off. e Check cartridge seal for leaks.3. see 6.1.1 Changing Fuel Filler 25882 0 o Close fuel stopcock. o Check oil pressure. o Apply light film of oil or diesel fuel to the rubber o Catch any fuel. Beware of burns from hot oil. e Clean any dirt from the filter carrier rim. Do not smoke! 0 Tighten the oil filter cartridge with a final half- turn. 8 Screw in the new cartridge finger tight against the gasket.2.2.1. e Open fuel stopcock. on construction sites where there is a high level of air·borne dust. Underground mine units Farm equipment. &. Compressors. Do not smoke! 6. . I Checking or Cleaning Intervals Guide Values (running hours) 2000 1000 500 250 125 ! Engine Aplication Ships.2 Fuel Pump Cleaning the Strainer e Close the fuel shut·off valve. . e Remove the fuel strainer cover 2. Replace if necessary.1 Cleaning Intervals e The amount of contamination in the cooling system depends on the engine application.3 Cooling System 6. e Tighten the hexagonal screw t.3. Tractors doing harvesting work . Be especially careful if the engine is used in dusty environments. Pumps Vehicles on paved roads Tractors. The cleaning intervals given in the table on the right can be used as a guide.in harvesting application where there are high concentrations of chaff and chopped straw in the vicinity of the machine. Fork·lift trucks. Keep naked flames away when working on the fuel system. e Spilled oil or fuel on the engine increases the risk · of contamination. Mobile gensets Vehicles on construction sites and unpaved roads. e Because applications vary.2 Fuel System 6. • Mount the tuel strainer cover 2.2. for example. cleaning intervals have to be determined from case to case. e Check for leaks. Construction machineriy. e Clean the fuel strainer with diesel fuel. e Place seals 3 in position.Service and Maintenance 6. e Serious contamination can occur. Generating sets in closed rooms. e Loosen and unscrew the hexagonal nut 1. Never clean airc!eanerwith gasoline. o Remove dirty oil and sludge.4. Ill Inspect and replace rubber gaskets 5 and 6 if necessary. Replace collector bowl if damaged. e Clean filter housing 1 if very dirty. • Remove collector bow/3 from lower section 4 and empty. Neverfi!l collector bowl with oil.1 Cleaning Intervals e The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used.4. If necessary prize element out with ascrewdriver. e Release snap clips 2 and remove oil cup 3 together with filter element 4.3 Cleaning Oil Bath Air Cleaner 1 I~ !II_& (5) ~ ~870 e Undo wing nut 1 and remove cover 2. ct Air cleaner servicing is needed when: . • If a dry type air cleaner is used. a cyclone-type prec/eaner can be fitted to the air cleaner.Service Switch the yellow pilot light comes on when the engine is running.Service Indicator the red signal 1 is fully visible when the engine is off. fasten cover 2 in place by tightening wing nut 1. Ill Cleaning inteNals will have to be determined from case to case. Ill Refit oil cup and element to filter housing and secure with snap clips. strawandotherforeign matter from lower section of prec!eaner. e Clean filter element 4 in diesel fuel and allow to drip-dry.4.2 Emptying Cyclone Type Precleaner 6. If a high level of dust is anticipated. Clean leaves. e Turn engine offandwaitabout 10minutesforthe oil to drain from filter housing 1. reset the signal by pressing the button on the service indicator.2). .Service and Maintenance 6. Ill Fill oil cup with engine oil up to the mark (arrow) (for viscosity. . Ill Repositioncollectorbowl3 onto lower section 4. taking care not to damage the rubber gasket 5. Dispose of old oil in accordance with environmental regulations.1.4 Combustion Air Cleaner 6. clean when indicated by the service indicator or switch. • After carrying out service work. see 4. 6. Clean oil cup. . insert and tighten hex. 15 minutes running time. Replace if necessary.Undo hex.Position gauge on V-belt 2. or wash according to manufacturer's instructions). e Remove any caked dirt by pressing together the upper section of the valve. check the belt tension after approx. nut 5 and remove cartridge 4. . Check tension and change belts only with the engine off. Never clean filler cartridge with gasoline or hot fluids. .4 Combustion Air Cleaner Filter Cartridge e e e e Undo clip fasteners 1. 8 After five cleaner services or after two years at the latest. the gaskets on the filter cartridge can become damaged. e After installing new belts. Check paper filter (light showing through) and gaskets for damage. Clean cartridge (replace at least once a year).1 . When newV-belts are fined. 6. if provided. tap out. run engine for 15 minutes. To do so: . e Through regular removal and replacement. 6. nut.4 Dry Type Air Cleaner Dust Discharge Valve e Empty dust discharge valve 1 by pressing apart lips of discharge slot as indicated by arrows. e To checkthetension of the V-belt. replace hood 2 and do up clip fasteners 1. (or in difficult cases. .Read off the value: Turn the gauge sideways to see the exact spot where the top of the black indicator arm '1 intersects scale 5 (arrow).5. . 5 bar).If necessary. e Clean discharge slot from time to time. . see 9. For settings.Service and Maintenance 6.Install new cartridge. Clean cartridge 3: Blow out from inside out with dry compressed air (max. .Place indicator arm 1 into gauge. midway between the pulleys. use atension gauge. replace safety cartridge4 (neverclean). taking care notto damage the cartridge.4. Refit belt guard.Push slowly on the black pad 4 at right angles to belt 2 until the spring is heard or felt to trigger. Take off hood 2 and remove cartridge 3.5 Belt Drives 6.1 Checking V·Belts etnspect entire V-belt for damage. with flange 3on bottom of gauge against the edge of belt.Carefully remove the gauge without altering the position of the indicator arm 1. e Install cartridge 3. retension belt and measure again. e Replace damaged V-bells. then check belt tension. Ill Check the face and back of the teeth along the complete length of the toothed belt (see arrows). Ill If damaged.2 and 3. • Adjust alternator 4 in direction of arrow by turning boJt3 until correct belt tension is achieved.5.2 Tensioning Alternator Belts 6. e Replace the cover 1 with hex.3 Changing Alternator Belts e Slacken off bolts 1. 6. e Retighten bolts 1. 2 and 3 e Adjust alternator 4 in direction of arrow by turning bolt 3 e Remove and replace belt.2 and 3. rotate the engine through nvo turns.5 Belt Drives 6. replace the toothed beiVsprocket (see workshop manual).4 Checking Toothed Belts Timing Belts e Unscrew hex. bolts 2. Check. if provided. tension and change belts only with the engine off.5. e Slacken off bolts 1.Service Maintenance 6. bolts 2. e Retighten bolts 1. until correct belt tension is achieved. Remove the cover.5. e Adjust alternator 4 against the direction of the arrowbyturning bolt 3. Refit belt guard. Ill To facilitate this.2 an 3. . Valve Clearance Adjustment Schematic e Crankshaft Posilion 1: Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close. 8 Position crankshaft as per schematic 6.1.6. allow engine to cool down lor at least 30 minutes. 1 2 3 4 []l[[]l[i]l[[]] '- r- 6. inlet valve about to open). see 9.6. e Before adjusting valve clearance.1 e Adjust valve clearance il necessary: .6 Adjustments . For permissible valve clearance.Service and Maintenance 6.1 Checking/Adjusting Valve Clearances e Remove the cylinder head cover. The oil temperature should be below 80 'C.1.Use screwdriver 7 to turn setscrew 5 so that the correct clearance is attained after locknut 4 has been tightened. e Check valve clearance 1 between rocker arm I tappet contact face 2and valve stem 3with feeler gauge 6 (there should be only slight resistance when feeler blade is inserted). Adjust clearance ol valves marked in black on schematic. Adjust clearance ol valves marked in black on schematic. e Replace cylinder head cover (use new gasket il needed). Mark respective rocker arm with chalk to show that adjustment has been done. . • Check and adjust valve clearance on aU remaining cylinders.Release locknut 4.1.6. e Crankshaft Position 2: - Turn crankshaft one lull revolution (360').1 6. tropics e Measure the specific gravity of individual cells with a commercial hydrometer. Wear protective goggles.7. ensure that clamps make good contact.23 32 27 Fully'charged 1. . and grease with acid-free and acidresistant grease.1 6.1 Battery Checking Battery and Cable Connectors 6. If testers 2are used.1.3 Checking Specific Gravity of Electrolyte 25 895 0 o Keep battery clean and dry.12 * Measurement of specific gravity in o Be is out of date and rarely used today. e When reassembling. 0 Undo dirty clamps. The gases emitted by the battery are explosive.1. During measurement.1.7. Do up clamp bolts finger tight.2 Checking Electrolyte Level 6.20 1'12 1. top up with distilled water. o If necessary.08 24 16 16 Half charged. Do not allow battery acid to come into contact with skin or clothing. Keep sparks and naked flames away from the battery. the electrolyte should come up to their base. o Replace caps. e Specific Gravity in kg/1 in' Be (Baumegrad)" State of Charge normal tropics normal 1.7 Accessories 6.Service and Maintenance 6. 0 lftestersare not used. recharge immediately 1.28 1. the temperature of the electrolyte should preferably be 20 'C. recharge 11 Discharged. 0 Remove caps 1.7. Do not rest tools on the battery. theelectrolytelevel should be 10-15 mm above the top of the plates. 0 Clean terminal posts (+and-) and clamps of the battery. The hydrometer reading (see table on following page) indicates the state of charge. 7. e When washing the engine. disconnect the regulator from the alternator before starting. e Empty or replace the depressurized fluid container. it is necessary to start and operate the engine wrrhout the battery. . The starting fluid is inflammable.1 Ether Starting System Changing the Fluid Container • Before removing the container. cover up the alternator and regulator. II Check for leaks. • Place the container 1 on th8 solenoid valve 2 and tighten by hand. II Replace defective bulb of the charge pilot lamp immediately.3 Lifting Tackle Notes on the three-phase system: between battery. o Pull in the bracket. Before commissioning. 7.4.7. e After transportation and before commissioning of the engine: Remove the attachment eyes 2.2 Three·Phase Alternator 6.4 6. 7. Check for leaks. e Be sure not to confuse the battery terminals. leave the fluid container of the ether starting system in position for 15 minutes. 7 Accessories 6. o When mounting. ensure that gasket 3 is seated correctly. Use only the correct lifting tackle. II The habit of touching a lead against the frame to check whether it is live must under no circumstances be used with three-phase electrical systems. e Loosen the bracket 1. connect the ground terminal on the welder directly to the piece being welded. clean the container support and the top of the solenoid valve. The fluid container must not be stored at temperatures above 50 °C. however. 6. • In case of electric welding. alternator and regulator while the engine is e Never disconnect the cables running. e If.7. Prevent foreign substances from entering the container. Ensure that the container is not damaged. o Always use properliftingtac~ewhen transporting the engine. • Unscrew the fluid container.Service and Maintenance 6. 1 Diagnosis Chart D .Troubleshooting 7. Troubleshooting 7.. i • PIW r+ Cooling system: PI R I P~W ~ ! PI A Electrics • LOA= Manifold-pressure compensator D Fault i Remedy Engine fails or is difficult to start I Engine starts but runs unevenly or stalls Engine overheats. !• '. split or loose V-belt I Cooling air temperature rise I heating short circuit I Resistance in cooling system too great I through-flow quantity too small ! Battery defective or discharged ! Section Operation I I p p ! A r=+= Operating I w media I w Combustion air PI W . • •i• I •• • • •• • le • I . • • • • '•• • ... p E w R A s I i I Section I Electrics ! . p E w R A s ' I Cause I Not declutched (where possible) Below starting limit temperature ·. • . Temperature monitor gives warning Engine gives poor performance Engine not firing on all cylinders Engine has little or no oil pressure Engine oil consumption excessive Engine smokes -blue -white -black Cause \ Electric cable connections to starter electrical system loose or oxidised • J Starter defect or pinion does not engage Incorrect varve clearance Leaking injection line I Injection valve defective : Check ' Adjust Replace Glean Top up ! lower level •• • • •• • ••• • • •• .. Engine •r• E p PIW I ! I ' ! p p I ' . I• I• I• .1 Diagnosis Chart Remedy Check Adjust Replace Glean Top up lower level Faull Engine fails or is difficult to start Engine starts but runs unevenly or stalls Engine overheats. . Oil level too low Oil level too high Excessive inclination of engine ' Incorrect lube oil SAE class or quality Fuel quality not as per operating manual Air cleaner clogged I turbocharger defective e 1 Air cleaner service switch I indicator defective LOA' defective J• Charge air line leaking Oil cooler panels clogged Cooling fan defective. I · . I ... .e I. Temperature monitor gives warning Engine gives poor performance Engine not firing on all cylinders Engine has little or no oil pressure Engine oil consumption excessive Engine smokes -blue -white I -black I I I I I i I I I •• . 1 Preservation .Engine Preservation 8. e Drain fuel tank. see also section 5.1. Removeanti-corrosionagentfrom grooves in Vbelt pulleys. and fill with anti-corrosion oil.2 Removing Engine Preservatives e Clean e engine (with cold cleansing agent if preferred) using high pressure equipment. • Spray grooves of V-belt pulleys with anticorrosion spray. and refill fuel tank. • Set the engine in operation. clean oil bath cleaner.1. The preservative measures described here will protect the engine for up to 6 months. • Turn engine over manually several times to preserve the cylinders and combustion chamber.3. • Make up a mixture of 90% diesel fuel and 10% anti-corrosion oil.5.1 Preserving Engine 8. Gl Close off intake ports and exhaust ports. Retension after brief operation if necessary. • Run engine for about 10 minutes. • Remove covers from intake port and exhaust port. annotation 2. see 6.1. e Anti·corrosion oils to specification: MIL-L-212608 TL 9150-037/2 Nato code C640/642 e Anti-corrosion media for exterior protection only to specification: Nato Code c 632 e Recommended cleansing agent to remove preservatives when recommissioning engine: Petroleum benzine (hazardous materials class A3) 8. see 6. then turn off. e If necessary. e Drain engine oil.Engine Preservation If the engine is to remain idle for an extended period of time. 8 Run engine until warm. e Install V-belts. . The procedure will have to be reversed before the engine is recommissioned.4. • Remove V-belts and store in wrapped condition. see 6.2.1. and fill with anticorrosion oil.1 Preservation 8. it is necessary to take protective measures to prevent rust formation. e Turn engine off. 2 Torque Wrench Settings 9.1 Engine Specifications and Settings 9.3 Tools .Technical Specifications 9. inlet 0. <J 9. The upper oil dipstick marking should always be taken as authoritative. approx. bar r--.1 10. see 3.. Approx.5 - (kg approx.2 w ("C) " 0·1 - 1 ' Engine power.inlet 0.5 Exhaust manrrold 22 Oil drain plug 55 Injector mounting 21 Injection Uoo mounting 30 Oil pan (cast iron) 31 Oil pan (sheet metal) 21 Torx . I (kg approx. start of delivery are stamped on engine rating plate (see also 2.1 Engine Specifications and Settings Model FM 1011F 4 3 vertic! e.) 1. in line Number of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle I Combustion system Direction of rotation 91 (mm] (mm) (cm'' 18.3 • 1. cooling system Weight without cooling system as per DIN 70020-A Engine power Speed Valve clearance (cold engine) Injector opening pressure Start of delivery Firing order vertic! e. 3l Only required for winter operation.2 Torque Wrench Settings Preload (Nml Torquing load INmJ location Totai(Nm! 1st Stage 2nd Stage 3rd Stage lsi Stage 2nd Stage 3rd Stage Remarks 4th Stage Rocker cover 8. 5 4-Siroke diese ld irecl injectioncounter cl ockwise Reier to head-office Reier lo hea d-office 200 243 1) 1) 1) 1) 1-.5 Rocker arm setscrew 21 Air intake manrrold 8. oil pressure in warm condition (130°C) and low idling speed Oil change quantity with filter Oil content of external cooling system (Cooler and pipes) 91 112 2184 (e) Weight incl.1 ).5 ' 210 bar 0·1 - 1) 1) 1-2-3 1-3-4-2 pressure tubrica.) 2.3 •o.Technical Specifications 9.1 8 1.1 I exhaust0. value can vary depending on oil sump or radiator design (external cooling system}..5' 0·1 210 .6 4.5.exhaust 0.1) (ltr. speed. in line 4-Siroke diese ld irect injectioncounter cl ockwise - 112 291 2 18.5" (see3.) (kW) (1/min] (mm) (bar) ("crank angle bTDC] Lubrication SAE oil Oil temperature in the oil sump Min.tion 20 20 130 pressure lu bricalion 20 w 20 130 (bar] (ltr.1. approx. TORX tools can be ordered from: FA. This system was chosen because of the many advantages it offers: The V·belt tension gauge can be obtained under order number 91107 from: e Outstanding accessibility to bolts. PosHach 14 05 80 0·42826 Remscheid e High load transfer when loosening and tightening.WJLBAR . 0 Almost impossible for socket to slide off or break.WILBAR PosHach 14 05 80 0·42826 Remscheid FA.Technical Specifications 9.3 Tools V·bell Tension Gauge TORX 1f= 26002 0 ATORXwrenchsetis used with engines in the 1011 series. Notes . A "SERVICE REGISTER WORLD" can be ordered under No.Southeurope North America Asia Australia South America Algeria Africa Greece.m.West-.00 a. At night.1 07 Postfach 80 05 09 0·51057 Kiiln Germany Austria Switzerland East Europe North-. 0297 4709 A "list of Service Documentation WORLD" can be ordered under No.Service DEUTZ SERVICE INTERNATIONAL GmbH Deutz·Miilheimer str. to 5.00 p. on weekends and holidays automatic phone answerer. 0297 5198 SERVICE Phone for technical questions: (0221)822 5454 Direct dial from 8. Turkey (0221) 822 5247/5281 (0221) 822 5224 (0221) 822 5245 Telefax (0221) 822 3674/822 5462 (0221) 822 2909 Telex 8812 253 KHD D Region Telephone Sales service products Telephone Order processing Service Engineering DEUTZ (0221) 822 5580/5556 (0221) 822 5557/2737 Telefax (0221) 822 2700/ 822 5304/ 822 2665 Telex 8812 251 KHD D Telephone (0221) 822 3209 Telefax (0221) 822 3204 Telex 8812 241 KHD 0 (0221) 822 5559 Give us a ring and we furnish you with the address of the DEUTZ SERVICE INTERNATIONAL GmbH outpost nearest to your facility. (We shall responds the next working day.m.) . SA. Printed in U. .r i All rights rese!Ved. . Sht 1 Jack Assembly. Sht 2 Battery and Mounting. Sht 2 < BOOK 35389816 (5/95) ILLUSTRATION 36525814 36525814 36511368 36511368 36522597 36522597 36522605 36522605 36512473 36512473 36512515 36512515 36512499 36512499 36514545 36514545 36512507 36512507 36522613 36522613 36511426 36511426 36511418 36511418 36512523 36512523 36512531 36512531 36522621 36522621 36522621 36522621 36521045 36521045 36520716 36520716 36512549 36512549 36512549 36512549 36522639 36522639 PAGE 9-2 9-3 9-4 9-5 9-6 9-7 9-8 9-9 9-10 9-11 9-12 9-13 9-14 9-15 9-16 9-17 9-18 9-19 9-20 9-21 9-22 9-23 9-24 9-25 9-26 9-27 9-28 9-29 9-30 9-31 9-32 9-33 9-34 9-35 9-36 9-37 9-38 9-39 9-40 9-41 9-42 9-43 . Sht 1 Airend Complete. Sht 1 Air Cleaner Assembly. Sht 2 Air Cleaner Assembly. Sht 2 Running Gear Complete. Sht 1 Liquid Cooling Complete. Sht 2 Air and Oil Piping. Sht 1 Enclosure Complete. Sht 1 Airend Assembly. Sht 2 Liquid Cooling Complete. Sht 1 Wiring Diagram. Sht 3 Air and Oil Piping. Sht 1 Tire & Wheel Assembly.PARTS LIST 9-0 PARTS LIST CONTENTS Frame & Running Gear. Sht 2 Airend Complete. Sht 2 lnst/Control Panel. Sht 2 Air and Oil Piping. Sht 1 Separator Tank Complete. Sht 2 Enclosure Complete. Sht 3 Enclosure Complete. Sht 1 Air and Oil Piping. Sht 4 Wiring Diagram. Sht 2 Tire & Wheel Assembly. Sht 2 Jack Assembly. Sht 1 Running Gear Complete. Sht 2 Fuel Tank Complete. Sht 1 Air Service Complete. Sht2 Seperator Tank Complete. Sht 1 Fuel Tank Complete. Sht 1 Acoustic Panels. Sht 1 Engine Complete. Sht 2 Air Intake Complete. Sht 4 Acoustic Panels. Sht 1 Battery and Mounting. Sht 1 Frame & Running Gear. Sht 2 Airend Assembly. Sht 2 Enclosure Complete. Sht 2 Air Intake Complete. Sht 1 lnst/Control Panel. Sht 2 Engine Complete. Sht 1 Air Service Complete. Sht 2 Keyed Ignition Option.PARTS LIST 9-1 PARTS LIST CONTENTS "' Decal Location. Sht 1 Diagnostic Module Option. Sht 2 Diagnostic Module Option.Sht 1 Adjustable Drawbar Option. Sht 1 Option Wiring Diagram. Sht 2 Single Hose Reel Option. Sht 1 Extended Drawbar Option. Sht 2 Extended Drawbar Option. Sht 2 ILLUSTRATION 36513729 36513729 36513729 36513729 36521052 36521052 36512929 36512929 36512812 36512812 36512879 36512879 36522647 36522647 36512895 36512895 36522654 36522654 36512853 36512853 36512846 36512846 36512838 36512838 PAGE 9-44 9-45 9-46 9-47 9-48 9-49 9-50 9·51 9-52 9-53 9·54 9-55 9·56 9-57 9·58 9·59 9·60 9-61 9-62 9-63 9-64 9-65 9·66 9·67 BOOK 35389816 (5/95) . Sht 1 Hose Reel Assembly. Sht 2 Decal Location. Sht 1 Keyed Ignition Option. Sht 1 Extd/Adj Drawbar Option. Sht 1 Single Hose Reel Option. Sht 2 Gauge Option. Sht 4 Option Wiring Diagram. Sht 2 Adjustable Drawbar Option.Sht 2 Extd/Adj Drawbar Option. Sht 1 Double Hose Reel Option. Sht 2 Double Hose Reel Option. Sht 2 Hose Reel Assembly. Sht 3 Decal Location. Sht 1 Gauge Option. Sht 1 Decal Location. PARTS LIST 9-2 A ( D c G H INGERSOLL-RAND COMPANY PORTABLI! DI!SCRIPTIOH BOOK 35389816 (5/95) OO~PRI!SSOR DIVISION FRAME COMPLETE . SHEeT ~:J~g 36525814 BOOK 2 of 2 f!.ATI!!/APVO BY A "-" '\-::. I~"!EI¢HKD ~!.SSOR DIVISION DESCRIPTION DATEIDWN BY:I 216195 ti FRAME COMPLETE H.C MODEL HTIILLUSTRATIOH HO. R~V./0 28136 35389816 (5/95) .N.PARTS LIST 9-3 ITEM A B c D E F G H J K L M N p a R s T u v C.. COJdPRe.P. 36874352 36773042 36765139 36767812 36763688 35068345 36780013 35605187 35376094 36795532 36769057 36780039 35148030 11A5D5Z1 12A5D8Z1 35374453 16M4JC26M3 35610377 35372432 36770386 QTY 1 1 1 1 8 2 1 1 2 1 4 1 4 8 2 2 4 2 2 4 DESCRIPTION FRAME BUMPER DRAWBAR RUNNING GEAR SCREW TIRE & WHEEL ASSEMBLY JACK ASSEMBLY PINTLE EYE SCREW U-BOLT SCREW SNAP RING SCREW WASHER WASHER NUT NUT CHAIN ASSEMBLY COUPLING LINK NUT INGERSOLL-RAND COMPANY PORTABLe._' 5 £?. PARTS LIST 9·4 RUNNING GEAR COMPLETE PART NO. 36767812 DEXTER 5-LUG INGERSOLL-RAND COMPANY PORTABLI!' COUPRI!:880R DIVISION BOOK 35389816 (5/95) . .: E/c 36511368 BOOK 2 of 2 23955 35389816 (5/95) .PARTS LIST ITEM A B c D E F G H J * * * ** * K L M N p Q R * s ** T u v w X y * QTY C. '\ ./ MODI!L P·100E'NO P·"""" R!:V: I?ATI!/CHKD "1ATI!IAPVO BY B ~.v · 5 §..N.C ILLUSTRATION HO.P....SHI!:U NO. 36767812 DEXTER 5-LUG INGERSOLL-RAND COMPANY PORTABL! COMPRESSOR DIVISION OI!SCRIPTION RUNNING GEAR COMPLETE (DEXTER\ PATE/OWN BY:I 9/28189 ~ NO. 36768752 36768778 36768760 35315142 35361864 35361872 35361880 35315183 35315191 35315209 35315217 35315225 35315233 35315241 35315258 35361898 35315274 35326958 35315340 35315357 35326966 35315365 35315373 35085398 1 2 4 2 2 2 2 2 2 2 2 2 2 2 8 10 10 2 2 2 2 2 2 9·5 DESCRIPTION AXLE SPRING U-BOLT GREASE SEAL BEARING CONE BEARING CUP HUB BEARING CUP BEARING CONE SPINDLE WASHER SPINDLE NUT COTTER PIN GREASE CAP TIE PLATE NUT WHEEL STUD WHEEL NUT FRONT HANGER SHACKLE BOLT SHACKLE NUT REAR HANGER KEEPER BOLT KEEPER NUT HUB KIT RUNNING GEAR COMPLETE PART NO. PARTS LIST 9-6 TIRE AND WHEEL ASSEMBLY 35068345 INGERSOLL-RAND COMPANY PORTABLI! COMPRI!SSOR DIVISION BOOK 35389816 (5/95) . V: rATI!!/CHKD fi(~~:ATI!IAPVD eY A ~.. s L7. MODI!!L N~..PARTS LIST 9-7 ITEM A B c C.N. RI!. ILLUSTRATION P·100EWO P·12SEWO '-\-:J.I SHEET N~'J: E/C 36522597 BOOK 2 of 2 24193 35389816 (5/95) .C NO.!. 35292986 35282565 36773265 QTY 1 1 1 DESCRIPTION WHEEL VALVE STEM TIRE TIRE AND WHEEL ASSEMBLY 35068345 INGERSOLL-RAND COMPANY PORTABLE COMPRI!880R DIVISION OI!SCRIPTION DATIYDWN 4121/94 8r1 tl TIRE AND WHEEL ASSY.P. PARTS LIST 9·8 A c JACK ASSEMBLY36780013 INGERSOLL-RAND COMPANY PORTAIIU! COMPRI!880R DIVISION BOOK 35389816 (5/95) . '-\ • .C-Y A ..SCRIPTIOH JACK ASSEMBLY OATI!JDWN tiY:I 4121/94 tl RI!V: I~ATI!/CHKD &~jf~TI!fAPVJ._".P.l SHI!I!T H0.. MDDI!L H1'[1LLUBTRATIOH P-100EWD P-12SEWD Ho.0.1' 1!/C 36522605 BOOK 2 ol2 24940 35389816 (5/95) .PARTS LIST 9-9 ITEM A B c D QTY C. 36792489 36792513 36792505 36792497 1 1 1 1 DESCRIPTION HANDLE KIT WHEEL KIT PLUNGER PIN KIT BEVEL GEAR KIT JACK ASSEMBLY 36780013 INGERSOLL·RAND COMPANY PORTABLE! COMPRO'!SSOR DIVISION DI!.:>< 5 .N. PARTS LIST 9-10 INGERSOLL·RAND COMPANY PORTA.&ll!" COMPR~880R DIVISION Ot!SCRIPTIOH 27276 BOOK 35389816 (5/95) . N.. LIFTING WASHER SCREW ENGINE FUEL FILTER ENGINE OIL FILTER 92100981 92793223 INGERSOLL-RAND COMPANY PORTABLE COMPRI!SSOR DIVISION OI!SCRIPTION ENGINE ASSEMBLY OAT~OWH BY:' REV: ~~:Te'/CHKO I!Jb!'~I!!/~VDJH 1218189 tl G '-~ ~ ..5" 2 1 4 4 1 2 4 2 1 1 2 2 1 1 1 1 4 4 1 9 4 9-11 DESCRIPTION ENGINE VALVE. RUBBER MOUNT.::2< - MOO.: E/C 2of2 28107 35389816 (5/95) .PARTS LIST ITEM A B c D E F G H J K L M N p Q R s T u v w X y z C. DRAIN HOSE MOUNT. LH REAR SCREW WASHER MOUNT.. RUBBER MOUNT.P. RH FRONT SCREW WASHER PIPE. SHI!!I!!T P·100EWD P·125EWD 36512473 BOOK .!l H:·j ILLUSTRATION HO. EXHAUST CLAMP CLAMP FAN WASHER SCREW BAIL. 36871705 36774487 35285600 36775575 36775518 36772606 12A5D7Z1 36775542 36776136 36793032 36858660 36871630 36871648 35290113 35609874 36794485 35302223 36296342 36764587 12M5L29M3 35374842 36780633 12A5D4Z1 36769297 QTY 1 1 8._u/- NO. RH REAR SCREW NUT MOUNT. LH FRONT MOUNT. PARTS LIST 9·12 J A • / / INGERSOLL-RAND COMPANY PORTASLI! COMPRI!$80R DIVISION BOOK 35389816 {5/95} . .- L-7/ ldOOI!L Nr·J tlU8TRATIOH NO.N.PARTS LIST ITEM A B c D E F G H J K L C. I!IC 126782 35389816 (5/95) .ATfiAPVD BY c c. SHU:T H0. P-100EWO P-125EWD 36512515 BOOK 2 of 2 :.-~' .P..<. 36760726 36850436 36852218 36843928 35300771 92368687 36769024 12A5D2Z1 36769032 35144336 35252600 QTY 2 1 2 2 6 6 2 4 2 2 2 9-13 DESCRIPTION OIL COOLER FAN SHROUD FAN GUARD FAN SHROUD SUPPORT SCREW SCREW SCREW WASHER NUT SCREW NUT INGERSOLL·RAND COMPANY PORTABLE COMPRESSOR DIVISIOH OI!SCRIPTIOH LIQUID COOLING COMPLETE DATE/OWN BY:I 12/21/89 ti RI!V: t~IHCHKD B~t. PARTS LIST 9-14 G F B ./ c E INGERSOLL-RAND COMPANY PORTABLI! CONPRI!880R D!Vl810H BOOK 35389816 (5/95) . 35353978 35332295 36851939 35582295 35A2D67Z1 36769289 119M2A244M3 12A5D4Z1 109A2A5 QTY 6 6 1 1 3 1 10 9 1 9-15 DESCRIPTION SCREW DRIVER COUPLING BUSHING SCREW KEY SCREW WASHER SETSCREW INGERSOLL-RAND COMPANY PORTASU! COMPRI!SSOR DIVISION DI!SCRIPTIOH AIREND COMPLETE DAT!..PARTS LIST ITEM A B c D E F G H J C.N..rH!!T N0.5 .IDWN IIY:J RI!:V: ~~ATI!tCHKD e:tA'TI!IAPVD ay 1/24190 ~ D '"'' ~--.i. ILLUSTRATION HO. : 1!/C ~:~= 1 36512499 BOOK 2 of 2 127793 35389816 (5/95) .L}~ MOD!L N0.P. PARTS LIST I 9-16 3.69:1.CPRESSOR DIVISION . 85mm AIR END ASSEMBLY 36007839 INGERSOLL·RAND COMPANY PORTABL~ BOOK 35389816 (5/95) CO. 36506772 35375369 35611961 95022331 119M2AB221 36791689 95094306 35286004 39101449 95641734 36512134 36506442 35611953 95023115 35289057 35287556 35287655 36508471 36511623 90523107 35379817 35376342 35611557 35376334 36511615 35376359 35376326 35612175 95257333 35376318 36764553 35286491 35296920 35372986 QTY 1 1 4 1 32 2 2 1 1 1 1 1 7 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 DESCRIPTION SEAL COVER SEAL SCREW 0-RING SCREW SCREW WASHER BEARING PLUG 0-RING SCREW BEARING COVER SCREW 0-RING PLUG PLUG SCREW INLET COVER UNLOADER VALVE 0-RING SPRING CAP SPRING STEM SPRING PISTON SEAL SPRING CONNECTOR CAP BALL TUBEASSY ELBOW FILTER ELEMENT NIPPLE 3.69:1.N._~ '-\ -¥- s .P.IC 28107 35389816 (5/95} . ILLUSTRATION HO.l No.PARTS LIST 9-17 ITEM A B c D E F G H J K L M N p Q R s T u v w X y z A1 A2 A3 A4 A5 A6 A7 AS AS B1 C._!}.C MODI!.rHI!U ~~= 1 36525715 BOOK NOl 2of2 f. 85mm AIR END ASSEMBLY 36007839 INGERSOLL·RAND COMPANY PORTA&ll!! COMPRI!880R DIVISION OJ!! SCRIPTION OATE/DWN 1/31/95 sr:l ~ AI REND ASSEMBLY RJ!!V: IOATJ!!fCHKD ~~~ATI!/APVD BY A •. PARTS LIST 9·18 E ' E D INGERSOLL-RAND COMPANY PORTABLI! COUPAI!880R DIVISION DI!8CRIPTION PIOOEW Pt2SEWD BOOK 35389816 {5/95) AIR INTAKE COMPLETE 27511 . ri>HI!I!T No.PARTS LIST ITEM A B c D E F G H J K C. QTY 2 36862829 1 36773950 1 36773448 3 35374073 4 35585009 35M2AB360M3 8 4 12A5D3Z1 8 35278530 1 35295781 1 35300615 9·19 DESCRIPTION AIR CLEANER ASSEMBLY HOSE ELBOW HOSE ELBOW CLAMP MOUNTING BAND SCREW WASHER NUT CLAMP RESTRICTION INDICATOR INGERSOLL·RAND COMPANY PORTA!ILI! COMPRI!$80R DIVISION DESCRIPTION DATE/OWN IIY: AIR INTAKE COMPLETE RI!:V: ~ATI!:ICHKD B~~~TI!aY 12/14189 tl 1 D 1 \i> '-l-::H S MODI!L No. ~~= 1 36512507 BOOK 2of2 1C.P. ILLUSTRATION NO. EIC 127511 35389816 (5/95) .N. PARTS LIST 9·20 \---(A B c INGERSOLL·RAND COMPANY POFITA!ILe: COMPRI!!8SOR DIVISION DI!SCRIPTION AIR SERVICE COMPLETE 26062 BOOK 35389816 {5/95) . PARTS LIST ITEM A B c D E QTY C.ODI!. 36768828 35592377 35287747 19A7J53Z1 35576115 1 1 1 1 1 9-21 DESCRIPTION SERVICE PIPE SONIC ORIFICE BULKHEAD FITTING NIPPLE BALL VALVE INGERSOLL-RAND COMPANY PORTABLI! COMPRUSOR DIVISION DI!SCRIPTIOH DATf/DWH AIR SERVICE COMPLETE er:l 4125194 tl RI!V: IDATI!"ICHKO e.SHI!ET NO..j-::11 A M..N.P. m~~ 36522613 BOOK 2 of 2 /- :!IC 26062 35389816 (5/95) ..L NO. ILLUSTRATION HO.~A~VD BY A I~i> t. @r----$ I INGERSOLL-RAND COMPANY PORTAI!ILI! CONPRI!:880R OIVISIOH BOOK 35389816 (5/95) .PARTS LIST 9·22 0~---G. IPRI!SSOR DIVISION DUCRIPTIO~EPARATOR TANK ASSEMBLY OATI!/DWN BY:I 9/19/89 tl MODI!:L RI!. :C NO.V: ~~ATEICHKD l*ATI!!~J? BY D ~~ ~~~ic .P.I lLLUSTRATlON NO. 36846574 36845303 36766947 36763662 12A5D6Z1 174A10C6 35579630 36860468 35324849 92121532 92368687 67A7M4Z1 35325166 1 1 1 8 8 1 1 1 2 1 6 1 1 DESCRIPTION SEPARATOR TANK ELEMENT COVER SCREW WASHER PLUG PLUG FITTING GASKET TUBE SCREW ELBOW SAFETY VALVE INGERSOLL·RAND COMPANY PORTABLe COI. "c ~:= 36511426 BOOK 2of2 I 27366 35389816 (5/95) .PARTS LIST 9-23 ITEM A B c D E F G H J K L M N QTY C.I SHI!IH NO.N. PARTS LIST 9·24 AIR CLEANER ASSEMBLY 36862829 INGERSOLL-RAND COMPANY PORTAISLI! COMPRI!SSOR DIVISION DI!SCRIPTIOH PIOOEWD P12SEWD BOOK 35389816 (5/95) AIR CLEANER ASSEMBLY 27511 . N. MODI!l HO.IC ~:= 36511418 BOOK 2of2 27511 35389816 (5/95) ..>\<\.SHI!I!T HO.P..~ Li.PARTS LIST 9·25 ITEM A B c D E F G C.lLLUSTRA.1 ~ 1/-. : f!...TIOH NO. 35388883 35291970 35388891 35291475 35326032 35321637 35291475 QTY 1 1 1 1 1 DESCRIPTION BODY ELEMENT VACUATOR VALVE WING NUT COVER OPTIONAL SAFETY ELEMENT OPTIONAL WING NUT AIR CLEANER ASSEMBLY 368$2829 INGERSOLL-RAND COMPANY PORTA !ILl! COJiiPRI!SSOR DIVISION DI!SCRIPTION PATL'DWN AIR CLEANER ASSEMBLY DY:I 11/8189 tl RI!V: I~ATI!/CHKD !IJ-OATI!/~VP !IY D '<.. PARTS LIST 9·26 TO FUEL RETURN liNE ON ENGINE TO FUEL PUMP ON ENGINE ~ I INGERSOLL-RAND COMPANY PORTAISLI! COMPRI!SSOR DIVISION DI!SCRIPTIOH PIOOEWD P12$EWO BOOK 35389816 {5/95) FUEL TANK COMPLETE . . FUEL CAP HOSE CLAMP STRAP..bi.L I MOPI!:L HO. '-\·"-' s :.N.5' 6 2 1 2 1 4 4 2..I 12113189 tl FUEL TANK COMPLETE REV: IDATI!ICHKP 8\Y.l:.5' 1 1 1 42' 1 DESCRIPTION TANK. 36770212 36859049 35363498 35296342 36764272 35300771 36767051 36774388 35307818 12A5D2Z1 35363498 35316587 11A7S1Z1 36772747 35363498 36845501 QTY 1 1 37.PARTS LIST 9·27 ITEM A B c D E F G H J K L M N p Q R C. ~:= 36512523 2of2 1!/C 27278 BOOK 35389816 (5/95) . TANK SCREW FOAM HEATSHIELD SCREW WASHER HOSE ADAPTER COUPLING CONNECTOR HOSE FILTER n INGERSOLL-RAND COMPANY PORTABLE COMPRESSOR DIVISION PE$CRIPTIOH OAT~DWH BY. ILLUSTRATION HO."TI!/~ !_Y G I~:. SHEET HO.P. PARTS LIST 9-28 FRAME ENGINE E .1 INGERSOLL·RAND COMPANY PORTABLI!: COMPRI!&&OR DIVISION DI!:BCRIPTION BOOK 35389816 {5/95) BATIERY MOUNTING . N.£)/ C WODI!L No.J P·100EWD P·125EWO 36512531 BOOK 2 of2 E/C 27630 35389816 (5/95) . -.P.PARTS LIST ITEM A B c D E F G H J K L C..T NO. ILLUSTRATION NO._L~ s ..SHI!I!. 36844264 36766822 35591783 35579143 36779973 36764595 35278530 12A5D3Z1 92368687 35130293 35578194 QTY 1 1 1 1 1 2 4 2 5 1 1 9-29 DESCRIPTION BATIERY BATIERYTRAY HOLDDOWN FRAME NEGATIVE BATIERY CABLE POSITIVE BATIERY CABLE STUD NUT WASHER SCREW SCREW GROUND STRAP INGERSOLL·RAND COMPANY PORTAfiLII!: COMPRI!SSOR DIVISION DI!:SCRIPTION DATE/OWN IIY:I 1/24/90 tl BATTERY MOUNTING RI!V: ~~~1!/CHKP ~~~~~AU:/APYD 8 \(. PARTS LIST 9-30 NOTE: SEE SHEET 3 FOR MATCH POINTS [A][ID[Q][QJ[[) 42 t----{59 3l---~.j 1-----< 15 34 J ~.. ""' -@ L ___ l I 59 0 I L 4 c 0 0 L E R 5 I I dJdJ 17 INGERSOLL·RAND COMPANY PORTABLI!" COl>IPRI!SSOR DIVISION o!SORIPTION AIR AND OIL PIPING 28107 BOOK 35389816 (5/95) .-46-----.. s . DESCRIPTION 35356484 35329861 36746308 36793248 36792778 36768828 TUBING UNION-12JIC HOSE ASSEMBLY TUBE ASSEMBLY TUBE ASSEMBLY SERVICE PIPE 35370386 35369354 ELBOW ELBOW 35283191 35294750 35358662 72A7M4Z1 35369503 ELBOW ELBOW HOSE ASSEMBLY TEE TEE 19A7JZ53 19A7JZ2 11A7SZ1 NIPPLE NIPPLE COUPLING 35592377 36846673 36766772 35603067 SONIC ORIFICE (P100 ONLY) HOSE ASSEMBLY ORIFICE.[). .II!/0 ~:= 36522621 BOOK 2ol4 28107 35389816 (5/95) . NO.. DESCRIPTION 35A7SZ4 PLUG 36757573 PRESSURE SWITCH 35287747 35323955 35324649 92121532 36781227 35329309 36770188 35579630 174A10C6 BULKHEAD FITTING SIGHT TUBE FITTING GASKET SIGHT TUBE SCAVENGE TUBE LENZ FITTING MANIFOLD VENTED PLUG W/ 0-RING PLUG W/ 0-RING 35295880 STRAIGHT CONNECTOR 36840411 INLINE ORIFICE/CHECK VLV 36766798 35322379 35301506 CHECK VALVE SLOWDOWN VALVE TEE W/ 0-RING 36779999 36874097 36792786 TEE W/ 0-RING HOSE ASSEMBLY HOSE ASSEMBLY INGERSOLL-RAND COMPANY PORTASL~ OI!SCR1PTION PATE/OWN 5120194 UODI!L ev:j ~ COiiiPRI!SSOR DIVISION AIR AND OIL PIPING RI!V: ~~AT!!tOHKD a.::.9-31 PARTS LIST ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 C.l .N.N..P.062 SONIC ORIFICE (P125 ONLY) 35576115 35325166 35369347 SERVICE BALL VALVE SAFETY VALVE CONNECTOR ITEM 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 C.LLUSTRATION NO..P.ISHI!!ET NO.~cl:ATI!IAPVD e c I\~ '-''"". 1--------{7 L 19 ~~ I I 9 II 1 I i I ~ I~_ -~-a---+-1----./ 2 9 1 (15" lg) 8 INGERSOLL-RAND COMPANY PORTABl.-®1 Jt - 1.-1-.-__.PARTS LIST 9-32 NOTE: SEE SHEET 1 FOR MATCH POINTS [AJ[[J[QJ[Q][§J ~ ~ 10 ~\1 Jl ~ I~ I l l r ..l!! COt..l-~ ~ i i ~ ~~r? L+--..iPRI!SSOR DIVISIOH DI!SCRIPTIOH BOOK 35389816 (5/95) AIR AND OIL PIPING .. ILLUSTRATION NO.P.N. WODI!:L NO.P. 9·33 DESCRIPTION 35596436 39404165 SHUTDOWN SWITCH 0-RING 35287556 35289057 35279959 PLUG W/ 0-RING PLUG W/ 0-RING 0-RING 36781540 PRESSURE REGULATOR 36840395 CHECK VALVE INGERSOLL-RAND COMPANY PORTABLe CONPRI!SSOR DIVISION D!:SCRIPTION AIR AND OIL PIPING &20/Q:t ~t/ REr ~~~e~~~:~:rs-n~:C . ~:= 36522621 BOOK 4 of 4 28107 35389816 {5/95) .N..JSHI!ET NO. 35369347 CONNECTOR ..140 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 C.PARTS LIST ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 C.. 35356484 36765105 36764553 35370386 35369354 35612175 35286491 35374867 35302314 35295880 DESCRIPTION ITEM TUBING HOSE ASSEMBLY TUBE ASSEMBLY ELBOW ELBOW CONNECTOR ELBOW ELBOW ADAPTOR CONNECTOR WI 0-RING 22 23 24 25 26 27 28 29 30 31 32 36766756 ORIFICE MUFFLER. PARTS LIST 9·34 REO· UNS'h1TCHEO 1z..rt:¢ POSffi~ Pti<f REO:ORN· SfflTCt£0 12\'0CPOSilTVE ) THERMAL 1 K ffiKMO 2 SA T$1 F2 ~.. COMPRESSOR CONTACT 3 FUSE SENSOR ~ lr TEMP S'NITCH No · ' S4 N.C. ffi!WLV r - LT Bt.U f'2-Q I ENGINE OIL c PRESS SINITCH .t'"'l SS N.O. . A 0 ~ ~ SPARE "l P2-2 B-i---+-----J---""""-- ~~ 5- r P2-1~ n-n It" J'-----""-""""'""'"'-loI P2-10 _ _I ENGINE r ** P2~ 11--+---i----''"-'!!!"'-"""-!!!!>>. PN!OORN •" I TEMP SWITCH DIAGNOSTIC N.C. MODULE Ut LT et.UQRJ ~FJIONAL) ~lr$6 ~ I lOW FUel ~Wl,';F' L~:::::::::::JJJ.I f'2:·11 LTBLUWHT I RESISTOR 820HM I AI f>2-3. J\'JOI'r1!:L '~ TO OPTION Pl·1 WIRING DIAGRAM MY * STARTER Bl !, CXJ' ''"""' AUXSTART ~~lf'Y Kt / 4 5 ~ ~'lr----, * START PROTECT ).. FUEL RElAYK32: ~ 0l 2 COIL g; 1 gj -4 SHUT DIODE ";.DOWN D3 6 ! RELAY K2 COIL . 8RN·12.VDCiiEG.I.TIVE r INGERSOLL-RAND COMPANY PORTA&LI! COMPRI!SSOR DIVISION DeSCRIPTION STD WIRING DIAGRAM OAUlOWH &YIJ RI!V; JpA;rl!tCHKD BYjDATI!/APVO ~y 11/9/92 tll C 1~1. \\.-:..1!1\S ,0,-c MOOI!L HO.IILLUSTRATIOH H0.,8HI!I!T HO., ~l: BOOK 35389816 (5/95) I 36511954 I 1 ot 2 Ef¢ 127757 PARTS LIST C.P.N. ITEM B1 BT1 D2 D3 F1 F2 G1 K1 K2 K3 L1 M5 R1 S1 S3 S4 S5 S6 TS1 U1 * 36844264 35376169 35376169 36782456 36782654 * 35364611 35583442 35583442 * 35605229 36774198 36509396 36757573 35596436 36757581 36788503 36865756 ~ ** 9-35 DESCRIPTION STARTER BATTERY DIODE DIODE FUSE15A FUSE5A ALTERNATOR RELAY AUX START RELAY SHUTDOWN RELAY START PROTECT FUEL SOLENOID HOURMETER RESISTOR 82 OHM START SWITCH START PROTECT SWITCH N.C. COMPRESSOR TEMP SWITCH N.C. ENGINE OIL PRESSURE SWITCH N.O. ENGINE TEMP SWITCH N.C. THERMAL SENSOR DIAGNOSTIC MODULE HARNESS ENGINE 36859908 HARNESS GAGE 36853422 * FURNISHED BY ENGINE MANUFACTURER **OPTIONAL EQIUPMENT INGERSOLL-RAND COMPANY PORTABLe COMPRESSOR DIVISION DESCRIPTION STD WIRING DIAGRAM DATr:toWN ev:J RI!V: ~~ATI!ICHKD e~ATI!!fAPVD ey 11/9/92 ~ D ~ \l,-oJ5\ MODI!L HO.,ILLUSTRATIOH ~)= 36511954 BOOK 2J,C NO.I SHI!tT NO.I: E/C 2of2 27923 35389816 (5/95) PARTS LIST 9·36 >----fE I I I ~ INGERSOLL-RAND COMPANY PORTABL~ COMPRI!SSOR DJVISION 26872 BOOK 35389816 {5/95) N.~ 1!/C 2 ol2 26872 35389816 (5/95) .. 36850030 36850048 36768851 36850022 36850089 36850378 36513695 36785921 36781540 36509396 36853414 35605229 36767440 35607829 36772028 35607837 12A5D2Z1 67A4C1Z1 QTY 1 1 1 1 1 1 1 16 1 1 1 1 6 1 1 1 1 1 DESCRIPTION INSTRUMENT PANEL INSRTUMENT PANEL DECAL SHUTDOWN DECAL HINGE DOOR OPERATING INSTRUCTIONS DECAL PRESTIGE DECAL RIVET 2-WAYVALVE IGNITION SWITCH PRESSURE GAUGE HOURMETER HOLE PLUG EYEBOLT NYLON WASHER SPRING WASHER NUT INGERSOLL-RAND COMPANY PORTABLI! COMPJU!8SOR DIVISION DI!SCRIPTION INSTRUMENT/CONTROL PANEL ASSY DATE/OWN IIY:I 2122/93 tl RI!Vi-tATI!fCHKO ~~ATEIA.£)/-' NO.~D BY B '... SHI!I!~T HO..... ..~ MODI!L HO..IILLUSTRATION ~:= 36520716 BOOK '\ _.P..PARTS LIST 9-37 ITEM A B c D E F G H J K L M N p Q R s T C. / INGERSOLL-RAND COMPANY PORTAeL~ D!SCRIPTION PIOOEWD P12:SEWO BOOK 35389816 (5/95) COUPRI!SSOR DIVISION .PARTS LIST 9-38 . P..PARTS LIST 9-39 ITEM A B c D E F G H J K L M N p Q R s T u v w X y z A1 A2 A3 A4 A5 A6 C.L s JdOPEL NO.. 92368687 36774529 12A5D2Z1 36769032 36783520 36769024 36797652 36794816 36796266 36783496 36783504 16M4JC22M3 12A5D3Z1 35337328 35600287 36764678 36852945 36797124 36793602 36770956 36764710 36764728 36766780 36770980 36768166 36768174 36768182 36768190 36768208 36796274 QTY 60 1 2 2 8 2 48 8 1 8 8 4 4 4 2 1 1 2 2 1 1 1 2 1 1 1 4 1 1 1 DESCRIPTION SCREW TOP BAFFLE WASHER NUT STUD SCREW SCREW RIVET RH COOLER BAFFLE RETAINER RECEIPTACLE NUT WASHER BALL STUD GAS SPRING REAR ENDCAP FRONT ENDCAP DOOR LATCH ROOF LH SIDE SUPPORT RH SIDE SUPPORT HINGE AIR FOIL BAFFLE TOP EXHAUST BAFFLE BOTIOM EXHAUST BAFFLE BRACKET LH BRACKET RH BRACKET LH COOLER BAFFLE INGERSOLL·RAND COMPANY PORTAI!Ill!: COMPRI!:SSOR DIVISION ENCLOSURE COMPLETE ••• CRIPTIOH DATE/OWN 716190 BY:I tl REV: I. ILLUSTRATION NO.N. '-\ .ATIE/CHKD ~~~~4~ATE/APVO BY F ~-\..: HOT 2of4 l!!fC 26872 35389816 (5/95) .ISHI!I!T ~:= 36512549 BOOK <£). PARTS LIST 9·40 INGERSOLL-RAND COMPANY PORTA8LI! COMPRI!SSOR DIVISION DI!SCRIPTIOH ENCLOSURE COMPLETE 26215 BOOK 35389816 (5/95) . P..I!!Vz. SHI!I!T HO.ILLUSTRATIOH HO.I!!SCRIPTION OATEIOWH 7/6/90 8r1 tl R.N..7ATI!/CHKD B~tATI!i?~O ~y E "~ "~!\ I 1- MODEL HO.PARTS LIST 9-41 ITEM A B c D E F G H J K L M N p Q R s T u C.. 92368687 36769024 36769032 12A5D2Z1 36783512 36797652 36783496 36783504 36799922 36799930 36765568 36768398 36772044 36772036 36769552 36767663 36768372 36764634 36764744 QTY 40 5 6 2 2 23 2 2 1 1 2 1 1 1 1 1 1 1 1 DESCRIPTION SCREW SCREW NUT WASHER STUD SCREW RETAINER RECEIPTACLE LOWER RH ENCLOSURE LOWER LH ENCLOSURE FENDER INTAKE BAFFLE RH FRONT BELLY PAN LH FRONT BELLY PAN RH REAR BELLY PAN LH REAR BELLY PAN SEPARATOR TANK GUARD TOOLBOX GUARD COOLER COVER INGERSOLL·RAND COMPANY PORTABLe COWI'RII!880R OIVISIOH ENCLOSURE COMPLETE O.: 1!!/C m~~~ 36512549 BOOK 4 of 4 26215 35389816 (5/95) . PARTS LIST 9·42 D A L B L K E J (BOTH P100 & P125) INGERSOLL-RAND COMPANY PORTAI'Jll!: COMPRI!S80R DIVISION OI!:SCRIPTION BOOK 35389816 (5/95) ACOUSTICAL PANELS . PARTS LIST ITEM A B c D E F G H J K L C. EXCEPT ITEM GOES ON BOTH P-1 00 AND P-125. J INGERSOLL-RAND COMPANY PORTABLI! ¢0WPRI!880FI PIVISIOH ACOUSTICAL PANELS PI!:SCRIPTIOH PAT~DWH Br:l 5/24194 tl RI!V: rATI!/CHKD ~~~ATI!/~ ~0 BY A ·~"... ..1: 5 5 .: 1!/C ~Jm::g 36522639 BOOK 2 of 2 27793 35389816 (5/95) . .P. 36866630 36866648 36772853 36772861 36768216 36768224 36647911 36847929 36768380 36647903 36773182 QTY 2 2 1 1 1 1 1 1 1 1 2 9·43 DESCRIPTION TOP END CAP ACST PNL BOTTOM END CAP ACST PNL REAR ROOF ACST PNL FRONT ROOF ACST PNL TOP EXHAUST BAF ACST PNL BOTTOM EXHAUST BAF ACST PNL BOTTOM STSD DOOR ACST PNL TOP STSD DOOR ACST PNL INTAKE BAF ACST PNL BOTTOM CRBSD DOOR ACST PNL TOP CRBSD DOOR ACST PNL NOTE: ACOUSTICAL PANELS FOR P-125 ONLY...4 .:: MODEL HO.j ILLUSTRATION HO.SHI!U NO.N. . &WARNING ~ Combustlblo gas. Do not operata without {IUard In plac•. Cencauu sovoraburn-. Can cauM Mv-lnjuryor Alt6e:h ufaty tcwrestrletof to each hose •at lhe &OUree of supply or branch line· In doath. Close teMe9 vMre and vent tapped alr OO!ae perlonning Nrf Will cauu uverelnjury or death. . ~~v. BOOK 35389816 (5/95) &WARNING &WARNING ~-- DlaconnKted air hosot whip. Can cause severe~~ Injury.ilhOSHA Reou!ation 29CFR S&e:tion 1m.PARTS LIST 9-44 Lt WARNING &WARNING Collapsing Jackstand.302(b). Keep sparke and open fiamn away from batterie1.) Rotal!ng fan blade. MveralnJury TI"'Ippo<lalr p .s or doath. f\"( Do NOT exceed 50 mptl {SO km/hr. 11ura. op&rate tool b Do not breathe this air. l>tfore & DANGER Discharged air can contain carbon monoxld& or other contamlmmts. Q Insert locking pin completely. bllndnu. &WARNING High prouuro etr.n etun aaverelnjury or death. can caun taVer•lnJury. «•!h.. C. seMee. Cfln cau.. ATI!/CHI<.. SHI!!T .I: 2 of 4 j: !IC 27923 35389816 {5/95) .Q- MODI!L HO.D ti~~ATI!/~0 BY G . ~..P..:.ILLUSTRATIOH No.:-.:: 36513729 BOOK No..N. 36523223 36523306 36522050 36794816 36519445 36518108 36522027 36512325 36850378 36520161 36512416 36768851 DESCRIPTION WIRING DIAGRAM SERIAL NUMBER PLATE WARNING ROTATING FAN RIVET WARNING BATTERY OIL FILL WARNING HIGH PRESSURE DANGER/WARNING 3-PART OPERATING INSTRUCTIONS WARNING 2-PART DRAWBAR SPEED/PRESSURE REGULATION SHUTDOWN DECAL INGERSOLL-RAND COMPANY PORTABLI! COMPRI!&SOR DIVISION DECAL LOCATION CHART ••scRIPTION OAT~OWH 716190 8Y:I ~ RI!V: I..PARTS LIST 9-45 ITEM A B c D E F G H J K L M C. PARTS LIST BOOK 9-46 35389816 (5/95) . ..IL.N.ATI!/CHKD ~~~ATEUD BY DATI!/OWH 11'1: 716190 tl 1 G ~~ 1\-~t: s F MODI!L HO.PARTS LIST ITEM A B c C.LUSTRATION HO.P. SHI!I!T HO'j:l!/0 i:: 36513729 BOOK 4 ol4 28107 35389816 (5/95) . 36525681 36522050 36516474 9-47 DESCRIPTION GENERAL DATA WARNING ROTATING FAN DIESEL FUEL INGERSOLL·RAND COMPANY PORTA8LI! COMPRI!BSOR DIVISION DECAL LOCATION CHART OI!SCfUPTIOH FII!V: r. . Ort:ICHKO llr~~TI!/~ J!!.LUSTRATION ::: BOOK 35389816 (5/95) '\ ~"-t s II- NO.PARTS LIST 9-48 /TnoNAt PANEL LIGHT ....I SHI!I!T NO.... K4 i i ~ i! • d ~b~ Rn • m:beRi RT2 FUEl. SWfTCH$2 v-o LOCATION PW {....RsR ~GINE FUEl g "' LEVEL RElAY COlt.0: DIAGRAM ! AJR ALTER ! 0 • ! ! 0 • ! • 0 • ! ~w~w~ """"' '"'''"" LOW FUEL 1K4 if CPRSR SWITCH LCWFLU OP110N CONTACT eiGJNE TEMP TEMP ~DRY :@(• ... PRESS GAGE GAG EMf SENDER i .. ~ AJR VOLT METER DISCHARGE PRESSURE M7 • R2 i M2 • i 'H ENG!NEOI!. LEVa ::@(• ~G GAGE G.....I: 1!/¢ 36521052 1 of 2 27310 . '"""" """'' to- ~~E """"-' Ul FlLTER m RESTRICT - SWITCHSS ~" "' ...!""' ~rtr C.o• OATeJOWN BY: 412193 ~ OPTION WIRING DIAGRAM fli!V.. ""' ~" """ """ . """'. ~:Y m~ '~ H 0 I H ..@Q Q INGERSOLL-RAND COMPANY PORTABLI! C05oiPRt:SSOR DIVISION ....@~~G:o ~e~G~ TACH ~:-~ N. ~~· ..O.Y B ~ MODI!L NOTI1..... lTIIW'm. CPJR n< TOM~~ARD ..... I FUEL LEVEl."" I H " .. 5 - / HO. ITEM K4 M1 M2 M3 M4 M6 M7 M8 R2 RT1 RT2 S2 S7 S8 89 U1 35583442 36853414 36853406 35604099 35604115 35371566 36769230 35604115 35604206 35372457 35367218 35337435 36508950 36778488 36778488 36771426 HARNESS ENGINE HARNESS GAGE RELAY FUEL LEVEL AIR DISCHG PRESS GAGE ENG OIL PRESS GAGE FUEL LEVEL GAGE ENGINE TEMP GAGE TACHOMETER VOLTMETER CPRSR TEMP GAGE FUEL SOLENOID CPRSR TEMP SENDER ENGINE TEMP SENDER LIGHT SWITCH LOW FUEL SWITCH ENG AIR FLTR SWITCH CPRSR AIR FLTR SWITCH DIAGNOSTIC MODULE 36859908 36853422 INGERSOLL·RAND COMPANY PORTABlt! COMPRI!SSOR DIVISION . 8 I~TI!/CHICD ~~DATE:OO ~y -.P.PARTS LIST 9·49 C.! ILLUSTRATION NO. . .t SHI!I!T HOl EtC : \ : 36521052 2of2 27310 MODEL BOOK 35389816 {5/95) .N. CRIPTION DATEJOWH 4/2/93 BY:I ti OPTION WIRING DIAGRAM RI!V.\ '-\ -..}l. PARTS LIST 9-50 INGERSOLL-RAND COMPANY PORTABLE COMPRESSOR DIVISION BOOK 35389816 (5/95) . .:l 4112190 ~ KEYED IGNITION OPTION Rt:V: IDATt:fcHKD a\.IILLUBTRATIOH HO.~ 1!/C 36512929 BOOK 2 of 2 24508 35389816 (5/95) .t:. "~' s .0.N. 36780252 QTY 1 DESCRIPTION KEYED IGNITION SWITCH INGERSOLL-RAND COMPANY PORTABLt: COWPRI!SSOR OIVIB!OH D!!SCRIPTION DATt/DWN a.PARTS LIST 9·51 ITEM A C.1\:Ali!IAP..P.<.vo e~v B '1. MODI!l HO.SHI!ET HO. PARTS LIST 9-52 • c B INGERSOLL-RAND COMPANY PORTADLI! CONPRIP:880R DIVISION BOOK 35389816 (5/95) . l_\ _ 1 MODEL HO..P.PARTS LIST 9-53 ITEM A B c C.J~ E/C B "'"' 36512812 BOOK s -' F 2of2 24420 35389816 (5/95) . 36771426 36768844 36775484 QTY 1 1 4 DESCRIPTION DIAGNOSTIC MODULE DIAGNOSTIC DECAL RIVET INGERSOLL·RAND COMPANY PORTAliU: CONPRt!SSOR DIVl8lOH ••scRIPTo'fliAGNOSTIC MODULE OPTION DATI!IDWH Bn RI!V: .N.T HO.j IlLUSTRATION HO.ATI!/OHKD ~~~AT~YD.. 3/21/90 ~ ~~o-". SHI!t. BOOK 35389816 (5/95) .PARTS LIST 9-54 INGERSOLL-RAND COMPANY PORTA&Lt: COMPRI!SSOR DIVISION . P..~DWN 8Y: 4/11/90 ~ ld.vo'F "_.I lLLUSTRATlON NO.::! 1!/C 36512879 BOOK 2 of 2 27001 35389816 (5/95) ..U HO..J~ BY NO.o.OD!L 1 ~~ RI!V: ~ . .N.... SH!. 35337435 35135037 35143320 36853406 36777589 35374008 35333715 35374701 35604099 35604206 36769230 35371566 35604115 35372457 35278571 35367218 36796571 1 1 2 1 1 1 60" 1 1 1 1 1 2 1 1 1 1 DESCRIPTION TOGGLE SWITCH ON-OFF PLATE TERMINAL LUG PRESSURE GAGE CONNECTOR FELT PLUG TUBING STREET TEE FUEL GAGE FUEL SENDER VOLTMETER TACHOMETER TEMPERATURE GAGE TEMPERATURE SENDER 0-RING TEE TEMPERATURE SENDER INGERSOLL-RAND COMPANY PORTABLI! COMPRI!SSOR DIVISION oescooPTo~'AGE & GAGE LIGHT OPTIONS DAT.PARTS LIST 9-55 ITEM A B c D E F G H J K L M N p Q R s QTY C. TI!(CHKD 1 B rm.. PARTS LIST 9-56 INGERSOLL-RAND COMPANY PORTABLI! COMPRI!880R DIVISION BOOK 35389816 (5/95) . .PARTS LIST 9-57 ITEM C..~ILLUSTRATIOH HO.~ E/C 3652264 7 BOOK 2 of 2 26287 35389816 (5/95) . MOD!L H~..N. A B 36778710 36765188 36765196 20A 11 C2M326 36762706 34A7S4Z1 X1091T331 W86708 19A7S5Z1 84A17B5 W86707 14A5C76Z1 35A2D115Z1 c D E F G H J K L M N QTY 1 2 1 2 1 1 1 1 1 1 1 4 4 DESCRIPTION HOSE REEL BEARING COVER BEARING SHAFT 0-RING HOSE REEL BEARING PLUG SPRING DETENT BALL NIPPLE GLOBE VALVE GREASE FITTING WASHER SCREW INGERSOLL-RAND COMPANY PORTABLI! COMPRI!SSOR DIVISION DI!SCRIPTIOH HOSE REEL ASSEMBLY DAUJOWH BY:/ AI!V: /'?A'TI!tCHKD ~*n/~o _BY 3/28190 tl B "-~ '\~i- J/.SHI!I!T NO.P. PARTS LIST 9-58 INGERSOLL-RAND COMPANY PORTAtiLI! COMPRI!!880R DIVISION BOOK 35389816 {5/95) . :.P.' 5 MOOI!L HO.. 2 of 2 .. j:' 1!/C 26062 2 35389816 (5/95) .IILLUSTRATIOH Ho.lsHI!!I!T 36512895 BOOK H0.N. 36002756 68A7M5Z1 67A7M5Z1 35364371 36778736 35316355 104A23S11 34A7S6Z1 35296748 92368687 W86709 W20664 12A5C10Z1 36779726 67A4C3Z1 34A7S8Z1 QTY 1 1 1 1 1 1 1 1 1 2 1 1 2 2 4 1 DESCRIPTION HOSE REEL ASSEMBLY ELBOW ELBOW CHECK VALVE HOSE BRACKET DISCHARGE HOSE ELBOW PLUG BRACKET SCREW HOSE LOCK HOSE LOCK CAP WASHER U-BOLT NUT PLUG INGERSOLL-RAND COMPANY PORTA!Il~ COMPRI!!SSOR OIVISIOH OESCRIPTIOMSINGLE DATE/OWN 419190 fJY:I ~ HOSE REEL OPTION RI!!V: IOATI!ICHKO B\Y~1TI!!/2J DY B \._i> ".PARTS LIST 9-59 ITEM A B c D E F G H J K L M N p Q R C. PARTS LIST 9-60 INGERSOLL-RAND COMPANY PORTAISL!! COMPRI!SSOR DIVISION BOOK 35389816 (5/95) PARTS LIST 9-61 ITEM A B c D E F G H J K L M N p Q QTY C.P.N. 36002756 68A7M5Z1 67A7M5Z1 35364371 36778736 35316355 104A23S11 34A7S6Z1 35296748 92368687 W86709 W20664 12A5C10Z1 36779726 67A4C3Z1 2 2 2 2 1 1 1 1 2 4 2 2 4 2 4 DESCRIPTION HOSE REEL ASSEMBLY ELBOW ELBOW CHECK VALVE HOSE BRACKET DISCHARGE HOSE ELBOW PLUG BRACKET SCREW HOSE LOCK HOSE LOCK CAP WASHER U-BOLT NUT INGERSOLL-RAND COMPANY PORTAIILI! COMPRI!SSOR DIVISION o•scRIPTIDHDOUBLE HOSE REEL OPTION PATI!IPWN D~:, RI!V: ~~ATI!/CHKD ~Y.!\ATEIA~D flY 419190 tl B ~~ '1: ~ S ,f)_;;· MODEL HO., ILLUSTRATION HO.' SHI!ET HO,~~ E/0 36522654 BOOK 2 of 2 26062 35389816 (5/95) PARTS LIST 9-62 A INGERSOLL-RAND COMPANY PORTABLI! COMPRI!SSOR DNISION BOOK 35389816 {5/95} C.L. 36778363 QTY 1 DESCRIPTION EXTENDED DRAWBAR NOTE: USE EXISTING HARDWEAR TO INSTALL OPTION INGERSOLL-RAND COMPANY PORTAliLI!: COMPRI!SSOR DIVISION o•scRoPT~JITENDED DRAWBAR OPTION DATI!JOWN BY. ~ . MOPI!L NO.J...i.S .P.N.! ILLUSTRATION HO.VD BY B 11-..PARTS LIST 9-63 ITEM A C.SHI!I!T HOli!/C 36512853 BOOK 2 of 2 24420 35389816 {5/95) .I 3/26/90 tl RI!V: I~ATI!:/CHI<D 8~~ATI!I-Y. PARTS LIST 9·64 I I I A I I I INGERSOLL-RAND COMPANY PORTABLe: COioiPRI!880R DIVISION BOOK 35389816 (5/95) I . o-~ BOOK 2~.:: MODEL No. s ..E:fT.:J..~Ho.PARTS LIST ITEM A QTY C.II~~.sc•"fiB~USTABLE DRAWBAR OPTION OAT~DWN en 3/26/90 ~ RI!V: ~0~~1!/CHKD ~~ATI!IAJ'VO flY B ._ ".'.N.P.R~... 36778322 1 9-65 DESCRIPTION ADJUSTABLE DRAWBAR NOTE: USE EXISTING HARDWEAR TO INSTALL OPTION INGERSOLL-RAND COMPANY PORTA!IU: COMPRtSSOR DIVISION o.20 35389816 (5/95) .:.s. PARTS LIST 9·66 INGERSOLL-RAND COMPANY PORTA!ILI! COMPRI!SSOR DIVIS!OH BOOK 35389816 (5/95) . IlLUSTRATION HO.N.P.rHe!T N0.PARTS LIST ITEM A QTY C.s MOO!L N0. 36778413 1 9-67 DESCRIPTION EXTND & ADJ DRAWBAR NOTE: USE EXISTING HARDWEAR TO INSTALL OPTION INGERSOLL·RAND COMPANY PORTAtiU: COMPR2880R DIVISION •••c•"E\:I¥ND & ADJ DRAWBAR OPTION PATEIDWN BY:I 3/26/90 ~ RI!V: IDA~I!/CHKD e~~AT:rJ'Vo e ~ I .. >\-"'.:- B . : 1!/¢ 1 36512838 BOOK 2 of 2 124420 35389816 {5/95) . '. I I . 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