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 - SAFETY

Look for these signs which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor.

(Red Background)

(Orange Background)

(Yellow Background)

(Blue Background)

Book 35389816 ( 4/95)

Indicates the presence of a hazard which WILL cause ~ injury, death or property damage, if ignored.

Indicates the presence of a hazard which CAN cause severe injury, death or property damage, if ignored.

Indicates the presence of a hazard which WILL or can cause injury or property damage, if ignored.

Indicates important set-up, operating_ or maintenance information.

(4)

' I I

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

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

DANGER I Never operate the engine of this machine Inside a building without adequate ventilation. Avoid breathing exhaust fumes when working on or near the machine.

!wARNING I A battery contains sulfuric acid and can give off gases which are corrosive and potentially ex-plosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area Immedi-ately with water.

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

FREE SAFETY DECALS! To promote communication of Safety Warnings on products manufactured by the Portable Compressor Division in Mocksville, N.C., Safety Decals are available free of charge. Safety decals are identified by the decal heading: DANGER -WARNING or CAUTION. Decal part numbers are on the bottom of each decal and are also listed In the compressor's parts manual. Submit orders for Safety Decals to the Mocksville Parts Service Department. The no charge order should contain only Safety Decals. Help promote product safety! Assure that decals are present on the machines. Replace decals that are not readable.

Book 35389816 (4/95) (5)

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

High pressure air. Can cause severe Injury or death. Relieve pressure before removing filler plugs/caps, fittings or covers.

Air pressure can remain trapped In air supply line which can result In serious Injury or death. Always carefully vent air supply line at tool or vent valve before performing any service.

Book 35389816 ( 4/95) (6)

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

Disconnected Air Hoses Whip. Can cause severe Injury or death. Always attach a safetyflowrestrlctor to each hose "at the source of supply or branch line" In accordance with OSHA Regulation 29CFR Section 1826.302(b).

!wARNING I

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

jwARNINGI Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result In serious Illness. Wear eye protection while cleaning unit with compressed air to prevent debris from Injuring eye(s).

I I

Collapsing jack stand. Will cause severe

Insert locking pin completely.

Hot pressurized fluid. Can cause severe burns. Do not open radiator while hot.

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

Ether Is an extremely volatile, highly flammable gas. USE SPARINGLYIIf too much Is Injected, It may result In costly damage to the engine.

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

Book 35389816 (4/95) (7)

Rotating fan blade. Can cause severe Injury. Do not operate without guard In

I WARNING I Always make sure wheels, tires and tow bar connectors are In safe operating condition and tow bar Is properly connected before towing.

I CAUTION~ Do not connect the air discharge on this unit onto 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.

WARNING

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof:

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

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

1. Removal or rendering inoperative any of the following: a. the engine exhaust system or parts thereof b. the air intake system or parts thereof c. enclosure or parts thereof

2. Removal of any of the following: a. fan shroud b. vibration mounts c. sound absorption material

3. Operation of the compressor with any of the enclosure doors open.

Book 35389816 ( 4/95) (8)

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

SUBSTANCE

Compressor Oil Engine Lubricating Oil Preservative Grease Rust Preventative Diesel Fuel Battery Electrolyte

PRECAUTION

A void ingestion, skin contact and breathing fumes. A void ingestion, skin contact and breathing fumes. A void ingestion, skin contact and breathing fumes. A void ingestion, skin contact and breathing fumes. A void ingestion, skin contact and breathing fumes. 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.

SUBSTANCE Engine Exhaust Fumes Engine Exhaust Fumes Brake Lining Dust

Book 35389816 (4/95)

PRECAUTION Avoid breathing. Avoid build-up of fumes in confined spaces. A void breathing during maintenance.

(9)

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INGERSOll-RAND AIR COMPRESSORS

PORTABLE COMPRESSOR SAFETY CARD

L1ii. DANGER

&WARNING

DANGER IS USED TO INDICATE THE PRESENCE OF A HA2ARO WHICH WILL CAUSE SEVERE INJURY OR DEATH IFrne WARNING IS IGNORED.

WARNING IS USED TO INDICATE THE PRESENCE OF A HAZARD WHICH CAN CAUSE SEVERE INJURY OR DEATH IF THE WARNING IS IGNORED.

CAUTION IS USED TO INDICATE THE PRESENCE OF A HAZARD WHICH WILL OR CAN CAUSE MINOR INJURY OR PROPERTY DAMAGE IF THE WARNING IS IGNORED.

Discharge Air can contain carbon monoxide or contaminants.

&CAUTION

&. WARNING

High pressure air. Can cause severe Injury or death.

Relieve pressure before removing filler plugs/caps,

This decaf near receiver tank.

Will cause severe Injury or death. Do not breathe this air.

&. WARNING

f ... ,~;'' ~2.w.~' ~.:-~,~=" Trapped air pressure. can cause severe injury or death.

Close service valve and operate tool to vent trapped air before performing any service.

rn1s dflCdl no:Jr sofllicc valve.

This docal near seNic.o

&. WARNING

Disconnected air hoses whip. Can cause severe InJury or death.

Attach safety flow restrictor to each hose .. at the source of supply or branch line" in accordance with OSHA Regulation 29CFR Section 1926.302(b).

This decaf near SoflliCC outlet.

&. WARNING

&. WARNING

Improper operation of this equipment Can cause severe InJury or death.

Read Operator's Manual supplied with this machine before operation or service.

&. WARNING

Combustible gas. Ct~n cause severe burns, blindness or death.

Keep sparks and open flame away from batteries.

Tflfs doctJI near battery.

Modification or alteration of this machine. Can result in severe InJury or death.

Do not alter or modify this machine without the express written consent of the manufacturer.

This decal rlNtr control pancf.

&. WARNING

Rotating fan blade. Can cause severe InJury.

Do not operate without guard in place.

This decal near Jan.

&. WARNING

Collapsing Jackstand. Can cause severe Injury.

Insert locking pin completely. ~~ !\'-..

Excessive towing speed. Can cause severe Injury or death.

Do NOT exceed 50 mph (80 km/ph.)

/ ...

~('

SECTION 2- WARRANTY Ingersoll-Rand, through its distributor, 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, whichever first occurs. With respect to the following types of equipment, the warranty period enumerated will apply in lieu of the foregoing warranty period.

Aftercoolers, Drill Mountings and Klemm Rotary Heads- The earlier of six (6) months from initial operation or nine (9) months from date of shipment to the initial user.

Portable Compressors, Portable Generator Sets (GENSET), Portable Light Towers and Abrasive Blasting Equipment- The earlier of twelve {12) months from shipment to, or the accumulation of 2,000 hours of service by, the initial user.

All Compressor Air Ends, GENSET Generators and Paving Breakers-The earlier of twenty-four (24) months from shipment to, or the accumulation of 4000 hours of service by, the initial user. For Air Ends, the warranty against defects will include replacement of the complete Air End, provided the original Air End is returned assembled and unopened.

Pavers, Milling Machines, Pedestrian Compactors (Including baseplates, upright and walk behinds) and Rotary Drills- The earlier of (6) months from shipment to, or the accumulation of 1 000 hours of service by, the initial user.

Jackhammers, Forklifts and Self-Propelled Compactors- The earlier of twelve (12) months from shipment to, or accumulation of 1000 hours of service by, the initial user.

Downhole Drills - In lieu of the repair or replacement of defective parts, Ingersoll-Rand may elect to Issue full or partial credit toward the purchase of a new part. The extent of credit issued will be determined by pro rating against the normal service life of the part in question.

Spare Parts (excluding downhill drills)- Three (3) months from date of shipment.

Book 35389816 (4/95) (11)

Warrantv

Ingersoll-Rand will provide a new part or repaired part, at its election, in place of any part which is found upon its inspection to be defective in material and workmanship during the period prescribed above. Such part will be repaired or replaced with-out 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 ln-gersolf-Rand. User must present proof of purchase and date at the time of exercising warranty.

This warranty does not apply to failures occurring as a result of abuse, misuse, negligent repairs, cor-rosion, erosion and normal wear and tear, alter-ations or modification made to the product without express written consent of Ingersoll-Rand; or fail-ure to follow the recommended operating practices and maintenance publications.

Accessories or equipment furnished by lngersolf-Rand, but manufactured by others, including, but not limited to, engines, tires, batteries, engine elec-trical equipment, hydraulic transmissions, carriers, shall carry whatever warranty the manufacturers have conveyed to Ingersoll-Rand and which can be passed on to the initial user. This warranty Is In lieu of all other warranties (except of title), expressed or implied, and there are no warranties of merchantablllty or of fitness for a particular purpose.

Limitation of Liabilitv 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, delivery, installation, repair or technical direction covered by or furnished under this sale whether based on contract, warranty, negligence, indemnity, strict liability or otherwise shall not exceed the purchase price of the unit of equipment upon which such liability is based. Ingersoll-Rand, its suppliers{s) and its distributors shall in no event be liable to the user, any successors in interest or any beneficiary or assignee relating to this sale for any consequential, incidental, indirect, special or punitive damages

Book 35389816 {4/95) (12)

arising out of this sale or any breach thereof, or any defects in, or failure of, or malfunction of the equipment under this sale whether based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other goods, loss by reason of shutdown or non-operation, increased expenses of operation of the equipment, 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, warranty, negligence, indemnity, strict liability or otherwise. 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. 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. Category "A": The airend must not be over two years old and must have reusable rotor housing{s) and rotor{s).

Category "B": The airend must be between two and five years old and returned with two or more reusable major castings.

Category "C": The airend must be over five years old.

Your nearest sales office, 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. The airend must be tagged with this preassigned number and returned to the factory prepaid. The airend must be intact, with no excluded parts, otherwise the exchange agreement may be cancelled. The warranty on an exchange or factory rebuilt airend is 365 days.

Note: Airends being returned to the factory in connection with a WARRANTY CLAIM must be processed through the Customer Service Department. If returned without a Warranty MRR {Material Return Request) Number, no warranty claim will be considered.

General Warranty Information

(20--50 KW) (2.5-6 KW)

Kubota

Book 35389816 ( 4/95)

24 2000

(13)

2 hrs. 1 yr/2000 hrs (parts &

hrs

major components 25-36 mo/3000 hrs

PRODUCT WARRANTY

ENGINE WARRANTY

PARTS WARRANTY

A/REND EXCHANGE WARRANTY

SECTION 3 - WARRANTY REGISTRATION

Complete Machine Registration

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

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

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

Ingersoll-Rand Company Portable Compressor Division

P.O. Box 868 Mocksville, North Carolina 27028

Attn: Warranty Department

Note: Completion of this form validates the warranty.

Engine Registration: No engine registration required. Must present Proof of Purchase whenever engine warranty service is required.

Book 35389816 ( 4/95) (14)

INGERSOLL-RAND AIR COMPRESSORS Warranty Registration Form

SELliNG O!SIB!B\JTOB

Name ____________________ __

Address -------------------Chy __________ _

County --------------------Slate ____________________ _

Zip Code ------------------

Telephone -------------------

SERVICING Q!SJB!Bl!TOB

Name ---------------------

Address-------------------Chy __________________ _

County __________________ __

Stale -------------------

Zip Code ------------------

Telephone-------------------

COMPLETE THE APPLICABLE BLOCKS Owner/User Type of Business

(check only one) CJ Construction-Heavy ~ Asphalt Contractor 0 Coal Mining ~

(Highway, excavation, etc.) CJ Construction-Light

(carpentry, plumbing, pools, mason, etc.)

0 Rental (rental center, rentallleet, etc.)

0 Industrial (plant use)

Model

Unit-Hours

CJ Government 0 Quarry (municipal, state, county, etc.)

o Building Contractor 0 Waterwell

C Other 0 Exploration specily ---------

Unrr SIN Engine SiN

Air End SIN Truck SIN

WARRANTY REGISTRA 110N Owner/User Name -------------

Address-------------------

City ----------------------County __________________ _

State ------------------

Zip Code -----------------

Telephone-------------------

:; Other Mining

:1 Shallow Oil & Gas

0 Utility Company (gas, electric, water, etc.)

0 Utility Contractor

Date Delv'd

Truck Engine SIN

SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT 1. The Purchaser has been instructed and/or has read the manual and understands proper preventative maintenance, general

operation and safety precautions 2. The warranty and limitation olliability (see reverse side) has been reviewed and understood by the owner/user. 3. In the event that this unh is to be used wrrhin a nuclear faciley, the owner/user shall notify fngersoiiRand of such use so that

Ingersoll-Rand may arrange for appropriate nuclear Iiabilhy protection from the owner-licensee of the facilny. 4. lngersoiiRand 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.

I hereby acknowledge acceptance of above and the conditions on reverse side.

Owner/User --------------------------------------- Date----------~----------------I hereby certify that the above is accurate and complete

Distributor/1-R Rep. ---------------------------------- Date-------------------------

COMPLETION OF THIS FORM VALIDATES THE WARRANTY X-4051-C

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SECTION 4 - OPERATION BEFORE TOWING

I wARNING I Failure to follow these Instructions could result In very serious personal Injury or death.

I CAUTION~ - Position the tow vehicle to align its hitch with the pintle eye or coupler of the compressor.

- Engage the parl

Control Panel D~al00@:111~G:J@. Pr6Stige SeriBS. 0 .l. C! '"(!)- ~AM

-0- ~"" ~ ~ 0 "i\0 CD ~-~ s~ Operating Controls/Instruments (Standard) 1. 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.

2. Service Air Button- Push After Warm-up (Optional) A wo-way valve that provides full air pressure at

the service outlet.

3. Light Switch (Option, for Gauges)-Otherwise, lights in gauges are controlled by the-Master Switch (1).

4. Air Discharge Pressure Gauge -

Indicates pressure in receiver tank, normally from 0 psi (kPa) to the rated pressure of the machine. 5. Hourmeter-

Records running time for maintenance.

Book 35389816 ( 4/95) (16)

0 0 0 0 -~ 0

BEFORE STARTING

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.

I WARNING 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 condi-tion. 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) (17)

WARNING

This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve (s) are open. Close 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.

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 con-nections while engine Is running.

STARTING

1. Turn the POWER switch to "ON".

2. Turn power switch to "START' position to crank engine.

NOTICE

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

Cold Weather Starting:

Open manual blowdown valve, if so equipped, and press ether inject button. Use ether sparingly. Close manual blowdown valve after engine is running.

I CAUTION~ 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.

4. Allow engine to warm up 5 to 10 minutes

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)

UNITS WITH OPTIONAL DIAGNOSTICS LAMPS

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

STOPPING Close air service valve.

Allow the unit to run at idle for 3 to 5 minutes to re-duce the engine temperatures.

Turn Power Switch to "OFF" position.

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.

NOTICE 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

(2} At the airend outlet. (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".

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

Before Starting 1. At the Pressure Regulator (on

service pipe near receiver tank), remove the cover to expose the adjusting screw. Loosen the jam nut (A). Turn screw (B) counterclockwise until tension is no longer felt at the screw. Then, tum screw clockwise one full turn.

2. On Air Cylinder rod (C), loosen lock nut (D). Remove bolt (E) and disconnect rod end bearing (F). Pull engine speed lever (G) toward air cylinder (Full Load Position). Adjust rod end bearing to line up with hole in lever. Replace bolt (E) and tighten.

3. Close service valve(s). After Starting Unit 4.

5.

Allow unit to warm up at an engine speed greater than IDLE speed for at least five minutes. The engine should speed up and then slow down.

If equipped, push the SERVICE AIR button on the control panel, making certain the button does not pop back out. The unit should speed up and then unload (and drop back to IDLE). With the unit unloaded, turn the adjusting screw on the pressure regulator clockwise until the discharge pressure gauge indicates 120--122 psi (827-841 kPa). Tighten the pressure regulator jam nut. Replace cover.

Book 35389816 (4/95)

DISCHARGE PRESSURE GAGE

PRESSURE REGULATOR A

B TO SEPARATOR TANK

[)==t:(~=ro UNLOADER

6.

7.

CHECKVALVE ORIFICE

AIRCVUNDER

" 36611896

Open the service valve and adjust the discharge pressure to 100 psi (689 kPa). If necessary, at full engine speed, adjust pressure regulator screw (B) clockwise to increase pressure.

With the discharge pressure at 100 psi, adjust the engine speed to the FULL load RPM by loosening lock nut (D) against rod end bearing (F).

8. While still maintaining 1 00 psi, turn the pressure regulator screw (B) until speed lever (G) just begins to move. Tighten jam nut (D).

9. Close the service valve and recheck IDLE speed. The engine will slow down. To set the idle or NO LOAD speed, loosen jam nut (H) on the side of engine. Turn adjusting screw (J) to the specified speed. Tighten jam nut (H).

10. To obtain maximum ctm at any pressure between 80 psi (552 kPa) and maximum pressure rating (*}, make adjustment at the pressure regulator to obtain desired discharge pressure at FULL engine speed. Lock adjusting screw and replace cover.

(19)

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

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

A. Find the "complainf' depicted as a bold heading.

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

ACTION PLAN

A. Think Before Acting

Study the problem thoroughly and ask yourself these questions:

(1) What were the warning signals that preceded the trouble?

(2) Has a similar trouble occurred before? (3) What previous maintenance work has been

done? (4) If the compressor will still operate, is it safe to

continue operating it to make further checks?

Book 35389816 ( 4/95)

B. Do The Simplest Things First

Most troubles are simple and easily corrected. For example, most complaints are "low capacity" which may be caused by too low an engine speed or "compressor over- heats" which may be caused by low oil level.

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

Note: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic.

c. Double Check Before Disassembly

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

D. Find And Correct Basic Cause

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

(20)

TROUBLE SHOOTING CHART Bold Headings depict the COMPLAINT- Subheadings depict the CAUSE

Note: Subheadings suggest order to follow in cause of troubleshooting.

Short Air Cleaner Life:

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. Tank Blown Down Too Quickly Defective Minimum Pressure Valve

Wlll Not Unload: Leaks in Regulator Piping Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Malfunctioning Inlet Unloader/Butterfly Valve Ice in Regulation Lines/Orifice

Ollln Air Cleaner: Incorrect Stopping Procedure

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)

Excessive Compressor Oil Temperature: 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

Engine RPM Low: 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

LowCFM: 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

Unit Shutdown: 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

Unit Falls To Shutdown: 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

Alternator Lamp Stays Off: Loose Wire Connection Malfunctioning Circuit Board

Book 35389816 (4/95) (22)

Won't Start/Run: Low Battery Voltage Blown Fuse Malfunctioning Start Switch Clogged Fuel Filters Out of Fuel Compressor Oil Temp. Too High Engine Water Temp. Too High Engine Oil Pressure Too Low Loose Wire Connection Defective Switches Malfunctioning Relay Engine Malfunctioning Airend Malfunctioning

Engine Temperature Lamps Stays On: 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

Engine 011 Pressure Lamp Stays On: Low Oil Level Out of Level > 15 degrees Wrong Lube Oil Engine Malfunctioning

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

SECTION 5- GENERAL DATA Unit Model: .......................................... P100WD ................... P125WD

Air Delivery- elm (litres/sec) ............................ 100 (47) . . . . . . . . . . . . . . . . . . . 125 (59) Engine Speed- RPM (Full Load} ........................ 2300 2800

- RPM (No Load} ........................ 2000 2000 COMPRESSOR

Rated Operating Pressure- psi (kpa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 00 {689) Safety Valve Setting- psi (kPa) ..................................................... 150 (1034) ENGINE (Diesel) Manufacturer ......................................... , . . . . . . . . . . . . . . . . . . . . . . . . . . . KHD/Deu1z

Model ........................................................................... F3M1011F

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

FLUID CAPACITIES

Compressor Lubricant ................................................... 10 quarts (9.51itres) Engine Lube (including cooler) ............................................ 10 quarts (9.5 litres) Fuel Tank .............................................................. 16.6 u.s. gal. (63 litres) UNITS MEASUREMENTS/WEIGHTS

Overall Length .......................................................... 11.8 feet (3.60 meters) Overall Height .......................................................... 4.7 feet (1.44 meters) Overall Width ........................................................... 5.2 feet (1.60 meters) Net Weight (less fuel} pounds (kg) ......................................... 1830 pounds (830 kg) RUNNING GEAR

1ire Size ............................................................... P185/80R x 13

Inflation Pressure (Cold) ................................................. 32 psi {220 kPa) Towing Speed (Maximum) ................................................ 50 mph (80 km/hr)

CAUTION: Any departure from the specifications may make this equipment unsafe.

EXPENDABLE SERVICE PARTS

Compressor Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35296920 Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36845303 Air Cleaner Element (compressor) ................................................... 35291970 Air Cleaner Element (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35291970

Book 35389816 (4/95) (23)

SECTION 6 - MAINTENANCE

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

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

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

Never operate this machine with any guards removed.

Inch and metric hardware was used in the design and assembly of this unit. Consult the parts manual for clarification of usage.

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

GENERAL

In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and post--{)peration procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need for repair. Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining your unit and keeping it clean at all times will facilitate servicing.

SCHEDULED MAINTENANCE

The maintenance schedule is based on normal operation of the unit. This page can be reproduced and used as a checklist by the service personnel. In the event unusual environmental operating conditions exist, the schedule should be adjusted accordingly. Book 35389816 (4/95) (24)

COMPRESSOR OIL LEVEL The oil level should be checked before the unit is started. The optimum operating level is midway of the sight tube on the side of the receiver tank. See the decal beside the sight tube. If the oil level is not in the "OK" range, make appropriate corrections (Add or Drain). A totally filled sight tube in which the level is not visible indicates an over-full condition and requires that oil be drained.

AIR CLEANER If this unit is equipped with the Optional Diagnostic Panel, it has an AIR FILTERS RESTRICTED lamp on the instrument panel, covering both the engine and the compressor.

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

Also weekly squeeze the rubber valve (precleaner dirt dump) on each air cleaner housing to ensure that they are not clogged.

The air filters restricted sensor will automatically re-set after the main power switch is turned to "OFF."

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

1.

2.

3.

4.

Loosen outer wing nut and remove with cover. Remove Element.

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

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

Inspect element by placing a bright light inside and rotating slowly. If any holes or tears are found in the paper, discard this element. If no ruptures are found, the element can be cleaned.

5.

6.

7.

If a new air filter element is to be used check it closely for shipping damage.

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

Inspect to ensure that the end cap seals tightly 360 degrees around the air cleaner body.

In the event that the filter element must be reused immediately, compressed air cleaning (as follows) is recommended since the element must be thoroughly dry. Direct compressed air through the element in the direction opposite to the normal air flow through the element.

Move the nozzle up and down while rotating the element. Be sure to keep the nozzle at least one inch (25.4 mm) from the pleated paper.

NOTE: To prevent damage to the element, never exceed a maximum air pressure of 100 psi (700 kPa).

In the event the element is contaminated with dry dirt, oil or greasy dirt deposits, and a new element is not available, cleaning can be accomplished by washing, using the air cleaner element manufactur-er's recommendations.

NOTE: It Is recommended that replacement efe ments be Installed In the unit. The elements just removed for cleaning can be washed and stored as future replacement elements.

In addition, the air cleaner system (housing and piping) should be inspected every month for any leakage paths or inlet obstructions. Make sure the air cleaner mounting bolts and clamps are tight. Check the air cleaner housing for dents or damage which could lead to a leak. Inspect the air transfer tubing from the air cleaner to the compressor and the engine for leaks. Make sure that all clamps and flange joints are tight.

Book 35389816 (4/95) (25)

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

FUEL TANK CLEAN fuel in the fuel tanks is vitally important and every precaution should be taken to ensure that only clean fuel is poured or pumped into the tank.

When filling the fuel tank on this unit, by methods other than a pump and hose, use a CLEAN non-metallic funnel.

BATIERY Keep the battery posts-to-cable connections clean, tight and lightly coated with a grease. Also the electroly1e level in each cell should cover the top of the plates. If necessary, top-up with clean distilled water.

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

COMPRESSOR OIL COOLER The compressor lubricating and cooling oil is cooled by means of the fin and tube-type oil cooler, located below the radiator. The lubricating and cooling oil, flowing internally through the core section, is cooled by the air stream from the cooling fan flowing past the core section. When grease, oil and dirt accumulate on the exterior suriaces of the oil cooler, its efficiency is impaired. Each month it is recommended that the oil cooler be cleaned by directing compressed air which contains a nonflammable, non-

I wARNING I High pressure air can cause severe Injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. 1. Open the service air valve(s) to ensure that system is relieved of all pressure. Close the valve(s). 2. Turn the spi~n filter element counterclockwise to remove it from the filter housing. Inspect the

filter.

NOTICE If there Is any Indication of formation of var nlshes, shellacs or lacquers on the oil filter ele ment, It Is a warning the compressor lubricating oil has Improper characteristics and should be Immediately changed. 3. Inspect the oil filter head to be sure the gasket was removed with the oil filler element. Clean the gasket seal area on the oil filter head.

Book 35389816 (4/95) (27)

NOTICE Installing a new oil filter element when the old gasket remains on the filter head, will cause an oil leak and can cause property damage. 4. Lubricate the new filter gasket with the same oil being used in the machine. 5. Install new filler by turning element clockwise until gasket makes initial contact. llghten an additional! /2 to 3/4 turn. 6. Start unit and allow to build up to rated pressure. Check for leaks before placing unit back into service.

FASTENERS Visually check entire unit in regard to bolts, nuts and screws being properly secured. Spot check several capscrews and nuts for proper torque. If any are found loose, a more thorough inspection must be made. Take corrective action.

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

RUNNING GEAR Every month or 500 miles, tighten the wheel lug nuts to 85 - 95 lbs.-ft. Every six months the wheel bearings, grease seals and axle spindles should be inspected for damage (corrosion, etc.) or excessive wear. Replace any damaged or worn parts. Repack wheel bearings. Use a wheel bearing grease conforming to specification MIL--G--10924 and suitable for all ambient temperatures.

Grease can be replaced in a wheel bearing using a special fixture or by hand as follows. Before installing bearing, place a light coat of grease on the bearing cups which are pressed in the hub.

Place a spoonful of grease in the palm of one hand and take the bearing in the other hand. Push a segment of the wider end of the bearing down into the outer edge of the grease pile closest to the thumb. 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. Then rotate the bearing to repeat this operation on the next segment. Keep doing this until you have the entire bearing completely filled with grease.

NOTICE 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. 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.

If bearing adjustment is required or the hub has been removed for any reason, the following procedure must be followed to ensure a correct bearing adjustment of 0.001 to .012 free play.

1. While rotating hub slowly to seat the bearings, tighten spindle nut to approximately 15 lbs.-ft. Grasp the tire at the top and bottom and rock, in and out. There should be no evidence of looseness (free play) at the bearing.

2.

3.

Loosen nut to remove preload torque. Do not rotate hub.

Finger tighten nut until just snug. Loosen nut until the first nut castellation lines up with cotter pin hole in spindle. Insert cotter pin.

4. Ensure a definite but minimal amount of free play by rocking the tire.

6. Nut should be free to move with only restraint being the cotter pin.

Book 35389816 (4/95) (28)

RECEIVER-sEPARATOR SYSTEMS

!wARNING I High pressure air can cause severe Injury or death from hot off and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system.

Open service valve at end of machine.

Ensure pressure Is relieved, with BOTH: -Discharge air pressure gauge reads zero (0). - No air discharging from service valve.

When draining oil, remove plug from bottom of separator tank.

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

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

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

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

The life of the oil separator element is dependent upon the operating environment (soot, dust, etc.) and should be replaced every twelve months or 2000 hours. To replace the element proceed as follows:

Ensure the tank pressure is zero.

Disconnect the hose from the scavenge tube.

Remove scavenge tube from tank cover.

Disconnect service line from cover.

Remove cover mounting screws.

Remove cover and element.

Remove any gasket material left on cover or tank.

Install new element.

NOTICE

Do not remove staples from the element/gasket connection.

Place a straightedge across top of element and measure from bot1om of straightedge to bot1om of element (See Fig. 4.1 ).

Replace scavenge tube in cover (cover is still off of tank). Measure from bot1om of cover to end of scavenge tube. Measurement should be from 1/8" to 1/4" less than the element measurement. If not, cut to size. Remove scavenge tube.

Reposition cover (use care not to damage gaskets).

Replace cover mounting screws: tighten in a crisscross pat1ern.

Reconnect service line. Replace scavenge tube. Reconnect hose.

Close service valve. Start unit and look for leaks.

When replacing the element, the scavenge lines, orifice, filter, and check valve should be thoroughly cleaned and the oil changed.

TANK TOP--' c;l i

' l J I I ...,._SCAVENGE TUBE

SHOULD BE 1/B" TO 1/4"--1!,_ ** SHORTERTHAN u ELEMENT MEASUREMENT

- - - - - cut line L ___ __j--01---- SEPARATOR TANK If necessary

Book 35389816 ( 4/95) (29)

SCAVENGE LINE

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

The scavenge line originates at the receiver-separator tank cover and terminates at the compressor airend near the oil filter element. An orifice check valve is located on the scavenge tube. Once a year or every 1000 hours of operation, whichever comes first, replace the separator element and clean the scavenge orifice/check valve.

NOTICE Excessive oil carry-over may be caused by an oil-logged separator element. Do not replace element without first performing the following maintenance procedure:

1. Check oil level. Maintain as Indicated earlier In this section.

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

3. Assure minimum pressure valve/or! flee Is operational.

4. Run unit at rated operating pressure for 30 to 40 minutes to permit element to clear Itself.

Book 35389816 (4/95) (30)

EXTERIOR FINISH CARE

This unit was painted and heat cured at the factory with a high quality, thermoset polyester powder coating. The following care will ensure the longest possible life from this finish.

1. If necessary to remove dust, pollen, etc. from housing, wash with water and soap or dish washing liquid detergent. Do not scrub with a rough cloth, pad, etc.

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

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

To touch-up or paint over and retain the superior fin ish requires the following:

1. The area to be painted should be finish sanded with 320 grit paper.

2. Remove all sanding dust with alco hoi using clean, lint free rag(s}. Change rag when soiled. Remove any lint and other loose contamlna tion with atitomobll9-iJrade tack rag(s}.

3. Before applying paint: Inspect to Insure that area Is free of all dirt, fibers, lint, grease, moisture or any other form of surface contamination. coat area with a solvent based, automotive-type, high quality liquid paint that will adhere to powder coatings. DO NOT USE WATER BORNE OR LATEX PRODUCTS.

4. If possible, allow 30 days before washing with anything but clean water.

PREVENTIVE MAINTENANCE SCHEDULE If operating In extreme environments (very hot, cold, dusty or wet), these time periods should be reduced.

3MO. 6MO. 12MO. Dally Wkly MO. 500 HRS 1000 HRS 2000 HRS

COMPRESSOR OIL LEVEL c ENGINE OIL LEVEL c

'RADIATOR COOLANT LEVEL c GAUGES/LAMPS c 'AIR CLEANER SERVICE INDICATORS c FUEL TANK (FILL AT END OF DAY) c DRAIN 'FUEL/WATER SEPARATOR DRAIN c AIR CLEANER PRECLEANER DUMPS c FAN ALTERNATOR BELTS c BATTERYCON SIELECTROLVTE c TIRE PRESSURE AND SURFACE c 'WHEEL LUG NUTS c HOSES (OIL,AIR,INTAKE,ETC.) c AUTOMATIC SHUTDOWN SYSTEM TEST c AIR CLEANER SYSTEM VISUAL c COMPRESSOR OIL COOLER EXTERIOR c CLEAN ENGINE RADIATOR/OIL COOLER EXTERIOR c CLEAN FASTENERS c

AIR CLEANER ELEMENTS WI

'FUEL/WATER SEPARATOR ELEMENT R COMPRESSOR OIL FILTER ELEMENT R COMPRESSOR OIL R 'WHEELS (BEARINGS, SEALS, ETC.) c 'ENGINE COOLANT TEST c R SHUTDOWN SWITCH SETTINGS TEST c SCAVENGER ORIFICE & RELATED PARTS CLEAN OIL SEPARATOR ELEMENT R

ENGINE (OIL CHANGES, FILTERS, ETC.) REFER TO ENGINE OPERATORs MANUAL

*Disregard If not appropriate for this particular machine. R=Replace Ingersoll-Rand

C=Check (and adjust or replace If necessary). WI=OR when Indicated. 36509966

Unit _____ _ Date: ____ _

Hours _____ _ Serviceman ____ _

Book 35389816 ( 4/95) (31)

LUBRICATION

FLUIDS AND LUBRICANTS TABLE ITEM FLUID AMBIENT TEMP. SPECIFICATION

Compressor Lubrlcan -10F to 125F Dexron or

Models: (-23C to 52C) Dexron II ATF VHP-(200+ MIL-L-46152

psi) SAE 10W, API CC HP-(150 psi)

-40F to 125 F 0 1-R PIN 35382472 XP-(125 psi) P-(100 pslj (-40C to 52C) Synthetic Fluid

XHP (300 psi) -10F to 125F Dexron II ATF (-23C to 52C) 1-R XHP 505 Synthetic

or Equivalent -10Fto 100F 1-RXHP 505

XHP (350 psi) (-23C to 38C) Synthetic 70F to 125F

or Equivalent

(21 C to 52C) 1-R XHP 1001 Synthetic or Equivalent Engine: 011

Coolan Fuel

Running Gear wheel Bearings Grease All MIL-G-10924 Other Grease All Multi-Purpose Hydraulic Brakes Fluid All Dot 3 or4

DEXRON- Reg. T.M. of General Motors Corp.

Book 35389816 (4/95) (32)

NOISE EMISSION CONTROL MAINTENANCE LOG

COMPRESSOR MODEL ______ _ SERIAL NO. __________ _ USER UNIT NO. _________ _

UNIT IDENTIFICATION

ENGINE MAKE & MODEL:------------

SERIAL NO.:----------------

PURCHASER OR OWNER:-----------

ADDRESS: ________________ _

DEALER OR DISTRIBUTOR FROM WHOM PURCHASED:

DATE PURCHASED:--------------

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

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

NOISE EMISSION WARRANTY The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was

designed. built and equipped to conform at the time of sale to the first retail purchaser. with all applicable U.S. EPA Noise Control Regulations.

This warranty is not limited to any particular part, component. or system of the air compressor. Defects in the design, assembly, or in any part, component, or system of the compressor which. at the time of sale to the first retail purchaser, caused noise emissions to exceed Federal Standards are covered by this warranty for the life of the air compressor. (40CFR204.58-1 ).

Book 35389816 (4/95) (33)

INTRODUCTION

The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air Compressors.

The purpose of this book is to provide (1) the Maintenance Performance Schedule below for all required noise emission controls and (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when. Detailed instructions on the maintenance items below are given on the following page.

MAINTENANCE SCHEDULE

ITEM AREA PERIOD

A. COMPRESSED AIR LEAKS AS DETECTED

B. SAFETY AND CONTROL SYSTEMS AS DETECTED

c. ACOUSTIC MATERIALS DAILY

D. FASTENERS 100 HOURS

E. ENCLOSURE PANELS 100 HOURS

F. AIR INTAKE & ENGINE EXHAUST 100 HOURS

G. COOLING SYSTEMS 250 HOURS

H. ISOLATION MOUNTS 250 HOURS

I. ENGINE OPERATION SEE OPERA TOR'S MANUAL

J. FUELS & LUBRICANTS SEE OPERATOR'S MANUAL

Book 35389816 {4/95) (34)

A. COMPRESSED AIR LEAKS

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

B. SAFETY AND CONTROL SYSTEMS

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

C. ACOUSTIC MATERIALS

In daily inspections observe these materials. Maintain all acoustic material as nearly as possible in its original condition. Repair or replace all sections that have: 1) sustained damage, 2) have partially separated from panels to which they were attached, 3) are missing, or have otherwise deteriorated due to severe operating or storage conditions.

D. FASTENERS

All fasteners such as hinges. nuts. bolts, clamps, screws, rivets, and latches should be inspected for loosenes& after each 100 hours of operation. They should be retightened. repaired, or- if missing-replaced immediately to prevent subsequent damage and noise emission increase.

E. ENCLOSURE PANELS

Enclosure panels should also be inspected at 100-hour operational intervals. All panels that are warped, punctured, torn, or otherwise deformed, such that their noise containment function is reduced, should be repaired or replaced before the next operation interval. Doors, access panels, and hatch closures especially, should be checked and adjusted at this time to insure continuous sealing between gasket or acoustic material and the mating frame.

Book 35389816 (4/95) (35)

F. AIR INTAKE AND ENGINE EXHAUST

Engine and compressor air intake and engine exhaust systems should be inspected after each 1 00 hours of operation for loose, damaged. or deteriorated components. Repairs or replacements should be made before the next period of use.

G. COOLING SYSTEMS

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

H. ISOLATION MOUNTS

Engine/airend isolation mounts should be inspected after each 250 hours of operation. Those mounts with cracks or splits in the molded rubber, or with bent or broken bolts due to operation or storage in severe environments. all should be replaced with equivalent parts.

I. ENGINE OPERATION

Inspect and maintain engine condition and operation as recommended in the manuals supplied by the engine manufacturer.

J, FUELS AND LUBRICANTS

Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand Company and Engine Manufacturer's Operator and Maintenance Manuals.

MAINTENANCE RECORD FOR NOISE EMISSION CONTROL

ITEM NO. DESCRIPTION OF WORK OR COMMENTS HOURMETER MAINTANSPECT LOCATION WORK DONE READING DATE CITY/STATE BY(NAME)

- -

Book 35389816 ( 4/95) (36)

SECTION 7 GENERAL

PARTS ORDERING This publication, which contains an illustrated parts breakdown, has been prepared as an aid in locating those parts which may be required In the maintenance of the unit. All of the compressor parts, listed in the parts breakdown, are manufactured with the same precision as the original equipment. For the greatest protection always insist on genuine Ingersoll-Rand Company parts for your compressor.

NOTICE Ingersoll-Rand Company can bear no responsibility for Injury or damages resulting directly from the use of non-approved repair parts.

Ingersoll-Rand Company service facilities and parts are available worldwide. There are Ingersoll-Rand Company Construction Equipment Group Sales Offices and authorized distributors located in the principal cities of the United States. In Canada our customers are serviced by the Canadian Ingersoll-Rand Company, Limited. There are also Ingersoll-Rand International autonomous companies and authorized distributors located in the principal cities throughout the free world.

Special order parts may not be included in this manual. Contact the Mocksville Parts Department with the unit serial number for assistance with these special parts.

DESCRIPTION

The illustrated parts breakdown illustrates and lists the various assemblies, subassemblies and detailed parts which make up this particular machine. This covers the standard models and the more popular options that are available.

A series of illustrations show each part distinctly and in location relative to the other parts in the assembly. The part number, the description of the part and the quantity of parts required are shown on each illustration or on adjacent page. The quantities specified are the number of parts used per one assembly and are not necessarily the total number Book 35389816 (4/95) (37)

of parts used in the machine. Where no quantity is specified the quantity is assumed to be one. Each description of a part is based upon the "noun first" method, i.e., the identifying noun or item name is always the first part of the description. The noun name is generally followed by a single descriptive modifier. The descriptive modifier may be followed by words or abbreviations such as upper, lower, inner, outer, front, rear, RH, LH, etc. when they are essential. In referring to the rear, the front or to either side of the unit, always consider the drawbar end of the unit as the front. Standing at the rear of the unit facing the drawbar (front) will determine the right and left sides.

FASTENERS

Both SAE!inch and I SO/metric hardware have been used in the design and assembly of these units. In the disassembly and reassembly of parts, extreme care must be taken to avoid damaging threads by the use of wrong fasteners. In order to clarify the proper usage and for exact replacement parts, all standard fasteners have been identified by part number, size and description. This will enable a customer to obtain fasteners locally rather than ordering from the factory. These parts are identified in tables that will be found at the rear of the parts illustrations. 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.

MARKINGS AND DECALS

NOTICE Do not paint over safety warnings or In-structional decals. If safety warning decals become Illegible, immediately order re-placements from the factory.

Part numbers for original individual decals and their mounting locations are shown within Parts List Section. These are available as long as a particular model is in production.

Afterwards, service sets of exterior decals and current production safety warning decals are available. Contact the Product Support Group at Mocksville for your particular needs and availability.

HOW TO USE PARTS LIST

a. Turn to Parts List Section.

b. locate the area or system of the compressor in which the desired part is used and find illustration page number.

c. Locate the desired part on the illustration by visual identification and make note of part number and description.

HOW TO ORDER

The satisfactory ordering of parts by a purchaser is greatly dependent upon the proper use of all available information. By supplying your nearest sales office, autonomous company or authorized distributor, with complete information, you will enable them to fill your order correctly and to avoid any unnecessary delays.

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. Always specify the model number of the unit as shown on the general data decal attached to the unit.

b. Always specify the serial number of the unit. THIS IS IMPORTANT. The serial number of the unit will be found stamped on a plate attached to the unit. (The serial number on the unit is also permanently stamped in the metal of the frame side rail.) c. Always specify the number of the parts list publication.

d. Always specify the quantity of parts required.

e. Always specify the part number, as well as the description of the part, or parts, exactly as it is given on the parts list illustration.

In the event parts are being returned to your nearest sales office, autonomous company or authorized distributor, for inspection or repair, it is important to include the serial number of the unit from which the parts were removed.

Book 35389816 (4/95) (38)

TERMS AND CONDITIONS ON PARTS ORDERS

Acceptance: Acceptance of an offer is expressly limited to the exact terms contained herein. If purchaser's order form is used for acceptance of an offer, 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. No additional or contrary terms will be binding upon the Company unless expressly agreed to in writing. Taxes: Any tax or other governmental charge now or hereafter levied upon the production, sale, 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. Shipping dates shall be extended for delays due to acts of God, acts of Purchaser, acts of Government, fires, floods, strikes, riot, war, embargo, transportation shortages, delay or default on the part of the Company's vendors, or any other cause beyond the Company's reasonable control. Should Purchaser request special shipping instruction, such as exclusive use of shipping facilities, including air freight when common carrier has been quoted and before change order to purchase order can be received by the Company, the additional charges will be honored by the Purchaser.

Warranty: The Company warrants that parts manufactured by it will be as specified and will be free from defects in materials and workmanship. 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, but in no event later than three (3) months from the date of shipment of such part by the Company. The only exception to the previous statement is the extended warranty as it applies to the special airend exchange program. Repairs and replacements shall be made by the Company F.O.B. point of shipment. The Company shall not be responsible for costs of transportation, removal or installation.

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.

Delivery: Shipping dates are approximate. The Company will use best efforts to ship by the dates specified; however, 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.

35389816

Operation Manual FM 1011F DEUTZ SERVICE

A KHD

DEU"'"Z

e Please read and observe the information given in this Operation Manual. This will enable you to avoid accidents, preserve the manufacturer's warranty and maintain the engine in peak operating condition.

0 This engine has been built exclusively for the application specified in the scope of supply-as described by the equipment manufacturer-and is to be used only for the intended purpose. Any use exceeding that scope is considered to be contrary to the intended purpose. The manufacturer will not assume responsibility for any damage resulting therefrom. The risks involved are to be borne solely by the user.

o Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for operation, maintenance and servicing. The engine should only be operated by personnel trained in its use and the hazards involved.

e The relevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be observed.

o Unauthorized engine modifications will invalidate any liability claims against the manu- facturer for resultant damage. Manipulations of the injection and regulating system may also influence the pertormance of the engine, and its emissions. Adherence to legislation on pollution cannot be guaranteed under such conditions.

Operation Manual FM 1011 F

Engine Serial Number I I I I I I I I 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. Conse-quently, 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 Oper-ation Manual are necessarily mounted to your engine. We have endeavored to highlight any differ-ences so that you will be able to locate the operating and maintenance instructions rele-vant 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 General 3.5.1 Winter Operation 6.5.3 Changing Alternator Belts D 3.5 Operating Conditions 6.5.4 Checking Toothed Belts 2 Engine Description 3.5.2 High Ambient Temperature, 6.6 Adjustments 2.1 Model 6.6.1 Checking I Adjusting Valve Clearances 2.1.1 Rating Plate 4 Operating Media 6.6.1.1 Valve Clearance 2.1.2 Rating Plate Location 4.1 Lube Oil 6.7 Accessories 2.1.3 Engine Serial Number 4.1.1 Quality Grade 6.7.1 Battery 2.1.4 Cylinder Numbering 4.1.2 Viscosity 6.7.1.1 Checking Battery and Cable Connectors D 2.1.5 Fuel Delivery Lock 4.2 Fuel Operating Media 6.7.1.2 Checking Electrolyle Level 2.2 Engine Illustrations 4.2.1 Quality Grade 6.7.1.3 Checking Specific Gravity of Electrolyle 2.2.1 Service side 4.2.2 Winter-Grade Fuel 6.7.2 Three-Phase Alternator 2.2.2 Service side 6.7.3 Lifting Tackle 2.3 Lube Oil Circuit 5 Routine Maintenance 6.7.4 Ether Starting System 2.3.1 Lube Oil Circuit Schematic 5.1 Maintenance Schedule 6.7.4.1 Changing the Fluid Container 2.4 Fuel System 5.2 Maintenance Chart 2.4.1 Fuel System Schematic 7 Troubleshooting D 6 Service and Maintenance 7.1 Diagnosis Chart 3 Engine Operation 6.1 Lubrication System 3.1 Commissioning 6.1.1 Oil Change Intervals 8 Engine Preservation 3.1.1 Adding Engine Oil 6.1.2 Changing Engine Oil 8.1 Preservation 3.1.2 Initial Engine Oil Fill-Up for 6.1.3 Changing Oil filter 8.1.1 Preserving Engine

BF4M 1011 Series 6.2 Fuel System 8.1.2 Removing Engine Preservations 3.1.3 Filling Oil Bath Air Cleaner 6.2.1 Changing Fuel Filter D 3.1.4 Adding Fuel 6.2.2 Fuel Pump 9 Technical Specifications 3.1.5 Other Preparations 6.3 Cooling System 9.1 Engine Specifications and Settings 3.1.6 Additional Maintenance Work 6.3.1 Cleaning Intervals 9.2 Torque Wrench Settings 3.2 Starting 6.4 Combustion Air Cleaner 9.3 Tools 3.2.1 Electric Starting 6.4.1 Cleaning Intervals 3.3 Monitoring Systems 6.4.2 Emptying Cyclone Type Precleaner 10 Deutz 3.3.1 Engine Oil Pressure 6.4.3 Cleaning Oil Bath Air Cleaner 3.3.2 Coolant Temperature 6.4.4 Dry Type Air Cleaner 3.4 Stopping 6.5 Belt Drives 3.4.1 Mechanical Shutdown 6.5.1 Checking V-Belts 3.4.2 Electrical Shutdown (Ignition Key) 6.5.2 Tensioning Alternator Belts

n

D

DEUTZ Diesel Engines

are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and lowfuelconsumption. It goes without saying that the highest standards for environmental protection are met.

Beware of Running Engine

Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started accidents may otherwise occur -. When the work is complete, be sure to refit any panels and guards that may have been removed. Never fHI the fuel tank while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.

Service and Maintenance

Sound service and maintenance practices will ensure thattheengine continues to meet your requirements. Recommended service intervals must be observed and service and maintenance work carried out conscientiously. Special care should be taken under abnormally demanding operating conditions.

Safety

& All safety instructions in this Manual are designated by the accompanying symbol. Please follow them carefully. The attention of operating personnel should be drawn to these safety

instructions. General safety and accident prevention regulations laid down by Jaw must also be observed.

General

DEUTZ SERVICE INTERNATIONAL GmbH

Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Our trained specialists will carry out repairs quickly and professionally, using only genuine spare parts. Genuine spare parts from DEUTZ SERVICE INTERNATIONAL GmbH are always manufactured to the highest technical standards. A table of DEUTZ SERVICE INTERNATIONAL GmbH contact numbers is given at the end of this Operation Manual.

Asbestos

[)

The seals and gaskets used in this engine are asbestos~free. When carrying out maintenance and repair work, please use appropriate spare parts.

D

2.1 Model 2.2 Engine Illustrations 2.3 Lube Oil Circuit Schematic 2.4 Fuel System Schematic

Engine Description

f)

Engine Description

2.1.1 Rating Plate

26 332 0

The model A, the engine serial number B and the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering spare parts.

2.1.4 Cylinder Numbering

Cylinders are numbered consecutively, beginning at the flywheel end.

2.1.2 Rating Plate Location

The rating plate C is attached to the ventilation hood.

2.1.5 Fuel Delivery Lock

The manufacturer shall not be held liable for damages resulting from adjustments made to the regulator by the operator. The lock screws are protected ln order to prevent this: 1. with locking paint on model:

torque balancer. 2. with plastic protective cap on model:

without torque balancer

Adjustments to the regulator are to be carried out only by authorized DEUTZ SERVICE specialists.

2.1 Model

2.1.3 Engine Serial Number

The engine serial number D is stamped on the crankcase as well as the rating plate.

2.2 Engine Illustrations Engine Description

2.2.1 Service side

13

6

Engine Description

2.3.1 Lube Oil Circuit Schematic

9 15 8 11

D

14 17 18 16 2 3 4 26 430 0

2.4.1 Fuel System Schematic

4 3 2 5 26 437 0

2.3 Lube Oil Circuit

1 Oil sump 2 Intake manifold 3 Oil pump 4 Main oil duct 5 Oil-cooled cylinder 6 Cylinder head cooling neck 7 Oil duct for rocker arm lubrication 8 Rocker arm 9 Oil manifold for the thermostat

10 Intake to external engine oil cooler 11 Return from external engine oil cooler 12 Thermostat housing with slide thermostat 13 Oil duct to oil filter 14 Oilfilter 15 Oil ductto the cam, con-rod and crank shaft

bearing 16 Injection jet for cooling the pistons 17 Oil return via crankcase to the oil sump

2.4 Fuel System

3.1 Commissioning 3.2 Starting 3.3 Monitoring Systems 3.4 Stopping 3.5 Operating Conditions

Engine Operation

Engine Operation

3.1.1 Adding Engine Oil

As a rule, engines are delivered empty of oil. Pour lube oil into the oil filler neck (arrow). For oil quantities, see 9.1 For oil grade and viscosity, see 4.1

3.1.3 Filling Oil Bath Air Cleaner

II I ~ ~

I 24 980 2 Fill oil cup 1 ofthe oil bath air cleaner with oil up to the arrow. For oil grade and viscosity, see 4.1.

A Do not fill the precleaner dust ~collector (if fitted) with oil.

3.1.2 Initial Engine Oil FiiiUp

Fill in the engine oil in two phases as follows:

Phase 1 o Fill the oil sump with initial quantity of oil. o Start the engine and le4ve it to run for approx.

one minute. e Switch off the engine and wait for approx. two

minutes.

Phase 2 0 Fill in oil up to the ,max" marking on the engine

dipstick.

3.1.4 Adding Fuel

FUEL 80 543 0

Use only commercial-grade diesel fuel. For fuel grade, see 4.2. Use summer or winter~grade fuel, depending on the ambient temperature.

Never fill the fuel tank while the engine is running. Keep the filler cap area clean and do not spill fuel.

3.1 Commissioning

3.1 Commissioning

3.1.5 Other Preparations

Gl Check battery and cableconnections, see 6. 7.1

Gl Transport hooks Remove if fitted (see 6.7.3).

e Trial run After the engine has been prepared, let it run for about 10 minutes without load.

During and after trial run - Check the engine for leaks After the engine has been turned off - Check the oil level,

see 6.1.2 If necessary, top up oil, see 3.1.1/2 Retension V-belts, see 6.5

e Breaking in During the break-in phase about 200 operating hours check the oil level twice a day. After the engine is broken in, checking once a day will be sufficient.

3.1.6 Additional Maintenance Work

The following maintenance should be carried out after 50 operating hours:

e Check the V-belts and retension as necessary

Gl Change lube oil, see 6.1.2

e Check valve clearance and adjust as necessary, see 6.6.1

e Check theengine for leaks

Gl Check the engine mount and adjust as necessary, see 9.2

Engine Operation

D

D

Engine Operation

3.2.1 Electric Starting

A Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine. After repair work: Check that all guards have been

replaced and that all tools have been removed from theengine. When starting with glow plugs, do not use any other starter substance (e.g. injection with start pilot). Doing so could result in an accident.

Do not actuate the starter for more than 20 seconds. If the engine does not catch, wait a minute then try again. If the engine does not catch after two attempts, refer to the Diagnosis Chart (see 7.1).

with ColdStart Aid - Glow Plugs

e Insert key.

25 746 2

- Position 0 = no operating voltage. e Turn key clockwise.

- Position 1 =operating voltage. - Pilot lights come on.

e Push key in and turn further clockwise against spring pressure. - Position 2 = Preheat, hold for approx.

1 minute. Preheat lamp comes on.

- Position 3 = start. 0 Release key as soon as engine fires.

- Pilot lights go out.

0 Where possible, disengage the clutch to separate the engine from any driven parts.

8 Move speed control lever 1 into idle position. e Move cutout handle 2 into operating position.

with ColdStart Aid - Ether Starting System

25 746 2

411 Insert key. - Position 0 = no operating voltage.

Turn key clockwise. - Position 1 =operating voltage. - Pilot lights come on.

e Push key in and turn further clockwise against spring pressure. - Position 2 = no function. - Position 3 = start.

e Release key as soon as engine fires. Pilot lights go out.

3.2 Starting

Starting without Cold-Start Aid

25 746 2

Insert key. - Position 0 = no operating voltage.

e Turn key clockwise. - Position 1 =operating voltage. - Pilot lights come on.

e Push the key in and turn it further clockwise against spring pressure. - Position 2 =no function - Position 3 = start

e Release key as soon as engine fires. - Pilot lights go out.

25 963 0

o Starting fluid is injected automatically in switch position A, as tong as the starter is operated.

e To assist acceleration at lowertemperatures and to avoid white fumes, briefly hold the arctic switch in switch position H.

The switch must not be moved to position H when the engine is switched off and the ignition is switched on.

3.3 Monitoring Systems

3.3.1 Engine Oil Pressure Oil Pressure Pilot Light

25 i52 1

0 The oil pressure pilot light comes on with operating voltage on and engine off.

e The oil pressure pilot light should go out when the engine is running.

3.3.2 Coolant Temperature Gauge Pointer

24 985 0

e The coolant temperature gauge pointer should remain in the green sector most of the time. It should rarely enter the yellow-green sector. If the pointer enters the orange sector, the engine is overheating. Turn it off and establish the cause from the Diagnosis Chart (see 7.1 ).

Oil Pressure Indicator

e The pointer must remain in the green sector over the entire operating range.

Engine Operation

Oil Pressure Gauge

25 754 0

e The pointer must indicate the minimum oil pressure (see 9.1).

D

D

Engine Operation

3.4.1 Mechanical Shutdown

e Move speed control lever 1 to low idle.

e Operate shutdown lever 2 untilthe engine comes to a stop. The charge pilot light and the oil pressure pilot light will come on when the engine stops.

41 Turn key counterclockwise (to Position 0) and remove. The pilot lights will go out.

3.5.1 Winter Operation

e Lube Oil Viscosity - Selectthe oil viscosity (SAE grade) according

to the ambient temperature when the engine is started, see 4.1.2.

- Increase oil changetrequencywhen operating below -10 c, see 6.1.1.

e 0/esel Fuel - Use winter-grade diesel fuel for operation

below 0 c, see 4.2.2

0 Additional Maintenance Work - Orain the sludge from the fuel tank once a

week. - Adjustthe oil level in the oit bath airc/eaner(if

fitted) to suit the ambient temperature. CD Cold-Start Aids

- At temperatures near or below freezing point, use glow plugs it necessary, see 3.2. t. This not only lowers the starting limit temperature, but provides easier starting at tern peratures normally not requiring a starting aid.

3.4.2 Electrical Shutdown (Ignition Key)

25 746 2

e Turn key counterclockwise (to Position 0) and remove. The pilot lights will go out.

e Battery - Efficient cold starting requires a healthy

battery, see 6.7.1. - The starting limittemperaturecan be lowered

by 4-5 c by heating the battery up to about +20 c. (To do so, remove the battery and store in a warm place).

3.4 Stopping

3.5 Operating Conditions

* l

3.5 Operating Conditions

3.5.2 High Ambient Temperature, High Altitude

Ill As the altitude and ambienttemperature rise, the density of the airtends to decrease, which affects the maximum power output of the engine, the exhaust gas quality and, in extreme cases, the starting behavior. Under transient conditions, the engine can be used at altitudes up to 1000 meters and temperatures up to 30'C. If the engine is to operate under more severe conditions (at higher altitudes or temperatures), it will be necessary to reduce the injected fuel quantity and thus, engine power.

Ill If you have any doubts about engine operation underthese or similar conditions, askyou r engine or equipment supplier whether the engine has been derated in the interests of reliability, service life and exhaust gas quality (smoke). Otherwise contact DEUTZ SERVICE.

Engine Operation

D

4.1 Lube Oil 4.2 Fuel

Operating Media

0

D

Operating Media

4.1.1 Quality Grade

lube oils are differentiated according to their performance and quality class. In common use are specifications named after the API (American Petroleum Institute) and CCMC (Committee of Common Market Automobile Constructors). Aooroved API Oils:

Naturally aspirated engines: CCISE CCISF

Aonroved CCMC Oils:

Naturally aspirated engines: 04

Oil change intervals, see 6.1.1 Oil capacities. see 9.1

4.2.1 Quality Grade

Use commercially available diesel fuel with less than 0.5% sulfur content. If the sulfur content is higher than 0.5%, oil change intervals should be reduced, see 6.1.1.

The following fuel specifications I standards are approved:

41 DIN 51 601 (Feb. 1986) 41 BS 2869: A 1 and A2

(With A2, take note of the sulfur content) 41 ASTM 0 97588; 1-0 and 2-D

It CEN EN 590 or DIN EN 590

C1 NATO Code F-54 and F-75

4.1.2 Viscosity

As the viscosity of the lube oil is dependent on temperature, the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site.