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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
I'

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.

Indicates the presence of a hazard which WILL cause


injury, death or property damage, if ignored.

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

(Orange Background)

Indicates the presence of a hazard which WILL or


can cause injury or property damage, if ignored.

(Yellow Background)
Indicates important set-up, operating_ or maintenance
information.

(Blue Background)

Book 35389816 (4/95)

(4)

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 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.

!wARNING

A battery contains sulfuric acid and can give off


gases which are corrosive and potentially explosive. Avoid contact with skin, eyes and
clothing. In case of contact, flush area Immediately with water.

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)

IWARNING I

IWARNING 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.

Never Inspect or service unit without first


disconnecting battery cable(s) to prevent
accidental starting.

I
Disconnected Air Hoses Whip.
Can cause severe Injury or death.

High pressure air.


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

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
unit
with
protection
while
cleaning
compressed air to prevent debris from Injuring
eye(s).

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)

Collapsing jack stand.


Will cause severe
Insert locking
pin completely.

Hot pressurized fluid.


Can cause severe burns.
Do not open radiator while hot.
Rotating fan blade.
Can cause severe Injury.
Do not operate without guard In

I CAUTION~

IWARNING I

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)

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.

2.

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

Removal of any of the following:


a.

3.

fan shroud

b.

vibration mounts

c.

sound absorption material

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

PRECAUTION

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

A void ingestion,
A void ingestion,
A void ingestion,
A void ingestion,
A void ingestion,
A void ingestion,

skin contact and breathing fumes.


skin contact and breathing fumes.
skin contact and breathing fumes.
skin contact and breathing fumes.
skin contact and breathing fumes.
skin contact and breathing fumes.

The following substances may be produced during the operation of this machine
and may be hazardous to health.
SUBSTANCE

PRECAUTION

Engine Exhaust Fumes


Engine Exhaust Fumes
Brake Lining Dust

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

Book 35389816 (4/95)

(9)

OJ

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INGERSOll-RAND

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PORTABLE COMPRESSOR
SAFETY CARD

AIR COMPRESSORS

L1ii. DANGER

DANGER IS USED TO INDICATE THE


PRESENCE OF A HA2ARO WHICH WILL
CAUSE SEVERE INJURY OR DEATH IFrne
WARNING IS IGNORED.

&WARNING

WARNING IS USED TO INDICATE THE


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

&CAUTION

contaminants.
CAUTION IS USED TO INDICATE THE
Will cause severe Injury or death.
PRESENCE OF A HAZARD WHICH WILL OR
CAN CAUSE MINOR INJURY OR PROPERTY Do not breathe this air.
DAMAGE IF THE WARNING IS IGNORED.
This docal near seNic.o

..

&. WARNING

&. WARNING

Discharge Air can contain carbon monoxide or

&. WARNING

&. WARNING

Improper operation of this


equipment
Can cause severe InJury or
death.

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

Read Operator's Manual


supplied with this machine
before operation or service.

Do not alter or modify this


machine without the express
written consent of the
manufacturer.
This decal rlNtr control pancf.

&. WARNING

&. WARNING

,~;''

f ~2.w.~'

-8-

Disconnected air hoses whip.


Can cause severe InJury or death.

High pressure air.


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

Close service valve and operate


Relieve pressure before
1926.302(b).
tool to vent trapped air before
removing filler plugs/caps,
performing any service.
This decaf near receiver tank.
rn1s dflCdl no:Jr sofllicc valve.
This decaf near SoflliCC outlet.

&. 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.)

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

Rotating fan blade.

Can cause severe InJury.

Keep sparks and open flame


away from batteries.

Do not operate without


guard in place.

Tflfs doctJI near battery.

This decal near Jan.

&. WARNING

...

~
('</]~

Hot pressurized fluid.


Can cause severe bums.

'

This decal on drawbar.

Do not open radiator while

hot.

~
~

~.:-~,~="

Trapped air pressure.


can cause severe injury or death.

'

([c
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.

,,\

~,

;',7

l!!g'];A
~

This dacal naar radiator cap.

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 1000 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 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. 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, corrosion, erosion and normal wear and tear, alterations or modification made to the product without
express written consent of Ingersoll-Rand; or failure to follow the recommended operating practices
and maintenance publications.
Accessories or equipment furnished by lngersolfRand, but manufactured by others, including, but
not limited to, engines, tires, batteries, engine electrical 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

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.

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.

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.

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

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.

Book 35389816 {4/95)

(12)

General Warranty Information

(20--50 KW)

hrs.

1 yr/2000 hrs (parts &


hrs

(2.5-6 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)

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
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 - - - - - - - - - - - - - - - - - -

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

Coal Mining

:;

Other Mining

(Highway, excavation, etc.)


CJ

Construction-Light
(carpentry, plumbing, pools,
mason, etc.)

CJ

Government
(municipal, state,
county, etc.)

Quarry

:1 Shallow Oil & Gas

Rental
(rental center,
rentallleet, etc.)

Building Contractor

Waterwell

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

Industrial
(plant use)

C Other
specily - - - - - - - - -

Exploration

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. 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

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SECTION 4 - OPERATION
BEFORE TOWING

IwARNING

- Ensure that tires are inflated to 32 psi (220kPa).

Failure to follow these Instructions could result


In very serious personal Injury or death.

I CAUTION~

- Do not tow this unit in excess of 50 mph (80


km/hr).
- Use a tow vehicle whose towing capacity is
greater than the gross weight of this unit.

DISCONNECT

- Position the tow vehicle to align its hitch with the


pintle eye or coupler of the compressor.

-Set the vehicle parl<ing brake. Chock wheels of


unit.

- Engage the parl<ing brake and chock the wheels


of the tow vehicle.

-Standing to the side, remove pin from tube of jack.


As jack tube swings down, FULLY insert pin in the
tube.

-Stand to the side and ensure pin is FULLY inserted


(secure) in tube of jack. Crank jack to seat pintle eye
or coupler onto hitch. Latch and lock hitch. Cross
safety chain(s) under drawbar. Attach to vehicle.
-Crank jack to raise pad off the ground, etc. Pull pin
from tube of jack. Fold jack handle down and
forward. Swing up jack tube and FULLY insert pin
in tube.

SETTING - UP (ALL UNITS)


Place the unit in an open, well-ventilated area.
Position as level as possible. The design of these
units permits a 15 degree sidewise limit on
out--<>f-level operation.
When the unit is to be operated out--<>f-level, it is
important: (1) to keep the engine crankcase oil level
near the high level mark (with the unit level), and (2)
to have the compressor oil level gauge show no
more than mid-scale (with the unit running at full
load). Do not overtill either the engine crankcase or
the compressor lubricating oil system.

-Disconnect safety chains. Crank jack to raise eye


or coupler from hitch. Tow vehicle can be moved.

UTILITY PACKAGE SET-UP


(no running gear)
The unit must be located on vehicle bed to allow
access for normal servicing and maintenance.
The air going into the inlet grille must be relatively
free of oil, dirt, soot and other debris. It must be no
more than 10 degrees F. (5 degrees C) over the
ambient temperature.

OIL COOLED ENGINE

I CAUTION~
Do not remove oil coolant hose or connections
while engine Is running.

TOWING

IwARNING I

IwARNING

Failure to follow these Instructions could result


In very serious personal Injury or death.
-Ensure that tires, wheels and running gear are in
good condition and secure.
Book 35389816 (4/95)

(15)

NO SMOKING, SPARKS or OPEN FLAME near


fuel.

Control Panel
D~al00@:111~G:J@.

Pr6Stige SeriBS.

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0 0 0

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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 248F (120C).
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.

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".

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.

2.

3.

DISCHARGE
PRESSURE

GAGE

PRESSURE REGULATOR

[)==t:(~=ro UNLOADER
CHECKVALVE ORIFICE

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.
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.

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.

7.

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

After Starting Unit


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.

5.

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)

"

6.

Close service valve(s).

4.

TO SEPARATOR TANK

(F).
8.

While still maintaining 100 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

B. Do The Simplest Things First

Trouble shooting for a portable air compressor


is an organized study of a particular problem or

Most troubles are simple and easily corrected.

For

series of problems and a planned method of

example, most complaints are "low capacity" which may

procedure for investigation and correction.

be caused by too low an engine speed or "compressor

The trouble

over- heats" which may be caused by low oil level.

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;


following this simple rule will save time and trouble.

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
The chart does give those
problems.

Note: For trouble shooting electrical problems, refer to


the Wiring Diagram Schematic.

c. Double Check Before Disassembly

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 potential cause or causes. The causes are

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.

listed in order (1 ,2,3 etc.) to suggest an


order to follow in trouble shooting.
D. Find And Correct Basic Cause

ACTION PLAN
A. Think Before Acting

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.

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, is it safe to


continue operating it to make further checks?

Book 35389816 (4/95)

(20)

TROUBLE SHOOTING CHART


Bold Headings depict the COMPLAINT- 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. 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

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. 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:

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)

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 {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
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.
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.

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

GENERAL

that they are not clogged.

In addition to periodic inspections, 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."

performance.

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. The primary function of preventive

1.

Loosen outer wing nut and remove with


cover. Remove Element.

2.

Inspect air cleaner housing for any condition


that might cause a leak and correct as
necessary.

3.

Wipe inside of air cleaner housing with a


clean, damp cloth to remove any dirt
accumulation, especially in the area where
the element seals against the housing.

4.

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.

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)

5.

If a new air filter element is to be used check


it closely for shipping damage.

6.

Install cleaned or new elements in the


reverse order to the above. Tighten wing nut
firmly.

GAUGES
The instruments or gauges are essential for safety,

7.

Inspect to ensure that the end cap seals


tightly 360 degrees around the air cleaner
body.

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.

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

FUEL TANK
CLEAN fuel in the fuel tanks is vitally important and
every precaution should be taken to ensure that

flow through the element.

only clean fuel is poured or pumped into the tank.

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.

When filling the fuel tank on this unit, by methods


other than a pump and hose, use a CLEAN
non-metallic funnel.

NOTE: To prevent damage to the element, never


exceed a maximum air pressure of 100 psi (700
kPa).

BATIERY
Keep the battery posts-to-cable connections

In the event the element is contaminated with dry

clean, tight and lightly coated with a grease. Also

dirt, oil or greasy dirt deposits, and a new element is

the electroly1e level in each cell should cover the top

not available, cleaning can be accomplished by

of the plates.

washing, using the air cleaner element manufactur-

distilled water.

er's recommendations.

If necessary, top-up with clean

TIRES

NOTE: It Is recommended that replacement efe


ments be Installed In the unit. The elements just
removed for cleaning can be washed and

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

stored as future replacement elements.

tightness.
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)

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,

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.

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-<:austic safety solvent

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

through the core of the oil cooler. This should

NOTICE

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

compound

in accordance with the

manufacturer's recommendations.

ENGINE OIL COOLER


The engine in this machine is oil cooled. The engine
oil cooler is located above the compressor oil cooler
and functions the same as the compressor oil
cooler.

HOSES
Each month it is recommended that all of the intake
lines to and from the air cleaners, the engine cooling
system hoses and all of the flexible hoses used for
air, oil, and fuel be inspected.
To ensure freedom from air leaks, all rubber hose
joints and the screw-type hose clamps must be
absolutely tight.
Regular inspection of these
connections for wear or deterioration is necessary.
Book 35389816 (4/95)

(26)

Piping systems operating at less than 150 psi


(1 050 kPa) may use a special nylon tubing. The
associated fittings are also of a special
"push-In" design. If so, features are as follows:
Pulling on the tubing will cause the inner sleeve to
withdraw and compress, thus tightening the
connection. The tubing can be withdrawn only while
holding the sleeve against the fitting. The tubing
can be removed and replaced numerous times
without losing its sealing ability.

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


grease pencil) approximately 7/8 inch from the end
of the tubing. Insert the tubing into the sleeve and
"push-in" past the first resistance to the bottom.
The mark should be approximately 1/16 inch from
the sleeve, for the 3/8 inchD.D. tubing; 1/8 inch for
the 0.25 inch O.D. tubing. This will ensure that the
tubing is fully engaged in the sealing mechanism.

NOTICE
The oil filter must be replaced every 500 hours
of operation or six (6) months, whichever
comes first. On new or overhauled units, replace the element after the first 50 and 150
hours of operation; thereafter, service the oil fll
ter every 500 hours.
To service the oil filters it will first be necessary to
shutthe unit down. Wipe off any external dirt and oil
from the exterior of the filter to minimize any
contamination from entering the lubrication system.
Proceed as follows:

I wARNING

NOTICE

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.

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.

Book 35389816 (4/95)

(27)

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

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.
While rotating hub slowly to seat the
bearings,

tighten

spindle

!wARNING

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.

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.

1.

RECEIVER-sEPARATOR SYSTEMS

nut

to

approximately 15 lbs.-ft. Grasp the tire at

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.

the top and bottom and rock, in and out.

2.

There should be no evidence of looseness


(free play) at the bearing.

Additional separation takes place in the


oil
separator element which is located in the top of the
tank.

Loosen nut to remove preload torque. 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.

not rotate hub.

3.

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)

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.

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).

Disconnect the hose from the scavenge tube.

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 from tank cover.

Remove scavenge tube.

Disconnect service line from cover.

Reposition cover (use care not to damage


gaskets).

Remove cover mounting screws.

Replace cover mounting screws: tighten in a


crisscross pat1ern.

Remove cover and element.


Remove any gasket material left on cover or tank.

Reconnect service line. Replace scavenge tube.


Reconnect hose.

Install new element.


Close service valve. Start unit and look for leaks.

NOTICE
Do not remove staples from the element/gasket
connection.

When replacing the element, the scavenge lines,


orifice, filter, and check valve should be thoroughly
cleaned and the oil changed.

TANK TOP--

'i

' l

SHOULD BE 1/B" TO 1/4"--1!,_


SHORTERTHAN
ELEMENT MEASUREMENT

L _____j--01---- SEPARATOR TANK

Book 35389816 (4/95)

c;l

**
u

J I
...,._SCAVENGE TUBE

- -

- - - cut line
If necessary

(29)

EXTERIOR FINISH CARE

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.

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, nonabrasive car wax may partially re
store the color and gloss.

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.

2.

Check oil level. Maintain as Indicated


earlier In this section.
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)

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.

Dally
COMPRESSOR OIL LEVEL

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

FAN ALTERNATOR BELTS

BATTERYCON

c
c

SIELECTROLVTE

'WHEEL LUG NUTS


HOSES (OIL,AIR,INTAKE,ETC.)
AUTOMATIC SHUTDOWN SYSTEM

TEST

AIR CLEANER SYSTEM


COMPRESSOR OIL COOLER
ENGINE RADIATOR/OIL COOLER

VISUAL
EXTERIOR
EXTERIOR

6MO.
3MO.
500 HRS 1000 HRS

12MO.
2000 HRS

DRAIN

AIR CLEANER PRECLEANER DUMPS

TIRE PRESSURE AND SURFACE

MO.

c
c
c
c
c

CLEAN

CLEAN

FASTENERS
AIR CLEANER ELEMENTS

c
WI
R

'FUEL/WATER SEPARATOR ELEMENT


COMPRESSOR OIL FILTER ELEMENT

COMPRESSOR OIL

c
c

'WHEELS (BEARINGS, SEALS, ETC.)


'ENGINE COOLANT

TEST

SHUTDOWN SWITCH SETTINGS

TEST

SCAVENGER ORIFICE & RELATED PARTS

CLEAN
R

OIL SEPARATOR ELEMENT


ENGINE (OIL CHANGES, FILTERS, ETC.)

REFER TO ENGINE OPERATORs MANUAL

*Disregard If not appropriate for this particular machine.


C=Check (and adjust or replace

If necessary). WI=OR when Indicated.

Unit _ _ _ _ __

Ingersoll-Rand
36509966

Date: _ _ _ __

Hours _ _ _ _ __

Book 35389816 (4/95)

R=Replace

Serviceman _ _ _ __

(31)

LUBRICATION

FLUIDS AND LUBRICANTS TABLE


ITEM

FLUID

Compressor
Models:

Lubrlcan

VHP-(200+
psi)
HP-(150 psi)
XP-(125 psi)
P-(100 pslj

AMBIENT TEMP.

(-23C to 52C)

Dexron or
Dexron II ATF
MIL-L-46152
SAE 10W, API CC

-40F to 125 F

-10F to 125F

(-40C to 52C)

XHP (300 psi)

-10F to 125F
(-23C to 52C)
-10Fto 100F
(-23C to 38C)
70F to 125F
(21 C to 52C)

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- 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

DEALER OR DISTRIBUTOR
FROM WHOM PURCHASED:

ENGINE MAKE & M O D E L : - - - - - - - - - - - SERIAL N O . : - - - - - - - - - - - - - - - PURCHASER OR O W N E R : - - - - - - - - - - ADDRESS: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

DATE P U R C H A S E D : - - - - - - - - - - - - - -

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

PERIOD

AREA

A.

COMPRESSED AIR LEAKS

AS DETECTED

B.

SAFETY AND CONTROL SYSTEMS

AS DETECTED

c.

ACOUSTIC MATERIALS

DAILY

D.

FASTENERS

100 HOURS

E.

ENCLOSURE PANELS

100 HOURS

F.

AIR INTAKE & ENGINE EXHAUST

100 HOURS

G.

COOLING SYSTEMS

250 HOURS

H.

ISOLATION MOUNTS

250 HOURS

I.

ENGINE OPERATION

SEE OPERATOR'S MANUAL

J.

FUELS & LUBRICANTS

SEE OPERATOR'S MANUAL

Book 35389816 {4/95)

(34)

A. COMPRESSED AIR LEAKS

F. AIR INTAKE AND ENGINE EXHAUST

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).

Engine and compressor air intake and engine exhaust


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

B. SAFETY AND CONTROL SYSTEMS

G. COOLING 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.

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.

C. ACOUSTIC MATERIALS

H. ISOLATION MOUNTS

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.

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.

D. FASTENERS

I. ENGINE OPERATION

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 missingreplaced immediately to prevent subsequent damage
and noise emission increase.

Inspect and maintain engine condition and operation


as recommended in the manuals supplied by the engine
manufacturer.

E. ENCLOSURE PANELS

J, FUELS AND LUBRICANTS

Enclosure panels should also be inspected at 100hour 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.

Use only the types and grades of fuels and lubricants


recommended in the Ingersoll-Rand Company and
Engine Manufacturer's Operator and Maintenance
Manuals.

Book 35389816 (4/95)

(35)

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)

SECTION 7

PARTS ORDERING

GENERAL

of parts used in the machine. Where no quantity is


specified the quantity is assumed to be one.

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.

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.

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 IngersollRand 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.

FASTENERS
Both SAE!inch and ISO/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

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)

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.

(37)

Do not paint over safety warnings or Instructional decals. If safety warning decals
become Illegible, immediately order replacements 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.

TERMS AND CONDITIONS ON PARTS ORDERS


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.

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.

Book 35389816 (4/95)

(38)

35389816

Operation Manual
FM 1011F

DEUTZ SERVICE

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 supplyas described by the equipment manufacturerand 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

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

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,

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

Routine Maintenance

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

Troubleshooting

7.1

Diagnosis Chart

Engine Preservation

Technical Specifications

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

n
D

General
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

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.
Special care should be taken under abnormally
demanding operating conditions.

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.

Safety

Asbestos

thattheengine continues to meet your requirements.

&

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.

The seals and gaskets used in this engine


are asbestos~free. When carrying out
maintenance and repair work, please
[ ) use appropriate spare parts.

Engine Description

2.1
2.2
2.3
2.4

Model
Engine Illustrations
Lube Oil Circuit Schematic
Fuel System Schematic

Engine Description

2.1 Model
2.1.2 Rating Plate Location

2.1.3 Engine Serial Number

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.

The rating plate C is attached to the ventilation


hood.

The engine serial number D is stamped on the


crankcase as well as the rating plate.

2.1.4 Cylinder Numbering

2.1.5 Fuel Delivery Lock

2.1.1 Rating Plate

f)
26 332 0

Cylinders are numbered consecutively, beginning


at the flywheel end.

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.

Engine Description

2.2 Engine Illustrations


2.2.1 Service side

13

Engine Description

2.3 Lube Oil Circuit

2.3.1 Lube Oil Circuit Schematic

9 15

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

8 11

16
17

14 17 18 16

26 430 0

2.4 Fuel System

2.4.1 Fuel System Schematic

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

26 437 0

Engine Operation

3.1
3.2
3.3
3.4
3.5

Commissioning
Starting
Monitoring Systems
Stopping
Operating Conditions

Engine Operation

3.1 Commissioning

3.1.1 Adding Engine 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.

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

FUEL
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.

3.1.4 Adding Fuel

Do not fill the precleaner dust


(if fitted) with oil.

~collector

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.

Engine Operation

3.1 Commissioning
3.1.5 Other Preparations
Gl

Check battery and cableconnections, see 6. 7.1

Gl Transport hooks

The following maintenance should be carried out


after 50 operating hours:

Remove if fitted (see 6.7.3).

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

Gl Change lube oil,


see 6.1.2

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

3.1.6 Additional Maintenance Work

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.

Check the V-belts and retension as necessary

Check valve clearance and adjust as necessary,


see 6.6.1

Check theengine for leaks

Gl

Check the engine mount and adjust as


necessary,
see 9.2

Engine Operation

3.2 Starting

3.2.1 Electric Starting


Starting without Cold-Start Aid
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.

25 746 2

8
e

Where possible, disengage the clutch to


separate the engine from any driven parts.
Move speed control lever 1 into idle position.
Move cutout handle 2 into operating position.

e
e

Do not actuate the starter for more than 20 seconds.


If the engine does not catch, wait a minute then try

Insert key.
- Position 0 = no operating voltage.
Turn key clockwise.
- Position 1 =operating voltage.
- Pilot lights come on.
Push the key in and turn it further clockwise
against spring pressure.
- Position 2 =no function
- Position 3 = start
Release key as soon as engine fires.
- Pilot lights go out.

again.

If the engine does not catch after two attempts,


refer to the Diagnosis Chart (see 7.1).

with ColdStart Aid


- Glow Plugs

with ColdStart Aid


- Ether Starting System

25 746 2

25 746 2

Insert key.
- 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.

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.

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.

Engine Operation

3.3 Monitoring Systems


3.3.1 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.
e The oil pressure pilot light should go out when
the engine is running.

3.3.2 Coolant Temperature


Gauge Pointer

24 985 0

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 Gauge

25 754 0

e The pointer must remain in the green sector over

the entire operating range.

e The pointer must indicate the minimum oil


pressure (see 9.1).

Engine Operation
3.4.1 Mechanical Shutdown

3.4 Stopping
3.4.2 Electrical Shutdown
(Ignition Key)

25 746 2

e Move speed control lever 1 to low idle.


e Operate shutdown lever 2 untilthe engine comes

Turn key counterclockwise (to Position 0) and


remove. The pilot lights will go out.

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 Operating Conditions


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 astarting
aid.

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 awarm place).

3.5 Operating Conditions

Engine Operation

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 rengine
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.

Operating Media

4.1 Lube Oil


4.2 Fuel

Operating Media

4.1 Lube Oil

4.1.1 Quality Grade

4.1.2 Viscosity

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).

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. Optimum operating
behavior will be attained if you take the
accompanying oil viscosity diagram as a guide.
Should the temperature fall temporarily below the
limits of the SAE grade selected, cold starting may
be affected but the engine will not be damaged.
In order to keep wear to a minimum, do not exceed
application limits for extended periods of time.
Oil changes dictated by the seasons can be avoided
by using multi-grade lube oils. Multi-grade oilsparticularly light-flowing oils - also reduce fuel
consumption.

Aooroved API Oils:


Naturally aspirated engines:

CCISE

CCISF

Aonroved CCMC Oils:


Naturally aspirated engines:

86

30

77
68

-t20

-1-~

59
50

.to

.o

32

04

23
14

Oil change intervals, see 6.1.1


Oil capacities. see 9.1

10

Ii

I _t
~

~ ~

~~

,.
0

-4

-20

~
'5

1~

-22

.,

.0

-30

~~"'.

-31
40-

.t

-40

4.2 Fuel
4.2.1 Quality Grade

4.2.2 Winter-Grade Fuel

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.

Waxing may occur at low temperatures, clogging


the fuel system and reducing engine efficiency. If
the ambient temperature is less than 0 C, winter
grade fuel (suitable down to -15 'C) should be used.
(This fuel is usually available from filling stations
well in advance of the cold months). Diesel fuel
containing additives (Super diesel) is often on sale
as well, for use down to 20 oc.

The following fuel specifications I standards are


approved:
41 DIN 51 601 (Feb. 1986)
41 BS 2869: A1 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

32

23

- 5

14

-10

-15

- 4

8 Attemperatures below -15 'C to -20 'G, kerosene


should be added to the diesel fuel. The relevant
percentages are given in the adjacent diagram.

If summer-grade diesel fuel must be used at


temperatures below 0 C, up to 60% kerosene can
be added (see diagram).

SUm~er diesel fuel

r-....
.........

I
""'- ........

"'"r-.... 'k
i'-

.........

Winter diesel fuel

-20,_

- 13

-25

-22

-301

.,t

to
c

10

20

L_____,j__ ....,.~~

30

40

"'"

~ r-..,.

Suoer diesel fuel ..

50

-'"90 ol k.,_,.

60%

-----+-

In most cases, adequate resistance to cold can be


obtained by adding a flow improver (additive).
Inquire at the nearest service representative.

Mix in tank only. Fill with the


appropriate amount of kerosene
first, then add the diesel fuel

Routine Maintenance

5.1 Maintenance Schedule


5.2 Maintenance Chart
5.3 Maintenance Record

Routine Maintenance

100H

chack

Operating Hours (OH')


every

once

"'~

5.1 Maintenance Schedule

clean

after

50 21

or daily

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 APICO or CCMC~D4 + 05

Oil level in engine/separate container

see
Section

change

Engine leaks
Oil bath- 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

6.1.2
6.4
6.7.1
6.3.1
6.1.1
6.1.3
6.2.1
6.6.1
9.2
6.5
6.5.4
6.2.2

5) change if required
6) for oil change intervals. see 6.1.1
7) change every 5 years or 4500 OH with sprocket

5.2 Maintenance Chart


The maintenance chart shown here is supplied as a
self-adhesive label with each engine. ft should be
affixed where it can be seen clearly on the engine or
driven equipment.
Check that this is the case.

If necessary, ask your engine or equipment supp lie r


for a fresh supply of labels.
Routine work should be carried out according to the
schedule in 5.1.

1011
0297 49n IQJ

Stop the engine before carrying


out any maintenance work.

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.

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.

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.

Date

Signature I Stamp

Service and Maintenance

6.1
6.2
6.3
6.4
6.5
6.6
6. 7

Lubrication System
Fuel System
Cooling System
Combustion Air Cleaner
Belt Drives
Adjustments
Accessories

Service and Maintenance

6.1 Lubrication System

6.1.1 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.


If the engine runs fewer hours during the year
than stated in the table, 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, e.g.:

at least once a year.

Road vehicles, tractors, industrial trucks, cranes,


construction machinery, ships, electrical units,
pumps, rail-run vehicles

II The table refers to the following conditions:

- For diesel fuel: sulfur content max. 0.5% by


weight.
- Continuous ambient temperatures down to
-10 'C (+14 'F).

Heavy-duty oil usage, e.g.:


Combine harvesters, emergency pumps, undergro
Wintequipment, sweeping machines, winter
operation equipment, emergency power generating
units.

II If the sulfur content is > 0.5 to 1% or the

oc

continuous ambient temperature below -10


(+14 'F), the intervals between oil changes should
be halved.

In the case of fuels containing more than 1%


sulfur, contact your service representative.

API classification

11 Lube oils having bolh aC- and an Sclassification (e.g. CD/SE) can be used. Oils with only a Cclassification
(e.g. CE) generally perform very well in diesel engines and are to be preferred.
21 05 grade oil with sulfate ash content> 1.8% by mass.
3J

SHPD lube oils can be used.


These are the equivalent of 05 grade.

Change the oil with the engine off but still warm
(lube oil temperature approx. 80'C).

6.1.2 Changing Engine Oil,


Checking Oil Level

OIL

?
II

II
I[

~~MAX

~<}-MIN

25729

26022 0

e Ensure that the engine or vehicle is on a level


surface.
CD Allow the engine to warm up
- Lube oil temperature approx. 80 G.

411 Turn the engine off.

e Place oil tray under the engine.


Unscrew drain plug.
e Drain oil.
e

411 Fit oil drain plug with new gasket and tighten
firmly (for torque, see 9.2).
411 Fill with lube oil
- For grade/viscosity, see 4.1
- For quantity, see 9.1.
0 Start engine and run at low idle for about 2
minutes.

Turn the engine off.


411 Check oil level.
- If necessary, top up with oil as far as the
upper bar.

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.

Service and Maintenance

6.1 Lubrication System


6.1.3 Changing Oil filter

258-80 0

e Undo the filter cartridge using acommercial tool


and spin off.
0 Catch any dripping oil.

e Clean any dirt from the filter carrier rim.

e Tighten the oil filter cartridge with another half

0 Lightly oil the rubber gasket of the new oil filter


cartridge.

0 Check oil level, see 6.1.2.

8 Screw in the nei'J cartridge finger tight against


the gasket.

turn.

o Check oil pressure, see 3.3.1.

e Check cartridge seal for leaks.

..&..

Beware of burns from hot oil.

6.2 Fuel System


6.2.1 Changing Fuel Filler

25882 0

o Close fuel stopcock.

e Clean any dirt from the filter carrier rim.

0 Undo fuel filter cartridge with commercial tool


and spin off.

o Apply light film of oil or diesel fuel to the rubber

o Catch any fuel.

8 Screw in the new cartridge finger tight against


the gasket.

Keep naked flames away when


working on the fuel system. Do

not smoke!

0 Tighten the oil filter cartridge with a final half-

turn.
gasket of the new fuel filter cartridge.

e Open fuel stopcock.


0 Check for leaks.

The fuel system does not need to be bled.

Service and Maintenance

6.2 Fuel System

6.2.2 Fuel Pump


Cleaning the Strainer

e Close the fuel shutoff valve.

Mount the tuel strainer cover 2.

e Loosen and unscrew the hexagonal nut 1.

e Tighten the hexagonal screw t.

e Remove the fuel strainer cover 2.

e Check for leaks.

e Clean the fuel strainer with diesel fuel.

Replace

if necessary.

e Place seals 3 in position.

&.

Keep naked flames away when


working on the fuel system. Do not
smoke!

6.3 Cooling System


6.3.1 Cleaning Intervals
e The amount of contamination in the cooling
system depends on the engine application.
e Spilled oil or fuel on the engine increases the risk
of contamination. Be especially careful if the
engine is used in dusty environments.

e Serious contamination can occur, for example;


- on construction sites where there is a high
level of airborne dust.
- in harvesting application where there are
high concentrations of chaff and chopped
straw in the vicinity of the machine.
e Because applications vary, cleaning intervals
have to be determined from case to case. The
cleaning intervals given in the table on the right
can be used as a guide.

Checking or Cleaning
Intervals
Guide Values
(running hours)

2000
1000
500
250
125

Engine Aplication

Ships, Generating sets in closed rooms, Pumps


Vehicles on paved roads
Tractors. Forklift trucks, Mobile gensets
Vehicles on construction sites and unpaved roads,
Construction machineriy, Compressors, Underground mine units
Farm equipment, Tractors doing harvesting work

Service and Maintenance

6.4 Combustion Air Cleaner


6.4.1 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. If a high level of dust is
anticipated, a cyclone-type prec/eaner can be
fitted to the air cleaner.
Ill Cleaning inteNals will have to be determined

from case to case.

If a dry type air cleaner is used, clean when


indicated by the service indicator or switch.

ct Air cleaner servicing is needed when:


- Service Indicator
the red signal 1 is fully visible when the
engine is off.
- Service Switch
the yellow pilot light comes on when the
engine is running.
After carrying out service work, reset the signal
by pressing the button on the service indicator.

6.4.2 Emptying Cyclone Type


Precleaner

6.4.3 Cleaning Oil Bath Air Cleaner

I~

!II_&

(5)

~
~870
e Undo wing nut 1 and remove cover 2.
Remove collector bow/3 from lower section 4
and empty. Clean leaves, strawandotherforeign

matter from lower section of prec!eaner.

Ill Repositioncollectorbowl3 onto lower section 4,


fasten cover 2 in place by tightening wing nut 1.

Neverfi!l collector bowl with oil. Replace collector


bowl if damaged.

e Turn engine offandwaitabout 10minutesforthe


oil to drain from filter housing 1.
e Release snap clips 2 and remove oil cup 3

together with filter element 4. If necessary prize


element out with ascrewdriver, taking care not to
damage the rubber gasket 5.
o Remove dirty oil and sludge. Clean oil cup.
e Clean filter element 4 in diesel fuel and allow to
drip-dry.

e Clean filter housing 1 if very dirty.


Ill Inspect and replace rubber gaskets 5 and 6 if
necessary.
Ill Fill oil cup with engine oil up to the mark (arrow)
(for viscosity, see 4.1.2).
Ill Refit oil cup and element to filter housing and
secure with snap clips.

Never clean airc!eanerwith gasoline.


Dispose of old oil in accordance with
environmental regulations.

Service and Maintenance


6.4.4 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 Clean discharge slot from time to time.
e Remove any caked dirt by pressing together the
upper section of the valve.

6.4 Combustion Air Cleaner

Filter Cartridge

e
e
e
e

Undo clip fasteners 1.


Take off hood 2 and remove cartridge 3.
Clean cartridge (replace at least once a year).
Clean cartridge 3:
Blow out from inside out with dry compressed
air (max. 5 bar), (or in difficult cases, tap out,
taking care notto damage the cartridge, or wash
according to manufacturer's instructions).
e Through regular removal and replacement, the
gaskets on the filter cartridge can become damaged. Check paper filter (light showing through)
and gaskets for damage. Replace if necessary.

8 After five cleaner services or after two years at


the latest, replace safety cartridge4 (neverclean).
To do so:
- Undo hex. nut 5 and remove cartridge 4.
- Install new cartridge, insert and tighten hex.

nut.

e Install cartridge 3, replace hood 2 and do up clip


fasteners 1.

Never clean filler cartridge with


gasoline or hot fluids.

6.5 Belt Drives

6.5.1 Checking VBelts

etnspect entire V-belt for damage.


e Replace damaged V-bells.
e After installing new belts, run engine for 15
minutes, then check belt tension.
e To checkthetension of the V-belt, use atension
gauge.
- Place indicator arm 1 into gauge.
- Position gauge on V-belt 2, midway between
the pulleys, with flange 3on bottom of gauge
against the edge of belt.
- Push slowly on the black pad 4 at right angles
to belt 2 until the spring is heard or felt to
trigger.

- Carefully remove the gauge without altering


the position of the indicator arm 1.
- 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). For settings, see 9.1
- If necessary, retension belt and measure again.

Check tension and change belts only


with the engine off. Refit belt guard,
if provided.

When newV-belts are fined, check the belt tension


after approx. 15 minutes running time.

Service Maintenance

6.5 Belt Drives


6.5.2 Tensioning Alternator Belts

6.5.3 Changing Alternator Belts

e Slacken off bolts 1,2 an 3.

e Slacken off bolts 1,2 and 3.

Adjust alternator 4 in direction of arrow by


turning boJt3 until correct belt tension is achieved.
e Retighten bolts 1, 2 and 3

e Adjust alternator 4 in direction of arrow by


turning bolt 3
e Remove and replace belt.
e Adjust alternator 4 against the direction of the
arrowbyturning bolt 3, until correct belt tension
is achieved.
e Retighten bolts 1,2 and 3.

Check, tension and change belts


only with the engine off. Refit belt
guard, if provided.

6.5.4 Checking Toothed Belts


Timing Belts

e Unscrew hex. bolts 2. Remove the cover.

Ill Check the face and back of the teeth along the
complete length of the toothed belt (see arrows).
Ill To facilitate this, rotate the engine through nvo
turns.
Ill If damaged, replace the toothed beiVsprocket
(see workshop manual).
e Replace the cover 1 with hex. bolts 2.

Service and Maintenance


6.6.1 Checking/Adjusting Valve
Clearances

Remove the cylinder head cover.


8 Position crankshaft as per schematic 6.6.1.1.
e Before adjusting valve clearance, allow engine to
cool down lor at least 30 minutes. The oil
temperature should be below 80 'C.
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).
For permissible valve clearance, see 9.1

6.6.1.1

e Adjust valve clearance il necessary:

- Release locknut 4.
- Use screwdriver 7 to turn setscrew 5 so that
the correct clearance is attained after locknut
4 has been tightened.
Check and adjust valve clearance on aU remaining
cylinders.
e Replace cylinder head cover (use new gasket il
needed).

Valve Clearance
Adjustment Schematic

Crankshaft Posilion 1:
Turn crankshaft until both valves in cylinder 1
overlap (exhaust valve about to close, inlet valve
about to open). Adjust clearance ol valves
marked in black on schematic. Mark respective
rocker arm with chalk to show that adjustment
has been done.

e Crankshaft Position 2:

Turn crankshaft one lull revolution (360').


Adjust clearance ol valves marked in black on
schematic.

[]l[[]l[i]l[[]]
'-

r-

6.6 Adjustments

Service and Maintenance

6.7 Accessories
6.7.1
6.7.1.1

Battery
Checking Battery and
Cable Connectors

6.7.1.2

Checking Electrolyte Level

6. 7.1.3

Checking Specific Gravity


of Electrolyte

25 895 0

o Keep battery clean and dry.


0 Undo dirty clamps.
0 Clean terminal posts (+and-) and clamps of the
battery, and grease with acid-free and acidresistant grease.
e When reassembling, ensure that clamps make
good contact. Do up clamp bolts finger tight.

0 Remove caps 1.
If testers 2are used, the electrolyte should come
up to their base.
0 lftestersare not used, theelectrolytelevel should
be 10-15 mm above the top of the plates.
o If necessary, top up with distilled water.
o Replace caps.

Specific Gravity
in kg/1

in' Be (Baumegrad)"

State of Charge

normal

tropics

normal

1,28

1,23

32

27

Fully'charged

1,20

1'12
1,08

24
16

16

Half charged, recharge

11

Discharged, recharge immediately

1,12

* Measurement of specific gravity in o Be is out of

date and rarely used today.

The gases emitted by the battery


are explosive. Keep sparks and
naked flames away from the
battery. Do not allow battery acid to come into
contact with skin or clothing. Wear protective
goggles. Do not rest tools on the battery.

tropics

e Measure the specific gravity of individual cells


with a commercial hydrometer.

The hydrometer reading (see table on following


page) indicates the state of charge.
During measurement, the temperature of the
electrolyte should preferably be 20 'C.

Service and Maintenance


6.7.2 ThreePhase Alternator

6. 7 Accessories

6.7.3 Lifting Tackle

Notes on the three-phase system:


between battery,
alternator and regulator while the engine is

e Never disconnect the cables


running.

e If, however, it is necessary to start and operate


the engine wrrhout the battery, disconnect the
regulator from the alternator before starting.
e Be sure not to confuse the battery terminals.
II Replace defective bulb of the charge pilot lamp
immediately.
e When washing the engine, cover up the alternator
and regulator.
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.
In case of electric welding, connect the ground
terminal on the welder directly to the piece being
welded.

o Always use properliftingtac~ewhen transporting


the engine.
e After transportation and before commissioning
of the engine:
Remove the attachment eyes 2.

Use only the correct lifting tackle.

6. 7.4
6. 7.4.1

Ether Starting System


Changing the Fluid Container

Before removing the container, clean the container


support and the top of the solenoid valve.
e Loosen the bracket 1.
Unscrew the fluid container.
e Empty or replace the depressurized fluid

container.

Place the container 1 on th8 solenoid valve 2 and


tighten by hand.
o When mounting, ensure that gasket 3 is seated
correctly.
o Pull in the bracket.
II Check for leaks.

Before commissioning, leave the


fluid container of the ether starting
system in position for 15 minutes.
Check for leaks. The starting fluid is
inflammable. Ensure that the container is not
damaged. Prevent foreign substances from entering
the container. The fluid container must not be
stored at temperatures above 50 C.

Troubleshooting

7.1 Diagnosis Chart

Troubleshooting

7.1 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. 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
I



le
I
;e

I.


'
.

'.

I
I
I

w
R

'

Cause

I Not declutched (where possible)

Below starting limit temperature


.
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, 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

,.

PIW

r+

Cooling system: PI R

I P~W

! PI A

Electrics

LOA= Manifold-pressure compensator

Fault

i Remedy

Engine fails or is difficult to start


I Engine starts but runs unevenly or stalls
Engine overheats. 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


..

.,.

w
R
A

Section

I Electrics
!

; Engine

E
p

PIW
I

'
!

p
p

I
'

Engine Preservation

8.1 Preservation

Engine Preservation

If the engine is to remain idle for an extended period


of time, it is necessary to take protective measures
to prevent rust formation. The preservative
measures described here will protect the engine for
up to 6 months. The procedure will have to be
reversed before the engine is recommissioned.
e Anticorrosion 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)

8.1 Preservation
8.1.1 Preserving Engine

8.1.2 Removing Engine


Preservatives

e Clean

engine (with cold cleansing agent if


preferred) using high pressure equipment.
8 Run engine until warm, then turn off.
e Drain engine oil, see 6.1.2, and fill with anticorrosion oil.
e If necessary, clean oil bath cleaner, see 6.4.3,
and fill with anti-corrosion oil.
e Drain fuel tank.
Make up a mixture of 90% diesel fuel and 10%
anti-corrosion oil, and refill fuel tank.
Run engine for about 10 minutes.
e Turn engine off.
Turn engine over manually several times to
preserve the cylinders and combustion chamber.
Remove V-belts and store in wrapped condition.
Spray grooves of V-belt pulleys with anticorrosion spray.
Gl Close off intake ports and exhaust ports.

Removeanti-corrosionagentfrom grooves in Vbelt pulleys.


e Install V-belts. Retension after brief operation if
necessary, see 6.5.
Remove covers from intake port and exhaust
port.
Set the engine in operation, see also section 5.1,
annotation 2.

Technical Specifications

9.1 Engine Specifications and Settings


9.2 Torque Wrench Settings
9.3 Tools

Technical Specifications

9.1 Engine Specifications and Settings

Model

FM 1011F

3
vertic! e. 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''

18.5
-

(kg approx. I
(kg approx.)
(kW)
(1/min]
(mm)
(bar)
("crank angle bTDC]

Lubrication
SAE oil
Oil temperature in the oil sump
Min. oil pressure in warm condition (130C)
and low idling speed
Oil change quantity with filter
Oil content of external cooling system
(Cooler and pipes)

91

112
2184

(e)

Weight incl. 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. in line

4-Siroke diese ld irect injectioncounter cl ockwise

112
291 2
18. 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-- inlet 0,3 o.1 I exhaust0,5' 01


210

,, bar

r--- inlet 0,3 1,,exhaust 0,5 '


210 bar
01

1)

1)

1-2-3

1-3-4-2

pressure tubrica.tion
20
20
130

pressure lu bricalion
20 w 20
130

(bar]
(ltr. approx.)

1,1
8

1,1
10,5" (see3.1)

(ltr. approx.)

2.6

4.2

("C)

"

01 -

1
'

Engine power, speed, start of delivery are stamped on engine rating plate (see also 2.1 ).
Approx. value can vary depending on oil sump or radiator design (external cooling system}.
The upper oil dipstick marking should always be taken as authoritative.
3l Only required for winter operation, see 3.5.1.
<J

9.2 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

Rocker arm setscrew

21

Air intake manrrold

8,5

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

Technical Specifications

9.3 Tools
Vbell Tension Gauge

TORX

1f=
26002 0

ATORXwrenchsetis used with engines in the 1011


series. This system was chosen because of the
many advantages it offers:

The Vbelt tension gauge can be obtained under


order number 91107 from:

e Outstanding accessibility to bolts.

PosHach 14 05 80
042826 Remscheid

High load transfer when loosening and tightening.


0 Almost impossible for socket to slide off or
break.
TORX tools can be ordered from:

FA.WILBAR
PosHach 14 05 80
042826 Remscheid

FA.WJLBAR

Notes

Service
DEUTZ SERVICE INTERNATIONAL GmbH
DeutzMiilheimer str.1 07

Postfach 80 05 09
051057 Kiiln
Germany
Austria
Switzerland
East Europe

North-,West-,Southeurope
North America
Asia
Australia

South America
Algeria
Africa
Greece, 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.
A "SERVICE REGISTER WORLD"
can be ordered under No. 0297 4709
A "list of Service Documentation WORLD"
can be ordered under No. 0297 5198
SERVICE Phone for technical questions: (0221)822 5454
Direct dial from 8.00 a.m. to 5.00 p.m.
At night, on weekends and holidays automatic phone answerer.
(We shall responds the next working day.)

All rights rese!Ved. Printed in U.SA.

PARTS LIST

9-0

PARTS LIST
CONTENTS
Frame & Running Gear, Sht 1
Frame & Running Gear, Sht 2
Running Gear Complete, Sht 1
Running Gear Complete, Sht 2
Tire & Wheel Assembly, Sht 1
Tire & Wheel Assembly, Sht 2
Jack Assembly, Sht 1
Jack Assembly, Sht 2
Engine Complete, Sht 1
Engine Complete, Sht 2
Liquid Cooling Complete, Sht 1
Liquid Cooling Complete, Sht 2
Airend Complete, Sht 1
Airend Complete, Sht 2
Airend Assembly, Sht 1
Airend Assembly, Sht 2
Air Intake Complete, Sht 2
Air Intake Complete, Sht 1
Air Service Complete, Sht 1
Air Service Complete, Sht2
Seperator Tank Complete, Sht 1
Separator Tank Complete, Sht 2
Air Cleaner Assembly, Sht 1
Air Cleaner Assembly, Sht 2
Fuel Tank Complete, Sht 1
Fuel Tank Complete, Sht 2
Battery and Mounting, Sht 1
Battery and Mounting, Sht 2
Air and Oil Piping, Sht 1
Air and Oil Piping, Sht 2
Air and Oil Piping, Sht 3
Air and Oil Piping, Sht 4
Wiring Diagram, Sht 1
Wiring Diagram, Sht 2
lnst/Control Panel, Sht 1
lnst/Control Panel, Sht 2
Enclosure Complete, Sht 1
Enclosure Complete, Sht 2
Enclosure Complete, Sht 3
Enclosure Complete, Sht 4
Acoustic Panels, Sht 1
Acoustic Panels, 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

PARTS LIST 9-1

PARTS LIST
CONTENTS

"'

Decal Location, Sht 1


Decal Location, Sht 2
Decal Location, Sht 3
Decal Location, Sht 4
Option Wiring Diagram, Sht 1
Option Wiring Diagram, Sht 2
Keyed Ignition Option, Sht 1
Keyed Ignition Option, Sht 2
Diagnostic Module Option, Sht 1
Diagnostic Module Option, Sht 2
Gauge Option, Sht 1
Gauge Option, Sht 2
Hose Reel Assembly, Sht 1
Hose Reel Assembly, Sht 2
Single Hose Reel Option, Sht 1
Single Hose Reel Option, Sht 2
Double Hose Reel Option, Sht 1
Double Hose Reel Option, Sht 2
Extended Drawbar Option, Sht 1
Extended Drawbar Option, Sht 2
Adjustable Drawbar Option,Sht 1
Adjustable Drawbar Option,Sht 2
Extd/Adj Drawbar Option, Sht 1
Extd/Adj 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
951
9-52
9-53
954
9-55
956
9-57
958
959
960
9-61
9-62
9-63
9-64
9-65
966
967

BOOK

35389816 (5/95)

PARTS LIST 9-2

(
D

INGERSOLL-RAND COMPANY
PORTABLI!
DI!SCRIPTIOH

BOOK

35389816 (5/95)

OO~PRI!SSOR

DIVISION

FRAME COMPLETE

PARTS LIST 9-3


ITEM
A
B

c
D
E
F
G
H
J
K
L
M
N

a
R

s
T

u
v

C.P.N.
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. COJdPRe.SSOR DIVISION
DESCRIPTION

DATEIDWN

BY:I

216195

ti

FRAME COMPLETE

H,

R~V; I~"!EIHKD ~!.ATI!!/APVO BY

A "-" '\-::._' 5 ?,C

MODEL HTIILLUSTRATIOH HO., SHEeT

~:J~g 36525814

BOOK

2 of 2

f!./0

28136

35389816 (5/95)

PARTS LIST

94

RUNNING GEAR COMPLETE


PART NO. 36767812
DEXTER 5-LUG
INGERSOLL-RAND COMPANY
PORTABLI!' COUPRI!:880R DIVISION

BOOK

35389816 (5/95)

PARTS LIST
ITEM
A
B

c
D
E
F
G
H

*
*
*
**
*

K
L
M
N
p
Q
R

s **
T

v
w
X

QTY

C.P.N.
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

95

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. 36767812
DEXTER 5-LUG

INGERSOLL-RAND COMPANY
PORTABL! COMPRESSOR DIVISION
OI!SCRIPTION

RUNNING GEAR COMPLETE (DEXTER\


PATE/OWN

BY:I

9/28189 ~

NO./

MODI!L
P100E'NO

P""""

R!:V: I?ATI!/CHKD "1ATI!IAPVO BY

~;,

'\ .;;v 5 ;C

ILLUSTRATION HO.,SHI!:U NO.,: E/c

36511368

BOOK

2 of 2

23955

35389816 (5/95)

PARTS LIST

9-6

TIRE AND WHEEL ASSEMBLY 35068345


INGERSOLL-RAND COMPANY
PORTABLI! COMPRI!SSOR DIVISION

BOOK

35389816 (5/95)

PARTS LIST 9-7


ITEM
A

C.P.N.
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.


RI!.V: rATI!!/CHKD fi(~~:ATI!IAPVD eY

~.,

MODI!!L N~., ILLUSTRATION

P100EWO

P12SEWO

'-\-:J.!. s L7;C
NO.I SHEET N~'J: E/C

36522597

BOOK

2 of 2

24193

35389816 (5/95)

PARTS LIST

98

JACK ASSEMBLY36780013

INGERSOLL-RAND COMPANY
PORTAIIU! COMPRI!880R DIVISION

BOOK

35389816 (5/95)

PARTS LIST 9-9


ITEM
A
B

c
D

QTY

C.P.N.
36792489
36792513
36792505
36792497

1
1
1
1

DESCRIPTION

HANDLE KIT
WHEEL KIT
PLUNGER PIN KIT
BEVEL GEAR KIT

JACK ASSEMBLY 36780013

INGERSOLLRAND COMPANY
PORTABLE! COMPRO'!SSOR DIVISION
DI!.SCRIPTIOH

JACK ASSEMBLY
OATI!JDWN

tiY:I

4121/94 tl

RI!V: I~ATI!/CHKD &~jf~TI!fAPVJ;C-Y

A .,_"- '-\ .:>< 5 ..0,

MDDI!L H1'[1LLUBTRATIOH

P-100EWD

P-12SEWD

Ho.l SHI!I!T H0.1' 1!/C

36522605

BOOK

2 ol2

24940

35389816 (5/95)

PARTS LIST

9-10

INGERSOLLRAND COMPANY
PORTA.&ll!"

COMPR~880R

DIVISION

Ot!SCRIPTIOH

27276

BOOK

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

C.P.N.
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
8.5"
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, DRAIN
HOSE
MOUNT, RUBBER
MOUNT, LH REAR
SCREW
WASHER
MOUNT, RH REAR
SCREW
NUT
MOUNT, RUBBER
MOUNT, LH FRONT
MOUNT, RH FRONT
SCREW
WASHER
PIPE, EXHAUST
CLAMP
CLAMP
FAN
WASHER
SCREW
BAIL, 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 '-~ ~ ..::2< -

MOO.!l H:j ILLUSTRATION HO., SHI!!I!!T

P100EWD

P125EWD

36512473

BOOK

._u/-

NO,,: E/C

2of2

28107

35389816 (5/95)

PARTS LIST 912

INGERSOLL-RAND COMPANY
PORTASLI! COMPRI!$80R DIVISION

BOOK

35389816 {5/95}

PARTS LIST
ITEM

A
B

c
D
E
F
G
H

J
K
L

C.P.N.
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

INGERSOLLRAND COMPANY
PORTABLE COMPRESSOR DIVISIOH
OI!SCRIPTIOH

LIQUID COOLING COMPLETE


DATE/OWN

BY:I

12/21/89 ti

RI!V: t~IHCHKD B~t;.ATfiAPVD BY

c;-~' .<;-

L-7/

ldOOI!L NrJ tlU8TRATIOH NO., SHU:T H0.

P-100EWO
P-125EWD

36512515

BOOK

2 of 2

:; I!IC
126782

35389816 (5/95)

PARTS LIST

9-14

,/

c
E

INGERSOLL-RAND COMPANY
PORTABLI! CONPRI!880R D!Vl810H

BOOK

35389816 (5/95)

PARTS LIST
ITEM
A
B

D
E
F
G
H

C.P.N.
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!.IDWN IIY:J RI!:V: ~~ATI!tCHKD e:tA'TI!IAPVD ay

1/24190 ~

D '"'' ~--;,.i- 5 .L}~

MOD!L N0. ILLUSTRATION HO.rH!!T N0. : 1!/C

~:~=

36512499

BOOK

2 of 2

127793

35389816 (5/95)

PARTS LIST

9-16

3.69:1, 85mm AIR END ASSEMBLY 36007839


INGERSOLLRAND COMPANY
PORTABL~

BOOK

35389816 (5/95)

CO.CPRESSOR DIVISION

PARTS LIST 9-17


ITEM
A
B

D
E
F
G
H

J
K
L
M
N
p
Q

u
v
w
X
y

z
A1
A2
A3
A4
A5
A6
A7
AS
AS
B1

C.P.N.
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, 85mm AIR END ASSEMBLY 36007839


INGERSOLLRAND 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 ._~ '-\ --

s ._!},C

MODI!.l No. ILLUSTRATION HO.rHI!U

~~=

1 36525715

BOOK

NOl

2of2

f.IC

28107

35389816 (5/95}

PARTS LIST

918

'

INGERSOLL-RAND COMPANY
PORTABLI! COUPAI!880R DIVISION
DI!8CRIPTION

PIOOEW
Pt2SEWD

BOOK

35389816 {5/95)

AIR INTAKE COMPLETE

27511

PARTS LIST
ITEM
A
B

c
D
E

F
G
H

J
K

C.P.N.

QTY

2
36862829
1
36773950
1
36773448
3
35374073
4
35585009
35M2AB360M3 8
4
12A5D3Z1
8
35278530
1
35295781
1
35300615

919

DESCRIPTION
AIR CLEANER ASSEMBLY
HOSE ELBOW
HOSE ELBOW
CLAMP
MOUNTING BAND
SCREW
WASHER
NUT
CLAMP
RESTRICTION INDICATOR

INGERSOLLRAND 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

MODI!L No. ILLUSTRATION NO,ri>HI!I!T No.

~~=

1 36512507
BOOK

2of2

1C.

EIC

127511

35389816 (5/95)

PARTS LIST

920

\---(A
B

INGERSOLLRAND 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.P.N.
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;~A~VD BY

A I~i> t.j-::11 A

M.ODI!.L NO., ILLUSTRATION HO.,SHI!ET NO.,

m~~

36522613
BOOK

2 of 2

/-

:!IC

26062

35389816 (5/95)

PARTS LIST

922

0~---G,

@r----$

INGERSOLL-RAND COMPANY
PORTAI!ILI! CONPRI!:880R OIVISIOH

BOOK

35389816 (5/95)

PARTS LIST 9-23


ITEM
A
B

c
D
E
F
G
H

J
K
L
M
N

QTY

C.P.N.
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

INGERSOLLRAND COMPANY
PORTABLe COI.IPRI!SSOR DIVISION

DUCRIPTIO~EPARATOR TANK ASSEMBLY


OATI!/DWN

BY:I

9/19/89 tl

MODI!:L

RI!.V: ~~ATEICHKD l*ATI!!~J? BY

D ~~ ~~~ic

:C

NO.I lLLUSTRATlON NO.I SHI!IH NO, "c

~:=

36511426
BOOK

2of2

I 27366

35389816 (5/95)

PARTS LIST

924

AIR CLEANER ASSEMBLY 36862829

INGERSOLL-RAND COMPANY
PORTAISLI! COMPRI!SSOR DIVISION
DI!SCRIPTIOH

PIOOEWD
P12SEWD

BOOK

35389816 (5/95)

AIR CLEANER ASSEMBLY

27511

PARTS LIST 925


ITEM
A
B

c
D
E
F
G

C.P.N.
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 '<.~

Li.,;>\<\.1

~ 1/-.

MODI!l HO.,lLLUSTRA.TIOH NO.,SHI!I!T HO., : f!.IC

~:=

36511418
BOOK

2of2

27511

35389816 (5/95)

PARTS LIST

926

TO FUEL RETURN
liNE ON ENGINE

TO FUEL PUMP

ON ENGINE

INGERSOLL-RAND COMPANY
PORTAISLI! COMPRI!SSOR DIVISION
DI!SCRIPTIOH

PIOOEWD
P12$EWO

BOOK

35389816 {5/95)

FUEL TANK COMPLETE

PARTS LIST 927


ITEM
A
B

c
D
E
F
G
H
J

K
L
M
N
p
Q

C.P.N.
36770212
36859049
35363498
35296342
36764272
35300771
36767051
36774388
35307818
12A5D2Z1
35363498
35316587
11A7S1Z1
36772747
35363498
36845501

QTY

1
1
37.5'
6
2
1
2
1
4
4
2.5'
1
1
1
42'
1

DESCRIPTION
TANK, FUEL
CAP
HOSE
CLAMP
STRAP, TANK
SCREW
FOAM
HEATSHIELD
SCREW
WASHER
HOSE
ADAPTER
COUPLING
CONNECTOR
HOSE
FILTER

INGERSOLL-RAND COMPANY
PORTABLE COMPRESSOR DIVISION
PE$CRIPTIOH

OAT~DWH

BY;I

12113189 tl

FUEL TANK COMPLETE


REV: IDATI!ICHKP 8\Y.l:."TI!/~ !_Y

G I~:, '-\"-' s :.bi..L

MOPI!:L HO., ILLUSTRATION HO. SHEET HO.,

~:=

36512523

2of2

1!/C

27278

BOOK 35389816 (5/95)

PARTS LIST 9-28

FRAME

ENGINE

,1

INGERSOLLRAND COMPANY
PORTABLI!: COMPRI!&&OR DIVISION
DI!:BCRIPTION

BOOK

35389816 {5/95)

BATIERY MOUNTING

PARTS LIST
ITEM
A
B

c
D
E
F
G
H

J
K
L

C.P.N.
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

INGERSOLLRAND COMPANY
PORTAfiLII!: COMPRI!SSOR DIVISION
DI!:SCRIPTION

DATE/OWN

IIY:I

1/24/90 tl

BATTERY MOUNTING
RI!V: ~~~1!/CHKP ~~~~~AU:/APYD 8

\(. -,_L~ s .)/

WODI!L No., ILLUSTRATION NO.,SHI!I!.T NO.J

P100EWD
P125EWO

36512531

BOOK

2 of2

E/C

27630

35389816 (5/95)

PARTS LIST

9-30

NOTE:
SEE SHEET 3 FOR MATCH POINTS

[A][ID[Q][QJ[[)

42
t----{59

3l---~,.j

1-----< 15
34

J ~,-46-----.,

""'
-@

L ___ l

59
0
I
L

0
0
L
E
R

I I
dJdJ

17

INGERSOLLRAND COMPANY
PORTABLI!" COl>IPRI!SSOR DIVISION
o!SORIPTION

AIR AND OIL PIPING

28107

BOOK

35389816 (5/95)

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.P.N.

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, .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.P.N.

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,~cl:ATI!IAPVD e

I\~

'-''""- .s ...[);::.

NO.l ;LLUSTRATION NO.ISHI!!ET NO.II!/0

~:=

36522621
BOOK

2ol4

28107

35389816 (5/95)

PARTS LIST 9-32


NOTE:
SEE SHEET 1 FOR MATCH POINTS

[AJ[[J[QJ[Q][J

~ ~

10

~\1
Jl

I~

l r ;-1

Jt -

1,- l-~
~ i i
~ ~~r? L+--,-1-,

1--------{7

19

~~
I I

II

I
i

I~_ -~-a---+-1----....-__./
2

(15" lg)

INGERSOLL-RAND COMPANY
PORTABl.l!! COt.iPRI!SSOR DIVISIOH
DI!SCRIPTIOH

BOOK

35389816 (5/95)

AIR AND OIL PIPING

PARTS LIST
ITEM

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

C.P.N.

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,

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.P.N.

933

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


.,.
WODI!:L NO., ILLUSTRATION NO.JSHI!ET NO,

~:=

36522621
BOOK

4 of 4

28107

35389816 {5/95)

PARTS LIST

934

REO UNS'h1TCHEO 1z..rt: POSffi~


Pti<f

REO:ORN SfflTCt0 12\'0CPOSilTVE

) THERMAL
1

K ffiKMO
2

SA

T$1

F2

~.. COMPRESSOR

CONTACT

FUSE

SENSOR

~ lr TEMP S'NITCH

No
'

S4 N.C.

ffi!WLV

r -

LT Bt.U

f'2-Q

ENGINE OIL

c PRESS SINITCH
.t'"'l SS N.O.
.
A

SPARE

"l
P2-2 B-i---+-----J---""""--

~~ 5-

P2-1~
n-n It"

J'-----""-""""'""'"'-loI P2-10
_ _I
ENGINE
r ** P2~ 11--+---i----''"-'!!!"'-"""-!!!!>>.

PN!OORN

"

TEMP SWITCH
DIAGNOSTIC
N.C.
MODULE Ut
LT et.UQRJ ~FJIONAL)

~lr$6

lOW FUel

~Wl,';F'

L~:::::::::::JJJ.I f'2:11
LTBLUWHT

RESISTOR
820HM

AI

f>2-3. J\'JOI'r1!:L

'~

TO OPTION

Pl1

WIRING
DIAGRAM

MY

STARTER

Bl

!,

CXJ'

''"""'

AUXSTART

~~lf'Y Kt /

~'lr----,

START
PROTECT ).. FUEL
RElAYK32: ~ 0l 2
COIL

g;

gj

-4

SHUT

DIODE

";.DOWN

D3

RELAY K2
COIL

8RN12.VDCiiEG.I.TIVE

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)

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 ~

~ \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

936

>----fE

I
I
I

INGERSOLL-RAND COMPANY
PORTABL~

COMPRI!SSOR DJVISION

26872

BOOK

35389816 {5/95)

PARTS LIST 9-37


ITEM
A
B

c
D
E
F
G
H

J
K
L
M
N
p
Q

s
T

C.P.N.
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.~D BY

';..~

MODI!L HO,IILLUSTRATION

~:=

36520716
BOOK

'\ _;;,,.

...)/-'

NO., SHI!I!~T HO.,~ 1!/C


2 ol2

26872

35389816 (5/95)

PARTS LIST

9-38

./

INGERSOLL-RAND COMPANY
PORTAeL~

D!SCRIPTION

PIOOEWD
P12:SEWO

BOOK

35389816 (5/95)

COUPRI!SSOR DIVISION

PARTS LIST 9-39


ITEM
A
B

c
D
E
F
G
H
J
K
L
M
N

p
Q

s
T

u
v
w
X

z
A1
A2
A3
A4
A5
A6

C.P.N.
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

INGERSOLLRAND COMPANY
PORTAI!Ill!: COMPRI!:SSOR DIVISION

ENCLOSURE COMPLETE

CRIPTIOH
DATE/OWN

716190

BY:I
tl

REV: I;ATIE/CHKD ~~~~4~ATE/APVO BY

~-\,

'-\ ,;,L

JdOPEL NO., ILLUSTRATION NO.ISHI!I!T

~:=

36512549
BOOK

<);:

HOT

2of4

l!!fC

26872

35389816 (5/95)

PARTS LIST

940

INGERSOLL-RAND COMPANY
PORTA8LI! COMPRI!SSOR DIVISION
DI!SCRIPTIOH

ENCLOSURE COMPLETE

26215

BOOK

35389816 (5/95)

PARTS LIST 9-41


ITEM
A
B

c
D
E
F
G
H

J
K
L

M
N

p
Q
R

s
T

C.P.N.
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

INGERSOLLRAND COMPANY
PORTABLe COWI'RII!880R OIVISIOH

ENCLOSURE COMPLETE

O.I!!SCRIPTION

OATEIOWH

7/6/90

8r1
tl

R.I!!Vz,7ATI!/CHKD B~tATI!i?~O ~y

E "~ "~!\

1-

MODEL HO,,ILLUSTRATIOH HO., SHI!I!T HO.,: 1!!/C

m~~~

36512549
BOOK

4 of 4

26215

35389816 (5/95)

PARTS LIST

942

L
B
L

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.P.N.
36866630
36866648
36772853
36772861
36768216
36768224
36647911
36847929
36768380
36647903
36773182

QTY
2
2
1
1
1
1
1
1
1
1
2

943

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, EXCEPT ITEM
GOES ON BOTH P-1 00 AND P-125.

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

~"- 4 .;,.1:

, , ;::

MODEL HO.j ILLUSTRATION HO.,SHI!U NO.,: 1!/C

~Jm::g

36522639
BOOK

2 of 2

27793

35389816 (5/95)

PARTS LIST 9-44

Lt WARNING

&WARNING

Collapsing Jackstand.
Can cause severe~~
Injury.

Insert locking pin

completely.

f\"(

Do NOT exceed 50 mptl


{SO km/hr.)

Rotal!ng fan blade.

can caun taVerlnJury.


Do not operata without {IUard
In plac.

&WARNING

Combustlblo gas.

Cencauu
sovoraburn-.

bllndnu.s or doath,

Keep sparke and


open fiamn away
from batterie1,

&WARNING

High prouuro etr.


C.n etun aaverelnjury
or death.
l>tfore

& DANGER

Discharged air can contain carbon monoxld&


or other contamlmmts.

BOOK

35389816 (5/95)

&WARNING &WARNING

~--

DlaconnKted air hosot whip.


Cfln cau.. MveralnJury

TI"'Ippo<lalr p ... 11ura.

!h.

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,

op&rate tool b

Do not breathe this air.

seMee.

~~v.ilhOSHA

Reou!ation 29CFR S&e:tion


1m.302(b).

PARTS LIST 9-45


ITEM
A
B

c
D
E
F
G
H

J
K
L

C.P.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;ATI!/CHI<.D ti~~ATI!/~0 BY

G ;,:-.

~.:;,,Q-

MODI!L HO.,ILLUSTRATIOH No., SHI!!T

;::

36513729

BOOK

No.I:

2 of 4

j:

!IC

27923

35389816 {5/95)

PARTS LIST

BOOK

9-46

35389816 (5/95)

PARTS LIST
ITEM
A
B

C.P.N.
36525681
36522050
36516474

9-47

DESCRIPTION
GENERAL DATA
WARNING ROTATING FAN
DIESEL FUEL

INGERSOLLRAND COMPANY
PORTA8LI! COMPRI!BSOR DIVISION

DECAL LOCATION CHART

OI!SCfUPTIOH

FII!V: r;ATI!/CHKD ~~~ATEUD BY

DATI!/OWH 11'1:

716190

tl

~~ 1\-~t:

MODI!L HO.,IL.LUSTRATION HO., SHI!I!T HO'j:l!/0

i::

36513729
BOOK

4 ol4

28107

35389816 (5/95)

PARTS LIST 9-48

/TnoNAt

PANEL LIGHT

,..,
~~
,.,.
""'
~"

"""
"""
,.,.

"""',.,.,.,

SWfTCH$2

v-o

LOCATION

PW

{,
lTIIW'm.

'""""
"""''

to-

~~E

""""-' Ul

FlLTER

RESTRICT

SWITCHSS

~"

"'
,..,

CPJR

n<
TOM~~ARD .0:
DIAGRAM

AJR
ALTER

~w~w~

""""'
'"'''""

LOW
FUEL

1K4

if

CPRSR

SWITCH

LCWFLU
OP110N

CONTACT

eiGJNE
TEMP

TEMP

~DRY

:@(

;@~~G:o ~e~G~

TACH

~:-~

N.O.

~:Y

m~

'~

..;!""'

~rtr

C;RsR

~GINE

FUEl

"'

LEVEL
RElAY
COlt. K4

i!

~b~
Rn

m:beRi
RT2

FUEl.
LEVa

::@(

~G

GAGE

G;""
I
H

"

..,,.,.

FUEL

LEVEl.

AJR
VOLT
METER DISCHARGE
PRESSURE

M7

R2

M2

'H

ENG!NEOI!..

PRESS
GAGE

GAG EMf

SENDER

;@Q

INGERSOLL-RAND COMPANY
PORTABLI! C05oiPRt:SSOR DIVISION

.....,,,o
OATeJOWN BY:

412193

OPTION WIRING DIAGRAM


fli!V; Ort:ICHKO llr~~TI!/~ J!!.Y

MODI!L NOTI1.LUSTRATION

:::
BOOK

35389816 (5/95)

'\ ~"-t s

II-

NO.I SHI!I!T NO.I: 1!/

36521052

of

27310

PARTS LIST

949

C.P.N.

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

INGERSOLLRAND COMPANY
PORTABlt! COMPRI!SSOR DIVISION

. . . CRIPTION
DATEJOWH

4/2/93

BY:I
ti

OPTION WIRING DIAGRAM


RI!V;

I~TI!/CHICD ~~DATE:OO ~y

-..\ '-\ -;}l- 5 -

HO.! ILLUSTRATION NO.t SHI!I!T HOl EtC


: \ : 36521052
2of2 27310
MODEL

BOOK

35389816 {5/95)

PARTS LIST

9-50

INGERSOLL-RAND COMPANY
PORTABLE COMPRESSOR DIVISION

BOOK

35389816 (5/95)

PARTS LIST 951


ITEM

C.P.N.
36780252

QTY
1

DESCRIPTION
KEYED IGNITION SWITCH

INGERSOLL-RAND COMPANY
PORTABLt: COWPRI!SSOR OIVIB!OH

D!!SCRIPTION

DATt/DWN

a;:l

4112190 ~

KEYED IGNITION OPTION


Rt:V: IDATt:fcHKD a\.1\:Ali!IAP.vo e~v

'1,<; "~'

s .0,t:.

MODI!l HO.IILLUBTRATIOH HO.,SHI!ET HO.,~ 1!/C

36512929
BOOK

2 of 2

24508

35389816 (5/95)

PARTS LIST

9-52

INGERSOLL-RAND COMPANY
PORTADLI! CONPRIP:880R DIVISION

BOOK

35389816 (5/95)

PARTS LIST 9-53


ITEM
A
B

C.P.N.
36771426
36768844
36775484

QTY
1
1
4

DESCRIPTION

DIAGNOSTIC MODULE
DIAGNOSTIC DECAL
RIVET

INGERSOLLRAND COMPANY
PORTAliU: CONPRt!SSOR DIVl8lOH

scRIPTo'fliAGNOSTIC MODULE OPTION


DATI!IDWH Bn RI!V: ;ATI!/OHKD ~~~AT~YD.,

3/21/90 ~
~~o-";l_\ _
1
MODEL HO.j IlLUSTRATION HO., SHI!t.T HO.J~ E/C

B "'"'

36512812
BOOK

s -' F

2of2

24420

35389816 (5/95)

PARTS LIST 9-54

INGERSOLL-RAND COMPANY
PORTA&Lt: COMPRI!SSOR DIVISION

- BOOK

35389816 (5/95)

PARTS LIST 9-55


ITEM
A
B

c
D
E
F
G
H

J
K
L
M
N

p
Q
R

QTY

C.P.N.

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.~DWN 8Y:

4/11/90 ~

ld.OD!L

1 ~~

RI!V: ~ ... TI!(CHKD

rm. .,.o.vo'F

"_;;J~

BY

NO.I lLLUSTRATlON NO., SH!.U HO.,::! 1!/C

36512879
BOOK

2 of 2

27001

35389816 (5/95)

PARTS LIST 9-56

INGERSOLL-RAND COMPANY
PORTABLI! COMPRI!880R DIVISION

BOOK

35389816 (5/95)

PARTS LIST 9-57


ITEM

C.P.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

"-~ '\~i-

J/..

MOD!L H~.~ILLUSTRATIOH HO.,SHI!I!T NO.,~ E/C

3652264 7
BOOK

2 of 2

26287

35389816 (5/95)

PARTS LIST 9-58

INGERSOLL-RAND COMPANY
PORTAtiLI! COMPRI!!880R DIVISION

BOOK

35389816 {5/95)

PARTS LIST 9-59


ITEM
A
B

c
D
E

F
G
H

J
K
L
M

N
p
Q
R

C.P.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

\,_i> ".:;,' 5

MOOI!L HO,IILLUSTRATIOH Ho.lsHI!!I!T

36512895
BOOK

H0.,

2 of 2

, j:'
1!/C

26062
2

35389816 (5/95)

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

oscRIPTIDHDOUBLE HOSE REEL OPTION


PATI!IPWN D~:, RI!V: ~~ATI!/CHKD ~Y.!\ATEIA~D flY

419190

tl

~~ '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

INGERSOLL-RAND COMPANY
PORTABLI! COMPRI!SSOR DNISION

BOOK

35389816 {5/95}

PARTS LIST 9-63


ITEM
A

C.P.N.
36778363

QTY
1

DESCRIPTION

EXTENDED DRAWBAR

NOTE:
USE EXISTING HARDWEAR TO INSTALL OPTION

INGERSOLL-RAND COMPANY
PORTAliLI!: COMPRI!SSOR DIVISION

oscRoPT~JITENDED DRAWBAR OPTION


DATI!JOWN

BY;I

3/26/90 tl

RI!V: I~ATI!:/CHI<D 8~~ATI!I-Y;VD BY

B 11-.i,.

- S ..L.J,C.

MOPI!L NO.! ILLUSTRATION HO.,SHI!I!T HOli!/C

36512853
BOOK

2 of 2

24420

35389816 {5/95)

PARTS LIST

964

I
I
I

INGERSOLL-RAND COMPANY
PORTABLe: COioiPRI!880R DIVISION

BOOK

35389816 (5/95)

PARTS LIST
ITEM
A

QTY

C.P.N.
36778322

9-65

DESCRIPTION

ADJUSTABLE DRAWBAR

NOTE:
USE EXISTING HARDWEAR TO INSTALL OPTION

INGERSOLL-RAND COMPANY
PORTA!IU: COMPRtSSOR DIVISION

o.sc"fiB~USTABLE DRAWBAR OPTION


OAT~DWN

en

3/26/90 ~

RI!V: ~0~~1!/CHKD ~~ATI!IAJ'VO flY

._ ";;:;,'.

s .:J;::

MODEL No.II~~;;R~;~Ho.,s;E:fT;o-~
BOOK

2~;20

35389816 (5/95)

PARTS LIST

966

INGERSOLL-RAND COMPANY
PORTA!ILI! COMPRI!SSOR DIVIS!OH

BOOK

35389816 (5/95)

PARTS LIST
ITEM
A

QTY

C.P.N.
36778413

9-67

DESCRIPTION

EXTND & ADJ DRAWBAR

NOTE:
USE EXISTING HARDWEAR TO INSTALL OPTION

INGERSOLLRAND COMPANY
PORTAtiU: COMPR2880R DIVISION

c"E\:IND & ADJ DRAWBAR OPTION


PATEIDWN

BY:I

3/26/90 ~

RI!V: IDA~I!/CHKD e~~AT:rJ'Vo e


~
I
;:-

..

>\-"'- s

MOO!L N0. IlLUSTRATION HO.rHe!T N0. : 1!/

1 36512838

BOOK

2 of 2

124420

35389816 {5/95)

',