OPERATION AND MAINTENANCE MANUAL

Portable Compressor 7/20

This manual contains important safety information and must be made

available to personnel who operate and maintain this machine.

SERIAL No. : 120001 ®

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
C.P.N.: 22311203 GB
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of DATE : September 2003
either.
Revised (10-12)
Machine models represented in this manual may be used in various locations world---wide. Machines sold and
shipped into European Union territories require that the machine display the CE Mark and conform to various
directives. In such cases, the design specification of this machine has been certified as complying with EC di-
rectives. Any modification to any part is absolutely prohibited and would result in the CE Certification and mark-
ing being rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

98/37/EC, 93/68/EEC, 89/336/EEC, 2000/14/EC
We
Ingersoll -- Rand Company Ingersoll -- Rand Company Limited
Portable Compressor Division Standard Products Division
P.O. Box 868 Represented In EC By: Swan Lane
501 Sanford Avenue Hindley Green
Mocksville, North Carolina 27028 Wigan WN2 4EZ
United Kingdom
Declare that, under our sole responsibility for manufacture and supply, the product(s)

7/20
to which this declaration relates, is (are) in conformity with the provisions of the
above directives using the folloving principal standards

EN29001 : EN292, EN60204---1, EN1012---1, PN8NTC2, EN50081, EN50082

Issued at Mocksville on
1-- 9-- 2003

Ric Lunsford
Manager of quality control

CONFORMITY WITH NOISE DIRECTIVE 2000/14/EC

Ingersoll -- Rand Company Limited declare that the following Portable Compressors have been
manufactured in conformity with the directive as shown
Machine Serial number Mean measured Guaranteed
Directive Notified body
Type kW range value Level
2000/14/EC A V Technology
Annex VI 7/20 17.5 120001 ® 98 99 Stockport UK
Part I Nr 1067

Issued at Prague on Dobroslav Rak

1-- 9-- 2003 Engineering manager

EC Pressure Equipment Directive and Related Regulations

We declare that this product has been assessed according to the Pressure Equipment Directive (97/23/EC)
and, in accordance with the terms of this Directive, has been excluded from the scope of this Directive.
It may carry CE marking in compliance with other applicable EC Directives.
 CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects, and other
reproductive harm.
 LIST OF EFFECTIVE PAGES

Total number of pages in this manual is 80 consisting of the following:

Page No. *Change No.

Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
A ........................................................0
B Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
i---v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
vi Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1---1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1---2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2---1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2---2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3---1 --- 3---6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4---1 --- 4---6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
5---1 --- 5---3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
5---4 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
6---1 --- 6---2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7---1 --- 7---4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8---1 --- 8---3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8---4 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
9---1 --- 9---11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
9---12 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
10---1 --- 10---2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11---1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11---2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
12---1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
12---2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
13---1 --- 13---15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
13---16 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
14---1 --- 14---4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

* Zero in this column indicates an original page.

A/(B blank)
 Portable Compressor 7/20

SECTION CONTENTS PAGE

1. ABBREVIATIONS & SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---1

2. FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---1

3. WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
3.1. GENERAL WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 1
3.2. EXTENDED LIMITED AIREND WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 4
3.3. WARRANTY REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 5
3.3.1. FOR UNITS SOURCED FROM HINDLEY GREEN, UK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 5
3.3.2. FOR UNITS SOURCED FROM MOCKSVILLE, USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 5

4. DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---1
4.1. GRAPHIC FORM AND MEANING OF ISO SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--- 1
4.2. FREE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--- 6

5. NOISE EMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---1

5.1. COMPRESSOR NOISE EMISSION CONTROL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--- 1
5.2. NOISE EMISSION CONTROL, MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--- 1
5.2.1. NOISE EMISSION WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--- 2
5.2.2. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--- 2
5.3. MAINTENANCE PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--- 2
5.4. MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY . . . . . . . . . . . . . . . . 5--- 3

6. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
6.1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 1
6.2. COMPRESSED AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 1
6.3. MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 1
6.3.1. AVOID INHALATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 1
6.3.2. AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 2
6.4. BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 2
6.5. RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 2
6.6. TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 2
6.7. SAFETY CHAINS / CONNECTIONS AND THEIR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 2

7. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7---1

7.1. COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 2
7.2. LUBRICATING OIL SPECIFICATION (FOR THE SPECIFIED AMBIENT TEMPERATURES) . . . . . . . . . . . . . . . . . . . 7--- 2
7.3. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 3
7.4. FIXED HEIGHT RUNNING GEAR (UNBRAKED VERSION KNOTT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 3
7.5. VARIABLE HEIGHT RUNNING GEAR (UNBRAKED VERSION KNOTT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 3
7.6. FIXED HEIGHT RUNNING GEAR (BRAKED VERSION KNOTT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 4
7.7. VARIABLE HEIGHT RUNNING GEAR (BRAKED VERSION KNOTT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 4
7.8. WHEELS AND TYRES (KNOTT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 4

8. OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8---1

8.1. COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 1
8.2. PRIOR TO STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 1
8.3. STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 2
8.4. STOPPING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 3
8.5. EMERGENCY STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 3
8.6. RE--- STARTING AFTER AN EMERGENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 3
8.7. MONITORING DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 3
8.8. DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 3

9. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---1
9.1. MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 1
9.2. ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 3
9.3. PROTECTIVE SHUTDOWN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 3
9.4. SCAVENGE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 3

SEPTEMBER 2003 i
 Portable Compressor 7/20

SECTION CONTENTS PAGE

9.5. COMPRESSOR OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 4

9.6. COMPRESSOR OIL SEPARATOR ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 4
9.7. COMPRESSOR OIL COOLER AND ENGINE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 4
9.8. AIR FILTER ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.9. VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.10. COOLING FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.11. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.12. FUEL FILTER WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.13. HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.14. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.15. BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.16. PRESSURE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.17. TYRES/TYRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.18. RUNNING GEAR/WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 5
9.19. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 6
9.20. ADJUSTING THE BRAKING SYSTEM (KNOTT RUNNING GEAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 6
9.20.1. RE--- ADJUSTING THE BRAKING SYSTEM (KNOTT RUNNING GEAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 7
9.21. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 7
9.21.1. ENGINE LUBRICATING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 7
9.21.2. ENGINE LUBRICATING OIL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 7
9.21.3. ENGINE OIL FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 7
9.21.4. COMPRESSOR LUBRICATING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 7
9.21.5. COMPRESSOR OIL FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 8
9.22. RUNNING GEAR WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 8
9.23. SPEED AND PRESSURE REGULATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 8
9.24. DRIVE BELT REPLACEMENT / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 9
9.25. TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 10
9.26. COMPRESSOR LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 10

10. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---1

11. PIPING AND INSTRUMENTATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11---1

12. LUBRICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12---1

12.1. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--- 1
12.2. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--- 1
12.3. OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--- 1
12.4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--- 1
12.5. FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--- 1

13. KUBOTA D1005 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---1

13.1. FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 1
13.2. EXTERNAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 1
13.3. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 2
13.3.1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 2
13.3.2. ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 2
13.3.3. INGERSOLL --- RAND ENGINE AFTER SALES SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 3
13.3.4. SERVICING OF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 3
13.4. FUEL, LUBRICANTS, AND COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 3
13.4.1. FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 3
13.4.2. FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 3
13.4.3. LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 4
13.4.4. COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 4
13.5. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 4
13.5.1. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 4
13.5.2. CHECK BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 4
13.5.3. STARTING THE ENGINE (NORMAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 5
13.5.4. CHECKS AND OPERATION AFTER START--- UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 7
13.5.5. OPERATION AND CARE OF A NEW ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 7

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13.6. PERIODICAL INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 8

13.6.1. LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 8
13.6.2. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 9
13.6.3. PERIODIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 10
13.6.4. AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 12
13.6.5. ENGINE ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 12
13.6.6. SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 12
13.7. COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 13
13.8. ENGINE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 14
13.8.1. SERVICE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 14

14. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14---1

14.1. COMPRESSOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--- 1
14.2. ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--- 2

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3--- 1. WARRANTY REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 6

4--- 1. GRAPHIC FORM AND MEANING OF ISO SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--- 3
4--- 2. SIGNS ON MACHINES SHIPPED TO MARKETS IN NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--- 6
5--- 1. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--- 1
7--- 1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 1
8--- 1. PRIOR TO STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 1
8--- 2. CONTROL OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--- 2
9--- 1. BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 6
9--- 2. EQUALISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 6
9--- 3. WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 6
9--- 4. SPEED AND PRESSURE REGULATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 8
9--- 5. DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 9
9--- 6. RATED OPERATING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 11
10--- 1. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--- 1
10--- 2. SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--- 2
10--- 3. SCHEMATIC DIAGRAM FOR AMERICAN SAE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--- 2
11--- 1. PIPING AND INSTRUMENTATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--- 1
13--- 1. EXTERNAL VIEWS KUBOTA D1005 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 1
13--- 2. ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 2
13--- 3. OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 4
13--- 4. OIL LEVEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 5
13--- 5. FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 5
13--- 6. FUEL FILTER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 6
13--- 7. PLACE THE SPEED CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 6
13--- 8. BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 6
13--- 9. OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 8
13--- 10. OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 8
13--- 11. GRAVITY FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 11
13--- 12. TANK BELOW INJECTION PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 11
13--- 13. FUEL PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 11
13--- 14. FUEL FILTER CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 11
13--- 15. FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 12
13--- 16. DUST INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 12

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2--- 1. THE USE OF THE MACHINE IN ANY OF THE SITUATION TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--- 1
3--- 1. GENERAL WARRANTY INFORMATION--- ESA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 2
3--- 2. LIMITED WARANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 4
5--- 1. MAINTENANCE PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--- 2
5--- 2. MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY . . . . . . . . . . . . . . . 5--- 3
7--- 1. COMPRESSOR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 2
7--- 2. LUBRICATING OIL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 2
7--- 3. ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 3
7--- 4. FIXED HEIGHT RUNNING GEAR (UNBRAKED VERSION KNOTT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 3
7--- 5. VARIABLE HEIGHT RUNNING GEAR (UNBRAKED VERSION KNOTT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 3
7--- 6. FIXED HEIGHT RUNNING GEAR (BRAKED VERSION KNOTT) ........................................ 7--- 4
7--- 7. VARIABLE HEIGHT RUNNING GEAR (BRAKED VERSION KNOTT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 4
7--- 8. WHEELS AND TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--- 4
9--- 1. MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 1
9--- 2. TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 10
9--- 3. COMPRESSOR LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 11
9--- 4. RECOMMENDED FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--- 11
12--- 1. FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--- 1
13--- 1. MAIN DATA AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 2
13--- 2. REQUIRED OF THE DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 3
13--- 3. FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 5
13--- 4. COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 9
13--- 5. OPERATION TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 9
13--- 6. GRADE OF DIESEL FUEL ACCORDING TO ASTM D975 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 10
13--- 7. PARAMETERS OF DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 10
13--- 8. SERVICE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 14
13--- 9. INTERVAL OF ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--- 15
14--- 1. COMPRESSOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--- 1
14--- 2. ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--- 2

SEPTEMBER 2003 v/(vi blank)

 Portable Compressor 7/20

1. ABBREVIATIONS & SYMBOLS

#### Contact Ingersoll--- Rand for Serial No.

®#### Up to Serial No.

####® From Serial No.

* Not illustrated

† Option

AR As required

BR Brazil

CN China

DE Germany

DK Denmark

ES Spain

FI Finland

FR France

GB Great Britain (English)

HA High ambient machine

IT Italy

NL Holland

NO Norway

PT Portugal

SE Sweden

US United States of America

F.H.R.G. Fixed height running gear

V.H.R.G Variable height running gear

I---R Ingersoll--- Rand

SEPTEMBER 2003 1---1/(1---2 blank)

 Portable Compressor 7/20

2. FOREWORD
The content of this manual is considered to be proprietary and
confidential to Ingersoll---Rand and should not be reproduced
without the prior written permission of Ingersoll---Rand.
Nothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied,
regarding the Ingersoll---Rand products described herein. Any
such warranties or other terms and conditions of sale of
products shall be in accordance with the standard terms and
conditions of sale for such products, which are available upon
request.
This manual contains instructions and technical data to cover all
routine operation and scheduled maintenance tasks by
operation and maintenance staff. Major overhauls are outside
the scope of this manual and should be referred to an authorised
Ingersoll---Rand service department.
The design specification of this machine has been certified as
complying with EC directives. As a result:
a. Any machine modifications are strictly prohibited, and will
invalidate CE certification.
b. A unique specification for U.S.A./Canada is adopted and
tailored to the territory.
All components, accessories, pipes and connectors added to
the compressed air system should be:
--- of good quality, procured from a reputable manufacturer
and, wherever possible, be of a type approved by
Ingersoll---Rand,
--- clearly rated for a pressure at least equal to the machine
maximum allowable working pressure,
--- compatible with the compressor lubricant/coolant,
--- accompanied with instructions for safe installation,
operation and maintenance.
NOTE
Details of approved equipment are available from
Ingersoll---Rand Service departments.
The use of repair parts / lubricants / fluids other than those
included within the Ingersoll---Rand approved parts list may
create hazardous conditions over which Ingersoll---Rand has no
control. Therefore Ingersoll---Rand cannot be held responsible
for equipment in which non---approved repair parts are installed.
Ingersoll---Rand reserves the right to make changes and
improvements to products without notice and without incurring
any obligation to make such changes or add such
improvements to products sold previously.
The intended uses of this machine are outlined below and
examples of unapproved usage are also given, however
Ingersoll---Rand cannot anticipate every application or work
situation that may arise.
CAUTION
IF IN DOUBT CONSULT SUPERVISION.
This machine has been designed and supplied for use only in
the following specified conditions and applications:
--- Compression of normal ambient air containing no known
or detectable additional gases, vapours. or particles
--- Operation within the ambient temperature range specified
in the 7. GENERAL INFORMATION section of this manual.
The use of the machine in any of the situation types listed in
Table 2 ---1 THE USE OF THE MACHINE IN ANY OF THE
SITUATION TYPES:
a. is not approved by Ingersoll---Rand,
b. may impair the safety of users and other persons,
c. may prejudice any claims made against Ingersoll---Rand.

Table 2-- 1. THE USE OF THE MACHINE IN ANY OF THE SITUATION TYPES
a. direct human consumption
Use of the machine to produce compressed air for: b. Indirect human consumption, without suitable filtration and
purity checks
Use of the machine outside the ambient temperature range specified in the 7.GENERAL INFORMATION section of this manual.
Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or vapours.
Use of the machine fitted with non Ingersoll---Rand approved components/lubricants/fluids.
Use of the machine with safety or control components missing or disabled.
Use of the machine for storage or transportation of materials inside or on the enclosure except when contained within the
toolbox.

The company accepts no responsibility for errors in translation @ COPYRIGHT 2003

of this manual from the original English version. INGERSOLL---RAND COMPANY

SEPTEMBER 2003 2---1/(2---2 blank)


3. WARRANTY
3.1. GENERAL WARRANTY
INFORMATION
Ingersoll---Rand, through its distributor, warrants that each
item of equipment manufactured by it and delivered hereunder
to the initial user will be free of defects in material and
workmanship for a period of three [3] months from initial
operation or six [6] months from the date of shipment to the
initial user, whichever occurs first.
With respect to the following types of equipment, the warranty
period enumerated below will apply in lieu of the foregoing
warranty period Table 3 ---1. GENERAL WARRANTY
INFORMATION ---ESA.
A. Aftercoolers
The earlier of nine [9] months from date of shipment to or
six [6] months from start up by initial user.
B. Portable Compressors, Portable Generator Sets --- 9 kVA
through to 550 kVA, Portable Light Towers and Air Dyers
The earlier of twelve [12] months from shipment to or the
accumulation of 2,000 hours of service by the initial user.
2.5 kVA Through to 8 kVA --- The Earlier of twelve [12]
months from shipment to or the accumulation of 2,000
hours of operation by the initial user.
Ingersoll---Rand will provide a new part or repaired part, at
its sole discretion, in place of any part which is found to be
defective in material or workmanship during the period
described above. Labor cost to replace the part is the
responsibility of the initial user.
C. Portable Compressor Airend
The earlier of twenty---four [24] months from shipment to or
the accumulation of 4,000 hours of service by the initial
user. For Airend, the warranty against defects will include
replacement of the complete Airend, provided the original
Airend is returned assembled and all original seals are
intact.
Portable Compressor Airend Limited Extended
Warranty
The earlier of sixty [60] months from shipment to or the
accumulation of 10,000 hours of operation by the initial
user. This extended warranty is limited to defects in design
or defective material or workmanship in rotors, housings,
bearings and gears and provided all the following
conditions are met:
The original air end is returned assembled and all original
seals are intact.
Continued use of genuine Ingersoll---Rand parts, fluids, oils
and filters.
Maintenance is performed at prescribed intervals by
authorized and properly trained service engineers.
D. Generator Alternator --- 9 kVA through to 550 kVA
The earlier of twenty---four [24] months from shipment to or
the accumulation of 4,000 hours of operation by the initial
user.
2.5 kVA Through to 8 kVA --- The earlier of twelve [12]
months from shipment to or the accumulation of 2,000
hours of operation by the initial user.
E. Portable Light Tower Alternator
The earlier of twelve [12] months from shipment to or the
accumulation of 2,000 hours of operation by the initial user.
Light Source model only, the earlier of twenty---four [24]
SEPTEMBER 2003
Portable Compressor 7/20
months from shipment to or the accumulation of 4,000
hours of operation by the initial user.
F. Ingersoll---Rand Engines
The earlier of twenty---four [24] months from shipment to or
the accumulation of 4,000 hours of operation by the initial
user.
G. Ingersoll---Rand Platinum Drive Train Limited Extended
Warranty
Platinum drive train pertains to the Ingersoll---Rand Engine
and Airend combination. The earlier of sixty [60] months
from shipment to, or the accumulation of 10,000 hours of
operation by the initial user. The starter, alternator, fuel
injection system and all electrical components are
excluded from the extended warranty. The Airend seal and
drive coupling are included in the warranty but Airend drive
belts are excluded. The optional warranty is automatically
available when meeting the following conditions are met:
(1.) The original Airend is returned assembled and
unopened.
(2.) Continued use of genuine Ingersoll---Rand parts,
fluids, oil and filters.
(3.) Maintenance is performed at prescribed intervals by
authorized properly trained service engineers.
Ingersoll---Rand shall be provided with such information as
it requires to confirm that these conditions have been
complied with.
H. Construction Tools, (Portable Power range only)
Twelve [12] months from shipment to initial user.
Ingersoll---Rand will provide a new part or repaired part, at
its sole discretion, in place of any part which is found to be
defective in material or workmanship during the period
described above. Labor cost to replace the part is the
responsibility of the initial user.
Construction Tools Limited Extended Warranty,
(Portable Power range only)
Thirty---six [36] months from shipment to initial user. This
extended warranty is automatically available only when the
tool is registered with Ingersoll---Rand by completing and
submitting the Warranty Registration form. Ingersoll---Rand
will provide a new part or repaired part, at its sole
discretion, in place of any part which is found to be
defective in material or workmanship during the period
described above. Labor cost to replace the part is the
responsibility of the initial user.
I. Spare Parts
Six [6] months from date of shipment to the initial user.
Ingersoll---Rand will provide a new part or repaired part, at its
sole discretion, in place of any part which is found to be defective
in material and workmanship during the period described
above. Such part will be repaired or replaced without charge to
the initial user during normal working hours at the place of
business of an Ingersoll---Rand distributor authorized to sell the
type of the equipment involved or other establishment
authorized by Ingersoll---Rand. User must present proof of
purchase at the time of exercising warranty.
The above warranties do not apply to failures occurring as a
result of abuse; misuse, negligent repairs, corrosion, erosion
and normal wear and tear, alterations or modifications made to
the product without express written consent of Ingersoll---Rand;
or failure to follow the recommended operating practices and
maintenance procedures as provided in the product’s operating
and maintenance publications.
3---1
Portable Compressor 7/20

Accessories or equipment furnished by Ingersoll---Rand, but CAUTION

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
EXPRESSED OR IMPLIED, (EXCEPT THAT OF TITLE),AND
THERE ARE NO WARRANTIES OF MERCHANTABILITY OR
OF FITNESS FOR A PARTICULAR PURPOSE.

Table 3-- 1. GENERAL WARRANTY INFORMATION---ESA

COMMENTS

COVERS CONTROLS, SWITCHES, SHEET METAL,

12 MONTHS / 2,000 RADIATOR, OIL COOLER, RECEIVER, PIPEWORK,
PACKAGE
HOURS ELECTRICAL CIRCUIT ETC.

PORTABLE COMPRESSOR 60 MONTHS / 10,000 HOURS. EXTENDED LIMITED

24 MONTHS / 4,000 WARRANTY AVAILABLE ON MAJOR COMPONENTS.
AIRED
HOURS REFER TO OPERATOR’S MANUAL.
ENGINE SEE BELOW

12 MONTHS / 2,000 CONTACT I---R NETWORK FOR WARRANTY (PARTS

PACKAGE
HOURS ONLY NO LABOUR).
2.5
2 5 kVA ÷ 8 kVA 12 MONTHS / 2,000 CONTACT I---R NETWORK FOR WARRANTY (PARTS
GENERATORS ALTERNATOR
HOURS ONLY NO LABOUR).
ENGINE SEE BELOW

12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,

PACKAGE
HOURS ELECTRICAL CIRCUIT ETC.
9 kVA ÷ 550 kVA 24 MONTHS / 4,000
GENERATORS ALTERNATOR CONTACT I---R NETWORK FOR WARRANTY.
HOURS
ENGINE SEE BELOW

12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,

PACKAGE
HOURS ELECTRICAL CIRCUIT ETC.
LIGHT TOWER 12 MONTHS / 2,000 EXTENDED WARRANTY OF 24 MONTHS / 4,000
ALTERNATOR
HOURS HOURS. FOR LIGHTSOURCE INTRODUCED 8/16/99.
ENGINE SEE BELOW

ENGINES

MONTHS HOURS COMMENTS

EXTENDED WARRANTY PROVIDED VIA ENGINE
CATERPILLAR 12 UNLIMITED SUPPLIER’S OWN APPROVED NETWORK AT TIME
OF PURCHASE.
EXTENDED WARRANTY PROVIDED VIA ENGINE
CUMMINS 24 2,000 SUPPLIER’S OWN APPROVED NETWORK AT TIME
OF PURCHASE.
IF UNDER 500 HOURS IN FIRST YEAR THEN BELOW
12 UNLIMITED
APPLIES.
PERKINS
ALL COMPONENTS COVERED EXCLUDING
24 1,000
INJECTORS.
EXTENDED WARRANTY PROVIDED VIA ENGINE
JOHN DEERE SUPPLIER’S OWN APPROVED NETWORK AT TIME
24 2,000
(IN COMPRESSOR) OF PURCHASE.
24 MONTHS / 4,000 HOURS. AVAILABLE FROM IR
WITH USE OF GENUINE I---R PARTS AND OILS AT
(IN GENERATORS) 24 2,000
PRESCRIBED SERVICE INTERVALS. CONTACT I---R
NETWORK.
(Continued on next page)

3---2 SEPTEMBER 2003

 Portable Compressor 7/20

ENGINES

MONTHS HOURS COMMENTS

0÷12 UNLIMITED ALL COMPONENTS COVERED.
MAJOR COMPONENTS COVERED. FURTHER
DEUTZ EXTENDED WARRANTY ON MAJOR COMPONENTS
13÷24 UNLIMITED
PROVIDED VIA ENGINE SUPPLIER’S OWN
APPROVED NETWORK AT TIME OF PURCHASE.
EXTENDED WARRANTY OF 60 MONTHS / 10,000
INGERSOLL---RAND 24 4,000 HOURS. WHEN USING GENUINE I---R FLUIDS AND
PARTS ON MAJOR COMPONENTS.
EXTENDED WARRANTY OF 60 MONTHS / 10,000
KUBOTA HOURS. WHEN USING GENUINE I---R FLUIDS AND
24 4,000
( 7/20 ONLY) PARTS ON MAJOR COMPONENTS.
MITSUBISHI 24 2,000 NO EXTENDED WARRANTY AVAILABLE.
EXTENDED WARRANTY PROVIDED VIA ENGINE
VOLVO 24 2,000 SUPPLIER’S OWN APPROVED NETWORK AT TIME
OF PURCHASE.
WARRANTY PROVIDED VIA ENGINE SUPPLIER’S
HONDA 12 UNLIMITED
OWN APPROVED NETWORK.
WARRANTY PROVIDED VIA ENGINE SUPPLIER’S
YANMAR 12 UNLIMITED
OWN APPROVED NETWORK.
WARRANTY PROVIDED VIA ENGINE SUPPLIER’S
VANGUARD 24 UNLIMITED
OWN APPROVED NETWORK.

PARTS

MONTHS HOURS COMMENTS

INGERSOLL---RAND
6 UNLIMITED PARTS ONLY AVAILABLE FROM I---R NETWORK.

AIREND EXCHANGE

MONTHS HOURS COMMENTS

AIREND 24 MONTHS / 4,000 HOURS. AVAILABLE FROM I---R
12 2,000
NETWORK.

CONSTRUCTION TOOLS

MONTHS HOURS COMMENTS

CONSTRUCTION TOOLS OPTIONAL 36 MONTHS EXTENDED WARRANTY

12 N/A AVAILABLE FROM I---R. ALL WARRANTY COVERS
PARTS ONLY REPLACEMENT.

NOTE
Actual warranty times may change.
Consult the Manufacturer‘s warranty policy as shipped with
each new product.

SEPTEMBER 2003 3---3

Portable Compressor 7/20

3.2. EXTENDED LIMITED AIREND WARRANTY

Ingersoll---Rand Portable Compressor Division is pleased to announce the availability of extended limited Airend warranty.
Announcement of the extended warranty coincides with the introduction of Pro---TecTM Compressor Fluid. Pro---TecTM Compressor
Fluid is an amber coloured fluid specially formulated for Portable Compressors and is being provided as the factory filled fluid for all
machines except 1 XHP650/900/1070.

All machines have the standard Airend warranty---the earlier of 24 months from shipment to, or the accumulation of 4,000 hours of
service by the initial user.

The warranty against defects will include replacement of the complete Airend, provided the original Airend is returned assembled and
unopened.

The optional limited warranty Table 3 ---2. LIMITED WARANTY is the earlier of 60 months from shipment to, or the accumulation of 10,000
hours of service. The optional warranty is limited to defects in major components (rotors, housings, gears and bearings), and is
automatically available when the following conditions are met:

(1.) The original airend is returned assembled and unopened.

(2.) Submissions of proof that Ingersoll---Rand fluid, filters and separators have been used.
Refer to the 8. OPERATING INSTRUCTIONS this manual for the correct fluids, filters and separator elements required.
(3.) Submissions of proof that maintenance intervals have been followed.

Table 3-- 2. LIMITED WARANTY

WARRANTY TIME *BARE AIREND **AIREND COMPONENTS

STANDARD 2 YEARS / 4,000 HOURS 100% PARTS & LABOUR 100% PARTS & LABOUR
OPTIONAL 5 YEARS / 10,000 HOURS 100% PARTS & LABOUR 0%
*BARE AIREND --- pertains to major airend parts (rotors, housings, gears and bearings).
**AIREND COMPONENTS --- pertains to auxiliary attachments to the bare airend (seals, pumps, valves, tubes, hoses, fittings
and filter housing).

PRO---TECTM AND XHP505 COMPRESSOR FLUIDS ARE AVAILABLE FROM YOUR LOCAL INGERSOLL---RAND BRANCH OR
DISTRIBUTOR.

FOR UNITS OPERATING WITHIN THE USA & CANADA, CALL THE MOCKSVILLE PRODUCT SUPPORT DEPARTMENT ON
1---800---633---5206.

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

3---4 SEPTEMBER 2003

 Portable Compressor 7/20

3.3. WARRANTY REGISTRATION

3.3.1. For Units Sourced From Hindley Green, UK

A. Complete Machine Registration
--- To initiate the machine warranty, fill out the ”Warranty Registration” form 83242 11/99 supplied as part of the machine
documentation, keep a copy for your records and mail the original to:
Ingersoll---Rand European Sales Ltd.
Portable Power
Paragon Bussines Park
Chorley New Road
Horwitch
Bolton
BL6 6JN
United Kingdom
Attn: Customer Service Department

NOTE
Completion of this form validates the warranty.

B. Engine Registration:
--- I---R powered machines do not require separate engine registration,
--- Deutz require a separate engine registration form to be completed and mailed direct to their Cologne office. The form is
supplied as part of the machine documentation for Deutz powered machines,
--- Caterpillar; Cummins and Perkins do not require a separate registration form but they stipulate that any new engine should
be registered with their local dealer to initiate warranty,
--- You must provide proof of the ”in---service” date when requesting engine warranty repairs.

3.3.2. For Units Sourced From Mocksville, USA

A. Complete Machine Registration:
--- Machines shipped to locations within the United States do not require a warranty registration unless the machine status
changes (i.e. change of ownership),
--- Machines shipped outside the United States require notification be made to initiate the machine warranty.
--- Fill out the Warranty Registration Form in this section, keep a copy for your records and mail form to:
Ingersoll---Rand Company
P.O. Box 868
Mocksville, North Carolina 27028
Attn. Warranty Department

NOTE
Completion of this form validates the warranty.

B. Engine Registration:
--- I---R powered machines do not require separate engine registration.
--- John Deere requires a separate engine registration be completed and mailed direct to John Deere.
--- Separate engine registration material is included with this literature package for John Deere powered machines.
--- All other engine manufacturers do not require a separate engine registration.
--- You must present proof of in---service date at time of requesting engine warranty service.

SEPTEMBER 2003 3---5

Portable Compressor 7/20

PORTABLE POWER
EXTENDED WARRANTY REGISTRATION FORM

Customer Details Service Provider Details

Company Name: Service Provider / Distributor:

Contact Name: Branch Office:

Signature:

Company Address: Machine Details

Product Type:

SAMPLE Model:

Serial Number:

Engine Serial Number:

Engine Model Number:

Post / Zip Code: Airend Serial Number:

Country: Alternator Serial Number:

Phone Number: Date of start up:

Fax Number:

e---mail:

Figure 3-- 1. WARRANTY REGISTRATION

3---6 SEPTEMBER 2003

 Portable Compressor 7/20

4. DECALS
4.1. GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions WARNING

WARNING --- Pressurised

WARNING --- Electrical shock risk. WARNING --- Hot surface.
component or system.

WARNING --- Pressure control. WARNING --- Corrosion risk. WARNING --- Air/gas flow or Air discharge.

WARNING --- Maintain correct tyre pressure.

WARNING --- Hot and harmful
WARNING --- Pressurised vessel. (Refer to the GENERAL INFORMATION
exhaust gas.
section of this manual).

0˚C

WARNING --- Before connecting the tow WARNING --- For operating temperature
WARNING --- Flammable liquid. bar or commencing to tow consult the below 0˚C, consult the operation and
operation and maintenance manual. maintenance manual.

Figure 4-- 1. GRAPHIC FORM AND MEANING OF ISO SYMBOLS (Sheet 1 of 3)

SEPTEMBER 2003 4---1

Portable Compressor 7/20

WARNING --- Do not undertake any maintenance on
this machine until the electrical supply is
disconnected and the air pressure is totally relieved.
WARNING --- Consult the operation
Do not breathe the compressed
and maintenance manual before
air from this machine.
commencing any maintenance.

Do not remove the Operating and Maintenance Do not operate the machine
Do not stack.
manual and manual holder from this machine. without the guard being fitted.

Do not stand on any service valve or Do not operate with the doors Do not use fork lift truck
other parts of the pressure system. or enclosure open. from this side.

Do not open the service valve

Do not exceed the trailer speed limit. No naked lights.
before the airhose is attached.

Use fork lift truck from this side only. Emergency stop. Tie down point.
Figure 4-- 1. GRAPHIC FORM AND MEANING OF ISO SYMBOLS (Sheet 2 of 3)

4---2 SEPTEMBER 2003

 Portable Compressor 7/20

Lifting point. On (power). Off (power).

Read the Operation and Maintenance

When parking use prop stand,
manual before operation or maintenance Compressor oil filling.
handrake and wheel chocks.
of this machine is undertaken.

Rough Service Designation.

Diesel fuel. Wet Location Operation.
Parking brake.
No open flame.

Replace any cracked protective

Oil drain.
shield.

Figure 4-- 1. GRAPHIC FORM AND MEANING OF ISO SYMBOLS (Sheet 3 of 3)

SEPTEMBER 2003 4---3

Portable Compressor 7/20

Look for these signs on machines shipped to markets in North America, which point out potential hazards to the safety of you and
others. Read and understand thoroughly. Heed warnings and follow instructions.

If you do not understand, inform your supervisor.

DANGER CAUTION
Red background Yellow background
Indicates the presence of a hazard which WILL cause Indicates the presence of a hazard which WILL or can
serious injury, death or property damage, if ignored. cause injury or property damage, if ignored.

WARNING NOTICE
Orange background Blue background
Indicates the presence of a hazard which CAN cause Indicates important set---up, operating or
serious injury, death or property damage, if ignored. maintenance information.

DANGER WARNING
Trapped air pressure. Can cause serious injury
or death.
Close service valve and operate tool
to vent trapped air before performing
any service.

Air discharged from this machine can contain carbon

monoxide or other contaminants which will cause
serious injury or death.
Do not breathe this air.
Ingersoll---Rand Co., Mocksville, N.C.27028 Ingersoll---Rand Co., Mocksville, N.C.27028

WARNING WARNING
Hot pressurized fluid. Rotating Fan Blade.
Can cause serious burns. CAN cause serious injury.
Do not open radiator while not. Do NOT operate with guard
removed.

Ingersoll---Rand Co., Mocksville, N.C.27028 Ingersoll---Rand Co., Mocksville, N.C.27028

Figure 4-- 2. SIGNS ON MACHINES SHIPPED TO MARKETS IN NORTH AMERICA (Sheet 1 of 3)

4---4 SEPTEMBER 2003

 Portable Compressor 7/20

WARNING WARNING
Improper operation of this equipment. Trapped air pressure.
CAN cause serious injury or death. Can cause serious injury or death.
Road Operator’s Manual supplied with this Close service valve and operate
machine before operation or servicing. tool to vent trapped air before
performing any service.
Modification or alteration of this machine.
CAN cause serious injury or death.
Do NOT alter or modify this machine without the
express written consent of the manufacturer.

Ingersoll---Rand Co., Mocksville, N.C.27028 Ingersoll---Rand Co., Mocksville, N.C.27028

WARNING

WARNING
Disconnected Air Hoses Whip.
CAN cause serious injury
or death.
When using air tools attach
safety device (OSHA Valve)
at source of air supply for each tool.

Falling off machine. CAN cause serious injury

or death.
Ingersoll---Rand Co., Mocksville, N.C.27028 Access Lifting Bail from inside machine.

WARNING

WARNING
High pressure air. Can
cause serious injury or death.
Relieve pressure before
removing filler plugs/caps,
fitting or covers.

Door under pressure CAN cause serious injury.

Use both hands to open door when machine is
Ingersoll---Rand Co., Mocksville, N.C.27028 running.

Figure 4-- 2. SIGNS ON MACHINES SHIPPED TO MARKETS IN NORTH AMERICA (Sheet 2 of 3)

SEPTEMBER 2003 4---5

Portable Compressor 7/20

WARNING
km/h

WARNING
Collapsing propstand.
Can cause serious injury.
Clamp propstand securely.

Excessive Towing Speed. CAN cause serious

injury or death.
Excessive towing speed. CAN cause Do NOT Tow on Highway.
serious injury or death. Do NOT exceed 20 mph (32 km/h).
Do NOT exceed 65 mph (105 km/h).

Ingersoll---Rand Co., Mocksville, N.C.27028

A. For Highway Towable Units. B. For Non---Highway Towable Machines.

Figure 4-- 2. SIGNS ON MACHINES SHIPPED TO MARKETS IN NORTH AMERICA (Sheet 3 of 3)

4.2. 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. 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.

4---6 SEPTEMBER 2003

 Portable Compressor 7/20

5. NOISE EMISSION a. fan shroud,

b. vibration mounts,
c. sound absorption material.
THIS SECTION PERTAINS ONLY TO MACHINES
DISTRIBUTED WITHIN THE UNITED STATES.
--- Operation of the compressor with any of the
enclosure doors open.

WARNING 5.1. COMPRESSOR NOISE EMISSION

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.
(2.) The use of the compressor after such a 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:
--- 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:
CONTROL INFORMATION
(1.) The removal or rendering inoperative, other than for the
purpose of maintenance, repair, or replacement of any
noise control device or an element of design incorporated
into this compressor in compliance with the noise control
act.
(2.) The use of this compressor after such a device or an
element of design has been removed or rendered
inoperative.
NOTE
The above information applies only to units that are built in
compliance with the U.S. Environmental Protection Agency.
Ingersoll---Rand Company reserves the right to make changes
or add improvements without notice and without incurring any
obligation to make such changes or add such improvements to
products sold previously.
The Purchaser is urged to include the above provisions in any
agreement for any resale of this compressor.
5.2. NOISE EMISSION CONTROL,
MAINTENANCE LOG

COMPRESSOR MODEL:

SERIAL No.:

USER UNIT No.:

DEALER OR DISTRIBUTOR FROM WHOM

UNIT IDENTIFICATION
PURCHASED:
ENGINE MAKE & MODEL:
SERIAL No:
PURCHASER OR OWNER:
ADDRESS: DATE PURCHASED:

Figure 5-- 1. MAINTENANCE LOG

The Noise Control Act of 1972 (86 Stat. 1234) prohibits of any device or element of design incorporated into any
tampering with the noise control system of any compressor new compressor for the purpose of noise control prior to its
manufactured and sold under the above regulations, sale or delivery to the ultimate purchaser or while it is in use.
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,

SEPTEMBER 2003 5---1

Portable Compressor 7/20

(2.) The use of the compressor after such a device or an 5.2.2. Introduction
element of design has been removed or rendered
The unit for which this Maintenance Log is provided conforms
inoperative by any person.
to U.S. EPA Regulations for Noise Emissions, applicable to
Portable Air Compressors.

5.2.1. Noise Emission Warranty The purpose of this book is to provide:

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.
(1.) The Maintenance Performance Schedule below for all
required noise emission controls,
(2.) Space so that the purchaser or owner can record what
maintenance was done, by whom, where
and when.

This warranty is not limited to any particular part, component, or Detailed instructions on the maintenace item bellow are given
system of the air compressor. Defects in the design, assembly, on the following page.
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. (40FR204.58---1). 5.3. MAINTENANCE PERIOD

Table 5-- 1. MAINTENANCE PERIOD

ITEM AREA PERIOD

A. COMPRESSED AIR LEAKS AS DETECTED

B. SAFETY AND CONTROL SYSTEM 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 9. MAINTENANCE SECTION OF THIS MANUAL
J. FUELS & LUBRICANT SEE 9. MAINTENANCE SECTION OF THIS MANUAL

A. COMPRESSED AIR LEAKS E. ENCLOSURE PANELS

Correct all compressed air leaks during the first shutdown
period after discovery. If severe enough to cause serious
noise problems and efficiency loss, shutdown immediately
and correct the leak(s).
B. SAFETY AND CONTROL SYSTEMS
Repair or replace all safety and control systems or circuits
as malfunction occurs. No compressor should be operated
with either system bypassed, disabled, or nonfunctional.
Enclosure panels should also be inspected at 100 hour
operational intervals. All panels that are warped,
punctured, torn, or otherwise deformed, such that their
noise containment function is reduced, should be repaired
or replaced before the next operation interval. Doors,
access panels, and hatch closures especially, should be
checked and adjusted at this time to insure continuous
sealing between a gasket or acoustic material and the
mating frame.

C. ACOUSTIC MATERIALS F. AIR INTAKE AND ENGINE EXHAUST

In daily inspections, observe these materials. Maintain all
acoustic material as soon as possible in its original
condition. Repair or replace all sections that have
sustained damage, have partially separated from the
panels to which they were attached, are missing, or have
otherwise deteriorated due to severe operating or storage
conditions.
G.
D. FASTENERS
All fasteners such as hinges, nuts, bolts, clamps, screws,
rivets and latches should be inspected for looseness after
each 100 hours of operation. They should be retightened,
repaired, or --- if missing --- replaced immediately to prevent
subsequent damage and noise emission increase.
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.
COOLING SYSTEMS
All components of the cooling systems for engine water
and compressor oil should be inspected every 250 hours
of use. Any discrepancies found should be corrected
before placing the unit back in operation. Unrestricted
airflow over the radiator and oil cooler must be maintained
at all times during operation.

5---2 SEPTEMBER 2003

 Portable Compressor 7/20

H. ISOLATION MOUNTS J. FUELS AND LUBRICANTS

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 placed with equivalent parts.
Use only the types and grades of fuels and lubricants
recommended in the Ingersoll---Rand. Refer to the
9. MAINTENANCE section of this manual.

I. ENGINE OPERATION
5.4. MAINTENANCE RECORD FOR NOISE
Inspect and maintain engine condition and operation as
recommended in 13.KUBOTA D1005 ENGINE section of EMISSION CONTROL AND
this manual. EXTENDED WARRANTY

Table 5-- 2. MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY

MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY

ITEM DESCRIPTION OF WORK OR HOUR METER MAINT/INSPECT LOCATION WORK DONE BY

No. COMMENTS READING DATE CITY/STATE NAME

SEPTEMBER 2003 5---3/(5---4 blank)


6. SAFETY
WARNING
WARNINGS CALL ATTENTION TO INSTRUCTIONS WHICH
MUST BE FOLLOWED PRECISELY TO AVOID INJURY
OR DEATH.
CAUTION
CAUTIONS CALL ATTENTION TO INSTRUCTIONS WHICH
MUST BE FOLLOWED PRECISELY TO AVOID DAMAGING
THE PRODUCT, PROCESS OR ITS SURROUNDINGS.
NOTE
Notes are used for supplementary information.
6.1. GENERAL INFORMATION
Never operate unit without first observing all safety warnings
and carefully reading the operation and maintenance manual
shipped from the factory with this machine.
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation.
Ensure that the Operation and Maintenance manual, and the
manual holder, are not removed permanently from the machine.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
Make sure that all protective covers are in place and that the
canopy/doors are closed during operation.
The specification of this machine requires that the machine is
not suitable for use in flammable gas risk areas. If such an
application is required then all local regulations, codes of
practice and site rules must be observed. To ensure that the
machine can operate in a safe and reliable manner, additional
equipment such as gas detection, exhaust spark arrestors, and
intake (shut---off) valves may be required, dependent on local
regulations or the degree of risk involved.
A weekly visual check must be made on all fasteners/fixing
screws securing mechanical parts. In particular, safety---related
parts such as a coupling hitch, drawbar components,
road---wheels, and a lifting bail should be checked for total
security.
All components which are loose, damaged or unserviceable,
must be rectified without delay.
Air discharged from this machine may contain carbon monoxide
or other contaminants which will cause serious injury or death.
Do not breathe this air.
This machine produces loud noise with the canopy open or
service valve vented. Extended exposure to loud noise can
cause hearing loss. Always wear hearing protection when
canopy is open or service valve is vented.
Never inspect or service unit without first disconnecting battery
cable(s) to prevent accidental starting.
Do not use petroleum products (solvents or fuels) under high
pressure as this can penetrate the skin and result in serious
illness. Wear eye protection while cleaning unit with
compressed air to prevent debris from injuring eye(s).
Rotating fan blade can cause serious injury. Do not operate
without a guard in place.
Use care to avoid contacting hot surfaces (engine exhaust
manifold and piping, air receiver and air discharge piping, etc.).
SEPTEMBER 2003
Portable Compressor 7/20
CAUTION
DO NOT USE ETHER AS A STARTING AID IN THIS
MACHINE.
Never operate unit with guards, covers or screens removed.
Keep hands, hair, clothing, tools, blow gun tips, etc. well away
from moving parts.
6.2. COMPRESSED AIR
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented
from the system and that the machine cannot be started
accidentally.
Ensure that the machine is operating at the rated pressure and
that the rated pressure is known to all relevant personnel.
All air pressure equipment installed in or connected to the
machine must have safe working pressure ratings of at least the
machine rated pressure.
If more than one compressor is connected to one common
downstream plant, effective check valves and isolation valves
must be fitted and controlled by work procedures, so that one
machine cannot accidently be pressurised / over pressurised by
another.
Compressed air must not be used for a direct feed to any form
of breathing apparatus or mask.
High Pressure Air can cause serious injury or death. Relieve
pressure before removing filler plugs/caps, fittings or covers.
Air pressure can remain trapped in air supply line which can
result in serious injury or death. Always carefully vent air supply
line at tool or vent valve before performing any service.
The discharged air contains a very small percentage of
compressor lubricating oil and care should be taken to ensure
that downstream equipment is compatible.
If the discharged air is to be ultimately released into a confined
space, adequate ventilation must be provided.
When using compressed air always use appropriate personal
protective equipment.
All pressure containing parts, especially flexible hoses and their
couplings, must be regularly inspected, be free from defects
and be replaced according to the Manual instructions.
Avoid bodily contact with compressed air.
The safety valve located in the separator tank must be checked
periodically for correct operation.
Whenever the machine is stopped, air will flow back into the
compressor system from devices or systems downstream of the
machine unless the service valve is closed. Install a check valve
at the machine service valve to prevent reverse flow in the event
of an unexpected shutdown when the service valve is open.
Disconnected air hoses whip and can cause serious injury or
death. Always attach a safety flow restrictor to each hose at the
source of supply or branch line in accordance with OSHA
Regulation 29CFR Section 1926.302(b).
Never allow the unit to sit stopped with pressure in the
receiver---separator system. As a precaution, open the manual
blowdown valve.
6.3. MATERIALS
The following substances may be produced during the
operation of this machine:
--- brake lining dust,
--- engine exhaust fumes.
6.3.1. Avoid Inhalation
Ensure that adequate ventilation of the cooling system and
exhaust gases is maintained at all times.
The following substances are used in the manufacture of this
machine and may be hazardous to health if used incorrectly:
6---1
Portable Compressor 7/20
--- compressor lubricant,
--- engine lubricant,
--- preservative grease,
--- rust preventative,
--- diesel fuel,
--- battery electrolyte.
6.3.2. Avoid Ingestion, Skin Contact And
Inhalation Of Fumes
Should compressor lubricant come into contact with the eyes,
then irrigate with water for at least 5 minutes.
Should compressor lubricant come into contact with the skin,
then wash it off immediately.
Consult a physician if large amounts of compressor lubricant are
ingested.
Consult a physician if compressor lubricant is inhaled.
Never give fluids or induce vomiting if the patient is unconscious
or having convulsions.
Safety data sheets for compressor and engine lubricants should
be obtained from the lubricant supplier.
Never operate the engine of this machine inside a building
without adequate ventilation. Avoid breathing exhaust fumes
when working on or near the machine.
This machine may include such materials as oil, diesel fuel,
antifreeze, brake fluid, oil/air filters and batteries which may
require proper disposal when performing maintenance and
service tasks. Contact local authorities for proper disposal of
these materials
6.4. BATTERY
A battery contains sulphuric 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.
CAUTION
DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY
SINCE THIS MAY CAUSE IT TO EXPLODE.
Exercise extreme caution when using a booster battery. To jump
a 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 the other end
to a ground connection away from a dead battery (to avoid a
spark occurring near any explosive gases that may be present).
After starting the unit, always disconnect cables in reverse order.
6.5. RADIATOR
Hot engine coolant and steam can cause injury. Ensure that the
header tank cap is removed with due care and attention.
Do not remove the header tank pressure cap from a hot
machine. Allow the radiator to cool down before removing a
pressure cap.
6.6. TRANSPORT
When loading or transporting machines ensure that the
specified lifting and tie down points are used.
When loading or transporting machines ensure that the towing
vehicle, its size, weight, towing hitch and electrical supply are all
suitable to provide safe and stable towing at speeds either, up
to the legal maximum for the country in which it is being towed
or, as specified for the machine model if lower than the legal
maximum.
6---2
Ensure that the maximum trailer weight does not exceed the
maximum gross weight of the machine (by limiting the
equipment load), limited by the capacity of the running gear.
NOTE
Gross mass (on data plate) is for the basic machine and fuel
only, excluding any fitted options, tools, equipment and foreign
materials.
Before towing the machine, ensure that:
--- the tyres and towing hitch are in a serviceable condition,
--- the canopy is secure,
--- all ancillary equipment is stored in a safe and secure
manner,
--- the brakes and lights are functioning correctly and meet
necessary road traffic requirements (when fitted),
--- break---away cables/safety chains are connected to the
towing vehicle.
The machine must be towed in a level attitude in order to
maintain correct handling, braking and lighting functions. This
can be achieved by correct selection and adjustment of the
vehicle towing hitch and, on variable height running gear,
adjustment of the drawbar.
When adjusting variable height running gear:
--- ensure front (towing eye) section is set level,
--- when raising towing eye, set rear joint first, then front joint,
--- when lowering towing eye, set front joint first, then rear joint.
After setting, fully tighten each joint by hand and then tighten
further to the next pin. Refit the pin.
When parking always use the handbrake when fitted and if
necessary, suitable wheel chocks.
Make sure wheels, tyres and tow bar connectors are in the safe
operating condition and the tow bar is properly connected
before towing.
6.7. SAFETY CHAINS / CONNECTIONS
AND THEIR ADJUSTMENT
The legal requirements for the joint operation of the breakaway
cable and safety chains are as yet unidentified by 71/320/EEC
or UK regulations. Consequently we offer the following
advice/instructions.
Where brakes only are fitted:
a. Ensure that the breakaway cable is securely coupled to the
handbrake lever and also to a substantial point on the
towing vehicle.
b. Ensure that the effective cable length is as short as
possible, whilst still allowing enough slackness for the
trailer to articulate without the handbrake being applied.
Where brakes and safety chains are fitted:
a. Loop the chains onto the towing vehicle using the towing
vehicle hitch as an anchorage point, or any other point of
similar strength.
b. Ensure that the effective chain length is as short as possible
whilst still allowing normal articulation of the trailer and
effective operation of the breakaway cable.
Where safety chains only are fitted:
a. Loop the chains onto the towing vehicle using the towing
vehicle hitch as an anchorage point, or any other point of
similar strength.
b. When adjusting the safety chains there should be sufficient
free length in the chains to allow normal articulation, whilst
also being short enough to prevent the towbar from
touching the ground in the event of an accidental
separation of the towing vehicle from the trailer.
SEPTEMBER 2003
 Portable Compressor 7/20

7. GENERAL INFORMATION

7/20 VARIABLE HEIGHT RUNNING GEAR

7/20 FIXED HEIGHT RUNNING GEAR

Figure 7-- 1. GENERAL INFORMATION

SEPTEMBER 2003 7---1

Portable Compressor 7/20

7.1. COMPRESSOR

Table 7-- 1. COMPRESSOR DATA

ITEM VALUE

ACTUAL FREE AIR DELIVERY 1.84 m3 min ---1 (65 CFM)

NORMAL OPERATING DISCHARGE PRESSURE 7 bar / 100 psi
MAXIMUM ALLOWABLE PRESSURE 8.6 bar (125 psi)
SAFETY VALVE SETTING 10 bar (145 psi)
MAXIMUM PRESSURE RATIO (ABSOLUTE) 7.5
OPERATING AMBIENT TEMPERATURE
Whisperized ---10˚C ÷ 46˚C (14˚F ÷ 115˚F)
Standard ---10˚C ÷ 52˚C (14˚F ÷ 126˚F)
MAXIMUM DISCHARGE TEMPERATURE 120˚C (248˚F)
COOLING SYSTEM Oil injection
OIL CAPACITY 2.3 l (0.61 gal)
MAXIMUM OIL SYSTEM TEMPERATURE 120˚C (248˚F)
MAXIMUM OIL SYSTEM PRESSURE 8.6 bar (125 psi)

7.2. LUBRICATING OIL SPECIFICATION

(For The Specified Ambient
Temperatures)

Table 7-- 2. LUBRICATING OIL SPECIFICATION

ABOVE ---23˚C (---9˚F) BELOW ---23˚C (---9˚F)

RECOMMENDED Pro---TecTM
MANDATORY I---R Performance 500
APPROVED SAE 10W, API CF---4/CG---4

Ingersoll---Rand Pro--- TecTM compressor fluid is factory---fitted,
for use at all ambient temperatures above ---23˚C (---9˚F).
NOTE
Warranty may be extended only by continuous use of
Pro---Tec TM and Ingersoll---Rand oil filters and separators.
system including separator/receiver, cooler and pipework must
be flushed clear of the first fill fluid and new Ingersoll---Rand oil
filters installed. When this has been completed, the following oils
are approved:
a. for ambient temperatures above ---23˚C (---9˚F), SAE 10W,
API CF---4/CG---4,

CAUTION b. for ambient temperatures below ---23˚C (---9˚F), IR

Performance 500 only.
NO OTHER OIL/FLUIDS ARE COMPATIBLE WITH Pro--- TecTM

No other oils/fluids should be mixed with Pro---TecTM because Safety data sheets can be obtained on request from the
the resulting mixture could cause damage to the airend. lubricant supplier.
In the event that Pro--- Tec TM is not available and/or the end user For temperatures outside the specified ambient range, consult
needs to use an approved single grade engine oil, the complete Ingersoll---Rand.

7---2 SEPTEMBER 2003

 Portable Compressor 7/20

7.3. ENGINE

Table 7-- 3. ENGINE DATA

ITEM VALUE

TYPE/MODEL
NUMBER OF CYLINDERS
OIL CAPACITY
SPEED AT FULL LOAD
SPEED AT IDLE
ELECTRICAL SYSTEM
POWER AVAILABLE AT 3,000
FUEL TANK CAPACITY
COOLANT CAPACITY
OIL SPECIFICATION
D1005---EBB---EC---LT---1
3
5.1 l (1.35 gal)
3,000 min ---1 (RPM)
2,000 min ---1 (RPM)
12 V negative earth
min ---1 (RPM) 17.5 kW (23.5 hp)
26 l (6.87 gal)
4 l (1.06 gal)
Refer engine section

7.4. FIXED HEIGHT RUNNING GEAR

(Unbraked version KNOTT)

Table 7-- 4. FIXED HEIGHT RUNNING GEAR (UNBRAKED VERSION KNOTT)

ITEM VALUE

SHIPPING WEIGHT 430 kg (948 lb)

MAXIMUM GROSS WEIGHT 500 kg (1,102 lb)
MAXIMUM HORIZONTAL TOWING FORCE 7,250 N (1,600 lbf)
MAXIMUM VERTICAL COUPLING LOAD (NOSE WEIGHT) 750 N (165 lbf)

7.5. VARIABLE HEIGHT RUNNING GEAR

(Unbraked version KNOTT)

Table 7-- 5. VARIABLE HEIGHT RUNNING GEAR (UNBRAKED VERSION KNOTT)

ITEM VALUE

SHIPPING WEIGHT 445 kg (981 lb)

MAXIMUM GROSS WEIGHT 500 kg (1,102 lb)
MAXIMUM HORIZONTAL TOWING FORCE 7,250 N (1,600 lbf)
MAXIMUM VERTICAL COUPLING LOAD (NOSE WEIGHT) 750 N (165 lbf)

SEPTEMBER 2003 7---3

Portable Compressor 7/20

7.6. FIXED HEIGHT RUNNING GEAR

(Braked version KNOTT)

Table 7-- 6. FIXED HEIGHT RUNNING GEAR (BRAKED VERSION KNOTT)

ITEM VALUE

SHIPPING WEIGHT 455 kg (1,003 lb)

MAXIMUM GROSS WEIGHT 500 kg (1,102 lb)
MAXIMUM HORIZONTAL TOWING FORCE 7,250 N (1,600 lbf)
MAXIMUM VERTICAL COUPLING LOAD (NOSE WEIGHT) 750 N (165 lbf)

7.7. VARIABLE HEIGHT RUNNING GEAR

(Braked version KNOTT)

Table 7-- 7. VARIABLE HEIGHT RUNNING GEAR (BRAKED VERSION KNOTT)

ITEM VALUE

SHIPPING WEIGHT 470 kg (1,036 lb)

MAXIMUM GROSS WEIGHT 500 kg (1,102 lb)
MAXIMUM HORIZONTAL TOWING FORCE 7,250 N (1,600 lbf)
MAXIMUM VERTICAL COUPLING LOAD (NOSE WEIGHT) 750 N (165 lbf)

7.8. WHEELS AND TYRES (KNOTT)

Table 7-- 8. WHEELS AND TYRES

ITEM VALUE

NUMBER OF WHEELS 2 x 41/2 J

TYRE SIZE 155 R13 82R AVON
TYRE PRESSURE 2.4 bar (35 psi)

CAUTION
FURTHER INFORMATION MAY BE OBTAINED BY REQUEST
THROUGH INGERSOLL---RAND CUSTOMER SERVICES
DEPARTMENT.

7---4 SEPTEMBER 2003


8. OPERATING INSTRUCTIONS
8.1. COMMISSIONING
Upon receipt of the unit, and prior to putting it into service, it is
important to adhere strictly to the instructions given below in
8.2 PRIOR TO STARTING.
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation.
Ensure that the position of the emergency stop device is known
and recognised by its markings. Ensure that it is functioning
correctly and that the method of operation is known.
Running gear drawbar---machines are shipped to some areas
with the drawbar removed. Fitting involves four nuts I bolts to
secure the drawbar to the axle and two bolts to fit the drawbar
to the front of the machine with the saddle and spacer block.
Support the front of the machine, fit the wheel chocks to stop the
machine moving and attach the drawbar. Refer to the Table 9 ---2.
TORQUE VALUES in the 9. MAINTENANCE section of this manual
for the correct torque values.
CAUTION
THIS IS A SAFETY CRITICAL PROCEDURE. DOUBLE CHECK
THE TORQUE SETTINGS AFTER ASSEMBLY
Fit the propstand and coupling. Remove the supports and set
the machine level.
Before towing the unit, ensure that the tyre pressures are correct
(refer to the 7. GENERAL INFORMATION section of this manual)
and that the handbrake is functioning correctly (refer to the
9. MAINTENANCE section of this manual). Before towing the unit
during the hours of darkness, ensure that the lights are
functioning correctly (where fitted).
Ensure that all transport and packing materials are discarded.
Ensure that the correct fork lift truck slots or marked liftingItie
down points are used whenever the machine is lifted or
transported.
A B
E F
Figure 8-- 1. PRIOR TO STARTING
SEPTEMBER 2003
Portable Compressor 7/20
When selecting the working position of the machine ensure that
there is sufficient clearance for ventilation and exhaust
requirements, observing any specified minimum dimensions (to
walls, floors etc.).
Adequate clearance needs to be allowed around and above the
machine to permit safe access for specified maintenance tasks.
Ensure that the machine is positioned securely and on a stable
foundation. Any risk of movement should be removed by
suitable means, especially to avoid strain on any rigid discharge
piping.
Attach the battery cables to the battery(s) ensuring that they are
tightened securely. Attach the negative cable before attaching
the positive cable.
WARNING
ALL AIR PRESSURE EQUIPMENT INSTALLED IN OR
CONNECTED TO THE MACHINE MUST HAVE SAFE
WORKING PRESSURE RATINGS OF AT LEAST THE
MACHINE RATED PRESSURE, AND MATERIALS
COMPATIBLE WITH THE COMPRESSOR LUBRICANT
(REFER TO THE 7.GENERAL INFORMATION SECTION).
IF MORE THAN ONE COMPRESSOR IS CONNECTED TO
ONE COMMON DOWNSTREAM PLANT, EFFECTIVE
CHECK VALVES AND ISOLATION VALVES MUST BE
FITTED AND CONTROLLED BY WORK PROCEDURES, SO
THAT ONE MACHINE CANNOT ACCIDENTLY BE
PRESSURISED BYANOTHER.
IF FLEXIBLE DISCHARGE HOSES ARE TO CARRY MORE
THAN 7 bar/100 psi PRESSURE THEN IT IS
RECOMMENDED THAT SAFETY RETAINING WIRES ARE
USED ON THE HOSES.
8.2. PRIOR TO STARTING
C D
G
8---1
Portable Compressor 7/20

A. Place the unit in a position that is in a possible level. The F. Canopy

design of the unit permits a 15˚ (degree) lengthways and
sideways limit on out of level operation. It is the engine, not
the compressor, that is the limiting factor.
When the unit has to be operated out of level, it is important
to keep the engine oil level near the high level mark (with
the unit level).
CAUTION
DO NOT OPERATE THE MACHINE WITH THE CANOPY IN
THE OPEN POSITION AS THIS MAY CAUSE OVERHEATING
AND OPERATORS TO BE EXPOSED TO HIGH NOISE
LEVELS.

G. Check the radiator coolant level (with the unit level).

CAUTION
Check the air restriction indicator(s). Refer to the
DO NOT OVERLILL EITHER THE ENGINE OR THE
9.MAINTENANCE section of this manual.
COMPRESSOR WITH OIL.
When starting or operating the machine in temperatures
below or approaching 0˚C (32˚F), ensure that the
B. Check the engine lubrication oil in accordance with the operation of the regulation system, the unloader valve, the
operating instructions in the 13. KUBOTA D1005 ENGINE. safety valve, and the engine are not impaired by ice or
C. Check the compressor oil level (with the unit level). snow, and that all inlet and outlet pipes and ducts are clear
of ice and snow.
CAUTION
FILL OIL UP TO THE FILLER NECK END.
8.3. STARTING THE MACHINE
D. Check the diesel fuel level. A good rule is to top up at the
end of each working day. This prevents condensation from
occurring in the tank. WARNING
CAUTION
USE ONLY A No. 2---D DIESEL FUEL OIL WITH A MINIMUM UNDER NO CIRCUMSTANCES SHOULD VOLATILE
OCTANE NUMBER OF 45 AND A SULPHUR CONTENT NOT LIQUIDS SUCH AS ETHER BE USED FOR STARTING THIS
GREATER THAN 0.5%. MACHINE.

CAUTION All normal starting functions are incorporated in the key

operated switch (Figure 8 ---2 CONTROL OF THE MACHINE,
WHEN REFUELLING: SWITCH OFF THE ENGINE, DO NOT position 1):
SMOKE, EXTINGUISH ALL NAKED LIGHTS, DO NOT ALLOW
THE FUEL TO COME INTO CONTACT WITH HOT SURFACES --- turn the key switch to position II (GLOW) and hold for
AND WEAR PERSONAL PROTECTIVE EQUIPMENT. 15 seconds to allow the glow plugs to reach working
temperature,
E. Open the service valve(s) to ensure that all pressure is --- turn the key switch to position III (ENGINE START),
relieved from the system. Close the service valve(s). --- release to position I (START) when the engine starts.

2 1 3

0 --- position OFF

1. Key switch I --- position START
2. Hour meter II --- position GLOW
3. Pressure gauge III --- position ENGINE START

Figure 8-- 2. CONTROL OF THE MACHINE

8---2 SEPTEMBER 2003

 Portable Compressor 7/20

At temperatures below 0˚C (32˚F) or if there is difficulty starting
first time:
--- open the service valve fully, with no hose connected,
--- complete starting sequence above,
--- close service valve as soon as engine runs freely,
--- do not allow the machine to run for long periods with
a service valve open,
--- allow the engine to reach the operating temperature,
--- at this point in the operation of the machine it is safe
to apply full load to the engine.
8.6. RE---STARTING AFTER AN
EMERGENCY
If the machine has been switched off because of a machine
malfunction, then identify and correct the fault before attempting
to re---start.
If the machine has been switched off for reasons of safety, then
ensure that the machine can be operated safely before
re---starting.
Refer to the 8.2. PRIOR TO STARTING and 8.3. STARTING THE
MACHINE instructions earlier in this section before re---starting
the machine.

NOTE
Wear hearing protection at all times when the engine is started 8.7. MONITORING DURING OPERATION
with the service valve open and air is flowing from the valve.
Should any of the safety shut---down conditions occur, the unit
will stop. These are:

8.4. STOPPING THE MACHINE

--- low engine oil pressure,
--- high air discharge temperature,
Operation:
--- high engine water temperature.
--- close the service valve,
--- allow the machine to run unloaded for a short period CAUTION
of time to reduce the engine temperature, TO ENSURE AN ADEQUATE FLOW OF OIL TO THE
--- turn the start switch to the 0 (OFF) position COMPRESSOR AT LOW TEMPERATURE, NEVER ALLOW
THE DISCHARGE PRESSURE TO FALL BELOW 3.5 bar
NOTE (51 psi).
As soon as the engine stops, the automatic blowdown valve
will relieve all pressure from the system.
8.8. DECOMMISSIONING
If the automatic blowdown valve fails to operate, then pressure When the machine is to be permanently decommissioned or
must be relieved from the system by means of the service dismantled, it is important to ensure that all hazard risks are
valve(s). either eliminated or notified to the recipient of the machine. In
particular:
CAUTION
--- do not destroy batteries or components containing
NEVER ALLOW THE MACHINE TO STAND IDLE WITH asbestos without containing the materials safely,
PRESSURE IN THE SYSTEM.
--- do not dispose of any pressure vessel that is not
clearly marked with its relevant data plate information
or rendered unusable by drilling, cutting etc,
8.5. EMERGENCY STOPPING --- do not allow lubricants or coolants to be released into
In the event that the unit has to be stopped in an emergency, turn land surfaces or drains,
the key switch located on the instrument panel to the 0 (OFF) --- do not dispose of a complete machine without
position. documentation relating to instructions for its use.

SEPTEMBER 2003 8---3/(8---4 blank)

 Portable Compressor 7/20

9. MAINTENANCE

9.1. MAINTENANCE SCHEDULE

Table 9-- 1. MAINTENANCE SCHEDULE

Initial Hours Monthly/Hours
km
Hours
(miles) Daily
y Weekly
y
200/400 1/
1/--- 3/250 6/500 12/1 000
12/1,000
850
50
(500)

Compressor Oil Level C

Engine Oil Level C
*Radiator Coolant Level C
Gauges/Lamps C
*Air Cleaner Service Indicators C
Fuel Tank (Fill at end of day) C
*Fuel/Water Separator Drain C
Oil Leaks C
Fuel Leaks C
Drain Water From Fuel Filters C
Coolant Leaks C
Header Tank Cap C
Fan/Alternator Belts C
Battery Connections/Electrolyte C
Tire Pressure and Surface C
*Wheel Lug Nuts C
Hoses (Oil, Air, Intake, etc.) C
Automatic Shutdown System C
Air Cleaner System C
Compressor Oil Cooler Exterior C
*Engine Radiator Exterior C
Fasteners, Guards C
Air Cleaner Elements R (WI)
*Fuel/Water Separator Element R
Compressor Oil Filter Element R
Compressor Oil R
Engine Oil Change R R/---
Engine Oil Filter R R/---
*Water Pump Grease R
*Wheels (Bearings, Seals, etc.) C
*Engine Coolant C
Fuel Filter Element ---/R
*Injection Nozzle Check C
Shutdown Switch Settings T
Scavenger Orifice
C
& Related Parts
(continued on next page)

SEPTEMBER 2003 9---1

Portable Compressor 7/20

Table 9-- 1. (continued) MAINTENANCE SCHEDULE

Initial Hours Monthly/Hours
km
Hours
(miles) Daily
y Weekly
y
200/400 1/
1/--- 3/250 6/500 12/1 000
12/1,000
850
50
(500)

Oil Separator Element R

*Feed Pump Strainer Cleaning C
Coolant Replacement R
*Valve Clearance Check C
Lights (running, brake,
CBT
& turn)
Pintle Eye Bolts CBT
*Brakes C
*Brake linkage C
*Emergency stop T
Fasteners C
*Running gear linkage G
Safety valve C
Running gear bolts (1) C
Scavenge line C
Pressure system C
*Engine breather element C
Pressure gauge C
Pressure regulator C
Separator tank (2) exterior CR
*Lubricator (Fill) C

2,000 Hours/ 2 Years 2 Years 4 Years 6 Years

Airend drive belt R
Safety valve C
Hoses R
Separator tank (2) interior C

*Disregard if not appropriate for this particular machine. D= Drain

G= Grease
(1) or 5,000 km / 3,000 miles whichever is the sooner R= Replace
(2) or as defined by local or national legislation T= Test
C= Check (adjust, clean or replace as necessary) WI = or When Indicated if earlier.
CBT = Check Before Towing
Refer to specific sections of the operator’s manual for more
CR = Check and Report information.

9---2 SEPTEMBER 2003

 Portable Compressor 7/20

9.2. ROUTINE MAINTENANCE --- the machine is suitably tested,

This section refers to the various components which require --- all guards and safety protection devices are refitted,
periodic maintenance and replacement. --- all panels are replaced, canopy and doors closed,
The Table 9 ---1. MAINTENANCE SCHEDULE indicates the --- hazardous materials are effectively contained and
various components’ descriptions and the intervals when disposed of.
maintenance has to take place. Oil capacities, etc., can be found
in the 7.GENERAL INFORMATION section of this manual.
For any specification or specific requirement on service or 9.3. PROTECTIVE SHUTDOWN SYSTEM
preventative maintenance for the engine, refer to the
13. KUBOTA D1005 EGINE. Comprises:
Compressed air can be dangerous if incorrectly handled. Before --- low engine oil pressure switch,
doing any work on the unit, ensure that all pressure is vented --- high discharge air temperature switch,
from the system and that the machine cannot be started
accidentally. --- high engine water temperature switch.

If the automatic blowdown fails to operate, then pressure must
be gradually relieved by operating the manual blowdown valve.
Suitable personal protective equipment should be worn.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
A. Prior to attempting any maintenance work, ensure that:
--- all air pressure is fully discharged and isolated from
the system. If the automatic blowdown valve is used
for this purpose, then allow enough time for it to
complete the operation,
--- the discharge pipe I manifold area must be kept
depressurised by opening the discharge valve, whilst
keeping clear of any airfiow from it,
--- the machine cannot be started accidently or
otherwise, by posting warning signs and/or fitting
appropriate anti---start devices,
--- all residual electrical power sources (mains and
battery) are isolated.
B. Prior to opening or removing panels or covers to work
inside a machine, ensure that:
--- anyone entering the machine is aware of the reduced
level of protection and the additional hazards,
including hot surfaces and intermittently moving
parts,
--- the machine cannot be started accidently or
otherwise, by posting warning signs and/or fitting
appropriate anti---start devices.
C. Prior to attempting any maintenance work on a running
machine, ensure that:
--- the work carried out is limited to only those tasks
which require the machine to run,
--- the work carried out with safety protection devices
disabled or removed is limited to only those tasks
which require the machine to be running with safety
protection devices disabled or removed,
--- all hazards present are known (e.g. pressurised
components, electrically live components, removed
panels, covers and guards, extreme temperatures,
inflow and outflow of air, intermittently moving parts,
safety valve discharge etc.),
--- appropriate personal protective equipment is worn,
--- loose clothing, jewellery, long hair etc. is made safe,
--- warning signs indicating that maintenance work is in
progress are posted in a position that can be clearly
seen.
D. Upon completion of maintenance tasks and prior to
returning the machine into service, ensure that:
A. Low Engine Oil Pressure Switch
At three month intervals, test the engine oil pressure switch
circuit as follows:
--- start the machine,
--- remove a wire from one terminal of the switch. The
machine should shutdown.
At twelve month intervals, test the engine oil pressure switch as
follows:
--- remove the switch from the machine,
--- connect it to an independent low pressure supply
(either air or oil). The switch should operate at 1.0 bar
(14.5 psi),
--- refit the switch.
B. Temperature Switch(es)
At three month intervals, test the temperature switch circuit(s) as
follows:
--- start the machine,
--- disconnect each switch in turn. The machine should
shutdown,
--- re---connect the switch.
C. High Discharge Air Temperature Switch(es)
At twelve month intervals, test the air discharge temperature
switch(es) by removing it from the machine and immersing in a
bath of heated oil. The switch should operate at 120˚C (248˚F).
Refit the switch.
D. High Water Temperature Switch
At twelve month intervals, test the water temperature switch by
re---moving it from the machine and immersing in a bath of
heated oil. The switch should operate at 115˚C (239˚F). Refit the
switch.
CAUTION
NEVER REMOVE OR REPLACE SWITCHES WHEN THE
MACHINE IS RUNNING.
9.4. SCAVENGE LINE
The scavenge line runs from the combined orifice/drop tube in
the separator tank, to the orifice fitting located in the airend.
Examine the orifice, check valve and hoses at every service or
in the event of oil carryover into the discharge air.
It is good preventative maintenance to check that the scavenge
line and tube are clear of any obstruction each time the
compressor lubricant is changed as any blockage will result in
oil carryover into the discharge air.

SEPTEMBER 2003 9---3

Portable Compressor 7/20
9.5. COMPRESSOR OIL FILTER
Refer to the Table 9 ---1. MAINTENANCE SCHEDULE in this
section for the recommended servicing intervals.
A. Removal
WARNING
DO NOT REMOVE THE FILTER(S) WITHOUT FIRST
MAKING SURE THAT THE MACHINE IS STOPPED AND
THE SYSTEM HAS BEEN COMPLETELY RELIEVED OF ALL
AIR PRESSURE. (REFER TO 8.4. STOPPING THE MACHINE
IN THE 8.OPERATING INSTRUCTIONS SECTION OF THIS
MANUAL).
Clean the exterior of the filter housing and remove the spin---on
element by turning it in a counter---clockwise direction.
B. Inspection
Examine the filter element.
CAUTION
IF THERE IS ANY INDICATION OF THE FORMATION OF
VARNISHES, SHELLACS OR LACQUERS ON THE FILTER
ELEMENT, IT IS A WARNING THAT THE COMPRESSOR
LUBRICATING AND COOLING OIL HAS DETERIORATED
AND THAT IT SHOULD BE CHANGED IMMEDIATELY. REFER
TO 9.21. LUBRICATION IN THIS SECTION.
C. Reassembly
Clean the filter gasket contact area and install the new element
by screwing in a clockwise direction until the gasket makes
contact with the filter housing. Tighten a further 1/2 to 3/4 of a
revolution.
CAUTION
START THE MACHINE (REFER TO 8.2. PRIOR TO STARTING
AND 8.3. STARTING THE MACHINE IN THE 8. OPERATING
INSTRUCTIONS SECTION OF THIS MANUAL) AND CHECK
FOR LEAKAGE BEFORE THE MACHINE IS PUT BACK INTO
SERVICE.
9.6. COMPRESSOR OIL SEPARATOR
ELEMENT
Normally the separator element will not require periodic
maintenance provided that the air and oil filter elements are
correctly maintained.
If, however, the element has to be replaced, then proceed as
follows.
A. Removal
WARNING
DO NOT REMOVE THE FILTER(S) WITHOUT FIRST
MAKING SURE THAT THE MACHINE IS STOPPED AND
THE SYSTEM HAS BEEN COMPLETELY RELIEVED OF ALL
AIR PRESSURE. (REFER TO 8.4. STOPPING THE MACHINE
IN THE 8.OPERATING INSTRUCTIONS SECTION OF THIS
MANUAL).
Disconnect all hoses and tubes from the separator tank cover
plate. Remove the drop---tube from the separator tank cover
9---4
plate and then remove the cover plate. Remove the separator
element.
B. Inspection
Examine the filter element. Examine all hoses and tubes, and
replace if necessary.
C. Reassembly
Thoroughly clean the orifice/drop tube and filter gasket contact
area before reassembly. Install the new element
WARNING
DO NOT REMOVE THE STAPLE FROM THE ANTI---STATIC
GASKET ON THE SEPARATOR ELEMENT SINCE IT
SERVES TO GROUND ANY POSSIBLE STATIC BUILD---UP.
DO NOT USE GASKET SEALANT SINCE THIS WILL
AFFECT ELECTRICAL CONDUCTANCE.
Reposition the cover plate, taking care not to damage the
gasket, and replace the cover plate screws tightening in a
criss---cross pattern to the recommended torque (refer to the
Table 9 ---2. TORQUE VALUES later in this section).
Engage the adaptor in the cover plate with the drop---tube
integral with the filter, reconnect all hoses and tubes to the
separator tank cover plate.
Replace the compressor oil (refer to 9.21. LUBRICATION later in
this section).
CAUTION
START THE MACHINE (REFER TO 8.2. PRIOR TO STARTING
AND 8.3. STARTING THE MACHINE IN THE 8. OPERATING
INSTRUCTIONS SECTION OF THIS MANUAL) AND CHECK
FOR LEAKAGE BEFORE THE MACHINE IS PUT BACK INTO
SERVICE.
9.7. COMPRESSOR OIL COOLER AND
ENGINE RADIATOR
When grease, oil and dirt accumulate on the exterior surfaces of
the oil cooler and radiator, the efficiency is impaired. It is
recommended that each month the oil cooler and radiator be
cleaned by directing a jet of compressed air, (carrying if possible
a non---flammable cleaning solvent) over the exterior core of the
cooler/radiator. This should remove any accumulation of oil,
grease and dirt from the exterior core of the cooler so that the
entire cooling area can radiate the heat of the lubricating and
cooling oil/water into the air stream.
WARNING
HOT ENGINE COOLANT AND STEAM CAN CAUSE
INJURY. WHEN ADDING COOLANT OR ANTIFREEZE
SOLUTION TO THE ENGINE RADIATOR, STOP THE
ENGINE AT LEAST ONE MINUTE PRIOR TO RELEASING
THE RADIATOR FILLER CAP. USING A CLOTH TO
PROTECT THE HAND, SLOWLY RELEASE THE FILLER
CAP, ABSORBING ANY RELEASED FLUID WITH THE
CLOTH. DO NOT REMOVE THE FILLER CAP UNTIL ALL
EXCESS FLUID IS RELEASED AND THE ENGINE
COOLING SYSTEM FULLY DEPRESSURISED.
SEPTEMBER 2003

WARNING
FOLLOW THE INSTRUCTIONS PROVIDED BY THE
ANTIFREEZE SUPPLIER WHEN ADDING OR DRAINING
THE ANTIFREEZE SOLUTION. IT IS ADVISABLE TO WEAR
PERSONAL PROTECTIVE EQUIPMENT TO PREVENT SKIN
AND EYE CONTACT WITH THE ANTIFREEZE SOLUTION.
9.8. AIR FILTER ELEMENTS
The air filter should be inspected regularly (refer to the Table
9 ---1. MAINTENANCE SCHEDULE) and the element replaced
when the restriction indicator shows red or every 6 Months (500
hours), whichever comes first. The dust collector box(es) should
be cleaned daily (more frequently in dusty operating conditions)
and not allowed to become more than half full.
A. Removal
CAUTION
NEVER REMOVE AND REPLACE ELEMENT(S) WHEN THE
MACHINE IS RUNNING.
Clean the exterior of the filter housing and remove the filter
element by releasing the nut.
B. Inspection
Check for cracks, holes or any other damage to the element by
holding it up to a light source, or by passing a lamp inside.
Check the seal at the end of the element and replace if any sign
of damage is evident.
C. Reassembly
Assemble the new element into the filter housing ensuring that
the seal seats properly.
Reset the restriction indicator by depressing the rubber
diaphragm.
Assemble the dust collector box parts, ensuring that they are
correctly positioned.
Before restarting the machine, check that all clamps are tight.
9.9. VENTILATION
Always check that the air inlets and outlets are clear of debris
etc.
CAUTION
NEVER CLEAN BY BLOWING AIR INWARDS.
9.10. COOLING FAN DRIVE
Periodically check that the fan mounting bolts in the fan hub
have not loosened. If, for any reason, it becomes necessary to
remove the fan or re---tighten the fan mounting bolts, apply a
good grade of commercially available thread locking
compound to the bolt threads and tighten to the torque value
shown in the Table 9 ---2. TORQUE VALUES later in this section.
The fan belt(s) should be checked regularly for wear and correct
tensioning.
9.11. FUEL SYSTEM
The fuel tank should be filled daily or every eight hours. To
minimize condensation in the fuel tank, it is advisable to top up
after the machine is shut down or at the end of each working day
At six month intervals drain any sediment or condensate that
may have accumulated in the tank.
SEPTEMBER 2003
Portable Compressor 7/20
9.12. FUEL FILTER WATER SEPARATOR
The fuel filter water separator contains a filter element which
should be replaced at regular intervals (see the Table 9 ---1.
MAINTENANCE SCHEDULE).
9.13. HOSES
All components of the engine cooling air intake system should
be checked periodically to keep the engine at peak efficiency.
At the recommended intervals, (see the Table 9 ---1.
MAINTENANCE SCHEDULE), inspect all of the intake lines to the
air filter, and all flexible hoses used for air lines, oil lines and fuel
lines.
Periodically inspect all pipework for cracks, leaks, etc. and
replace immediately if damaged.
9.14. ELECTRICAL SYSTEM
WARNING
ALWAYS DISCONNECT THE BATTERY CABLES BEFORE
PERFORMIN ANY MAINTENANCE OR SERVICE.
Inspect the safety shutdown system switches and the
instrument panel relay contacts for evidence of arcing and
pitting Clean where necessary.
Check the mechanical action of the components.
Check the security of electrical terminals on the switches and
relays le. nuts or screws loose, which may cause local hot spot
oxidation.
Inspect the components and wiring for signs of overheating le.
discolouration, charring of cables, deformation of parts, acrid
smells and blistered paint.
9.15. BATTERY
Keep the battery terminals and cable clamps clean and lightly
coated with petroleum jelly to prevent corrosion.
The retaining clamp should be kept tight enough to prevent the
battery from moving.
9.16. PRESSURE SYSTEM
At 500 hour intervals it is necessary to inspect the extemal
surfaces of the system (from the airend through to the discharge
valve(s)) including hoses, tubes, tube fittings and the separator
tank, for visible signs of impact damage, excessive corrosion,
abrasion, tightness and chafing Any suspect parts should be
replaced before the machine is put back into service.
9.17. TYRES/TYRE PRESSURE
See the 7. GENERAL INFORMATION section of this manual.
9.18. RUNNING GEAR/WHEELS
Check the wheel nut torque 30 km (20 miles) after refitting the
wheels. Refer to the Table 9 ---2. TORQUE VALUES later in this
section.
Lifting jacks should only be used under the axle.
The bolts securing the running gear to the chassis should be
checked periodically for tightness (refer to the Table 9 ---1.
MAINTENANCE SCHEDULE for frequency) and re---tightened
where necessary. Refer to the Table 9 ---2. TORQUE VALUES later
in this section.
9---5
Portable Compressor 7/20

9.19. BRAKES 8
5
Check and adjust the brake linkage at 850 km (500 miles) then
every 5,000 km (3,000 miles) or 3 months (whichever is the
sooner) to compensate for any stretch of the adjustable cables.
Check and adjust the wheel brakes to compensate for wear.
10

9.20. ADJUSTING THE BRAKING SYSTEM

(KNOTT RUNNING GEAR)
7 11
(1.) Preparation
7. Brake linkage
Jack up the machine. 8. Equalisation assembly
9. Compression spring
Disengage the hadbrake lever 1. 10. Equaliser plate
11. Bowden cable
Fully extend the draw bar 2 on the braking system.

Figure 9-- 2. EQUALISER

CAUTION
THE COMPRESSION SPRING 9 MUST ONLY BE LIGHTLY
2 PRE---TENSIONED AND WHEN OPERATING MUST NEVER
TOUCH THE AXLE TUBE.
NEVER ADJUST THE BRAKES AT THE BRAKE LINKAGE 7.
5
(2.) Brake Shoe Adjustment

4
12
3 1

6
1. Handbrake lever
2. Draw bar and bellows
3. Handbrake lever pivot
4. Spring sleeve complete
5. Brake cable
6. Breakaway cable
13

Figure 9-- 1. BRAKING SYSTEM

12. Adjusting screw
13. Cable entry

Figure 9-- 3. WHEEL BRAKE

Width across flats of adjusting screw 12.

Requirements
Brake size Key size
During the adjustment procedure always start with the wheel 160x35 / 200x50 SW 17
brakes.
250x40 SW 19
Always rotate the wheel in the direction of forward movement. 300x60 SW 22

Ensure that an M10 safety screw is fitted to the handbrake pivot.
The brake actuators must not be pre---tensioned---if necessary
loosen the brake linkage 7 on the brake equalisation
assembly 8.
Check that brake actuators and bowden cables 11 operate
smoothly.
Tighten adjusting screw 12 clockwise until the wheel locks.
Loosen adjusting screw 12 anti---clockwise (approx. ½ turn)
until the wheel can be moved freely.
Slight dragging noises that do not impede the free movement of
the wheel are permissible.
This adjustment procedure must be carried out as described on
both wheel brakes.

9---6 SEPTEMBER 2003


When the brake has been adjusted accurately the actuating
distance is approximately 5÷8 mm (0.18÷0.3 in) on the bowden
cable 11.
(3.) Compensator Assembly Adjustment
Variable Height models
Fit an M10 safety screw to the handbrake pivot.
Disconnect the brake cable 5 at one end.
Pre---adjust brake linkage 7 lenghtways (a little play is
permissible) and re---insert the brake cable 5, adjusting it to give
a small amount of play.
Remove the M10 safety screw from the handbrake pivot.
All models
Engage the handbrake lever 1 and check that the position of the
equaliser plate 10 is at right angles to the pulling direction. If
necessary correct the position of the equaliser plate 10 on the
bowden cables 11.
The compression spring 9 must only be slightly pre---tensioned
and when engaged must not touch the axle tube.
(4.) Brake Linkage Adjustment
Adjust the brake linkage 7 lengthways without pre---tension.
Readjustment
Engage the handbrake lever 1 forcefully a number of times to set
the brake.
Check the alignment of the equalisation assembly 8, this should
be at right angles to the pulling direction.
Check the play in the brake linkage 7.
If necessary adjust the brake linkage 7 again without play and
without pre---tensioning.
There must still be a little play in brake cable 5 (Variable Height
Only).
Check the position of the handbrake lever 1. The start of
resistance should be approximately 10÷15 mm (0.39÷0.59 in)
above the horizontal position.
Check that the wheels move freely when the handbrake is
disengaged.
Final test
Check the fastenings on the transmission system (cables, brake
equalisation system and linkage).
Check the brake cable 5 for a small amount of play and adjust
if necessary (Variable height only).
Check the compression spring 9 for pre---tensioning.
Test run
If necessary carry out 2÷3 test brake actions.
Test brake action
Check the play in brake linkage 7 and if necessary adjust the
length of brake linkage 7 until there is no play.
Apply the handbrake while rolling the machine forward, travel of
the handbrake lever up to 2/3 of maximum is allowed.
9.20.1. Re-- adjusting the braking system
(KNOTT Running Gear)
Re---adjustment of the wheel brakes will compensate for brake
lining wear. Follow the procedure described in (2.) ---Brake Shoe
Adjustment.
Check the play in the brake linkage 7 and re---adjust if necessary.
SEPTEMBER 2003
Portable Compressor 7/20
A. Important
Check the brake actuators and bowden cables 11. The brake
actuators must not be pre---tensioned.
Ixcessive operation of the handbrake lever, which may have
been caused by worn brake linings, must not be corrected by
re---adjusting (shortening) the brake linkage 7.
B. Re---adjustment
The handbrake lever 1 should be engaged forcefully several
times to set the braking system.
Check the setting of the brake equalisation assembly 8, which
should be at right angles to the pulling direction.
Check the play in the brake linkage 7 again, ensuring that there
is no play in the brake linkage and that it is adjusted without
pre---tension. Check the position of the handbrake lever 1, brake
cable 5 (with little play) and the compression spring 9 (only slight
pre---tension). The start of resistance of the handbrake lever
should be approximately 10÷15 mm (0.39÷0.59 in) above the
horizontal position.
C. Final Test
Check the fastenings on the transmission system (cables, brake
equalisation system and linkage).
Apply the handbrake while rolling the machine forward, travel of
the handbrake lever up to 2/3 of maximum is allowed.
Check the brake cable 5 for a small amount of play and adjust
if necessary (Variable height only).
Check the compression spring 9 for slight pre---tensioning.
CAUTION
CHECK THE WHEEL NUT TORQUE 30 km (20 miles) AFTER
REFITTING THE WHEELS (REFER TO THE Table 9 ---2.
TORQUE VALUES IN THIS SECTION).
9.21. LUBRICATION
The engine is initially supplied with engine oil sufficient for a
nominal period of operation (for more information 13. KUBOTA
D1005 EGINE section of this manual).
CAUTION
ALWAYS CHECK THE OIL LEVELS BEFORE A NEW
MACHINE IS PUT INTO SERVICE.
If for any reason the unit has been drained it must be re---filled
with newoil before it is put into operation.
9.21.1. ENGINE LUBRICATING OIL
The engine oil should be changed at the engine manufacturer’s
recommended intervals.
Refer to the 13. KUBOTA D1005 EGINE section of this manual.
9.21.2. ENGINE LUBRICATING OIL
SPECIFICATION
Refer to the 13. KUBOTA D1005 EGINE section of this manual.
9.21.3. ENGINE OIL FILTER ELEMENT
The engine oil filter element should be changed at the engine
manufacturer’s recommended intervals.
Refer to the 13. KUBOTA D1005 EGINE section of this manual.
9.21.4. COMPRESSOR LUBRICATING OIL
Refer to the Table 9 ---1. MAINTENANCE SCHEDULE in this
section for service intervals.
NOTE
If the machine has been operating under adverse conditions,
or has suffered long shutdown periods, then more frequent
service intervals will be required.
9---7
Portable Compressor 7/20
WARNING
DO NOT, UNDER ANY CIRCUMSTANCES, REMOVE ANY
DRAIN PLUGS OR THE OIL FILLER PLUG FROM THE
COMPRESSOR LUBRICATING AND COOLING SYSTEM
WITHOUT FIRST MAKING SURE THAT THE MACHINE IS
STOPPED AND THE SYSTEM HAS BEEN COMPLETELY
RELIEVED OF ALL AIR PRESSURE (REFER TO
8.4. STOPPING THE MACHINE IN THE 8.OPERATING
INSTRUCTIONS SECTION OF THIS MANUAL).
Completely drain the receiver/separator system including the
piping and oil cooler by removing the drain plug(s) and
collecting the used oil in a suitable container.
Replace the drain plug(s) ensuring that each one is secure.
NOTE
If the oil is drained immediately after the machine has been
running, then most of the sediment will be in suspension and
will therefore drain more readily.
1. Adjusting screw
2. Speed control lever
1 2
Figure 9-- 4. SPEED AND PRESSURE REGULATION ADJUSTMENT
Start the machine (refer to 8.3. STARTING THE MACHINE in the
8.OPERATING INSTRUCTIONS section of this manual).
Inspect the throttle arm on the engine governor to see that it is
extended in the full speed position when the engine is running
at full---load speed and the service valve is fully open (refer to the
7. GENERAL INFORMATION section of this manual).
Adjust the service valve on the outside of the machine to
maintain 7 bar/100 psi without the throttle arm moving from the
9---8
CAUTION
SOME OIL MIXTURES ARE INCOMPATIBLE AND RESULT IN
THE FORMATION OF VARNISHES, SHELLACS OR
LACQUERS WHICH MAY BE INSOLUBLE.
NOTE
Always specify I---R Pro--- Tec TM oil for use at all ambient
temperatures above ---23˚C ( ---11.4˚F).
9.21.5. COMPRESSOR OIL FILTER ELEMENT
Refer to the Table 9 ---1. MAINTENANCE SCHEDULE in this
section for service intervals.
9.22. RUNNING GEAR WHEEL BEARINGS
Wheel bearings should be packed with grease every 6 months.
The type of grease used should conform to specification
MIL ---G---10924.
9.23. SPEED AND PRESSURE
REGULATION ADJUSTMENT
Normally, regulation requires no adjusting, but if correct
adjustment is lost, proceed as follows:
Refer to the Figure 9 ---4 SPEED AND PRESSURE REGULATION
ADJUSTMENT.
full speed position. If the throttle arm moves away from the full
speed position before 7 bar/100 psi is attained, then turn the
adjusting screw clockwise to increase the pressure. Optimum
adjustment is achieved when the throttle arm just moves from its
full speed position and the pressure gauge reads 7.2 bar
(104 psi).
Close the service valve. The engine will slow to idle speed.
SEPTEMBER 2003
 Portable Compressor 7/20

CAUTION Tighten main pivot bolt M16 and secure by nose washer.
NEVER ALLOW THE IDLE PRESSURE TO EXCEED 8.6 bar Check belt adjustment.
(125 psi) ON THE PRESSURE GAUGE, OTHERWISE THE Install drive belt guard.
SAFETY VALVE WILL OPERATE.

9.24. DRIVE BELT REPLACEMENT /

ADJUSTMENT

WARNING

DURING THE ADJUSTMENT / REPLACEMENT 1

PROCEDURE ALWAYS DISCONNECT BATTERY.

Remove drive belt guard. 2

Loosen securing screw M12 beside the Airend. 4
Loosen main pivot bolt M16.
Disconnect adjusting screw and pivot Airend towards engine to
slacken belt and remove belt from pulleys. 3
Fit new belt over pulleys, pivot Airend away from engine and
re---engage adjusting screw. 1. Main pivot bolt
2. Securing screw
Adjust drive belt tightening by means of adjusting screw with M8 3. Adjusting screw
head socket screw. 4. Airend
Adjustment values:
New drive belt 95÷104 Hz
Run in drive belt 78÷88 Hz
Tighten securing screw M12 beside the Airend. Figure 9-- 5. DRIVE BELT ADJUSTMENT

CHANGE
VALUE WAS CHANGE.

SEPTEMBER 2003 9---9

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9.25. TORQUE VALUES

Refer to Table 9 ---2. TORQUE VALUES.

Table 9-- 2. TORQUE VALUES

Nm (lbf ft)

Engine mounts to engine 39÷47 (29÷35)

Airend to pivot plate 39÷47 (29÷35)
Air filter to bracket 22÷27 (16÷20)
Autella clamp to exhaust 12÷15 (9÷11)
Cooler wall to frame 12÷15 (9÷11)
Discharge manifold to frame 39÷47 (29÷35)
Pulley to flywheel 77÷93 (57÷69)
Drop Leg 72÷85 (53÷63)
Engine/airend to chassis 73÷78 (54÷58)
Band clamp on discharge hose 78÷91 (58÷67)
Exhaust flange to manifold 23÷28 (17÷21)
Fan guard 12÷15 (9÷11)
Fan to hub 16÷20 (12÷15)
Lifting bail to frame 39÷47 (29÷35)
Band clamp on oil pipes 96÷119 (71÷88)
Radiator/Cooler to baffle 12÷15 (9÷11)
Running gear rear to chassis 82÷93 (63÷69)
Running gear drawbar to axle 39÷47 (29÷35)
Main pivot bolt 143÷180 (106÷133)
Pivot locking bolt 73÷78 (54÷58)
Separator tank cover 54÷68 (40÷50)
Separator tank to frame 24÷30 (18÷22)
Band clamp on hose 143÷180 (106÷133)
Wheel nuts 67÷109 (50÷80)

9.26. COMPRESSOR LUBRICATION for correct compressor fluid required. Note that the selection of
fluid is dependent on the design operating pressure of the
A. Portable Compressor Fluid Chart machine and the ambient temperature expected to be
Refer toTable 9 ---3. COMPRESSOR LUBRICANTS, these charts encountered before the next oil change.

9---10 SEPTEMBER 2003

 Portable Compressor 7/20

CONSULT
FACTORY

Figure 9-- 6. RATED OPERATING PRESSURE

Table 9-- 3. COMPRESSOR LUBRICANTS

Design Operating Pressure Ambient Temperature Specification
[bar (psi)] [˚C (˚F)]

6.9÷20.7 (100÷300) ---23÷52 (---10÷125) I---R Pro---TecTM, Mil---PRF 2104G SAE 10W
6.9÷20.7 (100÷300) ---40÷52 (---40÷125) I---R Performance 500, Mil---L---46167
24.1 (350) ---23÷52 (---10÷125) I---R XHP 505
18÷52 (65÷125) I---R XHP 1001
---40÷18 (---40÷6) I---R Performance 500, Mil---L---46167
34.5 (500) 10÷52 (50÷125) I---R XHP 1001
---12÷18 (10÷65) I---R XHP 505
below ---12 (10) Consult Factory

Recommended Ingersoll---Rand Fluids---Use of these fluids with operator’s manual warranty section for details or contact your
original l---R filters can extend airend warranty. Refer to I---R representative.

Table 9-- 4. RECOMMENDED FLUID

Recommended Fluid 3.8 l (1 gal) 19.0 l (5 gal) 208.2 l (55 gal)

I---R Pro---TecTM 36899698 36899706 36899714

I---R XHP 505 35365188 35365170
I---R Performance 500 35382928 35382936 35382944
I---R XHP 1001 35612738 35300516

SEPTEMBER 2003 9---11/(9---12 blank)

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10. ELECTRICAL SYSTEM

B BATTERY, 12V
S0 KEY SWITCH
CF1 FUSE
TS1 HIGH AIR TEMPERATURE SWITCH (AIREND)
TS2 ENGINE HIGH WATER TEMPERATURE SWITCH
PS1 ENGINE OIL PRESSURE SWITCH
D1,D2 DIODE (BLOCKING)
FP FUEL PUMP
NP 1--- 4 NODE POINT
RT1 RELAY, TEMPERATURE SWITCH
SV1 SOLENOID, FUEL
h HOUR METER
GP GLOW PLUGS
G ALTERNATOR
M STARTER MOTOR

Figure 10 ---1. ELECTRICAL SYSTEM

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2 R. H.
Y
INDICATOR
STOP
R
B
TAIL

1
L/I
54G/2

54/6
3 U 58L/7
FOG W 3I/3
58R/5
B Black
R/4 G Green
K Pink
N Brown
O Orange
TAIL
N P Purple
4 R R Red
STOP
G S Grey
INDICATOR U Blue
W White
L. H. W Y Yellow

1. Plug
2. Light (right hand)
3. Fog light
4. Light (left hand)

Figure 10 ---2. SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM

1
B Black
2 G Green
K Pink
N Brown
3 O Orange
P Purple
R Red
S Grey
U Blue
W White
Y Yellow
4 Y
1. Stop/turn (left hand)
2. Tail (left hand)
W
3. Front side marker (left hand)
4. Front side marker (right hand)
5 5. Ground/earth
B
6. Stop/turn (right hand)
6 G 7. Tail (right hand)

Figure 10 ---3. SCHEMATIC DIAGRAM FOR AMERICAN SAE LIGHTING SYSTEM

10---2 SEPTEMBER 2003

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11. PIPING AND INSTRUMENTATION SYSTEM

3 2 4 5

8 7

AIR
OIL
AIR/OIL

1. Air discharge
2. Sonic orifice (restricts flow)
3. Pressure gauge
4. Separator tank
5. Safety valve
6. Compressor
7. Engine
8. Oil filter
9. Oil cooler

Figure 11 ---1. PIPING AND INSTRUMENTATION SYSTEM

SEPTEMBER 2003 11---1/(11---2 blank)

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12. LUBRICATOR CAUTION

IF THE NYLON TUBES TO THE LUBRICATOR ARE
DISCONNECTED THEN ENSURE THAT EACH TUBE IS RE
12.1. SAFETY CONNECTED IN THIS ORIGINAL LOCATION.

WARNING 12.2. GENERAL INFORMATION

Oil capacity: 2 l (0.53 gal).
ENSURE THAT THE LUBRICATOR FILLER CAP IS Oil specification: Refer to the Tool
RE ---TIGHTENED CORRECTLY AFTER REPLISHING Manufacturer‘s Manual.
WITH OIL.

12.3. OPERATING INSTRUCTIONS

A. Commissioning
Check the lubricator oil level and fill as necessary.
WARNING
B. Prior to starting
Check the lubricator oil level and replenish as necessary.
DO NOT REPLENISH THE LUBRICATOR OIL, OR SERVICE
THE LUBRICATOR WITHOUT FIRST MAKING SURE THAT
THE MACHINE IS STOPPED AND THE SYSTEM HAS BEEN
COMPLETELY RELIEVED OF ALL AIR PRESSURE (REFER
12.4. MAINTENANCE
TO 8.4. STOPPING THE MACHINE IN THE 8. OPERATING Check the lubricator oil level and replenish as necessary.
INSTRUCTIONS SECTION OF THIS MANUAL).

12.5. FAULT FINDING

Table 12 ---1. FAULT FINDING

Fault Cause Remedy

No oil flow Incorrect connection Reverse the nylon tube connections to the lubricator

SEPTEMBER 2003 12---1/(12---2 blank)

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13. KUBOTA D1005 ENGINE
13.1. FOREWORD
In order to get the fullest use and benefit from your engine, it is
important that you operate and maintain it correctly. This section
is designed to help you do this.
Please read this manual carefully and follow its operating and
maintenance recommendations. This will ensure many years of
trouble--- free and economical engine operation.
Should your engine require servicing, please contact your
nearest Ingersoll--- Rand branch or distributor.
All information, illustrations, and specifications contained in this
manual are based on the latest product information available at
the time of publication.
Ingersoll--- Rand reserves the right to make changes in this
manual at any time without prior notice.
13.2. EXTERNAL VIEWS

10 6 14 11

12
19

1
2
15
4
3

8
16

7 9

13

5
17 18
1. Intake manifold
2. Speed control lever
3. Engine stop lever
4. Injection pump
5. Fuel feed pump
6. Cooling fan
7. Fan drive pulley
8. Oil filter cartridge
9. Water drain cock
10. Oil filler plug
11. Exhaust manifold
12. Alternator
13. Starter
14. Oil level gauge
15. Oil pressure switch
16. Flywheel
17. Oil drain plug
18. Oil pan
19. Engine hook

Figure 13 ---1. EXTERNAL VIEWS KUBOTA D1005 ENGINE

SEPTEMBER 2003 13---1

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13.3. GENERAL INFORMATION

13.3.1. Specifications
Table 13 ---1. MAIN DATA AND SPECIFICATIONS
Model KUBOTA D1005 ---EBB ---EC ---LT ---1
Type Vertical, water--- cooled, 4--- cycle diesel engine
Number of cylinders 3
Bore and atroke mm (in) 76x73.6 (2.99x2.90)
Total displacement cm3 (cu in) 1,001 (61.08)
Combustion chamber Spherical Type (E--- TVCS)
SAE J995 Gross Intermittent kW (hp) / min --- 1 (RPM) 17.5 (23.5) / 3,000
SAE J1349 Net Intermittent kW (hp) /min --- 1 (RPM) 16.8 (22.5) / 3,000
SAE J1349 Net Continuous kW (hp) / min --- 1 (RPM) 14.2 (19.5) / 3,000
Maximum bare speed min --- 1 (RPM) 3,200
Minimum bare idling speed min --- 1 (RPM) 850÷950
Order of firing 1--- 2--- 3
Direction of rotation Counter--- clockwise (viewed from flywheel side)
Injection pump Bosch MD Type Mini Pump
Injection pressure 13.73 MPa (1,991 psi)
Injection timing (Before T.D.C.) 19˚
Compression ratio 23
Fuel Diesel Fuel No.2--- D (ASTM D975)
Lubricant (API classification) above CD grade
Dimensions (length x width x height) mm (in) 497.8x396x608.7 (19.60x15.59x23.96)
Dry weight kg (lb) 89.0 (196.2)
Starting system Cell starter (with glow plug)
Starting motor 12 V, 1.0 kW
Charging generator 12 V, 360 W
Recommended battery capacity 12 V, 65 Ahr, equivalent

NOTE

Specifications are subject to change without notice.

13.3.2. Engine Identification

A. Serial Number Location

The engine serial number is stamped on the front upper right side
of the cylinder body.

B. Confirmation Of Engine Serial Number

It is advisable to quote the engine serial number together with the

machine serial number, as it is required when you contact the
Ingersoll--- Rand branch or distributor for repair, service or parts 1. Engine SERIAL No. 1
ordering.

Figure 13 ---2. ENGINE IDENTIFICATION

13---2 SEPTEMBER 2003

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13.3.3. Ingersoll ---Rand Engine After Sales 13.4.2. Fuel Requirements

Support
A. Ingersoll--- Rand Engine After Sales Service NOTICE

Please feel free to contact your Ingersoll--- Rand branch or The fuel injection pump, injector or other parts of the fuel
system and engine can be damaged if you use any fuel or fuel
distributor for periodical inspection and maintenance.
additive other than those specifically recommended by
Ingersoll ---Rand.
B. Ingersoll--- Rand Genuine Parts
Genuine Ingersoll--- Rand parts are identical with those used in
NOTE
the engine production, and accordingly, they are warranted by
Ingersoll--- Rand. If any fuel other than the one specified is used, engine
operation will be impaired. Engine failure or malfunction
Genuine Ingersoll--- Rand parts are supplied by your resulting from use of such improper fuel will not be warranted
Ingersoll--- Rand branch or distributor. by Ingersoll ---Rand.
Please ensure that only genuine Ingersoll--- Rand parts,
lubricants and fluids are used for service and/or repair. To help avoid fuel system or engine damage, please read the
following:
13.3.4. Servicing of the Engine Do not use diesel fuel which has been contaminated with engine
oil. Besides causing the engine damage, such fuel can also affect
Your dealer is interested in your new engine and has the desire emission control. Before using any diesel fuel, check with the fuel
to help you get the most value from it. After reading this manual supplier to see if the fuel has been mixed with engine oil.
thoroughly, you will find that you can do some of its regular
maintenance yourself. Your engine is designed to use either No. 1--- D or No. 2--- D diesel
fuel. However, for better fuel economy, use No. 2--- D diesel fuel
However, when in need of parts or major service, be sure to see whenever possible. At temperatures less than --- 7˚C, (20˚F), No.
your Ingersoll--- Rand dealership from which you purchased your 2--- D fuel may pose operating problems (refer to the
engine or your local Ingersoll--- Rand dealer. 13.7. COULD WEATHER OPERATION section of this manual). At
When in need of parts, be prepared to give your dealer the colder temperatures, use No. 1--- D fuel (if available) or use a
engine serial number. “winterized” No. 2--- D (a blend of No. 1--- D and No. 2--- D). This
blended fuel is usually called No. 2--- D also, but can be used in
Locate the serial number now and record them in the space
colder temperatures than No. 2--- D fuel which has not been
provided.
“winterized”.
TYPE SERIAL No.
Check with the fuel supplier to be sure you get the properly
Engine blended fuel.
Date of Purchase
NOTICE
Name of Dealer
Do not use home heating oil or gasoline in your diesel engine;
(To be filled in by purchaser)
either may cause engine damage.

A. Handling Of The Fuel

13.4. FUEL, LUBRICANTS, AND COOLANT Any fuel containing dust particles or water might cause engine
failure.
13.4.1. Fuel Therefore, the following must be observed.
Fuel Selection Take care to protect the fuel from ingress of dust particles or water
when filling the fuel tank.
The following properties are required of the diesel fuel.
If refuelling is done from an oil drum directly, ensure that it has
Must be free from minute dust particles.
been kept stationary to allow any dust, sediment or water to settle
Must have adequate viscosity. at the bottom. Do not draw fuel direct from the bottom of the drum
Must have high cetane value. to prevent pickup of any settled foreign material.
Must have high fluidity at low temperature. Always fully fill the fuel tank. Drain the sedimented particles in the
fuel tank frequently.
Must have low sulphur content.
Must have little residual carbon. B. Water In Fuel
It is strongly advisable to use ASTM D975 No. 2--- D (the general During refueling, it is possible for water (and other contaminants)
automotive diesel engine purpose diesel fuel) or equivalent to be pumped into your fuel tank along with the diesel fuel. This
which fully meets the above requirements. can happen if a fuel provider does not regularly inspect and clean
its fuel tanks, or receives contaminated fuel from its supplier(s).
To protect your engine from contaminated fuel, there is a fuel filter
Table 13 ---2. REQUIRED OF THE DIESEL FUEL system on the engine which allows you to drain excess water.
Applicable Standard Recommendation
CAUTION
JIS (Japanese Industrial Standard) No. 2
THE WATER/DIESEL FUEL MIXTURE IS FLAMMABLE, AND
DIN (Deutsche Industrie Normen) DIN 51601 COULD BE HOT. TO AVOID PERSONAL INJURY AND/OR
SAE (Society of Automotive Engineers) No. 2--- D PROPERTY DAMAGE, DO NOT TOUCH THE FUEL COMING
Based on SAE--- J --- 313C FROM THE DRAIN VALVE, AND DO NOT EXPOSE THE FUEL
TO OPEN FLAMES OR SPARKS.
BS (British Standard) Based on Class A--- 1
BS/2869--- 1970
Be sure you do not overfill the fuel tank. Heat (such as from the
engine) can cause the fuel to expand. If the tank is too full, fuel

SEPTEMBER 2003 13---3

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could be forced out. This could lead to a fire and the risk of
personal injury and/or equipment damage.
C. Biocides
In warm or humid weather, fungus and/or bacteria may form in
diesel fuel if there is water in the fuel.
NOTICE
Fungus and / or bacteria can cause fuel system damage by
plugging the fuel lines, fuel filters or injector. They can also
cause fuel system corrosion.
If fungus and/or bacteria has caused fuel system problems, your
local Ingersoll--- Rand dealer should have correct these
problems. Then, use a diesel fuel biocide to sterilize the fuel
system. Biocides are available from your dealer, service stations,
parts stores and other automotive places. See your local
Ingersoll--- Rand dealer for advice on using biocides in your area
and for recommendations on which biocides you should use.
13.4.3. Lubricant
The quality of engine oil can effect engine performance, stability
and engine life.
Use of unsuitable engine oil will result in piston ring and cylinder
seizure and accelerate surface wear causing increased oil
consumption, lowered output and finally engine failure. To avoid
this, use the specified engine oil.
(1.) Engine oil selection
Pro--- TecTM
(2.) Oil viscosity
Engine oil viscosity affects engine startability, performance, oil
consumption, wear and the potential for seizure, etc. Always
ensure that lubricants with the correct viscosity for the operating
temperature are used. Refer to Figure 13 ---3 OPERATING
TEMPERATURE.
NOTE
Using a mixture of different brands or quality of oils will
adversely affect the original oil quality; therefore, never mix
different brand or different type oils.

D. Smoke Suppressants Do not use API, CA, CB grade and reconstituted engine oil.
The use of a smoke suppressant additive is not allowed because Engine damage due to improper maintenance, or using oil of
of the greater possibility of stuck rings and valve failure, resulting the improper quality and/or viscosity, is not covered by the
from excessive ash deposits. warranty.

A. Single grade
B. Ambient temperature
C. Multi grade

Figure 13 ---3. OPERATING TEMPERATURE

13.4.4. Coolant DO NOT RUN THE ENGINE IN CONFINED AREAS (SUCH AS

GARAGES OR NEXT TO A BUILDING). KEEP THE EXHAUST
All Ingersoll--- Rand portable compressor engines are factory TAILPIPE AREA CLEAR OF SNOW AND OTHER MATERIAL
filled with a 50/50 % ethylene glycol base antifreeze/water mix TO HELP REDUCE THE BUILDUP OF EXHAUST GASES
which provides protection to --- 33˚C (--- 27˚F). UNDER THE EQUIPMENT. THIS IS PARTICULARLY
IMPORTANT WHEN PARKED IN BLIZZARD CONDITIONS.

13.5. OPERATION
13.5.2. Check Before Operation
CAUTION
13.5.1. Engine Operation
FOR SAFETY REASONS, CONDUCT THE INSPECTION WITH
Engine Exhaust Gas Caution (Carbon Monoxide) THE ENGINE STOPPED.

CAUTION A. Engine Oil Level

DO NOT BREATHE EXHAUST GAS BECAUSE IT CONTAINS CAUTION
CARBON MONOXIDE, WHICH BY ITSELF HAS NO COLOR BE SURE TO STOP THE ENGINE BEFORE CHECKING AND
OR ODOR. CARBON MONOXIDE IS A DANGEROUS GAS. IT CHANGING THE ENGINE OIL AND THE OIL FILTER
CAN CAUSE UNCONSCIOUSNESS AND CAN BE LETHAL. CARTRIDGE.

13---4 SEPTEMBER 2003

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DO NOT TOUCH MUFFLER OR EXHAUST PIPES WHILE

THEY ARE HOT; SEVERE BURNS COULD RESULT. ALWAYS
STOP THE ENGINE AND ALLOW IT TO COOL BEFORE 2
CONDUCTING INSPECTIONS, MAINTENANCE, OR FOR A
CLEANING PROCEDURE.

CONTACT WITH ENGINE OIL CAN DAMAGE YOUR SKIN.

PUT ON GLOVES WHEN USING ENGINE OIL. IF YOU COME
IN CONTACT WITH ENGINE OIL WASH IT OFF IMMEDIATELY. 2
A

NOTE
Be sure to inspect the engine, locating it on a level place. If
placed on gradients accurately, oil quantity may not be
measured.
1. Fan belt 1
2. Bolt and nut
Checking oil level and adding engine oil.
A deflection of between
(1.) Check the oil level before starting or more than 5 minutes A=7÷9 mm (0.28÷0.35 in)
after stopping the engine. under load of 100 N (22.1 lbf)
(2.) Remove the oil level gauge wipe it clean and reinstall it.
(3.) Take the oil level gauge out again, and check the oil level Figure 13 ---5. FAN BELT TENSION

Table 13 ---3. FAN BELT TENSION

1 2
Deflection of between A=7÷9 mm
Proper fan belt
(0.28÷0.35 in) when the belt is
tension
pressed in the middle of the span.

A
(1.) Stop the engine and remove the key.
(2.) Apply moderate thumb pressure to belt between pulleys.
(3.) If tension is incorrect, loosen the alternator mounting bolts
and, using a lever placed between the alternator and the
engine block, pull the alternator out until the deflection of the
belt falls within acceptable limits.
(4.) Replace fan belt if it is damaged.

C. Coolant Level Check

[Lower end of oil level gauge] The coolant level must be between “MAX COLD” and “MIN”
marks on the reserve tank depending on the temperature of the
A Engine oil level within this range is proper engine. Check and ensure that level is correct.
1. Oil filler plug
2. Oil level gauge CAUTION
WHEN REMOVING THE RADIATOR FILLER CAP, WHILE THE
ENGINE IS STILL HOT, COVER THE CAP WITH CLOTH, THEN
TURN IT SLOWLY TO GRADUALLY RELEASE THE INTERNAL
Figure 13 ---4. OIL LEVEL GAUGE STEAM PRESSURE. THIS WILL PREVENT ANYONE FROM
BEING SCALDED BY HOT STEAM SPURTING OUT FROM
THE FILLER NECK.
(4.) If the oil level is too low, remove the oil filler plug, and add
new oil to the prescribed level. Add coolant mixed to the correct ratio: 50/50 % ethylene
glycol/water.
(5.) After adding oil, wait more than 5 minutes and check the oil
level again. It takes some time for the oil to drain down to the
oil pan. 13.5.3. Starting The Engine (Normal)
CAUTION
B. Fan Belt Check DO NOT ALLOW CHILDREN TO APPROACH THE MACHINE
WHILE THE ENGINE IS RUNNING.
Adjusting Fan Belt Tension
BE SURE TO INSTALL THE MACHINE ON WHICH THE
ENGINE IS INSTALLED, ON A FLAT PLACE.
CAUTION DO NOT RUN THE ENGINE ON GRADIENTS.
BE SURE TO STOP THE ENGINE AND REMOVE THE KEY DO NOT RUN THE ENGINE IN AN ENCLOSED AREA.
BEFORE CHECKING THE BELT TENSION. EXHAUST GAS CAN CAUSE AIR POLLUTION AND EXHAUST
BE SURE TO REINSTALL THE DETACHED SAFETY SHIELD GAS POISONING.
AFTER MAINTENANCE OR CHECKING. KEEP YOUR HANDS AWAY FROM ROTATING PARTS (SUCH
AS FAN, PULLEY, BELT, FLYWHEEL ETC.) DURING
BY AWARE OF HOT EXHAUST WHEN ADJUSTING FAN BELT. OPERATION.

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DO NOT OPERATE THE MACHINE WHILE UNDER THE

INFLUENCE OF ALCOHOL OR DRUGS.

DO NOT WEAR LOOSE, TORN OR BULKY CLOTHING

AROUND THE MACHINE. IT MAY CATCH ON MOVING PARTS
OR CONTROLS, LEADING TO THE RISK OF ACCIDENT. USE
ADDITIONAL SAFETY ITEMS, E.G. HARD HAT, SAFETY A
BOOTS OR SHOES, ETC., AS APPROPRIATE OR REQUIRED.

DO NOT WEAR RADIO OR MUSIC HEADPHONES WHILE B

OPERATING ENGINE.
C
CHECK TO SEE IF IT IS SAFE AROUND THE ENGINE
BEFORE STARTING.
D
REINSTALL SAFEGUARDS AND SHIELDS SECURELY AND
CLEAR ALL MAINTENANCE TOOLS WHEN STARTING THE
ENGINE AFTER MAINTENANCE.
A “IDLE”
1 2 B “OPERATION”
1. Speed control lever C “START”
NOTE 2. Engine stop lever D “STOP”
Do not use ether or any starting fluid for starting the engine, or
a severe damage will occur. Figure 13 ---7. PLACE THE SPEED CONTROL
LEVER
When starting the engine after a long storage (of more than 3 A. Header Tank Cap Condition
months), first set the engine stop lever to the “STOP” position After the replenishment of the coolant, install the header tank
and then activate the starter for about 10 seconds to allow oil to cap. Make sure the cap is securely installed.
reach every engine part.
B. Battery Cable Connection
Check the battery cable connections for looseness or corrosion.
A loosened cable connection will result in hard engine starting or
(1.) Set the fuel lever to “ON”. insufficient battery charge. The battery cables must be tightened
securely. never reverse “+” and “ --- ” terminals when
reconnecting cables after disconnection. Even a short period of
reverse connection will damage the electrical parts.

1. Battery cable
B 2. Connections
1
1
A “ON”
B “OFF”
Figure 13 ---8. BATTERY CABLE
1. Fuel filter lever
2. Fuel filter pot A 2
C. Battery Electrolyte Level
The amount of electrolyte in the batteries will be reduced after
Figure 13 ---6. FUEL FILTER LEVER repeated discharge and recharge. Check the electrolyte level in
the batteries, replenish with a commercially available electrolyte
such as distilled water, if necessary. The battery electrolyte level
checking procedure will vary with battery type.
NOTICE
Do not replenish with dilute sulfuric acid in the daily service.
(2.) Place the engine stop lever in the “START” position.
CAUTION
(3.) Place the speed control lever at more than half WHEN INSPECTING THE BATTERIES, BE SURE TO STOP
“OPERATION”. THE ENGINE FIRST.

13---6 SEPTEMBER 2003


As dilute sulphuric acid is used as electrolyte, be careful not to
contaminate your eyes, hands, clothes, and metals with the
electrolyte. If it gets in your eye, wash with a large amount of water
at once, then seek medical advice.
As highly flammable hydrogen gas is released from the batteries,
do not create a spark or allow any naked flame near the batteries.
When handling such metallic articles as tools near the batteries,
be sure not to contact the “+” terminal because the compressor
body is “ --- ” and a dangerous short circuit might result.
When disconnecting the terminals, start with “ --- ” terminal. When
connecting them, connect the “ --- ” terminal last.
13.5.4. Checks And Operation After Start ---Up
Checks During Operation
While running, make the following checks to see that all parts are
working correctly.
Radiator Cooling Water (Coolant)
WARNING
Do not remove radiator cap until coolant temperature is
well below its boiling point. Then loosen cap slightly to the
stop position, to relieve any pressure, before removing cap
completely.
When the engine overheats and hot coolant overflows through
the radiator and hoses, stop the engine immediately and make
the following checks to determine the cause of trouble:
Check Item
(1.) Check to see if there is any coolant leak,
(2.) Check to see if there is any obstacle around the cooling air
inlet or outlet,
(3.) Check to see if there is any dirt or dust between radiator fins
and tube,
(4.) Check to see if the fan belt is too loose,
(5.) Check to see if radiator water pipe is clogged,
(6.) Check to see if anti--- freeze is mixed to a 50/50 % mix of
water and anti--- freeze.
13.5.5. Operation And Care Of A New Engine
Your Ingersoll--- Rand engine is carefully tested and adjusted in
the factory, however, further run--- in is necessary. Avoid any
harsh engine operation within the initial 100 operating hours.
Do not operate the unit at full load until the engine is warmed --- up.
Do not allow the engine to run unloaded for extended periods so
as to minimise the risk of cylinder bore glazing.
During operation, pay attention to the following points if the
engine shows any sign of abnormalities.
(1.) Engine Oil Pressure
The engine oil pressure is monitored by a switch that will stop the
engine if the pressure falls below a pre--- set value.
(2.) Coolant Temperature
The engine performance will be adversely affected if engine
coolant temperature is too hot or too cold. The normal coolant
temperature is 75÷85˚C (167÷185˚F).
SEPTEMBER 2003
Portable Compressor 7/20
Overheating
CAUTION
IF YOU SEE OR HEAR ESCAPING STEAM OR HAVE OTHER
REASON TO SUSPECT THERE IS A SERIOUS OVERHEAT
CONDITION, STOP THE ENGINE IMMEDIATELY.
If the engine coolant temperature gage (where fitted) shows an
overheat condition, or you have reason to suspect the engine
may be overheating, take the following step:
--- Close the service valve to reduce the load,
---
Let the engine run at normal idle speed for two or three
minute. If the engine coolant temperature does not
start to drop, turn off the engine and proceed as
follows:
CAUTION
DO NOT OPEN THE CANOPY IF YOU SEE OR HEAR STEAM
OR ENGINE COOLANT ESCAPING. WAIT UNTIL NO STEAM
OR ENGINE COOLANT CAN BE SEEN OR HEARD BEFORE
OPENING THE ENGINE CANOPY.
DO NOT REMOVE THE RADIATOR FILLER CAP IF THE
ENGINE COOLANT IN THE RESERVE TANK IS BOILING.
ALSO DO NOT REMOVE THE RADIATOR FILLER CAP WHILE
THE ENGINE AND RADIATOR ARE STILL HOT. SCALDING
FLUID AND STEAM CAN BE BLOWN OUT UNDER PRESSURE
IF EITHER CAP IS TAKEN OFF TOO SOON.
If no steam or engine coolant can be seen or heard, open the
canopy. If the engine coolant is boiling, wait until it stops before
proceeding. The engine coolant level should be between the
“MAX COLD” and “MIN” marks on the reserve tank.
Make sure the fan belt is not broken, or off the pulley, and that the
fan turns when the engine is started. If the engine coolant level
in the reserve tank is low, look for leaks at the radiator hoses and
connections, radiator, and water pump. If you find major leaks,
do not run the engine until these problems have been corrected.
If you do not find a leak or other problem, wait until the engine has
cooled down then carefully add engine coolant to the reserve
tank.
Engine coolant is a mixture of ethylene glycol antifreeze and
water. Refer to the Table 13 ---5. OPERATION TEMPERATURE of
this section for the proper antifreeze and mixture.
CAUTION
TO AVOID BEING BURNED, DO NOT SPILL ANTIFREEZE OR
ENGINE COOLANT ON THE EXHAUST SYSTEM OR HOT
ENGINE PARTS. UNDER SOME CONDITIONS THE
ETHYLENE GLYCOL IN ENGINE COOLANT IS
COMBUSTIBLE.
If the engine coolant level in the reserve tank is at the correct level
but there is still an indication of an overheat condition and no
cause was found, please consult your local Ingersoll--- Rand
branch or dealer.
Overcooling
Operating the engine at low coolant temperature will not only
increase the oil and fuel consumption but also will lead to
premature parts wear which may result in engine failure. Ensure
that the engine reaches normal operating temperature 75÷85˚C
(167÷185˚F) within ten minutes of starting.
(3.) Hour meter
This meter indicates the machine operation hours. Make sure
that the meter is always working during engine operation.
Periodical machine maintenance is scheduled on the operation
hours indicated on the hourmeter.
(4.) Liquid And Exhaust Smoke Leakage
Make regular checks for lubricant, fuel, coolant and exhaust
smoke leakage.
13---7
Portable Compressor 7/20

(5.) Abnormal Engine Noise
In the event of any abnormal engine noise, please consult your
local Ingersoll--- Rand branch or dealer.
(6.) State Of The Exhaust Smoke
Check for any abnormal exhaust smoke color.
A. Engines Stopping
(1.) Close service valves.
(2.) Before stopping the engine, cool down the engine by
operating it at reduced load about three minutes. In this
period, check the engine noise and the engine oil pressure
(where a gage is fitted) for abnormalities.
B. Long Term Storage
If the equipment is to be out of operation for an extended period,
it should be started at least once per week and run on load for
about 15 minutes after it has reached normal operating
temperature.
Use a filter wrench to remove the cartridge type oil filter element
taking care to prevent any oil spillage into the enclosure.
C. Replacing the oil filter cartridge
CAUTION
BE SURE TO STOP THE ENGINE BEFORE CHANGING THE
OIL FILTER CARTRIDGE.
ALLOW ENGINE TO COOL DOWN SUFFICIENTLY, OIL CAN
BE HOT AND CAUSE BURNS.
(1.) Replace the oil filter cartridge every 200 hours of operation.
(2.) Remove the old oil filter cartridge with a filter wrench.
(3.) Apply a film of oil to the gasket for the new cartridge.
(4.) Screw in the cartridge by hand. When the gasket contacts
the seal surface, tighten the cartridge enough by hand.
Because, if you tighten the cartridge with a wrench, it will be
tightened too much.

13.6. PERIODICAL INSPECTION AND

MAINTENANCE
13.6.1. Lubricating System
Servicing of the engine oil and oil filter element will affect the
engine performance as well as the engine life. Change the
engine oil and the oil filter in accordance with the recommended
service intervals.

A. Engine Oil And Oil Filter Element Change

CAUTION
BE SURE TO STOP THE ENGINE BEFORE DRAINING
ENGINE OIL.
1
WHEN DRAINING ENGINE OIL, PLACE SOME CONTAINER 1. Oil filter cartridge
UNDERNEATH THE ENGINE AND DISPOSE IT ACCORDING Remove with a filter wrench. Tighten with your hand.
TO LOCAL REGULATIONS.
DO NOT DRAIN OIL AFTER RUNNING THE ENGINE. ALLOW Figure 13 ---10. OIL FILTER
ENGINE TO COOL DOWN SUFFICIENTLY.
(5.) After the new cartridge has been replaced, the engine oil
(1.) Change oil after the initial 50 hours of operation and ever level normally decreases a little. Thus, run the engine for a
200 hours thereafter. while and check for oil leaks through the seal before
(2.) Remove the oil drain plug at the bottom of the engine, and checking the engine oil level. Add oil if necessary.
drain all the old oil. Oil will drain easier when the oil is warm. NOTE
Wipe off any oil sticking to the machine completely.

D. Engine Oil Additives

Engine oils contain a variety of additives. Your engine should not
need any extra additives if you use the recommended oil quality
and change intervals.

Used Oil Disposal

Do not dispose of used engine oil (or any other oil) in a careless
manner such as pouring it on the ground, into sewers, or into
1. Oil drain plug streams or bodies of water. Instead, recycle it by taking it to a
2. Oil pan used oil collection facility which may be found in your community.
2 If you have a problem disposing of your used oil, it is suggested
that you contact your local Ingersoll--- Rand branch or dealer. This
1 also applies to diesel fuel which is contaminated with water.

E. Used Engine Oil

Figure 13 ---9. OIL PAN
CAUTION
(3.) Add new engine oil, through the oil filler plug, up to the USED ENGINE OIL CONTAINS HARMFUL CONTAMINANTS
upper limit of the oil level gauge. THAT HAVE CAUSED SKIN CANCER IN LABORATORY
ANIMALS. AVOID PROLONGED SKIN CONTACT. CLEAN SKIN
B. Oil Filter Element Removal AND NAILS THOROUGHLY USING SOAP AND WATER --- NOT

13---8 SEPTEMBER 2003


MINERAL OIL, FUELS, OR SOLVENTS. LAUNDER OR
DISCARD CLOTHING, SHOES, OR RAGS CONTAINING USED
ENGINE OIL.
Discard used engine oil and other oils properly.
13.6.2. Cooling System
A. Changing Coolant
(1.) To drain coolant, always open both drain cocks and
simultaneously open the radiator cap as well. With the
radiator cap kept closed, a complete drain of water is
impossible.
(2.) Remove the overflow pipe of the radiator pressure cap to
drain the reserve tank.
(3.) An improperly tightened radiator cap or a gap between the
cap and the seat quickens loss of coolant.
(4.) Coolant (Radiator cleaner and anti--- freeze).
Table 13 ---4. COOLANT
Season Coolant
Pure water and radiator
Summer
cleaner
Winter (When temperature Pure water and anti--- freeze
drops below 0˚C (32˚F)) or (See 13.6.2. Cooling system,
all season F. Anti ---freeze)
B. Remedies for quick decrease of coolant
(1.) Check any dust and dirt between the radiator fins and tube.
If any, remove them from the fins and the tube.
(2.) Check the tightness of the fan belt. If loose, tighten it
securely.
(3.) Check the internal blockage in the radiator hose. If scale
forms in the hose, clean with the scale inhibitor or its
equivalent.
C. Checking Radiator Hoses And Clamp
CAUTION
BE SURE TO CHECK RADIATOR HOSES AND HOSE
CLAMPS PERIODICALLY. IF RADIATOR HOSE IS DAMAGED
OR COOLANT LEAKS, OVERHEATS OR SEVERE BURNS
COULD OCCUR.
Check to see if radiator hoses are properly fixed every 200 hours
of operation or 6 months, whichever comes first.
(1.) If hose clamps are loose or water leaks, tighten hose clamps
securely.
(2.) Replace hoses and tighten hose clamps securely, if radiator
hoses are swollen, hardened or cracked.
Replace hoses and hose clamps every 2 years, or earlier, if
checked and found that hoses are swollen, hardened or cracked.
D. Precaution At Overheating
Take the following actions in the even the coolant temperature is
nearly or more than the boiling point, what is called
“Overheating”. Take these action if the engine‘s alarm buzzer
sounds or the alarm lamp lights up.
(1.) Stop the engine operation in a safe place and keep the
engine unloaded idling.
(2.) Do not stop the engine suddenly. Stop it after about 5
minutes of unloaded idling.
(3.) If the engine stalls within about 5 minutes of running under
no load, immediately leave and keep yourself away from the
machine. Do not open the hood and any other part.
SEPTEMBER 2003
Portable Compressor 7/20
(4.) Keep yourself and others well away from the engine for
further 10 minutes or while the steam blown out.
(5.) Checking that there gets no danger such as burn, get rid of
the causes of overheating see 14. TROUBLESHOOTING
section of this manual. And then, start again the engine.
E. Cleaning Radiator Core (Outside)
If dust is between the find and tube, wash it away with running
water.
NOTE
Do not clean radiator with firm tools such as spatulas or
screwdrivers. They may damage specified fin or tube. It can
cause coolant leaks or decrease coolings performance.
F. Anti--- freeze
CAUTION
WHEN USING ANTI--- FREEZE, PUT ON SOME PROTECTION
SUCH AS RUBBER GLOVES.
IF SHOULD DRINK ANTI--- FREEZE, THROW UP AT ONCE
AND TAKE MEDICAL ATTENTION.
WHEN ANTI--- FREEZE COMES IN CONTACT WITH THE SKIN
OR CLOTHING, WASH IT OFF IMMEDIATELY.
DO NOT MIX DIFFERENT TYPES OF ANTI--- FREEZE.
KEEP FIRE AND CHILDREN AWAY FROM ANTI--- FREEZE.
BE MINDFUL OF THE ENVIRONMENT AND ECOLOGY.
BEFORE DRAINING ANY FLUIDS, FIND OUT THE CORRECT
WAY OF DISPOSING BY CHECKING WITH LOCAL CODES.
ALSO, OBSERVE THE RELEVANT ENVIRONMENT
PROTECTION REGULATIONS WHEN DISPOSING OF OIL,
FUEL, COOLANT, BRAKE FLUID, FILTERS AND BATTERIES.
If it freezes, coolant can damage the cylinders and radiator. It is
necessary, if the ambient temperature falls below 0˚C (32˚F), to
remove coolant after operating or to add anti--- freeze to it.
(1.) There are two types of anti--- freeze available; use the
permanent type (PT) for this engine.
(2.) Before adding anti--- freeze for the first time, clean the
radiator and engine interior by pouring fresh water, and
draining it a few times.
(3.) The procedure for the mixing of water and anti--- freeze
differs according to the make of the anti--- freeze and the
ambient temperature. Refer to SAE J1034 standard, more
specifically also to SAE J814c.
(4.) Mix the anti--- freeze with water, and then fill into the radiator.
NOTE
When the anti ---freeze is mixed with water, the anti ---freeze
mixing ratio must be less than 50%.
Table 13 ---5. OPERATION TEMPERATURE
Vol% Freezing Point Boiling Point :
Anti---freeze
Anti freeze ˚C (˚F) ˚C (˚F)
40 --- 24 (--- 12) 106 (222)
50 --- 37 (--- 34) 108 (226)
: At 1,013 hPa (760 mmHg) pressure (atmospheric).
A higher boiling point is obtained by using a radiator pres-
sure cap which permits the development of pressure within the
cooling system.
NOTE
The above data represents industry standards that necessitate a
minimum glycol content in the concentrated anti ---freeze.
13---9
Portable Compressor 7/20

When the coolant level drops due to evaporation, add water BE SURE TO STOP THE ENGINE WHILE REFUELING OR
only to keep the anti ---freeze mixing ratio less than 50%. In case BLEEDING AND WHEN CLEANING OR CHANGING FUEL
of leakage, add anti ---freeze and water in the specified mixing FILTER OR FUEL PIPES. DO NOT SMOKE WHEN WORKING
ratio before filling into the radiator. AROUND THE BATTERY OR WHEN REFUELING.

Anti ---freeze absorbs moisture. Keep unused antifreeze in a CHECK THE ABOVE FUEL SYSTEMS AT A WELL
tightly sealed container. VENTILATED AND WIDE PLACE.
WHEN FUEL AND LUBRICANT ARE SPILLED, REFUEL AFTER
Do not use radiator cleaning agents when anti ---freeze has been LETTING THE ENGINE COOL OFF.
added to the coolant. (Anti ---freeze contains an anti ---corrosive
agent, which will react with the radiator cleaning agent forming ALWAYS KEEP SPILLED FUEL AND LUBRICANT AWAY FROM
sludge which will affect the engine parts.) ENGINE.

B. Fuel Level Check And Refueling

G. Radiator Cement (1.) Check to see that the fuel level is above the lower limit of the
As the radiator is solidly constructed, there is little possibility of fuel level gauge.
water leakage. Should this happen, however, radiator cement (2.) If the fuel is too low, add fuel to the upper limit. Do not overfill.
can easily fix it. If leakage is serious, contact your local
Ingersoll--- Rand dealer.
No.2--- D is a distillate diesel fuel of lower volatility for engines in
industrial and heavy mobile service.
13.6.3. Periodic Service (SAE J313 JUN87)

A. Fuel
Table 13 ---6. GRADE OF DIESEL FUEL
Fuel is flammable and can be dangerous. You should handle fuel ACCORDING TO ASTM D975
with care.
CAUTION Flash Water and Carbon Residue
Ash,
Point, Sediment, on 10 percent
DO NOT MIX GASOLINE OR ALCOHOL WITH DIESEL FUEL. weight %
˚C (˚F) volume % Residuum %
THIS MIXTURE CAN CAUSE AN EXPLOSION.
BE CAREFUL NOT TO SPILL FUEL DURING REFUELING. IF Min Max Max Max
FUEL SHOULD SPILL, WIPE IT OFF AT ONCE, OR IT MAY
52
CAUSE A FIRE. 0.05 0.35 0.01
(125)
DO NOT FAIL TO STOP THE ENGINE BEFORE REFUELING.
KEEP THE ENGINE AWAY FROM THE FIRE.

Table 13 ---7. PARAMETERS OF DIESEL FUEL

Distillation temperatures, Viscosity Kinematic cSt or Viscosity Sayboit, SUS Sulfur Copper strip Cetane
˚C (˚F) 90% Point mm2.s --- 1 at 40˚C at 100˚F weight % Corrosion Number

Min Max Min Max Min Max Max Max Min

282 338
1.9 4.1 32.6 40.1 0.50 No. 3 40
(540) (640)
The cetane number is required not to be less than 45.

NOTE CAUTION

Be sure to use a strainer when filling the fuel tank, or dirt or DO NOT BLEED A HOT ENGINE AS THIS COULD CAUSE
sand in the fuel may cause trouble in the fuel injection pump. FUEL TO SPILL ONTO A HOT EXHAUST MANIFOLD
CREATING A DANGER OF FIRE.

Air bleeding of the fuel system is required if:

For fuel, always use diesel fuel. You are required not to use
alternative fuel, because its quality is unknown or it may be
inferior in quality. Kerosene, which is very low in cetane rating,
adversely affects the engine. Diesel fuel differs in grades
depending on the temperature.
--- after the fuel filter and pipes have been detached and
refitted,
--- after the fuel tank has become empty, or
--- before the engine is to be used after a long storage.

[PROCEDURE A] (gravity feed fuel tanks only)

(1.) Fill the fuel tank to the fullest extent. Open the fuel filter lever.
Be careful not to let the fuel tank become empty, or air can
enter the fuel system, necessitating bleeding before next (2.) Loosen air vent plug of the fuel filter a few turns.
engine start. (3.) Screw back the plug when bubbles do not come up any
more.
(4.) Open the air vent plug on top of the fuel injection pump.
C. Air Bleeding The Fuel System (5.) Retighten the plug when bubbles do not come up any more.

13---10 SEPTEMBER 2003

 Portable Compressor 7/20

1 2 --- If the clamp band is loose, apply oil to the screw of the
band, and tighten the band securely.
--- If the fuel pipes, made of rubber, become worn out,
replace them and the clamp bands every two years.
--- If the fuel pipes and clamp bands are found worn or
damaged before two years‘time, replace or repair
them at once.
--- After replacement of the pipes and bands, air--- bleed
the fuel system.

NOTE
When the fuel pipes are not installed, plug them at both ends
with clean cloth or paper to prevent dirt from entering. Dirt in
the pipes can cause fuel injection pump malfunction.

1. Air vent plug

1 3 2. Injection pump
3. Fuel filter
2

Figure 13 ---11. GRAVITY FEED SYSTEM

1
[PROCEDURE B] (fuel tanks lower than injection pump)
(1.) For fuel tanks that are lower that the injection pump. The fuel
system must be pressurized by the fuel system electric fuel
pump.
(2.) If an electric fuel pump is not used, you must manually
actuate the pump by lever to bleed.
(3.) The primary fuel filter 3 must be on the pressure side of the
pump if the fuel tank is lower than the injection pump.
(4.) To bleed follow (2) through (5) above. 1. Clamp band 1 2
2. Fuel pipe
NOTE
Tighten air vent plug of the fuel injection pump except when Figure 13 ---13. FUEL PIPES
bleeding, or it may stop the engine suddenly.
E. Cleaning The Fuel Filter Pot
Every 100 hours of operation, clean the fuel filter in a clean place
2 3
to prevent dust intrusion.
(1.) Close the fuel filter lever.

1 4 5 A
1. Fuel tank below injection pump
1
2. Pre--- filter
3. Electric or mechanical pump A “OFF”
4. Main filter B “ON”
5. Injection pump
1. Fuel filter lever
2. Fuel filter pot 2 B
Figure 13 ---12. TANK BELOW INJECTION PUMP
SYSTEM
Figure 13 ---14. FUEL FILTER CARTRIDGE
D. Checking The Fuel Pipes REPLACEMENT
CAUTION
CHECK OR REPLACE THE FUEL PIPES AFTER STOPPING (2.) Remove the top cap, and rinse the inside with diesel fuel.
THE ENGINE. BROKEN FUEL PIPES CAN CAUSE FIRES. (3.) Take out the element, and rise it with diesel fuel.
(4.) After cleaning, reinstall the fuel filter, keeping out of dust and
Check the fuel pipes every 50 hours of operation. When if: dirt.

SEPTEMBER 2003 13---11

Portable Compressor 7/20

(5.) Air--- bleed the injection pump.

3
NOTE
Entrance of dust and dirt can cause a mulfunction of the fuel
1
injection pump and the injection nozzle. Wash the fuel filter cup
periodically.
2 Red signal

A B
3
A Normal 1. Indicator
7 2. Window
B Clogged
5 3. “RESET“ button
4
2
5 3
8 Figure 13 ---16. DUST INDICATOR

2 5
B. Air Cleaner With Dust Indicator
1
1 This indicator is attached to the air cleaner. When the air cleaner
element is clogged, air intake resistance becomes greater and
the dust indicator signal turns to red indicating the element needs
6 to be changed.
When the signal turns to red, replace the element. Then press the
1. Filter bowl dust indicator “RESET“ button 2 to reset the indication.
2. Fuel filter cartridge
3. Cover
4. Air vent plug 13.6.5. Engine Electrical
5. O ring The Kubota engines use a 12 V system and a negative grounding
6. Screw ring for the electrical system.
7. Pipe joint
8. Spring Battery Servicing
A. Battery Terminal Connections
Check the battery cable connections for looseness or corrosion.
Figure 13 ---15. FUEL FILTER Poor cable connections will result in difficult engine starting or
insufficient battery charge.
The battery cables must be tightened securely.
Never reverse “+” and “ --- ” terminals when reconnecting cables
F. Fuel Filter Cartridge Replacement
after removal. Even a short period of reverse connection will
(1.) Replacement of the fuel filter cartridge with a new one every damage the electrical parts.
400 operating hours.
B. Cleaning Of Battery
(2.) Apply diesel fuel thinly over the gasket and tighten the
cartridge into position by hand --- tightening only. When the battery terminals are fouled clean them with clean tepid
water and wipe with a dry cloth to remove the water. Apply a light
(3.) Finally, vent the air. coat of vaseline or a grease.

NOTE C. Alternator Servicing

Replacement of the fuel filter cartridge periodically to prevent
wear of the fuel injection pump plunger or the injection nozzle,
due to dirt in the fuel.
13.6.4. Air Intake System
A. Air Cleaner
Engine performance and life vary with the air intake conditions.
A dirty air cleaner element reduces the amount of intake air,
causing reduced engine output and possible engine damage.
Also, a damaged element leads to abrasion of cylinders and
valves, resulting in increased oil consumption, reduced output
and shortened engine life.
The filter element should be changed at 500 hours or 6 months,
whichever comes first, or sooner if the restriction indicator shows
red. See Figure 13 ---16.
The polarity of the alternator is negative (--- ) grounding type.
Do not reverse the polarity connection, otherwise a short circuit
will occur resulting in alternator failure.
Do not put water directly on the alternator. Entry of water into the
alternator creates electrolytic corrosion causing failure.
When the battery is charged from an external source, be sure to
disconnect the battery cables.
D. Wiring Connections
Check all of the electric wiring connections for looseness and
damage on a regular basis.
13.6.6. Service And Maintenance
Please refer to the engine maintenance schedule.
For continued trouble free engine operation throughout its life,
the service procedures marked with an asterisk (*) need to be
carried out by a skilled and trained technician.

13---12 SEPTEMBER 2003


Please consult your local Ingersoll--- Rand branch or dealer when
these procedures become due.
Please also read the note refering to the service items marked
with the star L symbol.
13.7. COLD WEATHER OPERATION
A. Fuel Selection
In cold weather, the fuel might freeze resulting in difficult engine
starting; therefore, select a suitable fuel for such engine
operation. Use ASTM 975 No. 2--- D fuel if you expect temperature
above --- 7˚C (20˚F).
Use No. 1--- D if you expect temperatures below --- 7˚C (20˚F).
If No. 1--- D is not available, a “winter” blend of No. 1--- D and No.
2--- D is available in some areas during the winter months.
Check with your fuel supplier to be sure you get the correct
blended fuel.
B. Coolant
Where the ambient temperature falls below freezing point, the
cooling system should be drained after engine operation, but to
eliminate the need for repeated draining, refilling and to provide
all year protection against corrosion, the use of anti--- freeze
solution throughout the year is highly recommended.
All Ingersoll--- Rand portable compressor engines are factory
filled with a 50/50 % ethylene glycol base antifreeze/water mix
which provides protection to --- 33˚C (--- 27˚F).
Concentrations over about 65 % adversely affect freeze
protection, heat transfer rates, and silicate stability which may
cause wate pump leakage.
CAUTION
NEVER EXCEED A 60/40 % ANTIFREEZE/WATER MIX (WHICH
PROVIDES PROTECTION TO ABOUT --- 50˚C (--- 58˚F).
NOTE
Methyl alcohol base antifreeze is not recommended because of
its effect on the non ---metallic components of the cooling
system and because of its low boiling point.
SEPTEMBER 2003
Portable Compressor 7/20
NOTE
High silicate antifreeze is not recommended because of
causing serious silica gelation problems.
NOTE
Usage and mixing ratio etc. should be followed to the antifreeze
manufacture’s recommendations.
C. Engine Oil
At low ambient temperatures, engine oil viscocity can affect
engine starting. It is important to use the correct grade of oil as
recommended in Figure 13 ---3 OPERATING TEMPERATURE.
Try to position the compressor where it will not be affected by
cold winds when not running.
D. Battery
(1.) Always ensure that the batteries are kept fully charged in the
cold season. This takes a longer period of running than in
warm weather operation.
The electrolyte in a partly discharged battery will freeze easier
than when it is fully charged. Try to keep the batterys fully
charged and warm in cold weather operation.
(2.) Top up the battery with distilled water immediately before
starting the engine.
E. Cold Starting
When operating in cold ambient conditions, or when starting
from cold, observe the following procedures:
--- Turn the key switch to position II (GLOW) and hold for
between 5÷15 seconds. This action operates the glow
plugs.
--- If the engine does not start at the first attempt, allow the
battery to recove for at least 30 seconds then repeat step 1)
above.
--- In order protect the starter, do not engage for longer than 10
seconds during any attempt.
--- If during cranking, the starter motor reatedly engages and
disengages the battery power could be low. Either recharge
the battery or replace it with one that is fully charged.
NOTICE
Do not use starting “aids” in the air intake system. Such aids
can cause immediate engine damage.
13---13
Portable Compressor 7/20

13.8. ENGINE MAINTENANCE SCHEDULE
CAUTION
BE SURE TO CONDUCT DAILY CHECKS, PERIODIC
MAINTENANCE, REFUELING OR CLEANING ON A LEVEL
SURFACE WITH THE ENGINE SHUT OFF AND REMOVE THE
KEY.
BEFORE ALLOWING OTHER PEOPLE TO USE YOUR
ENGINE, EXPLAIN HOW TO OPERATE, AND HAVE THEM
READ THIS MANUAL BEFORE OPERATION.
WHEN CLEANING ANY PARTS, DO NOT USE GASOLINE BUT
USE REGULAR CLEANSER.
ALWAYS USE PROPER TOOLS, THAT ARE IN GOOD
CONDITION. MAKE SURE YOU UNDERSTAND HOW TO USE
THEM, BEFORE PERFORMING ANY SERVICE WORK.
WHEN INSTALING, BE SURE TO TIGHTEN ALL BOLTS LEST
THEY SHOULD BE LOOSE. TIGHTEN THE BOLTS BY THE
SPECIFIED TORQUE.
DO NOT PUT ANY TOOLS ON THE BATTERY, OR BATTERY
TERMINALS MAY SHORT OUT. SEVERE BURNS OR FIRE
COULD RESULT. DETACH THE BATTERY FROM THE ENGINE
BEFORE MAINTENANCE.
DO NOT TOUCH MUFFLER OR EXHAUST PIPES WHILE
THEY ARE HOT. SEVERE BURNS COULD RESULT.
13.8.1. Service Interval
Observe the following Table 13 ---8. SERVICE INTERVAL for
service and maintenance.

Table 13 ---8. SERVICE INTERVAL

Interval Item

Every 50 hours Check of fuel pipes and clamp bands @

See Table 13 ---9. INTERVAL OF ENGINE OIL Change of engine oil

Cleaning of air cleaner element *1 @

Cleaning of fuel filter

Every 100 hours
Check of battery electrolyte level

Check of fan belt tightness

Check of radiator hoses and clamp bands

Every
y 200 hours Replacement of oil filter cartridge

Check of intake air line @

Every 400 hours Replacement of fuel filter cartridge @

Removal of sediment in fuel tank

Every
y 500 hours Cleaning of water jacket (radiator interior)

Replacement of fan belt

Every one or two months Recharging of battery

Replacement of air cleaner element *2 @

Every year
Check of damage in electric wiring and loose connections

Every 800 hours Check of valve clearance

Every 1,500 hours Check of fuel injection nozzle injection pressure *3 @

Check of turbo charger *3 @

Every
y 3,000 hours Check of injection pump *3 @

Check of fuel injection timer *3 @

Check of radiator coolant (L.L.C.)

Replacement of battery

Every
y two years
y Replacement of radiator hoses and clamp bands

Replacement of fuel pipes and clamp bands *3 @

Replacement of intake air line *4 @

13---14 SEPTEMBER 2003

 Portable Compressor 7/20

NOTE *4 Replace only if necessary.

The jobs indicated by must be done after the first 50 hours
of operation.
*1 Air cleaner should be cleaned more often in dusty
conditions that in normal conditions.
*2 After 6 times of cleaning.
*3 Consult your local Ingersoll ---Rand dealer for this service.
When the battery is used for less than 100 hours in year, check
its electrolyte yearly. For refillable battery‘s only.
The items listed above (@ marked ) are registered as emission
related critical parts by Ingersoll ---Rand in the U.S. EPA nonroad
emission regulation. As the engine owner, you are responsible
for the performance of the required maintenance on the engine
according to the above instruction.
Please see the Warranty Statement in detail.

Table 13 ---9. INTERVAL OF ENGINE OIL

Oil pan depth
Models
Above 125 mm (4.9 in) : below 101 mm (4.0 in)
All models 200 hours 150 hours
Initial 50 hours

: 101 mm oil pan depth is optional. NOTE

L This is a recommended maintenance item. The failure to
:: Standard replacement interval
perform this maintenance item will not nullify the emission
API service classification: above CD grade warranty or limit recall liability prior to the completion engine
useful life. Ingersoll ---Rand, however, urges that recommended
Ambient temerature: below 35˚C (95˚F) maintenance service is performed at the indicated intervals.

SEPTEMBER 2003 13---15/(13---16 blank)

 Portable Compressor 7/20

14. TROUBLESHOOTING

14.1. COMPRESSOR TROUBLESHOOTING

If the compressor does not function properly, use the following chart to identify and correct the cause.

Table 14 ---1. COMPRESSOR TROUBLESHOOTING

Fault Cause Remedy

Engine speed too low Check the air cylinder and air filter(s)
Blocked air cleaner Check the restriction indicators and replace the element(s) if
necessary
Air discharge
High pressure air escaping Check for leaks
capacity too low
Incorrectly set regulation system Reset the regulation system.
Refer to 9.23. SPEED AND PRESSURE REGULATION
ADJUSTMENT in the 9. MAINTENANCE section of this manual.
Low oil level Top up the oil level and check for leaks
Dirty or blocked oil cooler Clean the oil cooler fins
Incorrect grade of oil Use Ingersoll--- Rand recommended oil
Compressor
overheats Recalculations of cooling air Move the machine to avoid recirculation
Faulty temperature switch Check the operation of the switch and replace if necessary
Reduced cooling air from fan Check the fan and the drive belts. Check for any obstruction
inside the fan cowl
Blocked scavenge line Check the scavenge line, drop tube and orifice. Clean and
Excessive oil replace
Perforated separator element
present in the
Pressure in the system is too low Replace the separator element
discharge air
Check the minimum pressure valve or sonic orifice
Operating pressure too high Check the setting and operation of the regulator valve piping
Incorrect setting of the regulator Adjust the regulator
Faulty regulator Replace the regulator
Safety valve Inlet valve set incorrectly Refer to 9.23. SPEED AND PRESSURE REGULATION
operates ADJUSTMENT section of this manual
Loose pipe/hose connections Check all pipe/hose connections
Faulty safety valve Check the relieving pressure. Replace the safety valve if faulty.
Do not attempt a repair.
Incorrect stopping procedure used Always employ the correct stopping procedure. Close the
discharge valve and allow the machine to run on idle before
stopping
Oil is forced back
into the air filter Faulty inlet valve(s) Check for free operation of the inlet valve(s)
Faulty discharge check valve Remove the valve from the discharge pipe and check the
operation
Machine goes to full Inlet valve set incorrectly Refer to 9.23. SPEED AND PRESSURE REGULATION
pressure when ADJUSTMENT section of this manual
started

SEPTEMBER 2003 14---1

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14.2. ENGINE TROUBLESHOOTING

Table 14 ---2. ENGINE TROUBLESHOOTING

Fault Cause Remedy

Low battery charge Check fan belt tension, battery and cable connections
Bad earth connection Check the earth cables, clean as required
Loose connection Locate and make the connection good
Engine fails to start Fuel starvation Check the fuel level and fuel system components. Replace the
fuel filter if necessary
Relay failed Replace the relay
Engine control not in ”run” position Check the speed cylinder and stop position
Electrical fault Test the electrical circuits
Engine starts but
stalls when the Low engine oil pressure Check the oil level and the oil filter(s)
switch returns to Faulty relay Check the relays
position I
Faulty key--- switch Check the key--- switch
Electrical fault Test the electrical circuits
Low engine oil pressure Check the oil level filter(s)
Safety shut--- down system in operation Check the safety shut--- down switches
Engine starts but Fuel starvation Check the fuel level and fuel system components. Replace the
will not run or fuel filter if necessary
engine shuts down Switch failure Test the switches
prematurely
High compressor oil temperature Check the compressor oil level and oil cooler. Check the fan
Water present in fuel system drive

Faulty relay Check the water separator and clean if required

Check the relay in the holder and replace if necessary
Reduced cooling air from fan Check the fan and the drive belts
Engine overheats
Check for any obstruction inside the cowl

Engine speed too Incorrect throttle arm setting Check the engine speed setting
high Faulty regulator valve Check the regulation system
Incorrect throttle arm setting Check the throttle setting
Blocked fuel filter Check and replace if necessary
Engine speed too Blocked air filter Check and replace the element if necessary
low Faulty regulator valve Check the regulation system
Premature unloading Check the regulation and the operation of the air cylinder
Drive belt too tight Check the drive belt tightening
Excessive vibration Engine speed too low See “Engine speed too low”
(continued on next page)

14---2 SEPTEMBER 2003


Table 14 ---2. (continued) ENGINE TROUBLESHOOTING
Fault Cause
Fuel is thick and doesn‘t flow
Air or water mixed in fuel system
Thick carbon deposits on orifice of
injection nozzle
Difficult to start the
Valve clearance is wrong
engine
Leaking valves
Fuel injection timing is wrong
Engine oil becomes thick in cold
weather and engine cranks slow
Low compression
Battery is discharged and the engine
will not crank
If the cause of trouble can not be found, contact your local Ingersoll ---Rand dealer.
Carbon stuck around orifice of nozzle
piece
Compression is insufficient
Leaking valves
Fuel is insufficient
When output is Overheating of moving parts
insufficient
Valve clearance is wrong
Air cleaner is dirty
Fuel injection pressure is wrong
Injection pump wear
SEPTEMBER 2003
Portable Compressor 7/20
Remedy
Check the fuel tank and fuel filter. Remove water, dirt and other
impurities
As all fuel will be filtered by the filter, if there should be water or
other foreign matters on the filter, clean the filter with kerosene
If air is in the fuel filter or injection lines, the fuel pump will not
work properly. To attain proper fuel injection pressure, check
carefully for a loosened fuel line coupling, a loose of cap nut,
etc.
Loosen join bolt, a top fuel filter and air vent screws of fuel
injection pump to eliminate all the air in the fuel system
This is caused when water or dirt is mixed in the fuel. Clean the
nozzle injection piece, being careful not to damage the orifice
Check to see if nozzle is working properly or not. If not, install a
new nozzle
Adjust valve clearance to 0.145÷0.185 mm (0.006÷0.007 in)
when the engine is cold
Grind valves
Adjust injection timing
The injection timing 0.33 rad (19˚) before the top dead center
Change grade of oil according to the weather (temperature)
Bad valve or excessive wear of rings, pistons and liners cause
insufficient compression Replace with new parts
Charge the battery
In winter, always remove the battery from machine, charge fully
and keep indoors. Instal in machine at time of use
NOTE
Clean the orifice and needle valve, being very careful not to
damage the nozzle orifice
Check nozzle to see if good. If not, replace with new parts
Bad valve and excessive wear of rings, pistons and liners cause
insufficient compression. Replace with new parts
Grind valves
Check fuel system
Check lubricating oil system
Check to see if lubricating oil filter is working properly
Filter element deposited with impurities would cause poor
lubrication. Change element
Check the clearance of bearing are within factory specs
Check injection timing
Adjust to proper valve clearance of 0.145÷0.815 mm
(0.006÷0.007 in) with engine cold
Clean the element every 100 hours of operation
Adjust to proper pressure. 13.7 MPa (1,991 psi)
Do not use poor quality fuel as it will cause wear of the pump. Only
use No.2--- D diesel fuel
Check the fuel injection pump element and delivery valve
assembly and replace as necessary
(continued on next page)
14---3
Portable Compressor 7/20

Table 14 ---2. (continued) ENGINE TROUBLESHOOTING

Fault Cause Remedy

Check the fuel tank and refill the fuel, if necessary

Lack of fuel
Also check the fuel system for air or leaks
Bad nozzle If necessary, replace with a new nozzle
Check amount of engine oil with oil level gauge
Moving parts are overheated due to Check lubricating oil system
Engine suddenly shortage of lubrication oil or improper At level 2 times of oil change, oil filter cartridge should be replaced
stops lubrication
Check to see if the engine bearing clearances is within factory
specs
NOTE
When the engine has suddenly stopped, decompress the engine by the decomp and turn the engine lightly
by pulling on the fan belt. If the engine turns easily without abnormalities, the cause of the trouble is usually
lack of fuel or bad nozzle.
Fuel governing device bad Contact dealer for repairs
Fuel is of extremely poor is quality Select good quality fuel Use No. 2--- D diesel fuel only

Color of exhaust is Nozzle is bad If necessary, replace with new nozzle

especially bad Cause is poor atomization, improper injection timing, etc.
Because of trouble in injection system or in poor valve adjustment
Combustion is incomplete
or compression leakage, poor compression, etc. Check for the
cause
Engine revolution suddenly decreases
Check the adjustments, injection timing and the fuel system
or increases
Unusual sound is heard suddenly Check all moving parts carefully
Check the fuel injection system, especially the fuel injection
Color of exhaust suddenly turns dark
nozzle
Engine must be
stopped
pp Bearing parts are overheated Check the lubricating system
i
immediately
di t l Check lubricating system
Check, if the engine bearing clearances are within factory specs
Check the function of the relieve valve in the lubricating system
Oil lamp lights up during operation
Check pressure switch
Check filter base gasket
Engine oil insufficient Check oil level. Replenish oil as required
Fan belt broken or elongated Check belt or adjust belt tension
Coolant insufficient Replenish coolant
Add water only or change to coolant with the specified mixing
Excessive concentration of anti--- freeze
radio
Radiator net or radiator fin clogged with
Clean net or fin carefully
dust
Inside of radiator or coolant flow route
Clean or replace radiator and parts
Engine
g overheats corroded
Fan or radiator or radiator cap defective Replace defective part
Thermostat defective Check thermostat and replace if necessary
Thermostat gauge or sensor defective Check temperature with thermometer and replace if necessary
Overload running Reduce load
Head gasket defective or water leakage Replace parts
Incorrect injection timing Adjust to proper timing
Unsuitable fuel used Use the specified fuel

14---4 SEPTEMBER 2003