OPERATING, MAINTENANCE,PARTS MANUAL

COMPRESSOR MODEL

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This manual contains important safety information and must be madeavailable to personnel who operate and maintain this machine.

–>SERIAL No : 8140009/235C.C.N. : 22488183 GBDATE : AUGUST 2004

Machine models represented in this manual may be used in various locations world–wide. Machines sold andshipped into European Union Territories require that the machine display the EC Mark and conform to variousdirectives. In such cases, the design specification of this machine has been certified as complying with EC directives.Any modification to any part is absolutely prohibited and would result in the CE Certification and marking beingrendered invalid. A declaration of that conformity follows:

We

Declare that, under our sole responsibility for manufacture and supply, the product(s)

98/37/EC, 93/68/EEC, 89/336/EEC, 2000/14/EC

Ingersoll–Rand Company Portable Compressor DivisionP.O. Box 868501 Sanford AvenueMocksville, North Carolina 27028

Ingersoll–Rand Company LimitedStandard Products DivisionSwan LaneHindley GreenWigan WN2 4EZUnited Kingdom

Represented in EC by:

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

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

________________________________

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Ric LunsfordManager of quality control

DECLARATION OF CONFORMITY WITH EC DIRECTIVES

Issued at Mocksville on15–4–2004

CONFORMITY WITH NOISE DIRECTIVE 2000/14/ECIngersoll–Rand Company Limited declare that the following Portable Compressors have been

manufactured in conformity with the directive as shown

DirectiveMachine Serial number Mean measured Guaranteed Notified bodyDirective

Type kWSerial number

rangeMean measured

valueGuaranteed

Level Notified body

2000/14/EC A V T h l2000/14/ECAnnex VI 9/235 205 814000 – 814999 101 4 LWA 102 LWA

A V TechnologyStockport UKAnnex VI

Part I9/235 205 814000 – 814999 101.4 LWA 102 LWA Stockport UK

Nr 1067Part I Nr 1067

________________________________

Issued at Prague. . . . . . . . . . . 1st Declaration April 2004. . . . .

Tomas HibsEngineering manager

EC Pressure Equipment Directive and Related RegulationsWe declare that this product has been assessed according to the Pressure Equipment Directive (97/23/EC) and, inaccordance 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.

CONTENTS & ABBREVIATIONS 1

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1 CONTENTS

2 FOREWORD

3 WARRANTY

8 DECALS

12 SAFETY

15 GENERAL INFORMATION

16 OPERATING INSTRUCTIONSCommissioningCompressor MountingPrior to startingStartingStoppingEmergency stoppingRe–startingMonitoring during operationDecommissioning

22 ENGINE INSTRUCTION MANUAL

43 MAINTENANCE

53 FAULT FINDING

55 PARTS ORDERING

ABBREVIATIONS & SYMBOLS

#### Contact Ingersoll–Rand for serial number

–>#### Up to Serial No.####–> From Serial No.

* Not illustrated† OptionAR As requiredD GermanyDK DenmarkE SpainF FranceGB Great BritainHA High ambient machineI ItalyN NorwayNL NetherlandsP PortugalS SwedenSF FinlandF.H.R.G. Fixed height running gearV.H.R.G. Variable height running gear

FOREWORD2

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The contents of this manual are considered to be proprietary andconfidential to Ingersoll–Rand and should not be reproduced withoutthe prior written permission of Ingersoll–Rand.

Nothing contained in this document is intended to extend anypromise, warranty or representation, expressed or implied, regardingthe Ingersoll–Rand products described herein. Any such warranties orother terms and conditions of sale of products shall be in accordancewith the standard terms and conditions of sale for such products, whichare available upon request.

This manual contains instructions and technical data to cover allroutine operation and scheduled maintenance tasks by operation andmaintenance staff. Major overhauls are outside the scope of thismanual and should be referred to an authorised Ingersoll–Rand servicedepartment.

The design specification of this machine has been certified ascomplying with EC directives. As a result:

(a) Any machine modifications are strictly prohibited, and will invalidateEC certification.

(b) A unique specification for USA/Canada is adopted and tailored tothe territory.

All components, accessories, pipes and connectors added to thecompressed 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 maximumallowable working pressure.. compatible with the compressor lubricant/coolant.. accompanied with instructions for safe installation, operation andmaintenance.

Details of approved equipment are available from Ingersoll–RandService departments.

The use of repair parts / lubricants / fluids other than those includedwithin the Ingersoll–Rand approved parts list may create hazardousconditions over which Ingersoll–Rand has no control. ThereforeIngersoll–Rand cannot be held responsible for equipment in whichnon–approved repair parts are installed.

Ingersoll–Rand reserves the right to make changes andimprovements to products without notice and without incurring anyobligation to make such changes or add such improvements toproducts sold previously.

The intended uses of this machine are outlined below and examplesof unapproved usage are also given, however Ingersoll–Rand cannotanticipate every application or work situation that may arise.

IF IN DOUBT CONSULT SUPERVISION.

This machine has been designed and supplied for use only in thefollowing specified conditions and applications:. Compression of normal ambient air containing no known ordetectable additional gases, vapours. or particles. Operation within the ambient temperature range specified in theGENERAL INFORMATION section of this manual.

UNITS MANUFACTURED IN NORTH AMERICA: Generation ofelectricity at 120V (1ph) at 60 Hertz.

UNITS MANUFACTURED IN EUROPE: Generation of electricity notapplicable.

The use of the machine in any of the situation types listed intable 1:–a) Is not approved by Ingersoll–Rand,b) May impair the safety of users and other persons, andc) May prejudice any claims made against Ingersoll–Rand.

TABLE 1

Use of the machine to produce compressed air for:a) direct human consumptionb) indirect human consumption, without suitable filtration and puritychecks.

Use of the machine outside the ambient temperature range

specified in the GENERAL INFORMATION SECTION of this manual.

This machine is not intended and must not be used in potentiallyexplosive atmospheres, including situations where flammable gasesor vapours may be present.

Use of the machine fitted with non Ingersoll–Rand approvedcomponents / lubricants / fluids.

Use of the machine with safety or control components missing or

disabled.

Use of the machine for storage or transportation of materials insideor on the enclosure except when contained within the toolbox.

GENERATOR

Use of the generator to supply load(s) greater than those specified.

Use of unsafe or unserviceable electrical equipment connected to

the generator.

Use of electrical equipment:(a) Having incorrect voltage and/or frequency ratings.

(b) Containing computer equipment and/or similar electronics.

The company accepts no responsibility for errors in translation ofthis manual from the original English version.

© COPYRIGHT 2004INGERSOLL–RAND COMPANY

WARRANTY 3

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Ingersoll–Rand, through its distributor, warrants that each item ofequipment manufactured by it and delivered hereunder to the initialuser will be free of defects in material and workmanship.

With respect to the following types of equipment, the warranty periodenumerated below will apply.

A. Aftercoolers – The earlier of nine (9) months from date ofshipment to or six (6) months from start up by initial user.

B. Portable Compressors, Portable Generator Sets (GENSET),Portable Light Towers and Air Dyers – The earlier of twelve(12) months from shipment to or the accumulation of 2,000 hoursof service by the initial user.

C. Portable Compressor Air Ends – The earlier of twenty–four(24) months from shipment to or the accumulation of 4,000 hoursof service by the initial user. For Air Ends, the warranty againstdefects will include replacement of the complete Air End,provided the original Air End, is returned assembled andunopened.

C.1 Portable Compressor Airend Limited Optional Warranty –The earlier of sixty (60) months from shipment to or theaccumulation of 10,000 hours of service. The optional warrantyis limited to defects in rotors, housings, bearings and gears andprovided all the following conditions are met:

The original airend is returned assembled and unopened.

Continued use of genuine Ingersoll–Rand parts, fluids, oils andfilters.

Maintenance is performed at prescribed intervals.

D. Genset Generators – The earlier of twenty–four (24) monthsfrom shipment to or the accumulation of 4,000 hours of serviceby the initial user.

E. Portable Light Tower Generators – The earlier of twelve (12)months from shipment to or the accumulation of 2,000 hours ofservice by the initial user. Light Source model only, the earlier oftwenty–four (24) months from shipment to or the accumulation of4,000 hours of service.

F. Ingersoll–Rand Engines – The earlier of twenty—four (24)months from shipment to or the accumulation of 4,000 hours ofservice.

G. Ingersoll–Rand Platinum Drive Train Warranty (Optional) –Platinum drive train pertains to the Ingersoll–Rand Engine andAirend combination. The earlier of sixty (60) months fromshipment to, or the accumulation of 10,000 hours of service. Thestarter, alternator, fuel injection system and all electricalcomponents are excluded from the extended warranty. Theairend seal and drive coupling are included in the warranty(air–end drive belts are not included). The optional warranty isautomatically available when meeting the following conditions:

The original airend is returned assembled and unopened.

Continued use of genuine Ingersoll–Rand parts, fluids, oil andfilters.

Maintenance is performed at prescribed intervals.

It is the obligation of the user to provide verification that theseconditions have been satisfied when submitting warranty claims.

H. Spare Parts – Six (6) months from date of installation

Ingersoll–Rand will provide a new part or repaired part, at its election,in place of any part which is found upon its inspection to be defectivein material and workmanship during the period prescribed above. Suchpart will be repaired or replaced without charge to the initial user duringnormal working hours at the place of business of an Ingersoll–Randdistributor authorized to sell the type of equipment involved or otherestablishment authorized by Ingersoll – Rand. User must present proofof purchase at the time of exercising warranty.

The above warranty does not apply to failures occurring as a result ofabuse; misuse, negligent repairs, corrosion, erosion and normal wearand tear, alterations or modifications made to the product without ex-press written consent of Ingersoll–Rand; or failure to follow the recom-mended operating practices and maintenance procedures as providedin the product’s operating and maintenance publications.

Accessories or equipment furnished by Ingersoll–Rand, butmanufactured by others, including, but not limited to, engines, tires,batteries, engine electrical equipment, hydraulic transmissions,carriers, shall carry whatever warranty the manufacturers haveconveyed to Ingersoll–Rand and which can be passed on to the initialuser.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIESEXPRESSED OR IMPLIED, (EXCEPT THAT OF TITLE), ANDTHERE ARE NO WARRANTIES OF MERCHANTABILITY OR OFFITNESS FORA PARTICULAR PURPOSE.

WARRANTY4

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GENERAL WARRANTY INFORMATION

GENERAL WARRANTY Extended Coverage

Portable Compressor Package 1 year/2000 hrs

Airend 2 yrs/4000 hrs 5 yrs/10,000 hrsLimited warranty, major components (re-fer to operator’s manual).

Portable Genset 8kW, 11KW, 20KVAthru 575KVA

Package 1 yr/2000 hrs None

Generator 2 yrs/4000 hrs None

Portable Genset 3.5KW thru 7.0KWand 10KW

Package 1 yr/2000 hrs (parts only) None

Generator 1 yrs/2000 hrs (parts only) None

Light Tower Package 1 yr/2000 hrs

Generator 1 yr/2000 hrs 2 years/4000 hours, for Lightsourceintroduced 8/16/99.

ENGINES

CATERPILLAR Months Hours Extended Coverage

12 unlimited Available at dealer

CUMMINS 24 2000 Major components 3 yrs/10,000 hrs Available at dealer

JOHN DEERE (in compressors) 24 2000 5 yrs/5000 hrs using OEM fluids and filters with $250deductible

(in generators as of 1/1/01) 24 2000 2 yrs/4000 hrs using IR fluids and filters

DEUTZ 24 2000 Available at dealer

INGERSOLL–RAND 24 4000 5 yrs/10,000 hrs when using genuine Ingersoll–Randfluids and parts. Refer to operator’s manual.

KUBOTA (North America only) 24 2000 Major components 36 mo/3000 hrs (parts only)

(Western Europe & Oceania) 24 2000 None

(Central & South America, Asia, Middle East & Africa) 12 1000 None

MITSUBISHI 24 2000 2 yrs/4000 hrs using IR fluids and filters

VOLVO 24 2000 2 yrs/4000 hrs using IR fluids and filters

HONDA 12 unlimited None

VANGUARD 24 unlimited None

PARTS

Months Hours Coverage

Ingersoll–Rand 6 No Limit Parts Only

AIREND EXCHANGE

Months Hours Extended Coverage

Airend 12 2000 2 yrs/4000 hrs – available from IR.

Note: Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with each newproduct.

WARRANTY 5

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Extended Limited Airend WarrantyIngersoll–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–Tec� Compressor Fluid. Pro–Tec� Compressor Fluid is an amber coloured fluid speciallyformulated 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 4000 hours of service by theinitial 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 is the earlier of 60 months from shipment to, or the accumulation of 10,000 hours of service. The optional warrantyis 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 Operation and Parts manual for the correct fluids,filters and separator elements required.

3. Submissions of proof that maintenance intervals have been followed.

WARRANTY TIME *BARE AIREND **AIREND COMPONENTS

STANDARD 2YRS / 4,000HRS 100% PARTS & LABOUR 100% PARTS & LABOUR

OPTIONAL 5YRS / 10,000HRS 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–Tec� 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.

WARRANTY6

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WARRANTY REGISTRATION

FOR UNITS SOURCED FROM HINDLEY GREEN, UK

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 LtdPortable Power BusinessSwan LaneHindley GreenWiganLancashireWN2 4EZ

U.K.

Attn: Customer Service Department

Note: Completion of this form validates the warranty.

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 machinedocumentation 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 localdealer to initiate warranty.

You MUST provide proof of the “in–service” date when requesting engine warranty repairs.

WARRANTY 7

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Selling Distributor Servicing Distributor WARRANTY REGISTRATION

Name Name Owner/User Name

Address Address Address

City City City

County County County

State State State

Zip code Zip code Zip code

Telephone Telephone Telephone

Complete the Applicable Blocks

Owner/User Type of Business (check one only)

Construction–Heavy(highway, excavation, etc.)

Asphalt Contractor Coal Mining Other Mining

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

Government(municipal, state,county, etc.)

Quarry Shallow Oil & Gas

Rental (rental center, rentalfleet, etc.)

Building Contractor Water well Utility Company (gas,electric, water, etc.)

Industrial(plant use)

Otherspecify

Exploration Utility Contractor

Model S/N Unit S/N Engine S/N Date delivered

Unit–Hours Airend S/N Truck S/N Truck Engine S/N

SERVICING DISTRIBUTOR / USER ACKNOWLEDGEMENT

1. The Purchaser has been instructed and/or has read the manual and understands proper preventativemaintenance, general operation and safety precautions.

2. The warranty and limitation of liability has been reviewed and understood by the owner/user.

3. In the event that this unit is to be used within a nuclear facility, the owner/user shall notify Ingersoll–Rand of suchuse so that Ingersoll–Rand may arrange for appropriate nuclear liability protection from the owner–licensee of thefacility.

4. Ingersoll–Rand reserves the right to make design changes or modifications of Ingersoll–Rand products at anytimewithout incurring any obligation to make similar changes or modifications on previously sold units.

DECALS8

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Look for these signs on machines manufactured in Europe, which point out potential hazards to the safetyof you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do notunderstand, inform you supervisor.

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING – Pressurised component orsystem.

WARNING – Hot surface.

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

X,XBAR

WARNING – Pressurised vessel. WARNING – Hot and harmful exhaust gas.WARNING – Maintain correct tyre pressure.

(Refer to the GENERAL INFORMATIONsection of this manual).

9DECALS

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0�C

WARNING – Flammable liquid.WARNING – Before connecting the tow bar

or commencing to tow consult theoperation and maintenance manual.

WARNING – For operating temperaturebelow 0�C, consult the operation and

maintenance manual.

WARNING – Do not undertake anymaintenance on this machine until the

electrical supply is disconnected and the airpressure is totally relieved.

WARNING – Consult the operation andmaintenance manual before commencing

any maintenance.

Do not breathe the compressed air from thismachine.

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

being fitted.

DECALS10

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Do not stand on any service valve or otherparts of the pressure system.

Do not operate with the doors or enclosureopen. Do not use fork lift truck from this side.

XXkm/h

Do not exceed the trailer speed limit. No naked lights. Do not open the service valve before theairhose is attached.

Use fork lift truck from this side only. Emergency stop. Tie down point

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

Read the Operation and Maintenance manualbefore operation or maintenance of this

machine is undertaken.

When parking use prop stand, handrake andwheel chocks. Compressor oil filling

Diesel fuelNo open flame. Parking brake. Rough Service Designation.

Wet Location Operation.

11DECALS

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Replace any cracked protective shield. Oil drain. Engine Oil

Fuel level/point Pressure control Malfunction

Battery charging condition Low pressure High pressure

Engine malfunction High compressor temperature Compressor malfunction

Low engine oil pressure Engine high temperature

SAFETY12

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WARNINGSWarnings call attention to instructions which must be followed

precisely to avoid injury or death.

CAUTIONSCautions call attention to instructions which must be followed

precisely to avoid damaging the product, process or its surroundings.

NOTESNotes are used for supplementary information.

General Information

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

Ensure that the operator reads and understands the decals andconsults the manuals before maintenance or operation.

Ensure that the Operation and Maintenance manual, and themanual 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 thecanopy/doors are closed during operation.

The specification of this machine is such that the machine is notsuitable for use in flammable gas risk areas. If such an application isrequired then all local regulations, codes of practice and site rules mustbe observed. To ensure that the machine can operate in a safe andreliable manner, additional equipment such as gas detection, exhaustspark arrestors, and intake (shut–off) valves may be required,dependant on local regulations or the degree of risk involved.

A weekly visual check must be made on all fasteners/fixing screwssecuring mechanical parts. In particular, safety–related parts such ascoupling hitch, drawbar components, road–wheels, and lifting bailshould be checked for total security.

All components which are loose, damaged or unserviceable, mustbe rectified without delay.

Air discharged from this machine may contain carbon monoxide orother contaminants which will cause serious injury or death. Do notbreathe this air.

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

Never inspect or service unit without first disconnecting batterycable(s) to prevent accidental starting.

Do not use petroleum products (solvents or fuels) under highpressure as this can penetrate the skin and result in serious illness.wear eye protection while cleaning unit with compressed air to preventdebris from injuring eye(s).

Rotating fan blade can cause serious injury. Do not operate withoutguard in place.

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

Ether is an extremely volatile, highly inflammable gas. When it isspecified as a starting aid, use sparingly. DO NOT USE ETHER IF THEMACHINE HAS GLOW PLUGS OR INLET HEATER STARTING AIDSOR ENGINE DAMAGE WILL RESULT.

Never operate unit with guards, covers or screens removed. Keephands, hair, clothing, tools, blow gun tips, etc. well away from movingparts.

Compressed air

Compressed air can be dangerous if incorrectly handled. Beforedoing any work on the unit, ensure that all pressure is vented from thesystem and that the machine cannot be started accidentally.

Ensure that the machine is operating at the rated pressure and thatthe rated pressure is known to all relevant personnel.

All air pressure equipment installed in or connected to the machinemust have safe working pressure ratings of at least the machine ratedpressure.

If more than one compressor is connected to one commondownstream plant, effective check valves and isolation valves must befitted and controlled by work procedures, so that one machine cannotaccidently be pressurised / over pressurised by another.

Compressed air must not be used for a direct feed to any form ofbreathing apparatus or mask.

High Pressure Air can cause serious injury or death. Relievepressure before removing filler plugs/caps, fittings or covers.

Air pressure can remain trapped in air supply line which can resultin serious injury or death. Always carefully vent air supply line at toolor vent valve before performing any service.

The discharged air contains a very small percentage of compressorlubricating oil and care should be taken to ensure that downstreamequipment is compatible.

If the discharged air is to be ultimately released into a confinedspace, adequate ventilation must be provided.

When using compressed air always use appropriate personalprotective equipment.

All pressure containing parts, especially flexible hoses and theircouplings, must be regularly inspected, be free from defects and bereplaced according to the Manual instructions.

Avoid bodily contact with compressed air.

The safety valve located in the separator tank must be checkedperiodically for correct operation.

Whenever the machine is stopped, air will flow back into thecompressor system from devices or systems downstream of themachine unless the service valve is closed. Install a check valve at themachine service valve to prevent reverse flow in the event of anunexpected shutdown when the service valve is open.

SAFETY 13

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Disconnected air hoses whip and can cause serious injury or death.Always attach a safety flow restrictor to each hose at the source ofsupply or branch line in accordance with OSHA Regulation 29CFRSection 1926.302(b).

Never allow the unit to sit stopped with pressure in thereceiver–separator system.

Materials

The following substances may be produced during the operation ofthis machine:. brake lining dust. engine exhaust fumes

AVOID INHALATION

Ensure that adequate ventilation of the cooling system and exhaustgases is maintained at all times.

The following substances are used in the manufacture of thismachine and may be hazardous to health if used incorrectly:

. anti–freeze

. compressor lubricant

. engine lubricant

. preservative grease

. rust preventative

. diesel fuel

. battery electrolyte

AVOID INGESTION, SKIN CONTACT AND INHALATION OFFUMES

Should compressor lubricant come into contact with the eyes, thenirrigate with water for at least 5 minutes.

Should compressor lubricant come into contact with the skin, thenwash off immediately.

Consult a physician if large amounts of compressor lubricant areingested.

Consult a physician if compressor lubricant is inhaled.

Never give fluids or induce vomiting if the patient is unconscious orhaving convulsions.

Safety data sheets for compressor and engine lubricants should beobtained from the lubricant supplier.

Never operate the engine of this machine inside a building withoutadequate ventilation. Avoid breathing exhaust fumes when working onor near the machine.

This machine may include such materials as oil, diesel fuel,antifreeze, brake fluid, oil/air filters and batteries which may requireproper disposal when performing maintenance and service tasks.Contact local authorities for proper disposal of these materials.

Battery

A battery contains sulphuric acid and can give off gases which arecorrosive and potentially explosive. Avoid contact with skin, eyes andclothing. In case of contact, flush area immediately with water.

DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERYSINCE THIS MAY CAUSE IT TO EXPLODE.

Exercise extreme caution when using booster battery. To jumpbattery, connect ends of one booster cable to the positive (+) terminalof each battery. Connect one end of other cable to the negative (–)terminal of the booster battery and other end to a ground connectionaway from dead battery (to avoid a spark occurring near any explosivegases that may be present). After starting unit, always disconnectcables in reverse order.

Radiator

Hot engine coolant and steam can cause injury. Ensure that theradiator filler cap is removed with due care and attention.

Do not remove the pressure cap from a HOT radiator. Allow radiatorto cool down before removing pressure cap.

Transport

When loading or transporting machines ensure that the specifiedlifting and tie down points are used.

When loading or transporting machines ensure that the towingvehicle, its size, weight, towing hitch and electrical supply are allsuitable to provide safe and stable towing at speeds either, up to thelegal maximum for the country in which it is being towed or, as specifiedfor the machine model if lower than the legal maximum.

Ensure that the maximum trailer weight does not exceed themaximum 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 necessaryroad traffic requirements.

. break-away cables/safety chains are connected to the towingvehicle.

The machine must be towed in a level attitude in order to maintaincorrect handling, braking and lighting functions. This can be achievedby correct selection and adjustment of the vehicle towing hitch and, onvariable height running gear, adjustment of the drawbar.

To ensure full braking efficiency, the front (towing eye) section mustalways be set level.

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 tothe next pin. Refit the pin.

SAFETY14

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When parking always use the handbrake and, if necessary, suitablewheel chocks.

Make sure wheels, tyres and tow bar connectors are in safeoperating condition and tow bar is properly connected before towing.

Safety chains / connections and their adjustment

The legal requirements for the joint operation of the breakawaycable and safety chains are as yet unidentified by 71/320/EEC or UKregulations. Consequently we offer the following advice / instructions.

Where brakes only are fitted:

a) Ensure that the breakaway cable is securely coupled to thehandbrake lever and also to a substantial point on the towing vehicle.

b) Ensure that the effective cable length is as short as possible, whilststill allowing enough slackness for the trailer to articulate without thehandbrake being applied.

Where brakes and safety chains are fitted:

a) Loop the chains onto the towing vehicle using the towing vehiclehitch as an anchorage point, or any other point of similar strength.

b) Ensure that the effective chain length is as short as possible whilststill allowing normal articulation of the trailer and effective operation ofthe breakaway cable.

Where safety chains only are fitted:

a) Loop the chains onto the towing vehicle using the towing vehiclehitch as an anchorage point, or any other point of similar strength.

b) When adjusting the safety chains there should be sufficient freelength in the chains to allow normal articulation, whilst also being shortenough to prevent the towbar from touching the ground in the event ofan accidental separation of the towing vehicle from the trailer.

GENERAL INFORMATION 15

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Actual free air delivery. 23.4m3/min. (825 CFM)

Normal operating discharge pressure.8,6 bar (125 psi)

Maximum allowable pressure.10,3 bar (150 psi)

Safety valve setting.14 bar (200 psi)

Maximum pressure ratio (absolute).9,6 : 1

Operating ambient temperature.Whisperized –10�C TO +46�C (14�F TO 115�F)

Cooling system. Oil injection

Oil capacity. 64 litres (17 GAL)

Maximum oil system temperature. 120�C (248�F)

ENGINE9/235

Type/model. Ingersoll–Rand6IRC8A

Number of cylinders. 6

Oil capacity. 31.7 litres (8.4 gal)

Speed at Full Load min–1 (RPM) 2000

Speed at Idle. min–1 (RPM) 1500

Power available at Full Load 205kW (275hp)

Electrical system. 24V negative earth

Fuel tank capacity 462 litres (122 gal)

Oil specification Refer engine section

Coolant capacity 34 litres(9 gal)

SOUND LEVEL DATA

A) To Pneurop code PN8NTC2.Equivalent continuous sound pressure level.*

Rated load 86 dB(A)

(Operator position :–1m from machine)

Sound power level (2000/14/EC) 102 Lwa

B) In compliance with 86/188/EEC.

Average sound pressure level at 10m to ISO 3744.* 74 dB(A)

(*Machine only :– at maximum load in open site conditions)

C) EPA Noise 76 dB(A)

WHEELS AND TYRES

Number of wheels. 4

Tyre size. 7.50 – 16 LT

Tyre pressure. 4,5 bar (65 psi)

Net Weight (Less Fuel) 3900kg (8600 lb)

Further information may be obtained by request throughIngersoll–Rand customer services department.

OPERATING INSTRUCTIONS16

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COMMISSIONING

Upon receipt of the unit, and prior to putting it into service, it isimportant to adhere strictly to the instructions given below in PRIOR TOSTARTING.

Ensure that the operator reads and understands the decals andconsults the manuals before maintenance or operation.

Ensure that the position of the emergency stop device is known andrecognised by its markings. Ensure that it is functioning correctly andthat the method of operation is known.

Ensure that all transport and packing materials are discarded.

Ensure that the correct fork lift truck slots or marked lifting / tie downpoints are used whenever the machine is lifted or transported.

When selecting the working position of the machine ensure thatthere is sufficient clearance for ventilation and exhaust requirements.

Adequate clearance needs to be allowed around and above themachine to permit safe access for specified maintenance tasks.

Ensure that the machine is positioned securely and on a stablefoundation. Any risk of movement should be removed by suitablemeans, especially to avoid strain on any rigid discharge piping.

COMPRESSOR MOUNTING

Portable compressors, which are modified to remove the running gearand mount the machine direct to trailers, truck beds or frame, etc. mayexperience failure of the enclosure, frame, and/or other components.It is necessary to isolate the compressor package from the carrier basewith a flexible mounting system. Such a system must also preventdetachment of the package from the carrier base in the event theisolators fail. Contact Ingersoll–Rand representative for flexiblemounting kits.

Warranty does not cover failures attributable to mounting of thecompressor package to the carrier base unless it is anIngersoll–Rand provided system.

Attach the battery cables to the battery(s) ensuring that they aretightened securely. Attach the positive cable before attaching thenegative cable.

WARNING: All air pressure equipment installed in or connectedto the machine must have safe working pressure ratings of at leastthe machine rated pressure, and materials compatible with thecompressor lubricant (refer to the GENERAL INFORMATIONsection).

WARNING: If more than one compressor is connected to onecommon downstream plant, effective check valves and isolationvalves must be fitted and controlled by work procedures, so thatone machine cannot accidently be pressurised / over pressurisedby another.

WARNING: When flexible discharge hoses are used, it isrecommended that safety retaining wires are fitted.

OPERATING INSTRUCTIONS 17

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PRIOR TO STARTING

1. Place the unit in a position that is as level as possible. The designof the unit permits a 15 degree lengthways and sideways limit on outof level operation. It is the engine, not the compressor, that is the limitingfactor.

When the unit has to be operated out of level, it is important to keepthe engine oil level near the high level mark (with the unit level).

2. Check the engine lubrication oil in accordance with the operatinginstructions in the Engine Operator’s Manual or section.

3. Check the compressor oil level in the sight glass located on theseparator tank.

4. Check the diesel fuel level. A good rule is to top up at the end of eachworking day. This prevents condensation from occurring in the tank.Refer to the engine operator’s manual/section for diesel fuelspecification.

CAUTION: When refuelling:–. switch off the engine.. do not smoke.. extinguish all naked lights.. do not allow the fuel to come into contact with hot surfaces.. wear personal protective equipment.

5. Drain the fuel filter water separator of water, ensuring that anyreleased fuel is safely contained.

6. Open the service valve(s) to ensure that all pressure is relievedfrom the system. Close the service valve(s).

7. CAUTION: Do not operate the machine with the canopy/doors inthe open position as this may cause overheating and operators to beexposed to high noise levels.

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

Check the air restriction indicator(s). Refer to the MAINTENANCEsection of this manual.

When starting or operating the machine in temperatures below orapproaching 0�C, ensure that the operation of the regulation system,the unloader valve, the safety valve, and the engine are not impairedby ice or snow, and that all inlet and outlet pipes and ducts are clear ofice and snow.

OPERATING INSTRUCTIONS18

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62

7 8

9 10

1 3

11

4

5 12

Control Panel

1. Hourmeter – Records running time for maintenance.

2. Compressor Discharge Pressure Gauge – Indicates pressurein receiver tank, psi (kPa).

3. Fuel Level Gauge – Indicates amount of fuel in tank.

4. Power Switch – Flip “ON” to activate systems prior to Starting. Flip“OFF” to stop engine.

5. Service Air Switch – After warm–up, PUSH. Provides full airpressure at the service outlet.

6. Engine Speed Gauge – Indicates engine speed. (RPM)

7.. Discharge Air Temp. Gauge – Indicates airend dischargetemperature.

8. Engine Oil Pressure Gauge – Indicates engine oil pressure (psi(kPa).

9. Engine Water Temp Gauge – Indicates coolant temperature, with normal operating range from 180�F/82�C to 210�F /99�C.

10. Voltmeter – Indicates charging system voltage.

11. Spare– Used for optional accessories.

12. Spare– Used for optional accessories.

OPERATING INSTRUCTIONS 19

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1

2

3

4

5

6

7

8

9

DIAGNOSTIC DISPLAY PANEL.

The diagnostic display panel is arranged as shown above. Adescription of each diagnostic indicator is as follows.

1. High Compressor Temp: Fault indicator lamp. Indicatesshutdown due to high compressor temperature.

2. Low Engine Oil Pressure: Fault indicator lamp. Indicatesshutdown due to low engine oil pressure.

3. High Engine Coolant Temp: Fault indicator lamp. Indicatesshutdown due to high engine water temperature.

4. Low Fuel Level: Fault indicator lamp. Indicates shutdown due tolow fuel level. Lamp blinks at low fuel warning.

5. Low Battery Voltage: Alarm indicator lamp. Indicates battery orcharging system requires service.

6. Low Engine Coolant Level: Alarm indicator lamp. Indicatescoolant level in engine radiator is low.

7. Restricted Air Filter: Alarm indicator lamp. Indicatesengine/compressor air inlet filters need service.

8. DIAGNOSTICS AUTO SHUTDOWN.

9. LAMP TEST – WITH ENGINE OFF, TURN POWER SWITCHTO “OFF”, THEN TO “ON”. ALL LAMPS SHOULD LIGHT.

OPERATING INSTRUCTIONS20

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STARTING THE MACHINE

1

3

2

All normal starting functions are incorporated in the key operatedswitch.

. Turn the key switch to position 1. The engine fault and compressorfault lamps will flash..

. Turn the key switch to crank position (3) (engine start position)

NOTE: Position (2) not used on this model. Pre–heaters or glowplugs are not fitted on this model.

. Release to position (1) when engine starts. The engine will now berunning at a reduced speed.

At temperatures below 32�F (0�C) or if there is difficulty starting firsttime:

Open the manual blowdown valve fully.

. Complete starting sequence above.

Close manual blowdown valve as soon as engine runs freely.

Do not allow machine to run for long periods with manualblowdown valve open.

. Allow the engine to reach operating temperature.

. At this point in the operation of the machine it is safe to apply full loadto the engine.

NOTE: Wear hearing protection at all times when the engine isstarted with the manual blowdown valve open and air is flowing fromthe valve.

PUSH AFTER WARM UP

NOTE: In order to allow the machine to start at a reduced load, a valve,which is operated by a button located on the instrument panel, isincorporated in the regulation system. (The valve automatically returnsto the start position when the machine is switched off and air pressurerelieved from the system).

. Allow the engine to reach its operating temperature – then press thebutton.

. At this point in the operation of the machine it is safe to apply full loadto the engine.

DUAL PRESSURE REGULATION WHEN FITTED

Machines which operate in excess of 7 bar (100 psi) can optionally befitted with a dual pressure switch inside the unit. This switch selectsbetween 7 bar (100 psi) and the machine rated pressure, cfm remainsnominally constant.

Starting and stopping are unaffected by the selection and during normalrunning the selector switch may be safely operated. Precaution mustbe taken to ensure that downstream equipment is rated to suit theavailable pressure.

The pressure gauge indicates which setting has been selected.

STOPPING THE MACHINE

. Close the service valve.

. Allow the machine to run unloaded for a short period of time toreduce the engine temperature.

. Turn the start switch to the 0 (off) position.

NOTE: As soon as the engine stops, the automatic blowdown valve willrelieve all pressure from the system.

If the automatic blowdown valve fails to operate, then pressure mustbe relieved from the system by means of the service valve(s).

CAUTION: Never allow the machine to stand idle with pressure in thesystem.

EMERGENCY STOPPING

In the event that the unit has to be stopped in an emergency,TURN THE KEY SWITCH LOCATED ON THE INSTRUMENTPANEL TO THE 0 (OFF) POSITION, or push the EMERGENCYSTOP SWITCH (when fitted).

RE–STARTING AFTER AN EMERGENCY

If the machine has been switched off because of a machinemalfunction, then identify and correct the fault before attempting tore–start.

If the machine has been switched off for reasons of safety, thenensure that the machine can be operated safely before re–starting.

Refer to the PRIOR TO STARTING and STARTING THE UNITinstructions earlier in this section before re–starting the machine.

MONITORING DURING OPERATION

Should any of the safety shut-down conditions occur, the unit willstop.

Refer to the diagnostic display page for a listing of shutdownconditions.

CAUTiON: To ensure an adequate flow of oil to the compressor at lowtemperature, never allow the discharge pressure to fall below 3,5 bar(50 psi)

DECOMMISSIONING

When the machine is to be permanently decommissioned ordismantled, it is important to ensure that all hazard risks are eithereliminated or notified to the recipient of the machine. In particular:–

OPERATING INSTRUCTIONS 21

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. Do not destroy batteries or components containing asbestoswithout containing the materials safely.

. Do not dispose of any pressure vessel that is not clearly markedwith its relevant data plate information or rendered unusable by drilling,cutting etc.

. Do not allow lubricants or coolants to be released into land surfacesor drains.

. Do not dispose of a complete machine without documentationrelating to instructions for its use.

ENGINE INSTRUCTION MANUAL22

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6IRC8A ENGINE

CONTENTS

23 FOREWORD

24 EXTERNAL VIEWS: 6IRC8A

25 GENERAL INFORMATION: 6IRC8A

Main data and specifications

Engine identification

Ingersoll–Rand engine after sales support

26 FUEL, LUBRICANT, AND COOLANT

Fuel

Lubricant

Coolant

28 OPERATION

Check before operation

Check and operation after start– up

Operation and care of a new engine

31 PERIODICAL INSPECTION AND MAINTENANCE

Lubricating system

Cooling system

Fuel system

Air intake system

Routine maintenance

35 COLD WEATHER OPERATION

36 MAINTENANCE SCHEDULE

39 TROUBLESHOOTING

FOREWORD 23

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The INGERSOLL–RAND industrial diesel engines are a product of long years of experience, advanced technology, and up–to date productionfacilities. INGERSOLL–RAND takes great pride in the superior durability and operating economy of these engines.

In order to get the fullest use and benefit from your engine, it is important that you operate and maintain it correctly. This Manual is designed to helpyou do this.

Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of trouble–free andeconomical 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 ofpublication.

INGERSOLL–RAND reserves the right to make changes in this Manual at any time without prior notice.

The pictures contained within are for guidance only and might notreflect the physical characteristics of each individual engine covered.

24 EXTERNAL VIEWS

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DIESEL ENGINE Engine External View – Model 6IRC8A

Fig. 1 (Left–hand Side) Fig. 2 (Right–hand Side)

(1) Engine air inlet.

(2) Shutoff solenoid.

(3) Fuel filter

(4) Fuel transfer pump.

(5) Oil drain plug.

(6) Dipstick (engine oil)

(7) Engine dataplate.

(8) Fuel injection pump

(9) Fuel drain line.

(10) Intake manifold.

(11) Turbocharger wastegate actuator.

(12) Turbocharger air outlet.

(13) Oil filler cap.

(14) Lubricating oil pressure (after filter).

(15) Lubricating oil pressure (before filter).

(16) Coolant heater port.

(17) Lubricating oil cooler.

(18) Lubricating oil filter.

(19) Turbocharger oil drain.

(20) Coolant filter.

(21) Starter motor

(22) Turbocharger exhaust outlet.

25GENERAL INFORMATION

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EPA CERTIFIED ENGINE DATA and SPECIFICATIONS

Model: 6IRC8A

Engine model name 6IRC8AEngine type Water–Cooled, four cycle, in–line overhead valve type

Combustion type Direct injection

No. of cylinders – bore x stroke. mm (in) 6–114 x 134.9 (4.49 x 5.31)

Engine displacement L(cid) 8.3 (506)

Compression ratio 18:1

Firing order 1–5–3–6–2–4

Exhaust emission control system Engine modification

Governor Mechanical type

Specified fuel Diesel fuel (ASTM D975 No. 2–D)

Starter (V–kW) 24 – 7.2

Alternator (V–A) 24 – 50

Specified engine oil (API grade) CG – 4, CH – 4, or better

Coolant volume (Engine only) L (qts) 11.4 (12)

Engine dry weight kg (lb) 617 (1360)

Overall length mm (in) 1128 (44.4)

Engine dimensions Overall width mm(in) 749 (29.5)

Overall height mm(in) 1096 (43.2)

Valve clearance (cold) mm(in) Intake 0,30 (.012) Exhaust 0,61 (.024)

ENGINE IDENTIFICATION

Serial No Location

The engine serial number is stamped on a plate located on the rearright of the cylinder body, near the fuel filter

Fig. 3

A. Engine serial number

Confirmation of Engine Number

It is advisable to quote the engine serial number together with themachine serial number, as it is required when you contact theIngersoll–Rand branch or distributor for repair, service or partsordering.

CAUTION: Conduct confirmation of engine serial number with theengine stopped. To avoid being injured, do not check it, while the engineis still hot.

INGERSOLL–RAND ENGINE AFTER SERVICE

Please feel free to contact your Ingersoll–Rand dealer for periodicalinspection and maintenance.

Ingersoll–Rand Genuine Parts

Genuine Ingersoll–Rand parts are identical with those used in theengine production, and accordingly, they are warranted byIngersoll–Rand.

Genuine Ingersoll–Rand parts are supplied by your Ingersoll–Randbranch or distributor.

Please ensure that only genuine Ingersoll–Rand parts, lubricants andfluids are used for service and/or repair.

26 FUEL, LUBRICANTS, AND COOLANT

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FUEL

Fuel Selection

The following properties are required of the diesel fuel.

Must be free from minute dust particles.

Must have adequate viscosity.

Must have high cetane value.

Must have high fluidity at low temperature.

Must have low sulphur content.

Must have little residual carbon.

It is strongly advisable to use ASTM D975 No. 2D (the generalautomotive diesel engine purpose fuel oil) or equivalent which fullymeets the above requirements.

Applicable Standard Recommendation

JIS (Japanese Industrial Standard) NO. 2

DIN (DEUTSCHE INDUSTRIE NORMEN) DIN 51601

SAE (Society of Automotive Engineers) Basedon SAE–J–313C

NO. 2–D

BS (BRITISH STANDARD) Based onBS/2869–1970

Class A–1

EURONORM EN590

FUEL REQUIREMENTS

Notice: the fuel injection pump, injector or other parts of the fuel systemand engine can be damaged if you use any fuel or fuel additive otherthan those specifically recommended by Ingersoll–Rand.

NOTE: If any fuel other than the one specified is used, engine operationwill be impaired. Engine failure or malfunction resulting from use of suchimproper fuel will not be warranted by Ingersoll–Rand.

To help avoid fuel system or engine damage, please read the following:

Do not use diesel fuel which has been contaminated with engine oil.Besides causing engine damage, such fuel can also affect emissioncontrol. Before using any diesel fuel, check with the fuel supplier to seeif the fuel has been mixed with engine oil.

Your engine is designed to use either Number 1–D or Number 2–Ddiesel fuel. However, for better fuel economy, use Number 2–D dieselfuel whenever possible. At temperatures less than –7�C, (20�F),Number 2–D fuel may pose operating problems (see “Cold WeatherOperation” which follows). At colder temperatures, use Number 1–Dfuel (if available) or use a “winterized” Number 2–D (a blend of Number1–D and Number 2–D). This blended fuel is usually called Number 2–Dalso, but can be used in colder temperatures than Number 2–D fuelwhich has not been “winterized.”

Check with the fuel supplier to be sure you get the properly blendedfuel.

NOTICE: Do not use home heating oil or gasoline in your dieselengine; either may cause engine damage.

Handling of the Fuel.

Any fuel containing dust particles or water might cause enginefailure .

Therefore, the following must be observed.

Take care to protect the fuel from ingress of dust particles or waterwhen filling the fuel tank.

If refuelling is done from an oil drum directly, ensure that it has beenkept stationary to allow any dust, sediment or water to settle at thebottom. Do not draw fuel direct from the bottom of the drum to preventpickup of any settled foreign material.

Always fully fill the fuel tank. Drain the sedimented particles in thefuel tank frequently.

Water in Fuel

During refueling, it is possible for water (and other contaminants) to bepumped into your fuel tank along with the diesel fuel. This can happenif a fuel provider does not regularly inspect and clean its fuel tanks, orreceives contaminated fuel from its supplier(s). To protect your enginefrom contaminated fuel, there is a fuel filter system on the engine whichallows you to drain excess water.

CAUTION: The water/diesel fuel mixture is flammable, and could behot. To avoid personal injury and/or property damage, do not touch thefuel coming from the drain valve, and do not expose the fuel to openflames or sparks.

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 could be forcedout. This could lead to a fire and the risk of personal injury and/orequipment damage.

BiocidesIn warm or humid weather, fungus and/or bacteria may form in dieselfuel if there is water in the fuel.

NOTICE: Fungus or bacteria can cause fuel system damage byplugging the fuel lines, fuel filters or injector. They can also cause fuelsystem corrosion.

If fungus or bacteria has caused fuel system problems, you shouldhave your authorized dealer correct these problems. Then, use a dieselfuel biocide to sterilize the fuel system (follow the biocidemanufacturer‘s instructions). Biocides are available from your dealer,service stations, parts stores and other automotive places. See yourauthorized dealer for advice on using biocides in your area and forrecommendations on which biocides you should use.

Smoke Suppressants

The use of a smoke suppressant additive is not allowed because of thegreater possibility of stuck rings and valve failure, resulting fromexcessive ash deposits.

27FUEL, LUBRICANTS, AND COOLANT

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LUBRICANT.

Use of unsuitable engine oil will result in piston ring, piston andcylinder seizure and accelerate surface wear causing increased oilconsumption, lowered output and, finally engine failure. To avoid this,use the specified engine oil.

1) Engine Oil Selection

Pro Tec �2) Oil Viscosity

Engine oil viscosity affects engine startability, performance, oilconsumption, wear and the potential for seizure, etc. Always ensurethat lubricants with the correct viscosity for the operating temperatureare used. Refer to fig 5.

NOTE

Using a mixture of different brands or quality of oils will adversely affectthe original oil quality; therefore, never mix different brand or differenttype oils.

Do not use API, CA, CB grade and reconstituted engine oil

Engine damage due to improper maintenance, or using oil of theimproper quality and/or viscosity, is not covered by the warranty.

Fig. 5

A. (Single – grade)

B. Ambient Temperature

C. (Multi – grade)

COOLANT

All Ingersoll–Rand portable compressor engines are factory filledwith a 50/50 Ethylene glycol base antifreeze/water mix. which providesprotection to –33�C (–27�F)

28 OPERATION

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ENGINE OPERATION

Engine Exhaust Gas Caution (Carbon Monoxide)

CAUTION

Do not breathe exhaust gas because it contains carbon monoxide,which by itself has no color or odor. Carbon monoxide is a dangerousgas. It can cause unconsciousness and can be lethal.

Do not run the engine in confined areas (such as garages or next to abuilding). Keep the exhaust tailpipe area clear of snow and othermaterial to help reduce the buildup of exhaust gases under theequipment. This is particularly important when parked in blizzardconditions.

CHECK BEFORE OPERATION

CAUTION: For safety reasons, conduct the inspection with the enginestopped.

Engine Oil Level.

Place the engine or the machine on a level surface

Remove the dipstick, wipe it with a cloth. Insert it fully and take it outgently again.

Check the oil level against the marks on the dipstick. The oil levelmust be between the ”H” level mark and the ”L” level mark asillustrated

Fig. 6

Also check the sample oil on the dipstick for contamination andviscosity.Take care not to add too much engine oil

Oil can be poured either through the oil filler at the front of the cylinderhead cover or through the oil filler on the right side of the timing gearcase.

A certain period of time is required before the engine oil completelyflows down from the oil filler to the crankcase. Wait at least ten minutesbefore checking the oil level.

NOTE:Take care to avoid engine oil being splashed on the fan drivebelt because it causes belt slippage or slackness.

CAUTION: When adding oil, take care not to spill it. If you spill oil on theengine or equipment, wipe it properly, to prevent the risk of fire andpersonal injury and/or equipment damage.

Fan and Belt Check

The engine is fitted with an automatic belt tensioner

Check the fan belt for tension and abnormalities.

A loose belt will cause belt slippage which may result in a damaged belt,abnormal noise, poor battery charging and engine overheating.

Fig. 7

Use of Genuine Ingersoll–Rand Fan Belt.

Always use Genuine Ingersoll–Rand fan belts as they provide highdriving ability and long operating durability. Use of non–Ingersoll–Randfan belts could result in premature belt wear or belt elongation leadingto engine overheating or excessive belt noise.

Coolant Level Check

Check and ensure that the level is correct.

CAUTION: When removing the radiator filler cap, while the engine isstill hot, cover the cap with cloth, then turn it slowly to gradually releasethe internal steam pressure. this will prevent anyone from beingscalded by hot steam spurting out from the filler neck.

Add coolant mixed to the correct ratio: 50/50 ethylene glycol/water.

Radiator Cap Condition

After the replenishment of the coolant, install the radiator filler cap.Make sure the cap is securely installed.

Crankcase Breather

Check and clean the breather tube daily during cold weather.

Battery Cable Connection

Check the battery cable connections for looseness or corrosion. Aloosened cable connection will result in hard engine starting orinsufficient battery charge. The battery cables must be tightenedsecurely. Never reverse “+” and “–” terminals when reconnectingcables after disconnection. Even a short period of reverse connectionwill damage the electrical parts.

29OPERATION

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Fig. 8

A Battery cable

B Connections

Battery Electrolyte level

The amount of electrolyte in the batteries will be reduced after repeateddischarge and recharge. Check the electrolyte level in the batteries,replenish with a commercially available electrolyte such as distilledwater, if necessary. The battery electrolyte level checking procedurewill vary with battery type. NOTICE: Do not replenish with dilute sulfuricacid in the daily service.

CAUTION:

When inspecting the batteries, be sure to stop the engine first.

As dilute sulphuric acid is used as electrolyte, be careful not tocontaminate your eyes, hands, clothes, and metals with the electrolyte.If it gets in your eye, wash with a large amount of water at once, thenseek medical advice.

As highly flammable hydrogen gas is released from the batteries, do notcreate a spark or allow any naked flame near the batteries.

When handling such metallic articles as tools near the batteries, besure not to contact the “+” terminal because the compressor body is “–”and a dangerous short circuit might result.

When disconnecting the terminals, start with “–” terminal. Whenconnecting them, connect the “–” terminal last.

CHECKS AND OPERATION AFTER START–UP

Check after the Engine Start–up

Check the following items in the engine warming–up operation.

Engine oil pressure –

The engine oil pressure gauge readings (where fitted) may varydepending on ambient temperature and type of oil. The gauge shouldregister around 55 to 85 psi in the warming–up period.

Engine noise and exhaust smoke color –

Listen to the engine and, if any abnormal noise is heard, check todetermine the cause.

Check the fuel combustion condition by observing the exhaust smokecolor. The exhaust smoke color after engine warm–up and at no–loadcondition should be colorless or light blue.

Black or white smoke indicates incorrect combustion.

Note: After start–up from cold the engine might be noisier and theexhaust smoke color darker than when it has warmed up. However thiscondition will disappear after warm up.

Leakage in the systems –

Check the following items:

Lubrication oil leakage –

Check the engine for oil leaks, paying particular attention to oil filter andoil pipe joints.

Fuel leakage –

Check the fuel injection pump, fuel lines and fuel filter for leakage.

Coolant leakage – Check the radiator and water pump hoseconnections and the water drain cock on the cylinder block for leakage.

Exhaust smoke or gas leakage

Checking coolant level

The coolant level could drop because any mixed air is expelled in about5 minutes after the engine started.

Stop the engine, remove radiator cap, and add coolant.

CAUTION: Hot steam can rush out and you could get burnt if theradiator cap is removed when the engine is hot. Cover the radiator capwith a thick cloth and loosen the cap slowly to reduce the pressure, thenremove the cap.

30 OPERATION

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OPERATION AND CARE OF A NEW ENGINE.

Your Ingersoll–Rand engine is carefully tested and adjusted in thefactory, however, further run–in is necessary. Avoid any harsh engineoperation 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 tominimise the risk of cylinder bore glazing.

During operation, pay attention to the following points if the engineshows any sign of abnormalities.

(1) Engine Oil Pressure – The engine oil pressure is monitored by aswitch that will stop the engine if the pressure falls below a pre–setvalue.If the oil pressure gauge shows below 30 psi or if the readingfluctuates continually, stop the engine and check the oil level. If thelevel is correct, contact your local Ingersoll–Rand branch or dealerto establish the cause.

(2) Coolant Temperature – The engine performance will be adverselyaffected if engine coolant temperature is too hot or too cold. The normalcoolant temperature is 75 to 85�C (167 to 185�F).

Overheating

CAUTION:

If you see or hear escaping steam or have other reason to suspectthere is a serious overheat condition, stop the engine immediately.

If the Engine Coolant Temperature gage (where fitted) shows anoverheat condition, or you have reason to suspect the engine may beoverheating, take the following step:

� Close the service valve to reduce the load.

� Let the engine run at normal idle speed for two or three minutes. Ifthe engine coolant temperature does not start to drop, turn off theengine and proceed as follows:

CAUTION: To help avoid being burned –

� Do not open the canopy or door if you see or hear steam or enginecoolant escaping. Wait until no steam or engine coolant can be seen orheard before opening the engine canopy or door.

� Do not remove the radiator filler cap if the engine coolant in thereserve tank is boiling. Also do not remove the radiator filler cap whilethe engine and radiator are still hot. Scalding fluid and steam can beblown out under pressure if either cap is taken off too soon.

If no steam or engine coolant can be seen or heard, open the canopyor door. If the engine coolant is boiling, wait until it stops beforeproceeding. The engine coolant level should be between the “MAXCOLD” and “MIN” marks on the reserve tank.

Make sure the fan belt is not broken, or off the pulley, and that the fanturns when the engine is started. If the engine coolant level in thereserve tank is low, look for leaks at the radiator hoses andconnections, radiator, and water pump. If you find major leaks, do notrun the engine until these problems have been corrected. If you do notfind a leak or other problem, WAIT UNTIL THE ENGINE HAS COOLEDDOWN then carefully add engine coolant to the reserve tank.

(Engine coolant is a mixture of ethylene glycol antifreeze and water.See “Engine Care in cold season” for the proper antifreeze andmixture.)

CAUTION: To avoid being burned, do not spill antifreeze or enginecoolant on the exhaust system or hot engine parts. Under someconditions the ethylene glycol in engine coolant is combustible.

If the engine coolant level in the reserve tank is at the correct level butthere is still an indication of an overheat condition and no cause wasfound, please consult your local Ingersoll–Rand branch or dealer.

Overcooling

Operating the engine at low coolant temperature will not only increasethe oil and fuel consumption but also will lead to premature parts wearwhich may result in engine failure. Ensure that the engine reachesnormal operating temperature 75 to 85�C (167 to 185�F) within tenminutes of starting.

(3) Hourmeter

This meter indicates the machine operation hours. Make sure that themeter is always working during engine operation. Periodical machinemaintenance is scheduled on the operation hours indicated on thehourmeter.

(4) Liquid and Exhaust Smoke Leakage

Make regular checks for lubricant, fuel, coolant and exhaust smokeleakage.

(5) Abnormal Engine Noise

In the event of any abnormal engine noise, please consult your localIngersoll–Rand branch or dealer.

(6) State of the Exhaust Smoke

Check for any abnormal exhaust smoke color.

ENGINE STOPPING

(1) Close service valves.

(2) Before stopping the engine, cool down the engine by operating it atreduced load about three minutes. In this period, check the enginenoise and the engine oil pressure (where a gage is fitted) forabnormalities.

LONG TERM STORAGE

If the equipment is to be out of operation for an extended period, itshould be started at least once per week and run on load for about 15minutes after it has reached normal operating temperature.

31PERIODICAL INSPECTION AND MAINTENANCE.

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LUBRICATING SYSTEM.

Servicing of the engine oil and oil filter element will affect the engineperformance as well as the engine life. Change the engine oil and theoil filter in accordance with the recommended service intervals.

Engine Oil and Oil Filter Element Change.

Engine Oil Change and Oil Filter Element Change must be madesimultaneously according to the following change schedule.

Change intervals: Refer to maintenance schedule section.

Engine Oil draining –

CAUTION: To help avoid the risk of being burned, do not drain oil whilethe engine is still hot.

Wipe clean around the oil filler cap taking care so that no foreign articlesenter. Remove the filler cap.

It is advisable that draining be done while the engine is warm tominimize the draining time.

Remove the oil pan drain plug and drain the engine oil completely.

NOTICE: Use a receptacle to catch the drained oil so that the engineand equipment will not be contaminated.

Fig. 9

Remove drain plug arrowed to drain the engine oil completely.

Oil filter element removal

Fig. 10

A Cartridge

Oil filter element installation –

Lightly apply engine oil to the O–ring.

Fig. 11

Screw in the new cartridge hand tight as the O–ring comes incontact with the engine block. Tighten a further 3/4 to 11/4 turns. DONOT overtighten.

Engine oil refilling.

Reinstall the drain plug.

Fill with new engine oil via the most convenient oil filler port.

Wait at least ten minutes until the oil drains down to the oil pan. Thencheck the oil level with the dipstick.

Check after Oil and Filter Changes.

Oil leakage check:

Run the unit for five to ten minutes, then visually check for oil leakage.

Oil level recheck:

Stop the engine for at least ten minutes.

Use the dipstick to recheck the oil level. If necessary replenish withengine oil to the specified level

NOTE:When the engine is started, the oil level will slightly drop fromthe initial level as the oil fills the entire oil circuit.

Engine Oil Additives

Engine oils contain a variety of additives. Your engine should not needany extra additives if you use the recommended oil quality and changeintervals.

Used Oil Disposal – Do not dispose of used engine oil (or any otheroil) in a careless manner such as pouring it on the ground, into sewers,or into streams or bodies of water. Instead, recycle it by taking it to aused oil collection facility which may be found in your community. If youhave a problem disposing of your used oil, it is suggested that youcontact your local Ingersoll–Rand branch or dealer. This also appliesto diesel fuel which is contaminated with water.

Used Engine Oil

CAUTION: Used engine oil contains harmful contaminants that havecaused skin cancer in laboratory animals. Avoid prolonged skincontact. Clean skin and nails thoroughly using soap and water –notmineral oil, fuels, or solvents. Launder or discard clothing, shoes, orrags containing used engine oil.

Discard used engine oil and other oils properly.

32 PERIODICAL INSPECTION AND MAINTENANCE.

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COOLING SYSTEM

Coolant Change

The coolant must be changed at intervals of 1000 hours or twelvemonths, whichever come first.

If the coolant becomes sludged up it will lead to engine overheating orcoolant blow–off from the radiator.

Coolant draining.

WARNING: Hot engine coolant and steam can cause injury. When ad-ding to or draining coolant or antifreeze solution from the engine radi-ator, stop the engine at least one minute prior to releasing the radiatorfiller 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 capuntil all excess fluid is released and the engine cooling system fullydepressurised.

WARNING: Follow the instructions provided by the antifreeze supplierwhen adding or draining the antifreeze solution. It is advisable to wearpersonal protective equipment to prevent skin and eye contact with theantifreeze solution.

Remove the radiator cap.

Slacken the bottom radiator hose clamp to drain the coolant from theradiator.

Fig. 12

A Cylinder block water drain valve

Coolant Filter Replacement

Fig. 13

Rotate clockwise to close shut–off valve. Remove and replacecoolant filter. Open shut–off valve

Fig. 14

Filling with coolant

Ensure that the engine is cool.

Close the coolant drain plug and tighten the bottom hose clamp.

Use clean water mixed 50/50 with antifreeze as a coolant.

Fill slowly to prevent air entering the cooling system.

For Coolant volume, refer to ”General Information section”

When the system has been filled, operate the engine about five minutesat a low idle speed, then as the air contained in the coolant circuit is bledoff the coolant level will drop.

Stop the engine and replenish with the correct coolant mix.

Cleaning outside of Radiator, Oil cooler and Charge Air Cooler

Debris, mud or dried grass caught between radiator fins will block theair flow, resulting in lower cooling efficiency. Clean the radiator fins withsteam or low pressure (< 5 Bar) compressed air every 250 hours or 3months (whichever comes first) or more frequently in adverseoperating conditions.

Cooling System Circuit Cleaning

When the cooling system circuit is contaminated with water scales orsludge particles, cooling efficiency will be lowered. Periodically cleanthe circuit interior with a suitable cleaner.

Clean the cooling system circuit every 1000 operating hours or 12months, whichever comes first.

33PERIODICAL INSPECTION AND MAINTENANCE.

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FUEL SYSTEM

The fuel injection pump and injector nozzles are preciselymanufactured, and therefore, using fuel which contains water or dustparticles will result in either injection pump plunger seizure or injectornozzle seizure. A fuel filter element blocked with sludge or dustparticles will lead to reduced engine output.

Perform inspection and maintenance periodically as follows:

Fig. 15

A Filter element

B Drain valve

Draining Water from Fuel Filter/separator.

The fuel filter/separator is provided to allow water to be drained from thefuel system. Water is heavier than fuel so any water contained in thesystem will collect in the bottom of the bowl.

Place a suitable container under the separator to prevent any spillageinside the machine.

Slacken the drain valve ‘B’ until water drains from the vent tube.

When all the water has been evacuated, tighten the drain valve ‘B’.

Fuel filter/separator element change.

NOTE:The cartridge and bowl contain fuel. Take care not to spill it duringdisassembly and reassembly.

The fuel filter/separator also provides primary filtration and the element‘A’ should be changed every 500 operating hours or 6 months,whichever comes first.

Change procedure:

Disconnect fuel sensor (where fitted). Loosen drain plug B andempty fuel into suitable container

Fig. 16

Unscrew the element ‘A’ from the head taking care not to spill fuelinside the machine. Remove fuel sensor (where fitted) and re–fit tonew filter element

Discard the old element into a suitable container.

Using a clean cloth, wipe the sealing face of the filter/separator headto ensure correct seating of the sealing ring.

Fill the element/bowl assembly with clean fuel oil then apply a light coatof clean engine oil to the new element seal ring.

Screw the new element onto the head firmly by hand.

The engine has a self priming system that purges air from the fuelsystem.

AIR INTAKE SYSTEM

Air cleaner

Engine performance and life vary with the air intake conditions.

A dirty air cleaner element reduces the amount of intake air, causingreduced 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 shortenedengine 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 below.

Fig. 17

A Normal

B Clogged

C Indicator

D Red signal

34 PERIODICAL INSPECTION AND MAINTENANCE.

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Air cleaner with dust indicator

This indicator is attached to the air cleaner. When the air cleanerelement is clogged, air intake resistance becomes greater and the dustindicator signal turns to red indicating the element needs to bechanged.

When the signal turns to red, replace the element. Then press the dustindicator button to reset the indication.

Air Intake Piping

Inspect air intake and charge air cooling pipes and connections fordamage or loose fitting. Replace or re–fit as necessary.

Fig. 18

ENGINE ELECTRICAL

The Ingersoll–Rand engines uses a 24 volt system and a negativegrounding for the electrical system.

Battery Servicing

Battery terminal connections

Check the battery cable connections for looseness or corrosion.Poor cable connections will result in difficult engine starting orinsufficient battery charge.

The battery cables must be tightened securely.

Never reverse “+” and “–” terminals when reconnecting cables afterremoval. Even a short period of reverse connection will damage theelectrical parts.

Cleaning of Battery

When the battery terminals are fouled clean them with clean tepid waterand wipe with a dry cloth to remove the water. Apply a light coat ofvaseline or a grease.

Alternator Servicing

The polarity of the alternator is negative (–) grounding type.

Do not reverse the polarity connection, otherwise a short circuit willoccur resulting in alternator failure.

Do not put water directly on the alternator. Entry of water into thealternator creates electrolytic corrosion causing failure.

When the battery is charged from an external source, be sure todisconnect the battery cables.

Wiring Connections

Check all of the electric wiring connections for looseness and damageon a regular basis.

SERVICE AND MAINTENANCE

Please refer to the engine maintenance schedule.

For continued trouble free engine operation throughout its life, theservice procedures marked with an asterisk (*) need to be carried outby a skilled and trained technician.

Please consult your local Ingersoll–Rand branch or dealer when theseprocedures become due.

Please also read the note refering to the service items marked with thestar � symbol.

35COLD WEATHER OPERATION

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FUEL SELECTION

In cold weather, the fuel might freeze resulting in difficult enginestarting; therefore, select a suitable fuel for such engine operation.Use ASTM 975 No. 2–D fuel if you expect temperature above 20�F(–7�C).

Use Number 1–D if you expect temperatures below 20�F (–7�C).

If Number 1–D is not available, a “winter” blend of 1–D and 2–D isavailable in some areas during the winter months.

Check with your fuel supplier to be sure you get the correct blendedfuel.

COOLANT

Where the ambient temperature falls below freezing point, thecooling system should be drained after engine operation, but toeliminate the need for repeated draining, refilling and to provide all yearprotection against corrosion, the use of anti–freeze solution throughoutthe year is highly recommended.

All Ingersoll–Rand portable compressor engines are factory filledwith a 50/50 Ethylene glycol base antifreeze/water mix. which providesprotection to –33�C (–27�F)

Concentrations over about 65% adversely affect freeze protection,heat transfer rates, and silicate stability which may cause water pumpleakage.

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 itseffect on the non–metallic components of the cooling system andbecause of its low boiling point.

NOTE:

High silicate antifreeze is not recommended because of causingserious silica gelation problems.

NOTE:

Usage and mixing ratio etc. should be followed to the antifreezemanufacture’s recommendations.

ENGINE OIL

At low ambient temperatures, engine oil viscocity can affect enginestarting. It is important to use the correct grade of oil as recommendedin fig 4.

Try to position the compressor where it will not be affected by coldwinds when not running.

BATTERY

(1) Always ensure that the batteries are kept fully charged in the coldseason. This takes a longer period of running than in warm weatheroperation.

The electrolyte in a partly discharged battery will freeze easier thanwhen it is fully charged. Try to keep the batterys fully charged and warmin cold weather operation.

(2) Top up the battery with distilled water immediately before startingthe engine.

COLD STARTING

When operating in cold ambient conditions, or when starting fromcold. If the engine does not start at the first attempt, allow the batteryto recover for at least 30 seconds. Observe the following procedures:

In order to protect the starter, do not engage for longer than 10 secondsduring any attempt.

If during cranking, the starter motor repeatedly engages anddisengages the battery power could be low. Either recharge the batteryor replace it with one that is fully charged.

NOTICE: Do not use starting “aids” in the air intake system. Such aidscan cause immediate engine damage.

36 ENGINE MAINTENANCE SCHEDULE

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When performing the following items, the daily inspection items should also be carried out.

NoDescription of check

Daily(operation hours) Remark

NoDescription of check

and maintenance Daily250 500 750 1000 1250 1500

1 Oil level O2 Oil leakage O3 Oil pressure gage reading

(where fitted) O

4 Oil pressure warning lamp(where fitted) O

5 Engine oil replacement O O O6 Oil filter element

replacement O O O

7 Fuel leakage O8 Draining water in fuel

filter/separator OSee “EXPLANATION OF

9 Fuel filter elementreplacement O O O

See EXPLANATION OFMAINTENANCE SCHEDULE”

10 Injection nozzle check (*) O�

11 Coolant level O12 Coolant leakage check O13 Radiator filler cap fitting

condition O

14 Fan and belt check O O15 Coolant temperature gage

reading (where fitted) O

16 Coolant replacement O17 Coolant filter replacement O18 Radiator external face

cleaning O O O O O O

19 Cooling system circuitcleaning O

20 Radiator filler capfunction check (*) O O O

21 Electrolyte level check O22 Battery cleaning O23 Battery charge lamp O24 Starter and alternator check

and cleaning (*) O

25 Wiring and connectioncheck O O O

26 Air cleaner elementreplace O O O

27 Air intake piping O28 Engine starting conditions

and noise conditions O

29 Exhaust smoke condition O30 Cylinder compression

pressure (*) O

31 Valve clearance check (*) O32 Positive crankcase

ventilation valve cleaning O O�

Note:1. After every 1500 hours of operation, the service intervals should be repeated in accordance with this check and maintenance schedule.2. When servicing on the asterisked (*) items is necessary, consult your local Ingersoll–Rand branch or distributor.

37ENGINE MAINTENANCE SCHEDULE

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Note: � This is a recommended maintenance. The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability priorto the completion engine useful life. Ingersoll–Rand, however, urges that recommended maintenance service is performed at the indicated intervals.

EXPLANATION OF MAINTENANCE SCHEDULE

The following is a brief explanation of the services listed in the preceding Engine Maintenance schedule.

1. Oil level. Check that the oil level is within cross hatch area (ref fig. 6)Fill or drain as necessary.

2. Oil leakage check Replace any damaged or malfunctioning parts which could cause leakage.

3. Oil pressure gauge Normal oil pressure is 30 to 85 psi. Check and repair the lubrication system if it is abnormal.

4. Oil pressure warning lamp If it stays on whilst running check and repair the lamp and/or lubrication system.

5. Engine oil replacement Change at 500 hours or 6 months, whichever comes first.

6. Oil filter elementreplacement

Change at 500 hours or 6 months, whichever comes first.

7. Fuel leakage Replace any damaged or malfunctioning parts which could cause leakage.

8. Draining water in fuelfilter/separator.

Drain off water in the fuel filter/separator bowl.

9. Fuel filter elementreplacement

Replace both primary (filter/separator) and secondary elements at 500 hours or 6 months whichever come first.

10. Injection nozzle check Check injection opening pressure and spray condition. (This is a recommended maintenance item �). Consultyour local Ingersoll–Rand branch or distributor.

11. Coolant level. Check coolant level and add coolant if necessary.

12. Coolant leakage check Replace any damaged or malfunctioning parts which could cause leakage.

13. Radiator filler cap fittingcondition

The radiator cap must be installed tightly and sealing correctly.

14. Fan and belt check Look for cracks, fraying and wear. Replace if necessary

15. Coolant temperature Normal running temperature is 75 to 85�C (167 to 185�F). Check and repair the cooling system if temperatureis abnormal.

16. Coolant replacement Change coolant at intervals of 1000 hours or 12 months, whichever comes first.

17. Coolant filter replacement Replace filter at 500 hours

18. Radiator external facecleaning

Check monthly. Clean at intervals of 250 hours or 3 months, whichever comes first. In very dusty environments,more frequent cleaning might be necessary.

19. Cooling system circuitcleaning

Clean at intervals of 1000 hours or 12 months, whichever comes first.

20. Radiator filling capfunction check

Check radiator pressure cap periodically for proper operation. Consult your local Ingersoll–Rand branch ordistributor.

21. Battery electrolyte levelcheck

Replenish with distilled water if necessary.

38 ENGINE MAINTENANCE SCHEDULE

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22. Battery cleaning Clean the terminals.

23. Battery charge condition If the lamp stays on while engine is running, check charging circuit.

24. Starter and generatorcheck and cleaning

Check wear condition of brush and commutator. Consult your local Ingersoll–Rand branch or distributor.

25. Wiring and connectioncheck

Check for loose terminals/connections and integrity of insulation.

26. Air cleaner elementreplace

Change element at 500 hours or 6 months, whichever come first, or sooner if the restriction indicator shows red.

27. Air intake piping Check pipes and connections for damage or loose fitting

28. Engine starting conditionand noise condition

Check engine stability and noise.

29. Exhaust smoke condition Check exhaust smoke color.

30. Cylinder compressionpressure

Consult your local Ingersoll–Rand branch or distributor.

31. Valve clearance check Incorrect valve clearance will result in increased engine noise and lower engine output thereby adverselyaffecting engine performance. Check and adjust every 1000 hours. Consult your local Ingersoll–Rand branchor distributor.

32. Positive crankcaseventilation valve cleaning

Check and clean the breather tube daily during cold weather. Check according to the equipmentspecifications. Perform the adjustment, cleaning, repair or replacement every 1500 hours. (This is arecommended maintenance item �). Consult your local Ingersoll–Rand branch or distributor.

39ENGINE TROUBLESHOOTING

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This item contains a simple troubleshooting. When a failure takes place on your Ingersoll–Rand engine, diagnose the cause referring thistroubleshooting. Should the cause of failure not be detected or you are unable to manage the failure, consult your machine supply source or nearestIngersoll–Rand engine service outlet.

Engine does not start Battery discharged

Starter does not turn. Bad cable connections.

Starter or starter switch failure.

Safety relay failure.

Engine stop solenoid malfunction.

No fuel in the fuel tank.

No fuel injection. Clogged fuel filter element.

Air in the fuel system.

Starter turns but engine does notfire.

Control rack is stuck at no fuelposition.

Incorrect preheating operation.

Glow plug malfunction.

Fuel is injected but engine does notfire.

Incorrect injection timing.

Low cylinder compressionpressure.

Engine stop solenoid not fullyreturned.

Engine fires but stalls immediately. Air in the fuel system.

Incorrect low idle speed adjustment.

40 ENGINE TROUBLESHOOTING

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Unstable engine running Crack in injection pipe.

Injection nozzle failure.

Unstable low idling Engine stop solenoid return failure.

Uneven compression pressure between cylinders.

Incorrect high idle speedadjustment.

Incorrect control lever adjustment.

Governor internal malfunction.

Engine hunting in medium speedrange.

Governor spring deteriorated.

Air in the fuel system

Insufficient fuel supply. Clogged fuel filter element

Piping failure (squeezed/restrictedetc.)

Engine malfunction in high speedrange.

Uneven fuel injection amount between cylinders.

Deteriorated governor spring.

Incorrect valve clearance adjustment.

Deteriorated valve spring.

Engine speed stuck at high idle. Engine control restriction or seizure.

Engine overheat. Insufficient coolant volume.

Fan belt slippage.

Cooling system defect Thermostat malfunction.

Radiator filler cap malfunction.

Cooling system interior fouled.

Radiator clogged.

Engine over–loaded.

Improper servicing Air cleaner element clogged.

Insufficient airflow/restriction.

Restricted coolant flow (high concentration of antifreeze, etc.)

Low oil pressure Lack of oil Oil leakage

High oil consumption

Wrong oil Wrong type and viscocity.

High coolant temperature. Over heat.

Clogged filter and strainer.

Worn bearings and oil pump.

Faulty relief valve.

41ENGINE TROUBLESHOOTING

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Low engine output Incorrect injection timing Too far advanced.

Too far retarded.

Injection nozzle malfunction Incorrect injection pressure.

Incorrect spray condition.

Incorrect injection pump adjustment Lack of fuel in tank.

Insufficient fuel supply to theinjection pump

Air in injection pump.

Fuel filter clogged.

Overflow valve malfunction.

Governor malfunction Incorrect engine controladjustment.

Deteriorated governor spring.

Incorrect valve clearanceadjustment.

Cylinder compression leakage Injector nozzle misalignment.

Low cylinder compression pressure Cylinder bore wear.

Insufficient air intake volume. Air cleaner clogged.

Restricted air flow.

Excessive oil consumption Incorrect oil Wrong selection of type and viscosity.

Too much oil quantity.

Engine burning oil Faulty piston rings/damaged cylinder bores.

Faulty valve stem seal.

Damaged seal / Damaged turbocharger seal

Oil leakage Loose joints/gaskets.

Improper installation of filter and piping.

Fuel leakage Damaged seals.

Excessive fuel consumption Improper component installation or tightening.

Excessive injection volume. Injection pump defective.

Excessive mechanical loads

42 ENGINE TROUBLESHOOTING

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Improper exhaust Clogged air cleaner.

Damaged injector nozzle.

Excessive black smoke Wrong injector nozzle.

Injection timing incorrect.

Excessive injection volume.

Incorrect fuel.

Water mixing in fuel

Excessive white smoke Low compression pressure.

Injection timing incorrect.

Low coolant temperature

Faulty turbocharger

Battery overdischarge Low electrolyte level Crack in battery body.

Natural consumption.

Charging failure Loose or damaged belt.

Faulty alternator.

Damaged wiring or contact failure.

Excessive electrical loads Insufficient battery capacity for the application.

MAINTENANCE 43

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MAINTENANCEInitial 500

miles/850 km

Daily Weekly Monthly 3 Monthly.

500 hrs.

6 Monthly.

1000 hrs

12 Monthly.

2000 hrs

Compressor Oil Level C

Engine Oil Level C

*Radiator Coolant Level C

Gauges/Lamps C

*Air Cleaner Service Indicators C

Fuel Tank (Fill at end of day) C D

*Fuel/Water Separator Drain C

Oil Leaks C

Fuel Leaks C

Drain Water From Fuel Filters D

Coolant Leaks C

Radiator Filler Cap C

Air Cleaner Precleaner Dumps 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 Rad/Oil Cooler Exterior C

Fasteners, Guards C

Air Cleaner Elements R/WI

*Disregard if not appropriate for this particular machine.

(1) or 3000 miles/5000km whichever is the sooner

(2) or as defined by local or national legislation

C = Check (adjust, clean or replace as necessary)

CBT =check before towing.

CR = Check and report

D = Drain

G = Grease

R=Replace

T = Test

W I =or when indicated if earlier.

Refer to specific sections of the operator’s manual for more

information.

MAINTENANCE44

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Initial 500miles

/850 km

Daily Weekly Monthly 3 Monthly

500 hrs.

6 Monthly

1000 hrs

12

Monthly

2000 hrs

18

Monthly

3000 hrs

*Fuel/Water Separator Element R

Compressor Oil Filter Element R

Compressor Oil R

Engine Oil Change R

Engine Oil Filter R

*Water Pump Grease. R

*Wheels (Bearings, Seals, etc.) C G

*Engine Coolant C R

Fuel Filter Element R

*Injection Nozzle Check CShutdown Switch Settings T

Scavenger Orifice & Related Parts C

Oil Separator Element R

*Feed Pump Strainer Cleaning. C

*Valve Clearance Check C

Lights (running, brake, & turn) CBT

Pintle Eye Bolts CBT

*Brakes C C

*Brake linkage C

Emergency stop T

Running gear linkage G

Safety valve C

Running gear bolts(1) C

*Disregard if not appropriate for this particular machine.

(1) or 3000 miles/5000km whichever is the sooner

(2) or as defined by local or national legislation

C = Check (adjust, clean or replace as necessary)

CBT =check before towing.

CR = Check and report

D = Drain

G = Grease

R=Replace

T = Test

W I =or when indicated if earlier.

Refer to specific sections of the operator’s manual for more

information.

MAINTENANCE 45

9/235

Initial 500miles

/850 km

Daily Weekly Monthly 3 Monthly.

500 hrs.

6 Monthly.

1000 hrs

12 Monthly.

2000 hrs

Scavenge line C

*Engine breather element C

Separator tank (2) exterior CR

*Lubricator (Fill) C

2 Yrs 4 Yrs 6 Yrs

Safety valve C

Hoses R

Separator tank (2) interior C

*Disregard if not appropriate for this particular machine.

(1) or 3000 miles/5000km whichever is the sooner

(2) or as defined by local or national legislation

C = Check (adjust, clean or replace as necessary)

CBT =check before towing.

CR = Check and report

D = Drain

G = Grease

R=Replace

T = Test

W I =or when indicated if earlier.

Refer to specific sections of the operator’s manual for more

information.

ROUTINE MAINTENANCE

This section refers to the various components which requireperiodic maintenance and replacement.

The MAINTENANCE CHART indicates the various components’descriptions and the intervals when maintenance has to take place. Oilcapacities, etc., can be found in the GENERAL INFORMATIONsection of this manual.

For any specification or specific requirement on service orpreventative maintenance for the engine, refer to the Engine Section.

Compressed air can be dangerous if incorrectly handled. Beforedoing any work on the unit, ensure that all pressure is vented from thesystem and that the machine cannot be started accidentally.

If the automatic blowdown fails to operate, then pressure must begradually relieved by operating the manual blowdown valve. Suitablepersonal protective equipment should be worn.

Ensure that maintenance personnel are adequately trained,competent and have read the Maintenance Manuals.

Prior to attempting any maintenance work, ensure that:–

. all air pressure is fully discharged and isolated from the system. Ifthe automatic blowdown valve is used for this purpose, then allowenough time for it to complete the operation.

. the discharge pipe / manifold area is depressurised by opening thedischarge valve, whilst keeping clear of any airflow from it.

MINIMUM PRESSURE VALVE – WHEN FITTED

WARNING: Pressure will remain in the system between theminimum pressure valve and the service valve after shutdown andoperation of the auto blowdown valve.

This pressure must be relieved by:

(a) Disconnecting any downstream equipment.

(b) Opening the discharge valve to atmosphere.

. The machine cannot be started. Post warning signs and/or fitanti–start devices.

. Disconnect battery cables.

Prior to opening or removing panels or covers to work insidea machine, ensure that:–

. anyone entering the machine is aware of the reduced level ofprotection and the additional hazards, including hot surfaces andintermittently moving parts.

. The machine cannot be started.

Prior to attempting any maintenance work on a runningmachine, ensure that:–

. the work carried out is limited to only those tasks which require themachine to run.

. the work carried out with safety protection devices disabled orremoved is limited to only those tasks which require the machine to berunning 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 movingparts, safety valve discharge etc.).

MAINTENANCE46

9/235

. appropriate personal protective equipment is worn.

. loose clothing, jewellery, long hair etc. is made safe.

. warning signs indicating that Maintenance Work is in Progress areposted in a position that can be clearly seen.

Upon completion of maintenance tasks and prior to returningthe machine into service, ensure that:–

. the machine is suitably tested.

. all guards and safety protection devices are refitted.

. all panels are replaced, canopy and doors closed.

. hazardous materials are effectively contained and disposed of.

PROTECTIVE SHUTDOWN SYSTEM

Refer to the Wedge diagnostic display codes table for a listing ofshutdown conditions.

Low engine fuel level switch.

Test the low engine fuel level switch circuit as follows:

. Start the machine.

Note: Do not press the load button.

. Disconnect the switch, the machine should shutdown.

. Re–connect the switch.

Test the low engine fuel level switch by removing and operatingthe float manually.

WARNING: Never remove or replace switches when the machineis running.

SCAVENGE LINE

The scavenge line runs from the combined orifice/drop tube in theseparator tank, to the orifice fitting located in the airend.

Check that the scavenge line and tube are clear of anyobstruction each time the compressor lubricant is changed as anyblockage will result in oil carryover into the discharge air.

COMPRESSOR OIL FILTER

Refer to the MAINTENANCE CHART in this section for therecommended servicing intervals.

Removal

WARNING: Do not remove the filter(s) without first making surethat the machine is stopped and the system has been completelyrelieved of all air pressure. (Refer to STOPPING THE UNIT in theOPERATING INSTRUCTIONS section of this manual).

Clean the exterior of the filter housing and remove the spin–onelement by turning it in a counter–clockwise direction.

Inspection

Inspect the oil filter head to be sure the gasket was removed withthe oil filter element. Clean the gasket seal area on the oil filter head.

CAUTION: If there is any indication of the formation of varnishes,shellacs or lacquers on the filter element, it is a warning that thecompressor lubricating and cooling oil has deteriorated and that itshould be changed immediately. Refer to LUBRICATION later in thissection.

NOTICE: Installing a new oil filter element when the old gasketremains on the filter head, will cause an oil leak and can causeproperty damage.

Reassembly

Clean the filter gasket contact area and install the new element byscrewing in a clockwise direction until the gasket makes contact withthe filter housing. Tighten a further 1/2 to 3/4 of a revolution.

CAUTION: Start the machine (refer to PRIOR TO STARTING andSTARTING THE UNIT in the OPERATING INSTRUCTIONS sectionof this manual) and check for leakage before the machine is put backinto service.

COMPRESSOR OIL SEPARATOR ELEMENT

Refer to the MAINTENANCE CHART in this section for therecommended servicing intervals.

If, however, the element has to be replaced, then proceed asfollows:

Removal

WARNING: Do not remove the filter(s) without first making surethat the machine is stopped and the system has been completelyrelieved of all air pressure. (Refer to STOPPING THE UNIT in theOPERATING 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 plate and thenremove the cover plate. Remove the separator element.

Inspection

Examine the filter element. Examine all hoses and tubes, andreplace if necessary.

Reassembly

Thoroughly clean the orifice/drop tube and filter gasket contact areabefore reassembly. Install the new element.

WARNINGDo not remove the staple from the anti–static gasket on the

separator element since it serves to ground any possible staticbuild–up. Do not use gasket sealant since this will affect electricalconductance.

MAINTENANCE 47

9/235

Reposition the cover plate, taking care not to damage the gasket,and replace the cover plate screws tightening in a criss–cross patternto the recommended torque (refer to the TORQUE SETTING TABLElater in this section).

Reconnect all hoses and tubes to the separator tank cover plate.

Replace the compressor oil (refer to LUBRICATION later in thissection).

CAUTION: Start the machine (refer to PRIOR TO STARTING andSTARTING THE UNIT in the OPERATING INSTRUCTIONS sectionof this manual) and check for leakage before the machine is put backinto service.

COMPRESSOR OIL COOLER AND ENGINE RADIATOR

When grease, oil and dirt accumulate on the exterior surfaces of the oilcooler and radiator, the efficiency is impaired. It is recommended thateach month the oil cooler and radiator be cleaned by directing a jet ofcompressed air, (carrying if possible a non–flammable cleaningsolvent) over the exterior core of the cooler/radiator. This shouldremove any accumulation of oil, grease and dirt from the exterior coreof the cooler so that the entire cooling area can radiate the heat of thelubricating and cooling oil/water into the air stream.

WARNING: Hot engine coolant and steam can cause injury. Whenadding coolant or antifreeze solution to the engine radiator, stopthe engine at least one minute prior to releasing the radiator fillercap. Using a cloth to protect the hand, slowly release the filler cap,absorbing any released fluid with the cloth. Do not remove thefiller cap until all excess fluid is released and the engine coolingsystem fully depressurised.

WARNING: Follow the instructions provided by the antifreezesupplier when adding or draining the antifreeze solution. It isadvisable to wear personal protective equipment to prevent skinand eye contact with the antifreeze solution.

AIR FILTER ELEMENTS

The air filter should be inspected regularly (refer to theSERVICE/MAINTENANCE CHART) and the element replaced whenthe restriction indicator shows red or every 6 Months (500 hours),whichever comes first. The dust collector box(es) should be cleaneddaily (more frequently in dusty operating conditions) and not allowed tobecome more than half full.

Removal

CAUTION: Never remove and replace element(s) when the machineis running.

Clean the exterior of the filter housing and remove the filter elementby releasing the nut.

Reassembly

Assemble the new element into the filter housing ensuring that theseal seats properly. Secure element by tightening nut.

Before restarting the machine, check that all clamps are tight.

VENTILATION

Always check that the air inlets and outlets are clear of debris etc.

COOLING FAN DRIVE

Periodically check that the fan mounting bolts in the fan hub havenot loosened. If, for any reason, it becomes necessary to remove thefan or re–tighten the fan mounting bolts, apply a good grade ofcommercially available thread locking compound to the bolt threadsand tighten to the torque value shown in the TORQUE SETTINGTABLE later in this section.

The fan belt(s) should be checked regularly for wear and correcttensioning.

FUEL SYSTEM

The fuel tank should be filled daily or every eight hours. To minimisecondensation in the fuel tank(s), it is advisable to top up after themachine is shut down or at the end of each working day. At six monthintervals drain any sediment or condensate that may haveaccumulated in the tank(s).

Refer to MAINTENANCE CHART.

FUEL FILTER WATER SEPARATOR

The fuel filter water separator contains a filter element which shouldbe replaced at regular intervals (see the MAINTENANCE CHART).

CHARGE AIR COOLER PIPEWORK

Inspect all hoses and clips on the charge cooler pipe work.

Engine damage will occur if the charge cooling system leaks.

HOSES

All components of the engine cooling air intake system should bechecked periodically to keep the engine at peak efficiency.

At the recommended intervals, (see the MAINTENANCE CHART),inspect all of the intake lines to the air filter, and all flexible hoses usedfor air lines, oil lines and fuel lines.

Periodically inspect all pipework for cracks, leaks, etc. and replaceimmediately if damaged.

ELECTRICAL SYSTEM

WARNING: Always disconnect the battery cables beforeperforming any maintenance or service.

Check the security of electrical terminals on the switches and relaysi.e. nuts or screws loose, which may cause local hot spot oxidation.

Inspect the components and wiring for signs of overheating i.e.discolouration, charring of cables, deformation of parts, acrid smellsand blistered paint.

BATTERY

Keep the battery terminals and cable clamps clean and lightlycoated with petroleum jelly to prevent corrosion.

The retaining clamp should be kept tight enough to prevent thebattery from moving.

MAINTENANCE48

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PRESSURE SYSTEM

Regularly, it is necessary to inspect the external surfaces of thesystem (from the airend through to the discharge valve(s)) includinghoses, tubes, tube fittings and the separator tank, for visible signs ofimpact damage, excessive corrosion, abrasion, tightness and chafing.Any suspect parts should be replaced before the machine is put backinto service.

TYRE PRESSURE

See the GENERAL INFORMATION section of this manual.

RUNNING GEAR/WHEELS

Check the wheel nut torque 20 miles (30 kilometres) after refittingthe wheels. Refer to the TORQUE SETTING TABLE later in thissection.

Lifting jacks should only be used under the axle.

The bolts securing the running gear to the chassis should bechecked periodically for tightness (refer to the MAINTENANCECHART for frequency) and re–tightened where necessary. Refer to theTORQUE SETTING TABLE later in this section.

LUBRICATION

CAUTION: Always check the oil levels before a new machine is put intoservice.

If, for any reason, the unit has been drained, it must be re–filled withnew oil before it is put into operation.

ENGINE LUBRICATING OIL

The engine oil should be changed at the engine manufacturer’srecommended intervals. Refer to the Engine section of this manual.

Refer to the Engine operators’ manual/section for engine oilspecifications

Refer to the Engine section of this manual.

COMPRESSOR LUBRICATING OIL

Refer to the MAINTENANCE CHART in this section for serviceintervals.

NOTE: If the machine has been operating under adverse conditions,or has suffered long shutdown periods, then more frequent serviceintervals will be required.

WARNING: DO NOT, under any circumstances, remove any drainplugs or the oil filler plug from the compressor lubricating andcooling system without first making sure that the machine isstopped and the system has been completely relieved of all airpressure (refer to STOPPING THE UNIT in the OPERATINGINSTRUCTIONS section of this manual).

Completely drain the receiver/separator system including the pipingand oil cooler by removing the drain plug(s) and collecting the used oilin 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 beenrunning, then most of the sediment will be in suspension and willtherefore drain more readily.

CAUTION: Some oil mixtures are incompatible and result in theformation of varnishes, shellacs or lacquers which may be insoluble.Refer to Portable Compressor Fluid Chart

RUNNING GEAR WHEEL BEARINGS

Wheel bearings should be packed with grease every 6 months. Thetype of grease used should conform to specification MIL–G–10924.

MAINTENANCE 49

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PORTABLE COMPRESSOR FLUID CHART

Refer to these charts for correct compressor fluidrequired. Note that the selection of fluid is dependenton the design operating pressure of the machine andthe ambient temperature expected to be encounteredbefore the next oil change.

Note: Fluids listed as “preferred” are required forextended warranty.

Compressor oil carryover (oil consumption) maybe greater with the use of alternative fluids.

Design OperatingPressure

AmbientTemperature

Specification

100 psi to 300 psi –10�F to 125�F(–23�C to 52�C)

Preferred:IR Pro–Tec�

Alternate:ISO Viscosity Grade46 with rust andoxidation inhibitors,designed for aircompressor service

350 psi –10�F to 125�F(–23�C to 52�C)

Preferred:IR XHP 605

Alternate:IR XHP405ISO Viscosity Grade68 Group 3 or 5 withrust and oxidationinhibitors designedfor air compressorservice..

65�F to 125�F (18�Cto 52�C)

Preferred:XHP605IR XHP1001

XHP605

IR

PRO–TEC�

100 – 300 PSI

RATED OPERATING PRESSURE

350 PSI

IRXHP 1001

10�F

125�F50�C

40�C

30�C

20�C

10�C

0�C

–10�C

–20�C

–30�C

–40�C

104�F

86�F

65�F

50�F

32�F

14�F

–10�F

–22�F

–40�F

XHP405

consultfactory

IR

IR

consultfactory

Preferred Ingersoll–Rand Fluids – Use of these fluidswith original IR filters can extend airend warranty. Referto operator’s manual warranty section for details orcontact your I–R representative.

Ingersoll–RandPreferred Fluids

1 gal.(3.8 Litre)

5 gal.(19.0 Litre)

55 gal.(208.2Litre)

220 gal.(836 litre)

Preferred:

IR Pro–Tec� 36899698 36899706 36899714 36899722

IR XHP605 – 22252076 22252050 22252068

IR XHP1001 – 35612738 35300516 –

XHP405 – 22252126 22252100 22252118

MAINTENANCE50

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SPEED AND PRESSURE REGULATION ADJUSTMENT

Normally, regulation requires no adjusting, but if correct adjustmentis lost, proceed as follows:

Refer to the diagram above.

A. Throttle Arm

B. Adjusting Screw

C. Engine Governor

D. Separator Tank

E. Inlet Unloader

Start the machine (Refer to STARTING INSTRUCTIONS in theOPERATING INSTRUCTIONS section of this manual).

Inspect the throttle arm on the engine governor to see that it isextended in the full speed position when the engine is running atfull–load speed and the service valve is fully open. (Refer to theGENERAL INFORMATION section of this manual).

Adjust the service valve on the outside of the machine to maintainnormal operating discharge pressure without the throttle arm movingfrom the full speed position before normal operating dischargepressure is attained. Turn the adjusting screw clockwise to increasethe pressure.Optimum adjustment is achieved when the throttle armjust moves from its full speed position and the pressure gauge readsnormal operating discharge pressure.

Close the service valve. The engine will slow to idle speed.

CAUTION: Never allow the idle pressure to exceed maximumallowable pressure on the pressure gauge, otherwise the safety valvewill operate.

MAINTENANCE 51

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TABLE 1 INCH FASTENERS

NOMINAL DESIGN TORQUE

8AE J249GRADE 5

(HEAD MARKING)

8AE J249GRADE 8

(HEAD MARKING)TYPICAL RECTANGULAR TORQUE

PATTERN

CAPSCREWOR NUT

THREAD SIZEAND PITCH

TYPICAL SQUARE TORQUEPATTERN

(Nm.) (FT–LBF) (Nm.) (FT–LBF)

1/4 – 20 11 8 16 12

5/16 – 18 24 17 33 25

3/8 – 16 42 31 59 44

7/16 – 14 67 49 95 70

1/2 – 13 102 75 144 106

9/16 – 12 148 109 208 154

5/8 – 11 203 150 287 212TYPICAL CIRCULAR TORQUE

3/4 – 10 361 266 509 376

TYPICAL CIRCULAR TORQUEPATTERN

Wheel Torque Chart

Nut/Bolt Size Wheel Size Torque (ft–lb)

M12 13 inch 60–70

1/2” lug nuts 13 inch 80–90

1/2” lug nuts 15 inch 105–115

1/2” lug nuts 16 inch 105–115

1/2” lug nuts 16.5 inch 105–115

5/8” lug nuts 16 inch 190–210

5/8” lug nuts 17.5 inch 190–210

MAINTENANCE52

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TABLE 2 METRIC FASTENERS

NOMINAL DESIGN TORQUE

PROPERTYGRADE 8.8

(HEAD MARKING)

PROPERTYGRADE 10.9

(HEAD MARKING)

PROPERTYGRADE 12.9

(HEAD MARKING)

TYPICAL RECTANGULAR TORQUEPATTERN

CAPSCREWOR NUT

THREAD SIZEAND PITCH

TYPICAL SQUARE TORQUEPATTERN

(Nm.) (FT–LBF) (Nm.) (FT–LBF) (Nm.) (FT–LBF)

M6 X 1.0 11 8 15 11 18 13

M8 X 1.25 26 19 36 27 43 31

M10 X 1.5 52 38 72 53 84 62

M12 X 1.75 91 67 126 93 147 109

M14 X 2 145 107 200 148 234 173

M16 X 2 226 166 313 231 365 270TYPICAL CIRCULAR TORQUE

PATTERN

M20 X 2.5 441 325 610 450 713 526

Wheel Torque Moments – For Knott Running Gear

Wheel Nut / Bolt Size Torque Moment (Nm) Torque Moment (ft–lb)

M12 x 1.5 90± 5 66 ± 4

M14 x 1.5 150± 5 110 ± 4

M16 x 1.5 180± 5 133 ± 4

M18 x 1.5 210± 5 155 ± 4

FAULT FINDING 53

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FAULT CAUSE REMEDYNo reactionfrominstrument

Batteries not connected. Connect batteries.

instrumentpanel whenkey turnedto (I)position.

Fuse at starter motor‘blown’.

Replace fuse.

Engine failsto start.

Low battery charge. Check the fan belttension, battery andcable connections.

Bad earth connection. Check the earth cables,clean as required.

Loose connection. Locate and make theconnection good.

Fuel starvation. Check the fuel level andfuel system components.Replace the fuel filter ifnecessary.

Relay failed. Replace the relay.

Faulty stop solenoid Check the stop solenoid

Enginestops whilein service oris reluctantto start.

Low fuel level. Fill fuel tank and bleed airfrom fuel system ifnecessary. (Refer toMAINTENANCESECTION).

Safety shut-downsystem in operation.

Check the safetyshut-down switches.

Enginestarts butstalls when

Electrical fault Test the electricalcircuits.

stalls whenthe switchreturns to

iti I

Low engine oilpressure.

Check the oil level andthe oil filter(s).

position I. Faulty relay Check the relays.

Faulty key–switch Check the key–switch.

Enginestarts butwill not run

i

Electrical fault. Test the electricalcircuits.

will not runor engineshuts downprematurely.

Low engine oilpressure.

Check the oil level and oilfilter(s).

Enginestarts butwill not run

Safety shut-downsystem in operation.

Check the safetyshut-down switches.

will not runor engineshuts downprematurely.

Fuel starvation. Check the fuel level andfuel system components.Replace the fuel filter ifnecessary.

Switch failure. Test the switches.

High compressor oiltemperature.

Check the compressor oillevel and oil cooler.Check the fan drive.

Water present in fuelsystem.

Check the waterseparator and clean ifrequired.

Faulty relay. Check the relays andreplace if necessary.

EngineOverheats.

Low water level Check the level andreplenish if necessary.

Blocked radiator. Stop the machine andclean the cooling fins withcompressed air or steam.Use reduced pressure forcleaning the fins.

Reduced cooling airfrom fan.

Check the fan and thedrive belts. Check for anyobstruction inside thecowl.

Faulty thermostat Check the thermostatand replace if necessary.

Enginespeed toohigh.

Incorrect throttle armsetting.

Check the engine speedsetting.

Enginespeed toolow

Incorrect throttle armsetting.

Check the throttle setting.

low.Blocked fuel filter. Check and replace if

necessary.

Blocked air filter. Check and replace theelement if necessary.

Incorrectly setregulation system.

Reset the regulationsystem. Refer to SPEEDAND PRESSUREREGULATIONADJUSTMENT in theMAINTENANCE sectionof this manual.

Premature unloading. Check the regulationsystem.

Excessivevibration.

Engine speed too low. See ”Engine speed toolow”

Leaking oilseal.

Improperly fitted oil seal. Replace the oil seal.

Refer also to the Engine Manufacturer’s Manual.

Airdischargecapacity too

Engine speed too low. See “Engine speed toolow”

capacity toolow. Blocked air cleaner. Check the restriction

indicators and replacethe element(s) ifnecessary.

High pressure airescaping.

Check for leaks.

Incorrectly setregulation system.

Reset the regulationsystem. Refer to SPEEDAND PRESSUREREGULATIONADJUSTMENT in theMAINTENANCE sectionof this manual.

FAULT FINDING54

9/235

Compressoroverheats.

Low oil level. Top up the oil level andcheck for leaks.

Dirty or blocked oilcooler.

Clean the oil cooler fins.

Incorrect grade of oil. Use Ingersoll–Randrecommended oil.

Defective by-passvalve.

Check the operation ofthe element and replace ifnecessary.

Recirculation of coolingair.

Move the machine toavoid recirculation.

Reduced cooling airfrom fan.

Check the fan and thedrive belts. Check for anyobstruction inside the fancowl.

Excessive oilpresent inthedischarge

Blocked scavenge line. Check the scavenge line,drop tube and orifice.Clean and replace.

dischargeair. Perforated separator

element.Replace the separatorelement.

Pressure in the systemis too low.

Check the minimumpressure valve.

Safety valveoperates.

Operating pressure toohigh.

Refer to SPEED ANDPRESSURE REGULA-TION ADJUSTMENT inthe MAINTENANCE sec-tion of this manual.

Incorrect setting of theregulator.

Adjust the regulator.

Faulty regulator. Replace the regulator.

Inlet valve setincorrectly.

Refer to SPEED ANDPRESSUREREGULATIONADJUSTMENT in theMAINTENANCE sectionof this manual.

Loose pipe/hoseconnections.

Check all pipe/hoseconnections.

Faulty safety valve. Check the relievingpressure. Replace thesafety valve if faulty. DONOT ATTEMPT AREPAIR.

Oil is forcedback into theair filter.

Incorrect stoppingprocedure used

Always employ thecorrect stoppingprocedure. Close thedischarge valve andallow the machine to runon idle before stopping.

Faulty inlet valve. Check for free operationof the inlet valve(s).

Machinegoes to fullpressurewhenstarted.

Faulty load valve. Replace the valve.

Machine failsto load when

Faulty load valve. Replace the valve.to load whenthe load Faulty switch. Test switchthe loadswitch ispressed.

Loose pipe/hoseconnections.

Check all pipe/hoseconnections.

PARTS ORDERING 55

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GENERAL

This publication, which contains an illustrated parts breakdown, hasbeen prepared as an aid in locating those parts which may be requiredin the maintenance of the unit. All of the compressor parts, listed in theparts breakdown, are manufactured with the same precision as theoriginal equipment. For the greatest protection always insist ongenuine Ingersoll–Rand Company parts for your compressor.

NOTICE

Ingersoll–Rand Company can bear no responsibility for injury ordamages resulting directly from the use of non–approved repair parts.

Ingersoll–Rand Company service facilities and parts are availableworldwide. There are Ingersoll– Rand Company ConstructionEquipment Group Sales Offices and authorized distributors located inthe principal cities of the United States. In Canada our customers areserviced by the Canadian Ingersoll–Rand Company, Limited. Thereare also Ingersoll–Rand International autonomous companies andauthorized distributors located in the principal cities throughout the freeworld.

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

DESCRIPTION

The illustrated parts breakdown illustrates and lists the variousassemblies, subassemblies and detailed parts which make up thisparticular machine. This covers the standard models and the morepopular options that are available.

A series of illustrations show each part distinctly and in location relativeto the other parts in the assembly. The part number, the description ofthe part and the quantity of parts required are shown on eachillustration or on adjacent page. The quantities specified are thenumber of parts used per one assembly and are not necessarily thetotal number of parts used in the machine. Where no quantity isspecified the quantity is assumed to be one.

Each description of a part is based upon the “noun first” method, i.e.,the identifying noun or item name is always the first part of thedescription. The noun name is generally followed by a singledescriptive modifier. The descriptive modifier may be followed bywords or abbreviations such as upper, lower, inner, outer, front, rear,RH, LH, etc. when they are essential.

In referring to the rear, the front or to either side of the unit, alwaysconsider the drawbar end of the unit as the front. Standing at the rearof the unit facing the drawbar (front) will determine the right and leftsides.

FASTENERS

Both SAE/inch, ISO/metric hardware have been used in the design andassembly of these units. In the disassembly and reassembly of parts,extreme care must be taken to avoid damaging threads by the use ofwrong fasteners. In order to clarify the proper usage and for exactreplacement parts, all standard fasteners have been identified by partnumber, size and description. This will enable a customer to obtainfasteners locally rather than ordering from the factory. These parts areidentified in tables that will be found at the rear of the parts illustrations.Any fastener that has not been identified by both part number and sizeis a specially engineered part that must be ordered by part number toobtain the exact replacement part.

MARKINGS AND DECALS

NOTICE

Do not paint over safety warnings or instructional decals. If safetywarning decals become illegible, immediately orderreplacements from the factory.

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

Afterwards, service sets of exterior decals and current productionsafety warning decals are available. Contact the Product SupportGroup at Mocksville for your particular needs and availability.

PARTS ORDERING56

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HOW TO USE PARTS LIST

a. Turn to Parts List.

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

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

HOW TO ORDER

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

In order that all avoidable errors may be eliminated, the followinginstructions are offered as a guide to the purchaser when orderingreplacement parts:

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

b. Always specify the serial number of the unit. THIS ISIMPORTANT. The serial number of the unit will be foundstamped on a plate attached to the unit. (The serial number onthe unit is also permanently stamped in the metal of the frameside rail.)

c. Always specify the number of the parts list publication.

d. Always specify the quantity of parts required.

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

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

TERMS AND CONDITIONS ON PARTS ORDERS

Acceptance: Acceptance of an offer is expressly limited to the exactterms contained herein. If purchaser’s order form is used foracceptance of an offer, it is expressly understood and agreed that theterms and conditions of such order form shall not apply unlessexpressly agreed to by Ingersoll–Rand Company (“Company”) inwriting. No additional or contrary terms will be binding upon theCompany unless expressly agreed to in writing.

Taxes: Any tax or other governmental charge now or hereafter leviedupon the production, sale, use or shipment of material and equipmentordered or sold is not included in the Company’s price and will becharged to and paid for by the Purchaser.

Shipping dates shall be extended for delays due to acts of God, actsof Purchaser, acts of Government, fires, floods, strikes, riot, war,embargo, transportation shortages, delay or default on the part of theCompany’s vendors, or any other cause beyond the Company’sreasonable control.

Should Purchaser request special shipping instruction, such asexclusive use of shipping facilities, including air freight when commoncarrier has been quoted and before change order to purchase ordercan be received by the Company, the additional charges will behonored by the Purchaser.

Warranty: The Company warrants that parts manufactured by it willbe as specified and will be free from defects in materials andworkmanship. The Company’s liability under this warranty shall belimited to the repair or replacement of any part which was defective atthe time of shipment provided Purchaser notifies the Company of anysuch defect promptly upon discovery, but in no event later than three(3) months from the date of shipment of such part by the Company. Theonly exception to the previous statement is the extended warranty asit applies to the special airend exchange program.

Repairs and replacements shall be made by the Company F.O.B. pointof shipment. The Company shall not be responsible for costs oftransportation, removal or installation.

Warranties applicable to material and equipment supplied by theCompany but wholly manufactured by others shall be limited to thewarranties extended to the Company by the manufacturer which areable to be conveyed to the Purchaser.

Delivery: Shipping dates are approximate. The Company will use bestefforts to ship by the dates specified; however, the Company shall notbe liable for any delay or failure in the estimated delivery or shipmentof material and equipment or for any damages suffered by reasonthereof.

The company makes no other warranty or representation of any kindwhatsoever, expressed or implied, except that of title, and all impliedwarranties, including any warranty of merchantability and fitness for aparticular purpose, are hereby disclaimed.

Limitation of Liability: The remedies of the Purchaser set forth herein are exclusive, and thetotal liability of the Company with respect to this order whether basedon contract, warranty, negligence, indemnity, strict liability orotherwise, shall not exceed the purchase price of the part upon whichsuch liability is based.

The Company shall in no event be liable to the Purchaser, anysuccessors in interest or any beneficiary of this order for anyconsequential, incidental, indirect, special or punitive damages arisingout of this order or any breach thereof, or any defect in, or failure of, ormalfunction of the parts hereunder, whether based upon loss of use,lost profits or revenue, interest, lost goodwill, work stoppage,impairment of other goods, loss by reason of shutdown or non–operation, increased expenses of operation or claims of customers ofPurchaser for service interruption whether or not such loss or damageis based on contract, warranty, negligence, indemnity, strict liability orotherwise.

AIREND EXCHANGE PROGRAM

Ingersoll–Rand offers an airend exchange program to benefit portablecompressor users.

On the airend exchange program the exchange price is determined bythe age and condition of the airend.

Your nearest sales office, autonomous company or authorizeddistributor must first contact the Parts Service Department at thefactory at which your portable air compressor was manufactured for anairend exchange number. The airend must be tagged with thispreassigned number and returned to the factory prepaid. The airendmust be intact, with no excluded parts, otherwise the exchangeagreement may be cancelled. The warranty on an exchange or factoryrebuilt airend is 365 days.Airends being returned to the factory in connection with a WARRANTYCLAIM must be processed through the Customer Service Department.If returned without a Warranty MRR (Material Return Request)Number, no warranty claim will be considered.

PARTS ORDERING 57

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Telephone: +44 (0) 1942 257 171

Fax: +44 (0) 1942 523 417

Facility:

Office hours: Monday – Friday 8:00 a.m. to 4:30 p.m. (GMT)

For information on how to order parts or information regarding your local distributor (Europe, Middle East, Africa) please contact:

Portable Power Aftermarket ESAIngersoll–Rand European Sales LtdSwan Lane, Hindley GreenWigan WN2 4 EZUnited Kingdom

Emergency order telephone # +44 (0) 777 617 0921