Manual Operacion, Mantenimienjto y Partes

OPERATING, MAINTENANCE
AND PARTS MANUAL
COMPRESSOR MODEL
P250WJDU
Code: A
This manual contains important safety information.

Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
Doosan purchased Bobcat Company from Ingersoll-Rand Company in

Portable Power Division 2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
P.O. Box 868 - 501 Sanford Ave to Ingersoll-Rand Company in this manual is historical or nominative
Mocksville, N.C. 27028 in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
Book 22320717 (8/03) Revised (10-12) either.
QUALITY POLICY
We will supply products and services that consistently meet the require-
ments of our customers and each other.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the
State of California to cause cancer, birth defects, and other reproduc-
tive harm.
2 Book 22320717 (8/03)

Foreword
Nothing contained in this document is intended to extend any promise, warranty or representation, expressed
or implied, regarding the Ingersoll-Rand products described herein. Any such warranties or other terms and
conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such
products, which are available upon request.
This manual contains instructions and technical data to cover all routine operation and scheduled maintenance
tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be
referred to an authorized Ingersoll-Rand service department.
All components, accessories, pipes and connectors added to the compressed air system should be:
• of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by
Ingersoll-Rand.
• clearly rated for a pressure at least equal to the machine maximum allowable working pressure.
• compatible with the compressor lubricant/coolant.
• accompanied with instructions for safe installation, operation and maintenance.
Details of approved equipment are available from Ingersoll-Rand Service departments.
The use of repair parts other than those included within the Ingersoll-Rand approved parts list may create haz-
ardous conditions over which Ingersoll-Rand has no control. Therefore, Ingersoll-Rand cannot be held respon-
sible for equipment in which non-approved repair parts are installed.
Ingersoll-Rand reserves the right to make changes and improvements to products without notice and without
incurring any obligation to make such changes or add such improvements to products sold previously.
The intended uses of this machine are outlined below and examples of unapproved usage are also given.
However, Ingersoll-Rand cannot anticipate every application or work situation that may arise. If in doubt, con-
sult supervision.
This machine has been designed and supplied for above ground operation to be used for compression of nor-
mal ambient air containing no additional gases, vapors or particles within the ambient temperature range spec-
ified in the general data section of this manual.
This machine should not be used:
A. For direct or indirect human consumption of the compressed air.
B. Outside the ambient temperature range specified in the general data section of this manual.
C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists.
D. With other than Ingersoll-Rand approved components.
E. With guards, or controls or switches missing or disabled.
F. For storage or transportation of materials inside or on the enclosure.
This company accepts no responsibility for errors in translation of this manual from the original English version.
Book 22320717 (8/03) 3

4 Book 22320717 (8/03)
TABLE OF CONTENTS
P250WJDU
TITLE PAGE
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hazardous Substance Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
WARRANTY REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
NOISE EMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Compressor Noise Emission Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Noise Emission Control Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
General Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rated Delivery: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
UNITS MEASUREMENTS WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
EXPENDABLE SERVICE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Diagnostics/auto Shutdown (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Diagnostics/auto Shutdown (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Controls (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Utility Package Set-up (no running gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Setting - Up (All Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Before Starting:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5
TABLE OF CONTENTS
P250WJDU
TITLE PAGE
Cold Weather Starting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
After Starting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Operation Of Optional Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Units With Diagnostic Lamps:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Units With Optional Diagnostics Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Automatic Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
High Discharge AIR Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
After Starting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Compressor Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Receiver-separator Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Exterior Finish Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Compressor Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Action Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6
TABLE OF CONTENTS
P250WJDU
TITLE PAGE
PARTS ORDERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Markings And Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
How To Use Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
How To Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Terms And Conditions On Parts Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Frame Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Engine Complete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cooling Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Assy, Oil Temp Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Airend Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Unloader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Airend Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Air Service Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Separator Tank Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Central Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Air Intake Complete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Cleaner Assembly - Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Fuel Tank Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Remote Filters Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Air & Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Air & Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Instrument/control Panel Without Start/run Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Battery & Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Enclosure Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Acoustic Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7
TABLE OF CONTENTS
P250WJDU
TITLE PAGE
8
Section 1 - Safety
Book 22320717 (8/03) 9

Operating & Maintenance Manual Safety
Safety
Safety Precautions machine safety valve rating.

If more than one compressor is connected to
General Information one common downstream plant, effective
check valves and isolation valves must be
Ensure that the operator reads and fitted and controlled by work procedures, so
understands the decals and consults the that one machine cannot accidentally be
manuals before maintenance or operation. pressurized or over pressurized by another.
Ensure that the Operation and Maintenance Compressed air must not be used for a feed
manual, and manual holder if equipped, are to any form of breathing apparatus or mask.
not removed permanently from the machine. The discharged air contains a very small
Ensure that maintenance personnel are percentage of compressor lubricating oil and
adequately trained, competent and have care should be taken to ensure that
read the manuals. downstream equipment is compatible.
Make sure that all protective covers are in If the discharged air is to be ultimately
place and that the canopy/doors are closed released into a confined space, adequate
during operation. ventilation must be provided.
The specification of this machine is such that When using compressed air, always use
the machine is not suitable for use in appropriate personal protective equipment.
flammable gas risk areas. If such an All pressure containing parts, especially
application is required then all local flexible hoses and their couplings, must be
regulations, codes of practice and site rules regularly inspected, be free from defects and
must be observed. To ensure that machine be replaced according to the Manual
can operate in a safe and reliable manner, instructions.
additional equipment such as gas detection,
exhaust spark arrestors, and intake (shut-off) Avoid bodily contact with compressed air.
valves may be required, dependent on local The safety valve located in the separator
regulations or the degree of risk involved. tank must be checked periodically for correct
Air discharged from this machine may operation.
contain carbon monoxide or other Never operate unit without first observing all
contaminants which will cause serious injury safety warnings and carefully reading the
or death. Do not breathe this air. operation and maintenance manual shipped
Compressed air can be dangerous if from the factory with this machine.
incorrectly handled. Before doing any work Never operate the engine of this machine
on the unit, ensure that all pressure is vented inside a building without adequate
from the system and that the machine cannot ventilation. Avoid breathing exhaust fumes
be started accidentally. when working on or near the machine. Do not
Ensure that the machine is operating at the alter or modify this machine.
rated pressure and that the rated pressure is A battery contains sulfuric acid and can give
known to all relevant personnel. off gases which are corrosive and potentially
All air pressure equipment installed in or explosive. Avoid contact with skin, eyes and
connected to the machine must have safe clothing. In case of contact, flush area
working pressure ratings of at least the immediately with water.
10 Book 22320717 (8/03)

Safety Operating & Maintenance Manual
Exercise extreme caution when using Disconnected air hoses whip and can cause
booster battery. To jump battery, connect serious injury or death. Always attach a
ends of one booster cable to the positive (+) safety flow restrictor to each hose at the
terminal of each battery. Connect one end of source of supply or branch line in accordance
other cable to the negative (-) terminal of the with OSHA Regulation 29CFR Section
booster battery and other end to a ground 1926.302(b).
connection away from dead battery (to avoid
Rotating fan blade can cause serious injury.
a spark occurring near any explosive gases
Do not operate without guard in place.
that may be present). After starting unit,
always disconnect cables in reverse order. Use care to avoid contacting hot surfaces
(engine exhaust manifold and piping, air
Never operate unit without first observing all
receiver and air discharge piping, etc.).
safety warnings and carefully reading the
operation and maintenance manual shipped Ether is an extremely volatile, highly
from the factory with this machine. flammable gas. USE SPARINGLY! Do NOT
use ETHER if unit has GLOW Plug starting
A battery contains sulfuric acid and can give
aid. Engine damage will result.
off gases which are corrosive and potentially
explosive. Avoid contact with skin, eyes and Never allow the unit to sit stopped with the
clothing. In case of contact, flush area pressure in receiver-separator system. As a
immediately with water. precaution, open manual blowdown valve.
High Pressure Air can cause serious injury or Never operate unit with guards, covers or
death. Relieve pressure before removing screens removed. Keep hands, hair,
filler plugs/caps, fittings or covers. clothing, tools, blow gun tips, etc. well away
from moving parts.
Air pressure can remain trapped in air supply
line which can result in serious injury or Make sure wheels, tires and tow bar
death. Always carefully vent air supply line at connectors are in safe operating condition
tool or vent valve before performing any and tow bar is properly connected before
service. towing.
This machine produces loud noise with doors Whenever the machine is stopped, air will
open or service valve vented. Extended flow back into the compressor system from
exposure to loud noise can cause hearing devices or systems downstream of the
loss. Always wear hearing protection when machine unless the service valve is closed.
doors are open or service valve is vented. Install a check valve at the machine service
valve to prevent reverse flow in the event of
Never inspect or service unit without first
an unexpected shutdown when the service
disconnecting battery cable(s) to prevent
valve is open.
accidental starting.
Do not remove the pressure cap from a HOT
Hazardous Substance Precaution
radiator. Allow radiator to cool down before
removing pressure cap. The following substances are used in the
Do not use petroleum products (solvents or manufacture of this machine and may be
fuels) under high pressure as this can hazardous to health if used incorrectly.
penetrate the skin and result in serious Precaution: Avoid ingestion, skin contact
illness. and breathing fumes for the following
substances: Antifreeze, Compressor Oil,
Wear eye protection while cleaning unit with Engine Lubricating Oil, Preservative Grease,
compressed air to prevent debris from Rust Preventative, Diesel Fuel and Battery
injuring eye(s). Electrolyte.
Book 22320717 (8/03) 11

The following substances may be produced

during the operation of this machine and may
be hazardous to health: Avoid build-up of
Engine Exhaust Fumes in confined spaces.
Avoid breathing Exhaust Fumes.
Avoid breathing Brake Lining Dust during
maintenance.
12 Book 22320717 (8/03)

SAFETY LABELS
Look for these signs on machines shipped to markets in North America, which point
out potential hazards to the safety of you and others. Read and understand thoroughly.
Heed warnings and follow instructions. If you do not understand, inform you
supervisor.
! DANGER Indicates the presence of a hazard which WILL cause serious

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

WARNING injury, death or property damage, if ignored.
(Orange Background)
! CAUTION Indicates the presence of a hazard which WILL or can cause

injury or property damage, if ignored.
(Yellow Background)
Indicates important set-up, operating or maintenance

NOTICE information.
(Blue Background)
DANGER WARNIN
Trapped air pressure.
Can cause serious
injury or death.
Close service valve and
operate tool to vent
trapped air before
Discharged air can contain carbon performing any service.
monoxide or other contaminants.
Will cause serious injury or death.
Do not breathe this air.
WARNIN
WARNING
High pressure air.
Hot pressurized fluid. Can cause serious
Can cause serious injury or death.
burns
Book 22320717 (8/03) 13

105
km/h
WARNING WARNING
Improper operation of this equipment. Collapsing jackstand.
Can cause serious injury or death.
Can cause serious injury.
Read Operator’s Manual supplied with
this machine before operation or Insert locking pin completely.
servicing.
Modification or alteration of this machine. Excessive towing speed.
Can cause serious injury or death. Can cause serious injury
Do not alter or modify this machine or death.
without the express written consent of
the manufacturer. Do NOT exceed 65 mph
(105 km/hr.)
WARNING WARNING
Falling off machine.
Rotating fan blade.
Can cause serious Can cause serious injury
injury. or death.
Do not operate without

guard in place.
Access lifting bail from
inside machine.
WARNING WARNING
Disconnected air hoses whip.
Door under pressure.
Can cause serious
Can cause serious injury. injury or death.
When using air tools
Use both hands to open door attach safety device
when machine is running. (OSHA Valve) at source of
WARNING air supply for each tool.
CAUTION WARNING
DO NOT WELD
14 Book 22320717 (8/03)

WARNING
USE DIESEL High pressure air.
Can cause serious
injury or death.
FUEL ONLY Relieve pressure before

removing filler plugs/caps,
fittings or covers.
FREE SAFETY DECALS!

To promote communication of Safety Warnings on
products manufactured by the Portable Compressor
Division in Mocksville, N.C., Safety Decals are available
free of charge. Safety decals are identified by the decal
heading: DANGER, WARNING or CAUTION.
Decal part numbers are on the bottom of each decal and

are also listed in the compressor’s parts manual. Submit
orders for Safety Decals to the Mocksville Parts Service
Department. The no charge order should contain only
Safety Decals. Help promote product safety! Assure that
decals are present on the machines. Replace decals that
are not readable.
Book 22320717 (8/03) 15

16 Book 22320717 (8/03)

Section 2 - Warranty
Book 22320717 (8/03) 17

Operating & Maintenance Manual Warranty
Warranty
Ingersoll-Rand, through its distributors, warrants to the initial user that each portable air
compressor manufactured by it, will be free of defects in material and workmanship for a
period of the earlier of twelve (12) months from shipment to or the accumulation of 2,000 hours
of service by the initial user.
Portable compressor airends will be free of defects in material and workmanship for a period
of the earlier of twenty four months from shipment to or the accumulation of 4,000 hours of
service by the initial user. The warranty against defects will include replacement of the
complete airend, provided the original airend is returned assembled and unopened.
Portable Compressor Airend Limited Optional Warranty - The earlier of sixty (60) months from
shipment to or the accumulation of 10,000 hours of service. The optional warranty is limited
to defects in rotors, housings, bearings and gears and provided all the following conditions are
met:
1. The original air end is returned assembled and unopened.
2. Continued use of genuine Ingersoll-Rand parts, fluids, oil and filters.
3. Maintenance is performed at prescribed intervals.

Oil-Free airends are fee-based and may require a maintenance agreement. Formal
enrollment is required.
Ingersoll-Rand will provide a new part or repaired part, at its election, in place of any part,
which is found upon its inspection to be defective in material and workmanship during the
period prescribed above. Such part will be repaired or replaced without charge to the initial
user during normal working hours at the place of business of an Ingersoll-Rand distributor
authorized to sell the type of equipment involved or other establishment authorized by
Ingersoll-Rand. User must present proof of purchase at the time of exercising warranty.
The above warranty does not apply to failures occurring as a result of abuse; misuse, negligent
repairs, corrosion, erosion and normal wear and tear, alterations or modifications made to the
product without express written consent of Ingersoll-Rand; or failure to follow the
recommended operating practices and maintenance procedures as provided in the product's
operating and maintenance publications.
Accessories or equipment furnished by Ingersoll-Rand, but manufactured by others, including,
but not limited to, engines, shall carry whatever warranty the manufacturers have conveyed to
Ingersoll-Rand and which can be passed on to the initial user.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED,
(EXCEPT THAT OF TITLE),AND THERE ARE NO WARRANTIES OF MERCHANTABILITY
OR OF FITNESS FOR A PARTICULAR PURPOSE.
18 Book 22320717 (8/03)

Warranty Operating & Maintenance Manual
General Warranty Information
GENERAL WARRANTY Extended Coverage

Portable Compressor Package 1 year/2000 hours
Airend 2 years/4000 hours 5 years/10,000 hours Limited warranty, major
components (refer to operator’s manual).
Portable Genset 8KW, 11KW, Package 1 year/2000 hours None

20KVA thru 575KVA
Generator 2 years/4000 hours None
Portable Genset 3.5KW thru 7.0KW Package 1 year/2000 hours PARTS None
and 10KW ONLY
Generator 1 year/2000 hours PARTS None
ONLY
Light Tower Package 1 year/2000 hours

Generator 1 years/4000 hours 2 years/4000 hours, for Lightsource
introduced 8/16/99.
ENGINES
Caterpillar Months Hours Extended Coverage
12 No Limit Available at dealer
Cummins 24 2000 Major components 3 yrs/10,000 hours - available at dealer
John Deere (IN COMPRESSORS) 24 2000 5 yrs/5000 hours using OEM fluids & filters with $250 deductible.
(IN GENERATORS AS OF 1/1/01) 24 2000 2 yrs/4000 hours using IR fluids & filters
Deutz 24 2000 Available at dealer
Ingersoll-Rand 24 4000 5 years/10,000 hours when using genuine Ingersoll-Rand fluids
and parts. Refer to operator’s manual.
Kubota (North America Only) 24 2000 Major components 36 months/3000 hrs - parts only
(Western Europe & Oceania) 24 2000 None
(Central & South America, Asia, 12 1000 None
Middle East & Africa)
Mitsubishi 24 2000 2 years/4000 hours using IR fluids and filters
Volvo 24 2000 2 years/4000 hours using IR fluids and filters
Honda 12 unlimited None
Vanguard 24 unlimited None
PARTS
Ingersoll-Rand Months Hours Coverage
6 No Limit Parts Only
AIREND EXCHANGE
Airend Months Hours Extended Coverage
12 2000 hours 2 years/4000 hours - available from IR.
NOTE: Actual warranty times may change. Consult the manufacturer’s

warranty policy as shipped with each new product.
Book 22320717 (8/03) 19

WARRANTY REGISTRATION
Complete Machine Registration
Machines shipped to locations within the United States do not require a warranty registration
unless the machine status changes (i.e. change of ownership).
Machines shipped outside the United States require notification be made to initiate the
machine warranty.
Fill out the Warranty Registration Form in this section, keep a copy for your records and
mail form to:
Ingersoll-Rand Company
Portable Compressor Division
P.O. Box 868
Mocksville, North Carolina 27028
Attn: Warranty Department
NOTE: Completion of this form validates the warranty.
20 Book 22320717 (8/03)

Warranty Operating & Maintenance Manual
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 Asphalt Contractor Coal Mining Other Mining

(highway, excavation, etc.)
Construction-Light Government Quarry Shallow Oil & Gas
(carpentry, plumbing, (municipal, state,
pools, mason, etc.) county, etc.)
Rental (rental center, Building Contractor Waterwell Utility Company
rental fleet, etc.)
Industrial (plant use) Other specify Exploration Utility Contractor
Model Unit S/N Engine S/N Date Delivered
Model Unit S/N Engine S/N Date Delivered
SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT
1. The Purchaser has been instructed and/or has read the manual and understands
proper preventative maintenance, general operation and safety precautions.
2. The warranty and limitation 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 such use so that Ingersoll-Rand may arrange for appropriate
nuclear liability protection from the owner-licensee of the facility.
4. Ingersoll-Rand reserves the right to make design changes or modifications of Ingersoll-
Rand products at anytime without incurring any obligation to make similar changes or
modifications on previously sold units.
Book 22320717 (8/03) 21

22 Book 22320717 (8/03)

Section 3 - Noise Emission
Book 22320717 (8/03) 23

Operating & Maintenance Manual Noise Emission
Noise Emission
This section pertains only to machines distributed within the United

States.
! WARNING
Tampering with Noise Control System Prohibited
Federal law prohibits the following acts or the causing thereof:

1. The removal or rendering inoperative by any persons, other than for purposes
of maintenance, repair, or replacement, of any device or element of design
incorporated into any new compressor for the purpose of noise control prior to
its sale or delivery to the ultimate purchaser or while it is in use; or
2. the use of the compressor after such device or element of design has been
removed or rendered inoperative by any person.
Among those acts included in the prohibition against tampering are these:
3. Removal or rendering inoperative any of the following:
a.the engine exhaust system or parts thereof
b.the air intake system or parts thereof
c.enclosure or parts thereof
4. Removal of any of the following:
a.fan shroud
b.vibration mounts
c.sound absorption material
5. Operation of the compressor with any of the enclosure doors open.
Compressor Noise Emission Control Information

A. The removal or rendering inoperative, other than for the purpose of
maintenance, repair, or replacement of any noise control device or element of
design incorporated into this compressor in compliance with noise control act;
B. The use of this compressor after such device or element of design has been
removed or rendered inoperative.
NOTE: The above information applies only to units that are built in
compliance with the U.S. Environmental Protection Agency.
Ingersoll-Rand Company reserves the right to make changes or add improvements without
notice and without incurring any obligation to make such changes or add such improvements
to products sold previously.
The Purchaser is urged to include the above provisions in any agreement for any resale of this
compressor.
24 Book 22320717 (8/03)

Noise Emission Operating & Maintenance Manual
Noise Emission Control Maintenance Log
COMPRESSOR MODEL __________________________

SERIAL NO. ___________________________________
USER UNIT NO. ________________________________
UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM

WHOM PURCHASED:
Engine Make & Model: ________________ __________________________________
Serial No.: _________________________ __________________________________
Purchaser or Owner: _________________ __________________________________
Address: __________________________ Date Purchased: ____________________
The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control
system of any compressor manufactured and sold under the above regulations, specifically
the following acts or the causing thereof:
(1) the removal or rendering inoperative by any persons, other than for purposes of
maintenance, repair, or replacement, of any device or element of design incorporated into new
compressor for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use; or (2) the use of the compressor after such device or element
of design has been removed or rendered inoperative by any person.
Noise Emission Warranty

The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this
air compressor was designed, built and equipped to conform at the time of sale to the first retail
purchaser, with all applicable U.S. EPA Noise Control Regulations.
This warranty is not limited to any particular part, component, or system of the air compressor.
Defects in the design, assembly or in any part, component, or system of the compressor
which, at the time of sale to the first retail purchaser, caused noise emissions to exceed
Federal Standards are covered by this warranty for the life of the air compressor.
Introduction
The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for
Noise Emissions, applicable to Portable Air Compressors.
The purpose of this book is to provide (1) the Maintenance Performance Schedule for all
required noise emission controls and (2) space so that the purchaser or owner can record what
maintenance was done, by whom, where and when. The Maintenance Schedule and detailed
instructions on the maintenance items are given on following page.
Book 22320717 (8/03) 25

deformed, such that their noise containment

Maintenance Schedule function is reduced, should be repaired or
replaced before the next operation interval.
Item Area Period Doors, access panels, and hatch closures
A. Compressed Air Leaks As Detected especially, should be checked and adjusted
B. Safety and Control Systems As Detected
at this time to insure continuous seating
C. Acoustic Materials Daily
D. Fasteners 100 hours between gasket or acoustic material and the
E. Enclosure Panels 100 hours mating frame.
F. Air Intake & Engine Exhaust 100 hours
G. Cooling Systems 250 hours
H. Isolation Mounts 250 hours
F. Air Intake and Engine Exhaust
I. Engine Operation See Operator’s Manual Engine and compressor air intake and
J. Fuels & Lubricants See Operator’s Manual
engine exhaust systems should be inspected
after each 100 hours of operation for loose,
A. Compressed Air Leaks damaged, or deteriorated components.
Correct all compressed air leaks during the Repairs or replacements should be made
first shutdown period after discovery. If before the next period of use.
severe enough to cause serious noise
problems and efficiency loss, shut down G. Cooling Systems
immediately and correct the leak(s).
All components of the cooling system for
engine water and compressor oil should be
B. Safety and Control Systems inspected every 250 hours of use. Any
Repair or replace all safety and control discrepancies found should be corrected
systems or circuits as malfunction occurs. No before placing the unit back in operation.
compressor should be operated with either Unrestricted airflow over the radiator and oil
system bypassed, disabled, or cooler must be maintained at all times during
nonfunctional. operation.
C. Acoustic Materials H. Isolation Mounts

In daily inspections, observe these materials. Engine/airend isolation mounts should be
Maintain all acoustic material as nearly as inspected after each 250 hours of operation.
possible in its original condition. Repair or Those mounts with cracks or splits in the
replace all sections that have: 1) sustained molded rubber, or with bent or broken bolts
damage, 2) have partially separated from due to operation or storage in severe
panels to which they were attached, 3) are environments, all should be replaced with
missing, or have otherwise deteriorated due equivalent parts.
to severe operating or storage conditions.
I. Engine Operation
D. Fasteners Inspect and maintain engine condition and
All fasteners such as hinges, nuts, bolts, operation as recommended in the manuals
clamps, screws, rivets, and latches should be supplied by the engine manufacturer.
inspected for looseness after each 100 hours
of operation. They should be retightened, J. Fuels and Lubricants
repaired, or if missing, replaced immediately
Use only the types and grades of fuels and
to prevent subsequent damage and noise
lubricants recommended in the Ingersoll-
emission increase.
Rand Company and Engine Manufacturer’s
Operator and Maintenance Manuals.
E. Enclosure Panels
Enclosure panels should also be inspected at
100 hour operational intervals. All panels that
are warped, punctured, torn, or otherwise
26 Book 22320717 (8/03)

Noise Emission Operating & Maintenance Manual
Maintenance Record For Noise Emission Control And Extended Warranty

Item Hourmeter Maint/inspect Location Work Done
Description Of Work
No. Reading Date City/state By (Name)
Book 22320717 (8/03) 27

28 Book 22320717 (8/03)

Section 4 - General Data
Book 22320717 (8/03) 29

Operating & Maintenance Manual General Data
General Data
Model:
P250WJDU
Rated Delivery:
CFM - (litres/sec/) 250(118)
Engine:
Full - RPM *Constant 2300

Idle - RPM 1700
Engine Model 4045D
COMPRESSOR
Rated Operating Pressure ........................................100 psi (7.03 kgf per cm2) (700kPa)
Safety Valve Setting..................................................150 psi (10.5 kgf per cm2) (1030 kPa)
ENGINE (DIESEL)
Manufacturer.............................................................John Deere
Electrical System .....................................................12 Volt
FLUID CAPACITIES
Compressor Lubricant...............................................12 quarts (11.4 litres)
Engine Crankcase Lubricant (including filters)..........9 quarts (8.5 litres)
Engine Coolant Capacity ..........................................14.4 quarts (13.6 litres)
Fuel Tank (Diesel).....................................................28 U.S gal. (106 litres)
30 Book 22320717 (8/03)

General Data Operating & Maintenance Manual
UNITS MEASUREMENTS WEIGHTS . . . . . . . . . . . . . . .

Overall Length...........................................................85.3 (2165)
Overall Height ...........................................................52.3 (1327)
Overall Width ...........................................................33.3 (845)
Net Weight (less fuel) ...............................................2265 (1027)

Gross Weight (all fluids) ...........................................2460 (1116)
EXPENDABLE SERVICE PARTS

Compressor Oil FIlter Element..................................Part No. 36897353
Compressor Oil Separator Element ..........................Part No. 39831888
Air Filter Element .....................................................Part No. 36876423 & 54415377
Engine Oil Filter Element ..........................................Part No. 36881696
Engine Fuel Filter Element .......................................Part No. 36534659
! WARNING
Modification or alteration of this machine. Can result in severe injury or
death. Do not modify or alter without the express written consent of
Ingersoll-Rand Co.
Book 22320717 (8/03) 31

Operating & Maintenance Manual General Data
32 Book 22320717 (8/03)

Section 5 - Operation
Book 22320717 (8/03) 33

Operating & Maintenance Manual Operation
Operation
Control Panel 10. Compressor Discharge Pressure

Gauge - Indicates pressure in
receiver tank, psi (kPa).
11. Fuel Level Gauge - Indicates
amount of fuel in tank.
Controls (Standard)
12. Power Switch - Flip “ON” to activate

systems prior to Starting. Flip “OFF”
to stop engine.
Controls (Optional)
13. Tachometer - Indicates engine

speed.
14. Discharge Air Temp. Gauge -
Diagnostics/auto Shutdown
Indicates in °F and °C. Normal
(Optional)
operating range: 185°F/85°C to
248°F/120°C.
1. High Engine Temperature - Coolant
above 220°F (104°C) or more. 15. Engine Oil Pressure Gauge -
Indicates engine oil pressure.
2. Low Engine Oil Pressure - 12 psi or
less 16. Engine Water Temp. Gauge -
Indicates coolant temperature, with
3. High Compressor Temperature-
normal operating range from 180°F
248°F (120°C).
(82°C) to 210°F (99°C).
4. Air Filters Restricted - Needs
17. Voltmeter - Indicates battery
Servicing.
condition.
5. Spare
18. Ether Inject Button - Injects a
6. Spare measured shot. USE SPARINGLY.
19. Service Air Button - After warm-up,
Diagnostics/auto Shutdown PUSH. Provides full air pressure at
(Standard) the service outlet. Indicates engine
speed.
7. Alternator Not Charging - Needs
20. Spare
attention
21. Spare
8. Low Fuel Level - Must add fuel to
operate.
9. Hourmeter - Records running time
for maintenance.
34 Book 22320717 (8/03)

Operation Operating & Maintenance Manual
Utility Package Set-up (no running gear)
Installation
The unit must be secured while operating or transporting. See Figure X for mounting holes
provided in base. The compressor should be isolated by use of a flexible mounting system.
The air going into the inlet grilles must be relatively free of oil, dirt, soot and other debris. It
must be no more than 10 degrees F. (5 degrees C) over the ambient temperature.
The inlet and outlet grilles must not be restricted. See Figure Y for recommended clearance
around the compressor. The cross-sectional area of any ductwork must be larger by a
minimum of 10 percent.
The addition of any power-absorbing components (hydraulic pumps, paint mixers, etc.) must
be approved by Ingersoll-Rand to maintain the warranty. Units with the optional engine-
mounted auxiliary drive are approved for hydraulic pumps up to 15 HP.
! CAUTION
Units with the optional engine mounted auxiliary drive and/or 4.5 kw
generator can potentially overload the engine if the combination of air,
hydraulic power and electrical power exceeds the Horsepower capability
of the engine. This can lead to damage to the engine. Refer to Figure Z for
the maximum HP available for the auxiliary drive.
High loading/continuous operation requires engine oil changes at 1/2 normal interval.
Book 22320717 (8/03) 35

36 Book 22320717 (8/03)

Setting - Up (All Units) ! WARNING

• Position as level as possible. The design
of these units permits a 15 degree NO SMOKING, SPARKS or OPEN
sidewise limit on out-of-level operation. FLAME near fuel.
• When the unit is to be operated out-of-

level, it is important:
! CAUTION
1. To keep the engine crankcase oil level
near the high level mark (with the unit Do not connect the air discharge on
level). this unit into a common header with
any other unit of any description, or
2. To have the compressor oil level gauge
any other source of compressed air,
show no more than mid-scale. Do not
without first making sure a check
overfill either the engine crankcase or
valve is used between the header and
the compressor lubricating oil system.
the unit. If this unit is connected with
3. The side doors must be closed to another unit, a safety hazard could
maintain a cooling air path and to avoid occur.
recirculation hot air.
Compressor Oil Level ! WARNING

The oil level should be checked before the
unit is started. Always check the oil level Unrestricted air flow from a hose will
while the unit is level, the engine off, and result in a whipping motion of the
there is zero pressure in the separator tank. hose which can cause severe injury or
The optimum oil level is with the pointer at the death. A safety device must be
top of the green section on the level gage. attached to the hose at the source of
Add oil if the pointer reaches the bottom of supply to reduce pressure in case of
the green section. hose failure or other sudden pressure
release. Reference: OSHA regulation
NOTE: The oil level gage will not read 29 CFR Section 1926.302 (b).
properly while the engine is running.
Before Starting:
• All checks should be made while the unit

is level.
• Open service valve(s) to ensure pressure

is relieved in receiver-separator system.
Close valve(s) in order to build up full air
pressure and ensure proper oil
circulation.
• Check battery for proper connections and

condition.
Book 22320717 (8/03) 37

• Check the engine oil level. Maintain per Starting

marks on dipstick.
Turn the POWER switch to “ON”.
• Check the fuel level. Add only CLEAN
If so equipped, place the “Start-Run” Valve
DIESEL fuel for maximum service from Switch, located in the bottom right hand
the engine.
corner of the instrument panel, to the “Start/
Warm-Up” position.
• Check the compressor lubricating oil
level. The optimum oil level is with the Turn Power switch to “START” position to
pointer at the top of the green section on crank engine. Hold switch in “START”
the level gages. Add oil if the pointer position for approximately 5 seconds after
reaches the bottom of the green section. engine starts.
Do not overfill.
Check the coolant level in the radiator and
overflow bottle. NOTICE
The coolant must cover the tubes in the top
tank (approximately 1 inch high on a clean Do not operate the starter motor for
measuring rod stuck down filler neck). The more than 10 seconds without
coolant in the overflow bottle should be allowing at least 30 seconds cooling
above the “COLD” mark for cold engine time between start attempts.
(<120°F).
A fuel level gauge reading can be obtained Release Power Switch (it will automatically
without starting the unit, by turning the power move to the “ON” position) when the engine
switch to “ON”. Afterwards, turn the switch to starts and sustains running.
“OFF”. Allow engine to warm up 5 to 10 minutes.
Check the fuel level. Use Clean DIESEL fuel If so equipped, place the “Start-Run” Valve
for maximum service from the engine. Switch in the “AIR” position.
Cold Weather Starting:

! WARNING Open manual blowdown valve, if so
equipped, and press ether inject button. Use
This machine produces loud noise Ether sparingly. Close manual blowdown
with doors open. Extended exposure valve after engine is running.
to loud noise can cause hearing loss.
Wear hearing protection when doors If equipped with the optional cold starting aid
or valve (s) are open. (ETHER), operate the valve once or twice
ONLY while the engine is cranking.
• Close all doors to maintain a cooling air
path and to avoid recirculation of hot air.
This will maximize the life of the engine
and compressor and protect the hearing ! CAUTION
of surrounding personnel.
Ether is an extremely volatile, highly
• Be sure no one is IN or ON the flammable gas. Use sparingly! If too
compressor unit. much is injected, the uncontrolled
explosion may result in costly damage
to the engine.
38 Book 22320717 (8/03)

• In “Generator” position, the engine

will maintain idle speed, and the
generator will give a constant voltage
! CAUTION and frequency output, for use with
sensitive equipment like computers,
Exercise extreme caution when using fusion welders, etc. No compressed
a booster battery to start. To jump air is available at the service air
start: Connect the ends of one booster valves in this mode.
cable to the positive (+) terminals of
each battery. Then connect one end of • In “Gen/Air” position, voltage and
the other cable to the negative (-) frequency will vary as engine speed
terminal of the booster battery and the changes to meet air demands, and
other end to the engine block. NOT TO should only be used for lights and hand
THE NEGATIVE (-) TERMINAL OF THE tools.
WEAK BATTERY.
• In “Air” position, the generator provides
no electrical power.
After Starting:
1. Start compressor with the Start-Run
a. Reduce engine speed to IDLE. Switch located in the bottom right corner
b. Disconnect the negative (-) cable from of the instrument panel) in the “Start/
the engine block first, then from the Warm-up” position.
booster battery. 2. Close all service air valves.
c. Disconnect positive (+) cable from both 3. Place the start-run switch in the “Run”
batteries. position.
4. Place the generator control switch in
either “Generator” or “Gen/Air” position.
! CAUTION The red light on the front of the generator
control panel should glow, and the
voltage meter should read 120 Volts AC.
Do not remove pressure cap from a
HOT radiator. Allow radiator to cool 5. Plug electric tools or lights into the
down before removing pressure cap. receptacles on the front of the generator
Use extreme care when removing a control panel.
pressure cap from a liquid cooling
system for the engine. The sudden
Units With Diagnostic Lamps:
release of pressure from a heated
cooling system can result in a loss of In a shutdown situation, the function of the
coolant and possible severe personal panel lamps is to indicate what specific
injury. failure caused the unit to shut down.These
lamps will remain illuminated until the Power
Operation Of Optional Generator Switch is turned “OFF”.
This unit will operate in three modes,

depending on the position of the generator
control switch (located on the front of the
generator control panel).
Book 22320717 (8/03) 39

fluid level. Other possible causes are listed

on the Trouble Shooting Chart.
Units With Optional Diagnostics
Lamps All units in this family of machines are
protected by sensors or switches at the
following locations:
NOTICE 1. Low engine oil pressure, in the engine.

2. High engine coolant temperature, in the
None of the panel lamps should be engine.
glowing when machine is operating. If
they are, shut unit down and refer to High Discharge AIR Temperature
Trouble Shooting Section.
3. At the airend outlet.
Stopping 4. In separator tank.
Close air service valve.
Allow the unit to run at idle for 3 to 5 minutes
to reduce the engine temperatures. NOTICE
Turn Power Switch to “OFF” position.
Do NOT wire around or bypass a
When the engine stops, automatic blowdown shutdown sensor or switch.
valve should relieve system air pressure. If
automatic blow-down valve malfunction is
suspected, open manual blowdown valve.
Never allow unit to sit under pressure when
! DANGER
engine is not running.
Even after pressure is relieved from
the receiver-separator system, any air
supply line from the compressor to a
! WARNING tool or a machine could remain under
pressure and cause very serious
personal injury or death. After the
Since the service valve is closed, air
downstream of the valve may be compressor stops, carefully open a
valve at any tool or machine to
trapped. A vent hole in the service
exhaust the pressure in any line prior
valve will slowly bleed air from the
hose. Do not disconnect hoses until to removal or servicing.
all pressure has been vented.
Automatic Shutdown
This unit is protected with sensors (switches)
for high discharge air temperature, high
engine coolant temperature and low engine
oil pressure.
Should any of three situations occur, the unit
will stop. Before restarting the unit, check
these three areas for excessive heat and
40 Book 22320717 (8/03)

P250 Speed and Pressure Regulator Adjusting Instructions
The engine idle and full speed settings are After Starting Unit
set and sealed at the factory, and should not
be adjusted. Serious injury may result if the 5. Allow unit to warm up at an engine speed
full speed is increased. Removal of the seals greater than IDLE speed (*) for at least
without authorization could affect the five minutes. Do this by loosening jam nut
warranty. If speed settings are lost due to (H) on the IDLE screw (L). Turn the IDLE
engine fuel pump service or other repairs, the screw until the speed is properly set (*).
speed settings can be reset as follows:
6. If equipped, place the Start-Run Valve
Switch to the “AIR” position. The unit
Before Starting should speed up and then unload (and
drop back to IDLE). With the unit
1. At the Pressure Regulator (on service unloaded, turn the adjusting screw on the
pipe near receiver tank), remove the pressure regulator clockwise until the
cover to expose the adjusting screw. discharge pressure gauge indicates 125-
Loosen the jam nut and turn screw 130 psi. Tighten the pressure regulator
counterclockwise until tension is no jam nut. Replace cover.
longer felt at the screw. Then, turn screw
7. Open the service valve and adjust the
clockwise one full turn.
discharge pressure to 100 psi (700 kPa).
2. Close service valve(s). Now turn adjusting rod (C) until the
proper engine FULL speed setting (*) is
3. At air cylinder (A), loosen jam nut (B) on
reached.
adjusting rod (C). Turn rod (C) until it just
touches the piston inside of the cylinder. 8. If necessary, loosen jam nut (J) on FULL
This is determined by the movement of speed screw (K) and turn screw until it
the air cylinder piston rod (D). Rod (D) hits a stop. Recheck the FULL speed
should be fully retracted and just begin to setting and reset if required. Tighten jam
extend when the adjusting rod (C) is nuts (J) and (H).
properly set.
9. Close the service valve and recheck
4. Lock jam nut (B). IDLE speed (*). If necessary, adjust
Book 22320717 (8/03) 41

speed using screw (L). Tighten jam nut

(H).
10. To obtain maximum cfm at any pressure
between 80 psi (550 kPa) and maximum
pressure rating (*), make adjustment at
the pressure regulator to obtain desired
discharge pressure at FULL engine
speed. Lock adjusting screw and replace
cover.
* See General Data Specifications.
42 Book 22320717 (8/03)

Section 6 - Maintenance
Book 22320717 (8/03) 43

Operating & Maintenance Manual Maintenance
Maintenance
for repair. Preventive maintenance is the
easiest and the least expensive type of
! CAUTION maintenance. Maintaining your unit and
keeping it clean at all times will facilitate
Any unauthorized modification or servicing.
failure to maintain this equipment may
make it unsafe and out of factory
warranty. Scheduled Maintenance
The maintenance schedule is based on
If performing more than visual
normal operation of the unit. This page can
inspections, disconnect battery
be reproduced and used as a checklist by the
cables and open manual blowdown
service personnel. In the event unusual
valve.
environmental operating conditions exist, the
schedule should be adjusted accordingly.
Use extreme care to avoid contacting
hot surfaces (engine exhaust manifold
and piping, air receiver and air Compressor Oil Level
discharge piping, etc.).
The oil level should be checked before the
Never operate this machine with any unit is started. Always check the oil level
guards removed. while the unit is level, the engine off, and
there is zero pressure in the separator tank.
Inch and metric hardware was used in The optimum oil level is with the pointer at the
the design and assembly of this unit. top of the green section on the level gage.
Consult the parts manual for Add oil if the pointer reaches the bottom of
clarification of usage. green section.
NOTE: The oil level gage
NOTICE will not read properly while

the engine is running.
Disregard any maintenance pertaining

to components not provided on your
machine.
General
In addition to periodic inspections, many of
the components in these units require
periodic servicing to provide maximum
output and performance. Servicing may
consist of pre-operation and post-operation
procedures to be performed by the operating
or maintenance personnel. The primary
function of preventive maintenance is to
prevent failure, and consequently, the need
44 Book 22320717 (8/03)

Maintenance Operating & Maintenance Manual
Air Cleaner the element must be thoroughly dry. Direct

compressed air through the element in the
If this unit is equipped with the Optional direction opposite to the normal air flow
Diagnostic Panel, it has an AIR FILTERS through the element.
RESTRICTED lamp on the instrument panel,
Move the nozzle up and down while rotating
covering both the engine and the
the element. Be sure to keep the nozzle at
compressor.
least one inch (25.4 mm) from the pleated
This should be checked daily during paper.
operation. If the lamp glows (red) with the
unit operating at full speed, servicing of the NOTE: To prevent damage
cleaner element is necessary. to the element, never
Also weekly squeeze the rubber valve exceed a maximum air
(precleaner dirt dump) on each air cleaner pressure of 100 psi (700
housing to ensure that they are not clogged. kPa).
The air filters restricted sensor will In the event the element is contaminated with
automatically reset after the main power dry dirt, oil or greasy dirt deposits, and a new
switch is turned to “OFF.” element is not available, cleaning can be
To service the air cleaners on all units accomplished by washing, using the air
proceed as follows: cleaner element manufacturer’s
recommendations.
1. Loosen outer wing nut and remove with
cover. Remove Element.
NOTE: It is recommended
2. Inspect air cleaner housing for any that replacement elements
condition that might cause a leak and be installed in the unit. The
correct as necessary. elements just removed for
cleaning can be washed
3. Wipe inside of air cleaner housing with a
and stored as future
clean, damp cloth to remove any dirt
replacement elements.
accumulation, especially in the area
where the element seals against the
In addition, the air cleaner system (housing
housing.
and piping) should be inspected every month
4. Inspect element by placing a bright light for any leakage paths or inlet obstructions.
inside and rotating slowly. If any holes or Make sure the air cleaner mounting bolts and
tears are found in the paper, discard this clamps are tight. Check the air cleaner
element. If no ruptures are found, the housing for dents or damage which could
element can be cleaned. lead to a leak. Inspect the air transfer tubing
5. If a new air filter element is to be used from the air cleaner to the compressor and
check it closely for shipping damage. the engine for leaks.
Make sure that all clamps and flange joints
6. Install cleaned or new elements in the
are tight.
reverse order to the above. Tighten wing
nut firmly.
7. Inspect to ensure that end cap seals Gauges
tightly 360° around air cleaner body.
The instruments or gauges are essential for
In the event that the filter element must be safety, maximum productivity and long
reused immediately, compressed air service life of the machine. Inspect the
cleaning (as follows) is recommended since gauges and test any diagnostic lamps prior to
Book 22320717 (8/03) 45

start-up. During operation observe the engine cooling system hoses and all of the
gauges and any lamps for proper functioning. flexible hoses used for air, oil, and fuel be
Refer to Operating Controls, for the normal inspected.
readings. To ensure freedom from air leaks, all rubber
hose joints and the screw-type hose clamps
must be absolutely tight. Regular inspection
Fuel Tank
of these connections for wear or deterioration
CLEAN fuel in the fuel tanks is vitally is necessary.
important and every precaution should be Premature wear of both the engine and
taken to ensure that only clean fuel is poured compressor is ASSURED whenever dust-
or pumped into the tank. laden air is permitted to enter the engine’s
When filling the fuel tank on this unit, by combustion chamber or compressor intake.
methods other than a pump and hose, use a The flexible hoses used in the fuel, oil and air
CLEAN non-metallic funnel. lines on these units are primarily used for
their ability to accommodate relative
movement between components. It is
Battery important they be periodically inspected for
wear and deterioration. It is also important
Keep the battery posts-to-cable connections the operator does not use the hoses as
clean, tight and lightly coated with a grease. convenient hand hold or steps. Such use can
Also the electrolyte level in each cell should cause early cover wear and hose failure.
cover the top of the plates. If necessary, top-
up with clean distilled water.
Fasteners
NOTICE
Visually check entire unit in regard to bolts, Piping systems operating at less than
nuts and screws being properly secured. 150 psi (1050 kPa) may use a special
Spot check several capscrews and nuts for nylon tubing. The associated fittings
proper torque. If any are found loose, a more are also of a special “push-in” design.
thorough inspection must be made. Take If so, features are as follows:
corrective action.
Pulling on the tubing will cause the inner
sleeve to withdraw and compress, thus
Radiator tightening the connection. The tubing can be
withdrawn only while holding the sleeve
against the fitting. The tubing can be
removed and replaced numerous times
NOTICE without losing its sealing ability.
To install the nylon tubing, make a mark (with
The use of water alone in this engine tape or grease pencil) approximately 7/8 inch
can result in major engine failure. from the end of the tubing. Insert the tubing
into the sleeve and “push-in” past the first
resistance to the bottom. The mark should be
Hoses approximately 1/16 inch from the sleeve, for
the 3/8 inch O.D. tubing; 1/8 inch for the 0.25
Each month it is recommended that all of the
inch O.D. tubing. This will ensure that tubing
intake lines to and from the air cleaners, the
is fully engaged in the sealing mechanism.
46 Book 22320717 (8/03)

NOTICE NOTICE
The oil filter must be replaced every Installing a new oil filter element when
500 hours of operation or three (3) the old gasket remains on the filter
months, whichever comes first. On head, will cause an oil leak and can
new or overhauled units, replace the cause property damage
element after the first 50 and 150
hours of operation; thereafter, service 1. Lubricate the new filter gasket with the
the oil filter every 500 hours. same oil being used in the machine.
2. Install new filter by turning the element
To service oil filters it will first be necessary
clockwise until gasket makes initial
to shut the unit down. Wipe off any external
contact. Tighten an additional 1/2 to 3/4
dirt and oil from the exterior of the filter to
turn.
minimize any contamination from entering
the lubrication system. Proceed as follows: 3. Start unit and allow to build up to rated
pressure. Check for leaks before placing
unit back into service.
! WARNING Compressor Oil Cooler

High pressure air can cause severe The compressor lubricating and cooling oil is
injury or death from hot oil and flying cooled by means of the fin and tube-type oil
parts. Always relieve pressure before cooler, located beside the radiator. The
removing caps, plugs, covers or other lubricating and cooling oil, flowing internally
parts from pressurized air system. through the core section, is cooled by the air
1. Open the service air valve(s) to ensure stream from the cooling fan flowing past the
that system is relieved of all pressure. core section. When grease, oil and dirt
Close the valve(s). accumulate on the exterior surfaces of the oil
cooler, its efficiency is impaired.
2. Turn the spin-on filter element
counterclockwise to remove it from the Each month it is recommended that the oil
filter housing. Inspect the filter. cooler be cleaned by directing compressed
air which contains a nonflammable, non-
caustic safety solvent through the core of the
oil cooler. This should remove the
NOTICE accumulation of grease, oil and dirt from the
exterior surfaces of the oil cooler core so that
Piping systems operating at less than the entire cooling area can transmit the heat
150 psi (1050 kPa) may use a special of the lubricating and cooling oil to air stream.
nylon tubing. The associated fittings In the event foreign deposits, such as sludge
are also of a special “push-in” design. and lacquer, accumulate in the oil cooler to
If so, features are as follows: the extent that its cooling efficiency is
impaired, a resulting high discharge air
3. Inspect the oil filter head to be sure the temperature is likely to occur, causing shut
gasket was removed with the oil filter down of the unit. To correct this situation it
element. Clean the gasket seal area on will be necessary to clean it using a cleaning
the oil filter head. compound in accordance with the
manufacturer’s recommendations.
Book 22320717 (8/03) 47

Compressor Oil • Ensure the tank pressure is zero.

• Disconnect the hose from scavenge tube.
The lubricating and cooling oil must be
replaced every 500 hours of operation or six • Remove scavenge tube from tank cover.
(6) months, whichever comes first.
• Disconnect service line from cover.
• Remove cover mounting screws.
Receiver-separator Systems
• Remove cover and element.
• Remove any gasket material left on cover
or tank.
! WARNING • Install new element.
High pressure air can cause severe

injury or death from hot oil and flying
parts. Always relieve pressure before
removing caps, plugs, covers or other
NOTICE
parts from pressurized air system. Do not remove staples from the
element/gasket connection.
• Open service valve at end of machine.
• Ensure pressure is relieved, with BOTH: • Place a straightedge across top of element
and measure from bottom of straightedge
— Discharge air pressure gauge reads to bottom of element (See Fig. 4.1).
zero (0).
• Replace scavenge tube in cover (cover is
— No air discharging from service valve. still off of tank).
When draining oil, remove plug from the • Measure from bottom of cover to end of
separator tank drain fitting. scavenge tube. Measurement should be
When adding oil, remove and replace (make from 1/8” to 1/4” less than the element
tight) plug on side of separator tank. measurement. If not, cut to size.
In the compressor lubricating and cooling • Remove scavenge tube.
system, separation of the oil from the • Reposition cover (use care not to damage
compressed air takes place in the receiver- gaskets).
separator tank. As the compressed air enters
the tank, the change in velocity and direction • Replace cover mounting screws: tighten in
drop out most of the oil from the air. a crisscross pattern.
Additional separation takes place in the oil • Reconnect service line. Replace scavenge
separator element which is located in the top tube. Reconnect hose.
of the tank. • Close service valve. Start unit and look for
Any oil accumulation in this separator leaks.
element is continuously drained off by means
When replacing the element, the scavenge
of a scavenge tube which returns the
lines, orifice, filter, and check valve should be
accumulated oil to the system.
thoroughly cleaned and the oil changed.
The life of the oil separator element is
dependent upon the operating environment
(soot, dust, etc.) and should be replaced
every twelve months or 2000 hours. To
replace the element proceed as follows:
48 Book 22320717 (8/03)

cut line
if necessary
Scavenge Line 3. Assure minimum pressure valve/orifice is

operational.
4. Run unit at rated operating pressure for
! WARNING 30 to 40 minutes to permit element to
clear itself.

injury or death from hot oil and flying Exterior Finish Care
removing caps, plugs, covers or other This unit was painted and heat cured at the
parts from pressurized air system. factory with a high quality, thermoset
polyester powder coating. The following care
The scavenge line originates at the receiver- will ensure the longest possible life from this
separator tank cover and terminates at the finish.
compressor air-end near the oil filter
1. If necessary to remove dust, pollen, etc.
element. An orifice check valve is located on
the scavenge tube. from housing, wash with water and soap
or dish washing liquid detergent. Do not
Once a year or every 1000 hours of scrub with a rough cloth, pad, etc.
operation, whichever comes first, replace the
separator element and clean the scavenge 2. If grease removal is needed, a fast
orifice/check valve. evaporating alcohol or chlorinated
solvent can be used. Note: This may
NOTE: Excessive oil carry- cause some dulling of the paint finish.
over may be caused by an oil- 3. If the paint has faded or chalked, the use
logged separator element. Do of a commercial grade, non-abrasive car
not replace element without wax may partially restore the color and
first performing the following gloss.
maintenance procedure:
1. Check oil level. Maintain as indicated Field Repair of Texture Paint

earlier in this section.
1. The sheet metal should be washed and
2. Thoroughly clean scavenge line, any clean of foreign material and then
orifice and check valve. thoroughly dried.
Book 22320717 (8/03) 49

2. Clean and remove all grease and wax Tuffcoat Primer using a pressure pot and
from the area to be painted using use about 2-5 pounds of air pressure.
Duponts 3900S Cleaner prior to sanding. This will allow the primer to splatter
causing the textured look.
3. Use 320 grit sanding paper to repair any
scratches or defects necessary.
NOTE: You must be careful
4. Scuff sand the entire area to be painted not to put too much primer
with a red scotch brite pad. on at one time, this will
effect the amount of texture
5. Wipe the area clean using Duponts
that you are trying to
3900S.
achieve. Allow the texture
6. Blow and tack the area to be painted. coat to flash for 20 minutes
or until dry to touch.
7. Apply a smooth coat of Duponts 1854S
Tuffcoat Primer to all bare metal areas
10. Apply any of Duponts Topcoat Finishes
and allow to dry.
such as Imron™ or Centari™ according
8. Apply 2 medium - wet coats of Duponts to the label instructions.
222S Adhesion Promoter over the entire
area to be painted, with a 5 minute flash NOTE: To re-topcoat the
in between coats. textured surfaces when
sheet metal repairs are not
9. To apply the texture coat, use Duponts
necessary, follow steps 1,
1854S Tuffcoat Primer. The proper
2, 4, 5, 6, 8 and 10.
technique to do this is to spray the
50 Book 22320717 (8/03)

MAINTENANCE SCHEDULE
These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty
or wet).
Daily Weekly Monthly 3 MOS. 6 MOS. 6 MOS.

250 hours 550 hours 1000 hours
**Hydraulic Oil Level C
Compressor Oil Level C
Engine Oil Level C
Radiator Coolant Level C
Gauges/Lamps C
Air Cleaner Service Indicators C
Fuel Tank (fill at end of day) C DRAIN
**Fuel/Water Separator DRAIN C
Air Cleaner Precleaner Dumps C
Fan/Alternator Belts C
Battery Connections/Electrolyte C
Hoses (oil, air, intake, etc.) C
Automatic Shutdown System Test C
Air Cleaner System Visual C
Compressor Oil Cooler Exterior C CLEAN
Engine Radiator Exterior C CLEAN
Fasteners, Guards C
Air Cleaner Elements WI
** Fuel/Water Separator Element R
Compressor Oil Filter Element R
Compressor Oil R
Engine Coolant Test C R
Shutdown Switch Settings Test C
Scavenge Orifice & related parts CLEAN
Oil Separator Element R
**Disregard if not appropriate for this particular machine.

R=replace, C=check (adjust if necessary), WI=OR when indicated,
CBT = check before towing.
Book 22320717 (8/03) 51

52 Book 22320717 (8/03)

Section 7 - Lubrication
Book 22320717 (7/04) 53

Operating & Maintenance Manual Lubrication
Lubrication
General Information
Lubrication is an essential part of preventive NOTICE
maintenance, affecting to a great extent the
useful life of the unit. Different lubricants are Some oil types are incompatible when
needed and some components in the unit mixed and result in the formation of
require more frequent lubrication than varnishes, shellacs, or lacquers which
others. Therefore, it is important that the may be insoluble. Such deposits can
instructions regarding types of lubricants and cause serious troubles including
the frequency of their application be explicitly clogging of the filters. Where
followed. Periodic lubrication of the moving possible, do NOT mix oils of different
types and avoid mixing different
parts reduces to a minimum the possibility of
brands. A type or brand change is best
mechanical failures.
made at the time of a complete oil
The Preventive Maintenance Schedule drain and refill.
shows those items requiring regular service
and the interval in which they should be
performed. A regular service program should If the unit has been operated for the time/
be developed to include all items and fluids. hours mentioned above, it should be
These intervals are based on average completely drained of oil. If the unit has been
operating conditions. In the event of operated under adverse conditions, or after
extremely severe (hot, cold, dusty or wet) long periods in storage, an earlier change
operating conditions, more frequent period may be necessary as oil deteriorates
lubrication than specified may be necessary. with time as well as by operating conditions.
Details concerning lubrication of the running
gear are in Maintenance Section. All filters
and filter elements for air and compressor ! WARNING
lubricant must be obtained through Ingersoll-
Rand to assure the proper size and filtration
for the compressor.
injury or death from hot oil and flying
removing caps, plugs, covers or other
Compressor Oil Change
parts from pressurized air system.
These units are normally furnished with an Ensure following conditions are met:
initial supply of oil sufficient to allow operation
of the unit for approximately 6 months or 1000 — Discharge air pressure gauge
reads zero (0).
hours, whichever comes first. If a unit has been
completely drained of all oil, it must be refilled — No air discharging from an “open”
with new oil before it is placed in operation. manual blowdown valve.
Refer to specifications in Lubrication Table. An oil change is good insurance against the
accumulation of dirt, sludge, or oxidized oil
products.
54
Lubrication Operating & Maintenance Manual
the oil. Stop the machine and after

Completely drain the receiver-separator,
approximately 5 minutes, check the oil level.
piping, and oil cooler. If the oil is drained
Make corrections as required. DO NOT
immediately after the unit has been run for
OVERFILL.
some time, most of the sediment will be in
suspension and, therefore, will drain more
readily. However, the fluid will be hot and
care must be taken to avoid contact with the
skin or eyes.
NOTICE
After the unit has been completely drained of Ingersoll-Rand provides compressor
all old oil, close the drain valve. Add oil in the oil specifically formulated for Portable
specified quantity at the filler plug. Tighten Compressors and requires the use of
the filler plug and run the machine to circulate these fluids in order to obtain
extended limited airend warranty.
55
Operating & Maintenance Manual Lubrication
Portable Compressor Fluid

Chart
Refer to these charts for correct compressor
fluid required. Note that the selection of fluid
is dependent on the design operating
pressure of the machine and the ambient
temperature expected to be encountered
before the next oil change.
NOTE: Fluids listed as “preferred” are

required for extended warranty.
Compressor oil carryover (oil

consumption) may be greater with the use
of alternative fluids.
Design
Ambient
Operating Specification
Temperature
Pressure
100 psi to -100F to 1250F Preferred:
300 psi IR Pro•Tec™
(-230C to 520C)
Alternate:
Preferred Ingersoll-Rand Fluids - Use of
ISO Viscosity Grade 46 with rust these fluids with original I-R filters can extend
and oxidation inhibitors, designed airend warranty. Refer to operator’s manual
for air compressor service.
warranty section for details or contact your I-
350 psi (-230C to 520C) Preferred:
IR XHP 605 R representative.
-100F to 1250F
Alternate:
IR XHP405
ISO Viscosity Grade 68 Group 3
or 5 with rust and oxidation
inhibitors designed for air
compressor service.
650F to 1250F Preferred:
(-18°C to 52°C) XHP605
IR XHP1001
Ingersoll-Rand
1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Litre)
Preferred Fluids
Preferred:
IR Pro-Tec™ 36899698 36899706 36899714 36899722
IR XHP605 - 22252076 22252050 22252068
IR XHP1001 - 35612738 35300516 -
XHP405 - 22252126 22252100 22252118
Engine Oil 54480918 36875938 36866903
56
Section 8 - Trouble Shooting
Book 22320717 (8/03) 57

Operating & Maintenance Manual Trouble Shooting
Trouble Shooting
Introduction B. Do The Simplest Things First
Trouble shooting for a portable air Most troubles are simple and easily
compressor is an organized study of a corrected. For example, most complaints are
particular problem or series of problems and “low capacity” which may be caused by too
a planned method of procedure for low an engine speed or “compressor over-
investigation and correction. The trouble heats” which may be caused by low oil level.
shooting chart that follows includes some of
Always check the easiest and most obvious
the problems that an operator may encounter things first; following this simple rule will save
during the operation of a portable
time and trouble.
compressor.
The chart does not attempt to list all of the NOTE: For trouble shooting electrical
troubles that may occur, nor does it attempt problems, refer to the Wiring Diagram
to give all of the answers for correction of the Schematic found in Parts List Section.
problems. The chart does give those
problems that are most apt to occur. To use
C. Double Check Before Disassembly
the trouble shooting chart:
The source of most compressor troubles can
A. Find the “complaint” depicted as a bold be traced not to one component alone, but to
heading. the relationship of one component with
B. Follow down that column to find the another. Too often, a compressor can be
potential cause or causes. The causes partially disassembled in search of the cause
are listed in order (1,2,3 etc.) to suggest of a certain trouble and all evidence is
an order to follow in trouble shooting. destroyed during disassembly. Check again
to be sure an easy solution to the problem
has not been overlooked.
Action Plan
D. Find And Correct Basic Cause
A. Think Before Acting
After a mechanical failure has been
Study the problem thoroughly and ask corrected, be sure to locate and correct the
yourself these questions: cause of the trouble so the same failure will
not be repeated. A complaint of “premature
1. What were the warning signals that breakdown” may be corrected by repairing
preceded the trouble? any improper wiring connections, but
something caused the defective wiring. The
2. Has a similar trouble occurred before? cause may be excessive vibration.
3. What previous maintenance work has
been done?
4. If the compressor will still operate, is it
safe to continue operating it to make
further checks?
58 Book 22320717 (8/03)

Trouble Shooting Operating & Maintenance Manual
Trouble Shooting Chart
Bold Headings depict the COMPLAINT - Subheadings suggest the CAUSE
NOTE: Subheadings suggest sequence to follow troubleshooting.
Table 1: Unit Shutdown

Complaint Corrective Action
Out of Fuel Add CLEAN diesel Fuel
Compressor Oil Temp. Too High See Complaint 10
Engine Water Temp. Too High Check coolant level. If necessary, Add.
Engine Oil Pressure Too Low See Complaint 3 and Complaint 4.
Broken Engine Fan Belt Replace fan belt.
Loose Wire Connection Wiggle wires at switches & connector blocks. Make repairs.
Low Fuel Level Shutdown Switch Replace switch.
Defective Discharge Air Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Replace switch.
Defective Shutdown Solenoid Replace solenoid.
Malfunctioning Relay Replace relay.
* < 16 Volts at Shutdown Solenoid Check battery and alternator. Make repairs.
Blown Fuse Replace fuse.
Engine Malfunctioning See Trouble Shooting in Engine Manual.
Airend Malfunctioning See Complaint 10.
Table 2: Won’t Start/Run:

Low Battery Voltage Check electrolyte level. Check connections.
* <16 Volts at Shutdown Solenoid Charge battery and alternator. Make repairs.
Blown Fuse Replace fuse.
Malfunctioning Start Switch Replace switch.
Defective Safety Bypass Switch Replace switch.
Clogged Fuel Filters Service filters. See Engine Operator’s Manual.
Out of Fuel Add CLEAN fuel.
Compressor Oil Temp. Too High See Complaint 10.
Engine Water Temp. Too High Check fluid level. If necessary, Add.
Engine Oil Pressure Too Low See Complaint 3 and Complaint 4.
Loose Wire Connection Repair or replace connection.
Defective Discharge Air Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Replace switch.
Defective Shutdown Solenoid Replace solenoid.
Malfunctioning Relay Replace relay.
Airend Malfunctioning See Complaint 10.
Book 22320717 (8/03) 59

Table 3: Engine Temperature Lamps Stays On:

Broken Engine Fan Belt Replace fan belt set.
Malfunctioning Circuit Board Replace circuit board.
* Ambient Temp. >125×F (52×C) Above spec limit.
Dirty Operating Conditions Move unit to cleaner environment.
Dirty Cooler Clean exterior of cooler.
* Out of Level >15 degrees Relocate or reposition unit.
Operating Pressure Too High Reduce pressure to spec.
Recirculation of Cooling Air Close side doors.
Loose Wire Connection Repair or replace.
Malfunctioning circuit board. Replace circuit board.
Table 4: Engine Oil Pressure Lamp Stays On:

Low Oil Level Add oil.
Out of Level >15 degrees Relocate or reposition.
Wrong Lube Oil See Engine Oil Spec. Change oil.
Clogged Oil Filter Element(s) Replace element(s).
Loose Wire Connection. Repair or replace.
Malfunctioning circuit board Replace circuit.
Table 5: Engine Temperature Lamps Stays Off:

Bulb Burned Out Replace circuit board.
Malfunctioning circuit board Replace circuit board.
Table 6: Engine Oil Pressure Lamp Stays Off:

Table 7: Alternator Lamp Stays On:

Loose or Broken Belts Tighten or replace belt set.
Loose Wire Connection Repair or replace connection.
Low Battery Voltage Check electrolyte level. Add if necessary.
Check connectors. Clean & tighten.
Recharge battery.
Malfunctioning Alternator Repair or replace alternator.
60 Book 22320717 (8/03)

Table 8: Alternator Lamp Stays Off:

Loose Wire Connection Repair or replace connector.
Table 9: Unit Fails To Shutdown:

Defective Low Fuel Shutdown Switch Pull wire off shutdown solenoid. Replace switch.
Defective Discharge Air Temperature Switch Pull wire off. Replace switch.
Defective Engine Oil Pressure Switch Pull wire off. Replace switch.
Defective Shutdown Solenoid Carefully block air inlet to stop engine.
Malfunctioning Relay Replace solenoid.
Defective Safety Bypass Switch Pull wire off shutdown solenoid. Replace relay.
Pull wire off shutdown solenoid. Replace defective
item.
Table 10: Excessive Compressor Oil Temperature:

Ambient Temp. > 125×F (52×C) Above spec limit.
Out of Level > 15 degrees Relocate or reposition unit.
Low Oil Level Add oil. Look for any leaks.
Wrong Lube Oil Check spec in this manual.
Dirty Cooler Clean exterior surfaces.
Clogged Oil Filter Elements Replace elements. Change oil.
Loose or Broken Belts Tighten or replace belt set.
Operating Pressure Too High Reduce pressure to spec.
Recirculation Of Cooling Air Close side doors. Replace belly pan.
Malfunctioning Thermostat Replace thermostat in bypass valve.
Malfunctioning Fan Check fan belt tension. Tighten or replace belt set.
Defective Oil Cooler Relief Valve Replace valve.
Defective Minimum Pressure Valve Repair or replace valve.
Blocked or Restricted Oil Lines Clean by flushing or replace.
Airend Malfunctioning See Complaint 11, 12, 13, 15, 16 or 18.
Table 11: Engine RPM Down

Clogged Fuel Filter Clean primary filter. Replace final filter. Drain tanks.
Add CLEAN fuel.
Operating Pressure Too High Reduce pressure to spec limit.
Incorrect Pressure Regulator Adjustment See Section 6 in this manual.
Malfunctioning Pressure Regulator Replace regulator.
Incorrect Linkage Adjustment See Section 6 in this manual.
Dirty Air Filter Clean or replace elements.
Book 22320717 (8/03) 61

Malfunctioning Air Cylinder Replace air cylinder and adjust per Section 6.
Wrong Air Filter Element Install correct element.
Defective Separator Element Install new element per page 45.
Airend Malfunctioning Refer to Airend Rebuild Manual.
Table 12: Excessive Vibration

Rubber Mounts, Loose or Damaged Tighten or replace.
Defective Fan Replace fan.
Drive Coupling Defective Replace coupling.
Airend Malfunctioning See Complaint 15 and 17.
Anti-rumble valve not working. Repair or Replace.
Engine idle speed too low. Raise “No Load” speed per Section 6.
Table 13: Low CFM

Dirty Air Filter Clean or replace elements.
Incorrect Linkage Adjustment See Section 6 in this manual.
Incorrect Pressure Regulator Adjustment See Section 6 in this manual.
Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve. Make adjustment per Section 6.
Malfunctioning Air Cylinder Replace air cylinder.
Defective Minimum Pressure Valve Repair or replace valve.
Defective Separator Element Install new element per page 45.
Wrong Air Filter Element Install correct element.
Table 14: Short Air Cleaner Life

Inadequate Element Cleaning Install new element.
Incorrect Stopping Procedure Read procedure in this manual.
Wrong Air Filter Element Install proper element.
Oil Pump Drive Coupling Inspect coupling. If necessary, replace coupling.
Table 15: Excessive Oil In Air

High Oil Level Read procedure in this manual.
Out of Level > 15 degrees Relocate or reposition unit.
Clogged Scavenge Orifice Remove scavenge orifice. Clean and Replace.
Scavenge Tube Blocked Remove scavenge tube. Clean and Replace.
Defective Scavenge Check Valve Remove check valve. Replace with new valve.
Sep. Tank Blow Down Too Quickly Allow unit to blow down automatically.
Defective Minimum Pressure Valve Remove valve. Repair valve and replace.
62 Book 22320717 (8/03)

Table 16: Oil Seal Leak

Contaminated Lube Oil Drain and flush system. Add new CLEAN oil.
Blocked or Restricted Oil Line(s) Remove, clean and replace line(s).
Malfunctioning Seal Refer to Airend Rebuild Manual.
Scored Shaft See instructions in new seal kit.
Table 17: Will Not Unload

Leak in Regulator Piping Find and repair leak(s).
Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual.
Malfunctioning Inlet Butterfly Valve Inspect valve fit. Readjust per Section 6.
Ice in Regulation Lines/Orifice Apply heat to line(s) and or orifice.
Table 18: Oil In Air Cleaner

Incorrect Stopping Procedure Read Procedure in this manual.
Oil Pump Drive Coupling Inspect coupling. Replace if necessary.
Discharge Check Valve Faulty Replace.
Table 19: Safety Valve Relieves

Operating Pressure Too High Reduce pressure to spec limit.
Leak In Regulator Piping Repair leak(s).
Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual.
Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve fit. Readjust per Section 6.
Defective Safety Valve Replace safety valve.
Defective Separator Element Remove element. Install new.
Ice in Regulation Lines/Orifice Apply heat to lines and/or orifice.
Book 22320717 (8/03) 63

64 Book 22320717 (8/03)

Section 9 - Parts Ordering
Book 22320717 (8/03) 65

Operating & Maintenance Manual Parts Ordering
Parts Ordering
General A series of illustrations show each part

distinctly and in location relative to the other
This publication, which contains an illustrated parts in the assembly. The part number, the
parts breakdown, has been prepared as an description of the part and the quantity of
aid in locating those parts which may be parts required are shown on each illustration
required in the maintenance of the unit. All of or on adjacent page. The quantities specified
the compressor parts, listed in the parts are the number of parts used per one
breakdown, are manufactured with the same assembly and are not necessarily the total
precision as the original equipment. For the number of parts used in the machine. Where
greatest protection always insist on genuine no quantity is specified the quantity is
Ingersoll-Rand Company parts for your assumed to be one.
compressor.
Each description of a part is based upon the
“noun first” method, i.e., the identifying noun
or item name is always the first part of the
NOTICE description. The noun name is generally
followed by a single descriptive modifier. The
descriptive modifier may be followed by
Ingersoll-Rand Company can bear no
responsibility for injury or damages words or abbreviations such as upper, lower,
resulting directly from the use of non- inner, outer, front, rear, RH, LH, etc. when
approved repair parts. they are essential.
In referring to the rear, the front or to either
Ingersoll-Rand Company service facilities
side of the unit, always consider the drawbar
and parts are available worldwide. There are
end of the unit as the front. Standing at the
Ingersoll- Rand Company Sales Offices and
rear of the unit facing the drawbar (front) will
authorized distributors located in the
determine the right and left sides.
principal cities of the United States. In
Canada our customers are serviced by the
Canadian Ingersoll-Rand Company, Limited. Fasteners
There are also Ingersoll-Rand International
autonomous companies and authorized Both SAE/inch and ISO/metric hardware
distributors located in the principal cities have been used in the design and assembly
throughout the free world. of these units. In the disassembly and
reassembly of parts, extreme care must be
Special order parts may not be included in taken to avoid damaging threads by the use
this manual. Contact the Mocksville Parts of wrong fasteners. In order to clarify the
Department with the unit serial number for proper usage and for exact replacement
assistance with these special parts. parts, all standard fasteners have been
identified by part number, size and
description. This will enable a customer to
Description obtain fasteners locally rather than ordering
from the factory. These parts are identified in
The illustrated parts breakdown illustrates tables that will be found at the rear of the
and lists the various assemblies, parts illustrations. Any fastener that has not
subassemblies and detailed parts which been identified by both part number and size
make up this particular machine. This covers is a specially engineered part that must be
the standard models and the more popular ordered by part number to obtain the exact
options that are available. replacement part.
66 TM Book 22320717 (8/03)

Parts Ordering Operating & Maintenance Manual
Markings And Decals a. Always specify the model number of

the unit as shown on the general data
decal attached to the unit.
b. Always specify the serial number of the
NOTICE unit. THIS IS IMPORTANT. The serial
number of the unit will be found
Do not paint over safety warnings or stamped on a plate attached to the unit.
instructional decals. If safety warning (The serial number on the unit is also
decals become illegible, immediately permanently stamped in the metal of
order replacements from the factory. the frame side rail.)
c. Always specify the number of the parts
Part numbers for original individual decals list publication.
and their mounting locations are shown d. Always specify the quantity of parts
within Parts List Section. These are available required.
as long as a particular model is in production.
e. Always specify the part number, as well
Afterwards, service sets of exterior decals as the description of the part, or parts,
and current production safety warning decals exactly as it is given on the parts list
are available. Contact the Product Support illustration.
Group at Mocksville for your particular needs
In the event parts are being returned to your
and availability.
nearest sales office, autonomous company
or authorized distributor, for inspection or
How To Use Parts List repair, it is important to include the serial
number of the unit from which the parts were
removed.
a. Turn to Parts List.
b. Locate the area or system of the
compressor in which the desired part is Terms And Conditions On Parts
used and find illustration page number. Orders
c. Locate the desired part on the
Acceptance: Acceptance of an offer is
illustration by visual identification and
expressly limited to the exact terms
make note of part number and
contained herein. If purchaser’s order form is
description.
used for acceptance of an offer, it is
expressly understood and agreed that the
How To Order terms and conditions of such order form shall
not apply unless expressly agreed to by
The satisfactory ordering of parts by a Ingersoll-Rand Company (“Company”) in
purchaser is greatly dependent upon the writing. No additional or contrary terms will
proper use of all available information. By be binding upon the Company unless
supplying your nearest sales office, expressly agreed to in writing.
autonomous company or authorized Taxes: Any tax or other governmental
distributor, with complete information, you charge now or hereafter levied upon the
will enable them to fill your order correctly production, sale, use or shipment of material
and to avoid any unnecessary delays. and equipment ordered or sold is not
In order that all avoidable errors may be included in the Company’s price and will be
eliminated, the following instructions are charged to and paid for by the Purchaser.
offered as a guide to the purchaser when Shipping dates shall be extended for delays
ordering replacement parts:
Book 22320717 (8/03) 67

Operating & Maintenance Manual Parts Ordering
due to acts of God, acts of Purchaser, acts of The company makes no other warranty or
Government, fires, floods, strikes, riot, war, representation of any kind whatsoever,
embargo, transportation shortages, delay or expressed or implied, except that of title, and
default on the part of the Company’s all implied warranties, including any warranty
vendors, or any other cause beyond the of merchantability and fitness for a particular
Company’s reasonable control. purpose, are hereby disclaimed.
Should Purchaser request special shipping
instruction, such as exclusive use of shipping Limitation of Liability:
facilities, including air freight when common
carrier has been quoted and before change The remedies of the Purchaser set forth
order to purchase order can be received by herein are exclusive, and the total liability of
the Company, the additional charges will be the Company with respect to this order
honored by the Purchaser. whether based on contract, warranty,
negligence, indemnity, strict liability or
Warranty: The Company warrants that parts otherwise, shall not exceed the purchase
manufactured by it will be as specified and price of the part upon which such liability is
will be free from defects in materials and based.
workmanship. The Company’s liability under
this warranty shall be limited to the repair or The Company shall in no event be liable to
replacement of any part which was defective the Purchaser, any successors in interest or
at the time of shipment provided Purchaser any beneficiary of this order for any
notifies the Company of any such defect consequential, incidental, indirect, special or
promptly upon discovery, but in no event punitive damages arising out of this order or
later than in no event later than six (6) any breach thereof, or any defect in, or failure
months from the date of shipment of such of, or malfunction of the parts hereunder,
part by the Company. The only exception to whether based upon loss of use, lost profits
the previous statement is the extended or revenue, interest, lost goodwill, work
warranty as it applies to the special airend stoppage, impairment of other goods, loss by
exchange program. reason of shutdown or non- operation,
increased expenses of operation or claims of
Repairs and replacements shall be made by customers of Purchaser for service
the Company F.O.B. point of shipment. The interruption whether or not such loss or
Company shall not be responsible for costs damage is based on contract, warranty,
of transportation, removal or installation. negligence, indemnity, strict liability or
Warranties applicable to material and otherwise.
equipment supplied by the Company but
wholly manufactured by others shall be
limited to the warranties extended to the
Company by the manufacturer which are
able to be conveyed to the Purchaser.
Delivery: Shipping dates are approximate.
The Company will use best efforts to ship by
the dates specified; however, the Company
shall not be liable for any delay or failure in
the estimated delivery or shipment of
material and equipment or for any damages
suffered by reason thereof.
68 TM Book 22320717 (8/03)

Section 10 - Parts List
22320717-02
FRAME COMPLETE
70 Book 22320717 (8/03)

22320717-02
FRAME COMPLETE
ITEM COMM. NO. DESCRIPTION QTY DIMENSIONS/NOTES

A 36890457 Frame 1
B 36890515 Corner, Vert Street Cab 1
C 36890523 Corner, Vert Street Bed 1
D 36890564 Frame, Door Lower 1
E 36890556 Frame, Door Lower 1
F 36890671 Frame, Door Upper 1
G 36890663 Frame, Door Upper 1
H 22329114 Rear Door 1
J 22329122 Front Door 1
L 36890622 Bracket, Engine Oil/Fuel 1
N 36890465 Bridge, Cooler 1
P 36890572 Seal, Door Long 9
Q 36877587 Rivets 46 3/16" DIA
R 36895746 Nutsert 8 Hex M8
S 35279025 Screw, Tapping 50 M08-125 x 20
T 36890580 Seal, Door Short 1
U 36890499 Corner, Vert Curb Cab 1
V 36890507 Corner, Vert Curb Bed 1
W 36891810 Hinge, Door 2
X 36793602 Latch, Front Door 1
Y 36797652 Screw, Tapping 8 M06-1.00 x 12
Z 36794816 Rivet 8 187 x 020-125
A1 36865293 Bumper, Rubber 14
A2 36894210 Pan, Fuel Tank 1
A3 35114081 Clamp, Rubber Coated 2 1-1/16
A4 36797652 Screw 2 M6-1.0 x 12
A5 35140409 Foam 1/4 x 3/4
A6 36896785 Plug 1 5/16
A7 22333843 Rear Fork Tube Cover 1
*A8 22329163 Front Louver Assembly 1
A9 22343529 Front Louver Acoustical Foam 5
A10 22334874 Front Louver Crossmember 5
**A11 22331151 Rear Louver Assembly 1
A12 36877587 Rivet 30
A13 22334882 Rear Louver Crossmember 9
A14 22343537 Rear Louver Acoustical Foam 9
A15 22319867 Latch Rear Door 2
* A8 includes items A9, A10 & A12
** A11 includes items A12, A13 & A14
Book 22320717 (8/03) 71

22320717-04
ENGINE COMPLETE
72 Book 22320717 (8/03)

22320717-04
ENGINE COMPLETE

NA 36076784 Engine Complete
A 22302046 Engine 1 4 Cyl.
B 54471651 Bracket, Front Engine 2
D 36888055 Screw, Hex Flange HD 6 M12-1.75 x 30
F 36500197 Isolator 2
G 35279025 Screw, Tapping 8 M08-1.25 x 20
H 35304047 Nut, Hex Nyloc 2 M12-1.75
J 96739958 Screw, Hex 2 M12-1.75 x 70
K 54429295 Washer, Snubber 2
L 36892461 Spacer, Fan 1 22"
M 36878171 Fan 1 22"
N 96721154 Screw, Hex 4 M08-1.25 x 90
P 95934998 Washer, Flat 4 3/8 x 7/8
Q 36881563 Muffler 1
R 35851377 U-Bolt 1 3/8-16
S 95923322 Nut, Hex Lock 2 3/8-16
T 36796845 Clamp, Muffler 2
U 95935227 Screw, Hex 2 5/16-18 x 1 1/4
V 95929782 Nut, Hex 2 5/16 - 18
W 35209048 Clamp, Saddle 1 2 1/2
X 36775690 Pipe, Exhaust Tail 1
Y 36880839 Bracket, Muffler 1
Z 36877223 Support, Air Cylinder 1
A1 96702279 Screw, Hex 3 M10-1.50 x 20
A2 35328467 Bearing, Rod end 2
A3 96701461 Screw, Hex 2 M06-1.0 x 25
A4 36769032 Nut, Hex Lock 2 M06-1.0
A5 35592435 Cylinder, Pneumatic 1
A6 95923074 Nut, Hex Jam 2 5/16-24
A7 54429295 Washer Flat 2
A10 54471669 Bracket, Isolater 2
Note :
Element, Engine Oil filter 36881696
Element, Engine Fuel Filter 36534659
Book 22320717 (8/03) 73

22320717-06
COOLING COMPLETE
74 Book 22320717 (8/03)

22320717-06
COOLING COMPLETE

NA 36076768 Cooling Complete
A 36889780 Cooler, Oil 1
B 36889772 Radiator 1
C 36890473 Orifice, Fan 1
D 36891158 Hose, Radiator Bottom 1
E 36891141 Hose, Radiator Top 1
F 35221662 Clamp 4
G 35291384 Elbow 2 1.31 -12 x -16 JIC
H 22287247 Tube, Oil Cooler 1 -16
J 22287254 Tube, Oil Cooler 1 -16
K 35356468 Connector 2 1.06-12 x -16 JIC
L 54716360 Guard, Fan 1
M 54414420 Valve, Oil By-Pass 1 See page 76
N 36890481 Bracket, Oil Bypass 1
Q 36884948 Bottle, Coolant Recovery 1
T 35360775 Tubing 38 5/16
U 36881886 Screw, Tapping 10 M08-1.25
V 35279025 Nut, Hex Flange 7 M08-1.25 x 20
W 35294768 O-Ring 2
X 96702055 Screw, Hex 8 M08-1.25 x 20
Y 36797652 Screw, Tapping 6 M08-1.00 x 14
Z 36895746 Nutsert, Hex 19 M08
A2 35296342 Clamp, Wormgear 1
A3 35221662 Clamp, Rubber Coated 1 1/2"
A4 36769560 Cap, Radiator 1
A5 35221639 Clamp, Hose 1
A6 36878221 Grommet, Radiator Hose 2
A7 35294750 Elbow 1 1-1/16-12 x -12 JIC
A8 35613041 Plug, Hole 2 0.75 DIA
A9 36786382 Screw 2 M8-1.25 x 70
A10 95644019 Reducer 1
A11 95992632 Elbow, 45° 1 1.31 SAE x 1” Tubing
Book 22320717 (8/03) 75

22320717-08
ASSY, OIL TEMP BYPASS VALVE
76 Book 22320717 (8/03)

22320717-08
ASSY, OIL TEMP BYPASS VALVE

NA 54414420 Assy, Oil Temp Bypass valve
A 35288448 Ball 1
B 36782019 Element, Thermal 1
C 36788172 Seal, U-Type 1
D 36876779 Cover, Bypass Valve, Machined 1
E 54414305 Housing, Oil Temp Bypass Valve 1
F 54414677 Orifice, Oil 1
G 95022307 O-ring, Standard 1
H 96702659 Screw, Hex Head 4
J 35379940 Spring 1
Book 22320717 (8/03) 77

22320717-10
AIREND COMPLETE
78 Book 22320717 (8/03)

22320717-10
AIREND COMPLETE

A 54755087 Coupling 1
B 54755111 Bushing, Hex 1
C 54471685 Bracket, A/e Support 1
D 96701503 Screw, Hex 1 M16-2.0 X 90
E 95935052 Washer, Flat 1
F 22287155 Bracket, A/E Mounting 1
G 35358274 Screw, Socket head 4 M16-2.00 X 25
H 95376943 Screw, Socket Set 1 3/8-16 X 1/4
J 36880995 Screw, Hex Flange 8 M10-1.5 X 30
K 90544772 O-ring 1
L 35588532 Flange, Unloader Inlet 1
M 36889202 Gasket, Unloader 1
N 54436845 Unloader Assembly 1 See page 80
P 35282292 Tubing 14”
Q 35316587 Adapter, Barbed 1 1/8”
R 36769289 Key, Coupling 1 8 x 10 x 60 mm
S 54471057 Isolator, Rubber 1
T 35327212 Washer, Snubber 1
U 96704630 Nut, Nyloc 1 M16-2.0
V 54390943 Airend 1
W 96708201 Screw, Sockethead 8 M10-1.50 X 80
X 35323542 Adapter, Barbed 1 1/8”
Y 35323450 Stud 4 M16-2.0 X 55
Z 96701750 Nut, Hex 4 M16-2.0
A1 35279025 Screw, Tapping 6 M08-1.25 X 20
A2 39317599 Seal, Double Element 1
A3 39317581 Seal, Single Element 1
A4 96720545 Screw, Sockethead 4 M16-2.0 X 35
A5 35377621 Clamp, Spring 2 1/4”
A6 36766756 Muffler, Orifice 1 .140
A7 35114545 Tee, Street 1 1/4NPT
A8 35283464 Elbow 1 1/4NPT -4JIC
A9 35369347 Connector, Male 1 1/4NPT X 3/8 TUBE
B1 35588318 Gasket, Unloader Inlet 1
B2 96702048 Screw, Hex 4 M08-1.25 X 16
B3 93481455 Gasket, A/e Discharge 1
B4 54413042 Plate, Discharge 1
B5 54390950 Adapter 1 CF90 A/E
B6 95944666 Elbow 1 1/4 NPT
B7 95944690 Tee 1 1/4 NPT
B8 35283464 Elbow 1 1/4 NPT x -4 JIC
Book 22320717 (8/03) 79

22320717-12
UNLOADER ASSEMBLY
80 Book 22320717 (8/03)

22320717-12
UNLOADER ASSEMBLY

NA 54436845 Unloader Valve Assy.
A *35318013 Housing Bushing 1
B *35317205 Washer 1
C *35322767 Piston Spring 1
D *35318005 Piston Bushing 2
E 35588193 Piston Unloader 1
F *35317197 Diaphragm 1
G *35321603 Spring 1
H *35317239 Piston Washer 1
J *35321595 Capscrew 1
K 35836949 Piston Cover 1
L 35271162 Screw 4
M 96702287 Screw 6
N 35833227 Piston Housing 1
P *35588300 Piston Gasket 1
Q 35591122 Valve Plate 1
R 54425335 Unloader Body 1
S *35278555 Plug 1
T *35318914 Pin Spring 1
U *35317213 Unloader Pin 1
V 35289057 Plug 1
W 35278589 O-ring 1
X 35279959 O-ring 1
35088798 Repair Kit Includes items marked

thus (*)
Book 22320717 (8/03) 81

22320717-14
AIREND ASSEMBLY
82 Book 22320717 (8/03)

22320717-14
AIREND ASSEMBLY

A 95989695 Adapter 1 1/2NPT x 12mm
B 93481570 Tube Assembly 1 5/16”
C 95052387 Union 1 -4 x -5
D 95951646 Tee 1 -12 JIC
E 96739693 Adapter 1 26mm x -12
G 93186278 Reducer 1 -12 x -4
H 95986014 Connector 1
J 35373976 Tee 1 1/4 NPT x 3/8 Tubing
K 35296409 Connector 1 1-7/8-12 x -24
L 22287221 Tube, A/E Discharge 1 -24
M 36766756 Orifice 1 0.140
N 95944906 Elbow -24 x -24
P 22287189 Tube -12
Book 22320717 (8/03) 83

22320717-16
AIR SERVICE COMPLETE
84 Book 22320717 (8/03)

22320717-16
AIR SERVICE COMPLETE

A 22287171 Tube, Service 1
B 95219861 Elbow, Tube 1
C 35114545 Tee Street 1 1/4 NPT
D 95048914 Nipple 1 1/4 NPT
E 35279777 Elbow 1 90× 1 5/8
H 36923928 Nozzle Sonic 1 0.453
J 95953378 Elbow 1 90× 1.25
K 95916268 Nipple 1 1.25 x 8
M 36785277 Clamp, Saddle 1 1.62
N 36881076 Valve, WYE 1
R 35279942 O-Ring 3
S 95944666 Elbow 1 1/4 NPT
T 35324839 Valve 1 1/4
Book 22320717 (8/03) 85

22320717-18
SEPARATOR TANK COMPLETE
86 Book 22320717 (8/03)

22320717-18
SEPARATOR TANK COMPLETE

A 22287163 Tank, Separator 1
B 39831888 Element, Separator 1
D 36781227 Tube, Scavenge 1
F 35579630 Plug, Hex 1 1 5/8
G 36891083 Gage assembly, Oil level 1
H 36877793 Screw, Hex 8 M12-1.75 x 40
J 36890317 Fitting, Scavenge 1
K 95944708 Tee, Street NPT 1 1/2
L 35325224 Valve, Safety 1
M 95955993 Connector 1 1 5/16 - 12
N 35294750 Elbow 1 90× 1.06 x 12 x -12
P 35246438 Hose, Discharge 1 -24 x 21
Q 35279025 Screw, Tapping 4 M08-1.25 x 20
R 35279942 O-Ring 1
S 36891489 Pointer Assembly, Rotating 3
T 95928230 Plug 1 1/4 NPT
U 95431292 Elbow 1 90× 1.88-12 x -24
V 22287197 Tube 1 3/4 JIC
W 35283506 Hose 1 JIC -8 x 39
X 35322379 Blowdown Valve 1
Y 36766772 Orifice 1 0.62
Z 35114545 Tee 1 1/4 NPT
A1 95048914 Nipple 3 1/4 NPT
A2 36854149 Regulator 1
A4 35365774 Reducer 1 -12 x -8
A5 35369354 Elbow 1 1/4 NPT x 3/8 Tube
A6 95944666 Elbow 1 1/4 NPT
A7 95930301 Reducer 1 1/4 NPT x 1/8 NPT
A8 95954194 Tee 1 1/4 NPT
A9 35369347 Connector 1 1/4 NPT x 3/8 Tube
A10 36766756 Orifice 1 0.140
A11 36840437 Orifice 1 0.62
A12 36891547 Elbow
Book 22320717 (8/03) 87

22320717-20
CENTRAL DRAINS
88 Book 22320717 (8/03)

22320717-20
CENTRAL DRAINS

A 35294735 Elbow 1 3/4" NPT
B 35323807 Hose, Engine Oil Drain 1
C 95220844 Clamp, Hose 3 9/16"
D 35114081 Clamp, Hose 1 1.06
E 36891067 Tube, Radiator Drain 1
F 35279025 Screw, Tapping 6 M08-1.25 x 20
G 36891588 Bracket, Drain Piping 2
H 36892479 Hose 15" .50 ID
J 36892172 Hose, Drain Connector 1
K 95220851 Clamp, Worm Gear 2
L 35285451 Union, Bulkhead 3
M 35283506 Hose 1 JIC -8 x 38
N 35294750 Elbow 1 90° (1.06 -23 x 12)
P 36891208 Wrench, Plate 1
Q 95257325 Cap 3 3/4" - 16
R 36891042 Tube, Fuel Drain 1
S 95730172 Cap 1 1.06-12
T 95332599 Connector, Bulkhead 1 1.06-12
V 35365774 Reducer -12 x -8
Book 22320717 (8/03) 89

22320717-22
AIR INTAKE COMPLETE
90 Book 22320717 (8/03)

22320717-22
AIR INTAKE COMPLETE

NA 36076735 Air Intake Complete 1
A 36862829 Cleaner Assembly - Air 1 see page 94
B 35585009 Band - Air Cleaner 2
C 36889608 Screw Hex. Head 4 M8 x 16 Long
D 36881886 Nut Hex. Flange 4 M8
E 22287148 Bracket - Air Filter Mounting 1
F 35279025 Screw Hex. Head 4 M8 x 20 Long
G 22287205 Hose - Engine Air Intake 1
H 35314996 Clip 1
J 35374073 Clip 1
K 35165802 Clamp 2
L 22287122 Elbow - Rubber 1
M 22287130 Bracket - Air Cleaner 1
N 36879492 Screw Hex 2 Flange M12 x 25 Long
O 54471826 Air Cleaner Assembly 8” 1 See page 92
Book 22320717 (8/03) 91

22320717-24
AIR CLEANER ASSEMBLY
92 Book 22320717 (8/03)

22320717-24
AIR CLEANER ASSEMBLY

NA 54471826 Air Cleaner Assembly 1
A 54479811 Body - Air Cleaner 1
B 35393719 Cap - Plug 1
C 35393669 Clip - Retaining 3
D 35393677 Valve - Dust Ejector 1
E 54471834 Element - Primary Air Cleaner 1
F 54415393 Cover Assembly - Air Cleaner 1
G 54471842 Safety Element - Air Cleaner 1 Optional
Book 22320717 (8/03) 93

22320717-26
CLEANER ASSEMBLY - AIR
94 Book 22320717 (8/03)

22320717-26
CLEANER ASSEMBLY - AIR

NA 36862829 Cleaner Assembly - Air 1
A 35388883 Body - Air Cleaner 1
B 35326032 Cover - Air Cleaner 1
C 35388891 Valve - Vacuator 1
D 36876423 Element - Air Cleaner 1
E 35291475 Nut 1
F 36790277 Capnut 1
Book 22320717 (8/03) 95

22320717-28
FUEL TANK COMPLETE
96 Book 22320717 (8/03)

22320717-28
FUEL TANK COMPLETE

A 36889939 Tank, Fuel 1
B 36890200 Sender, Fuel Level 1
C 36885564 Cap, Fuel 1
D 35361849 Gasket, Fuel Sender 1
E 36892156 Standpipe Assembly, Pickup 1
F 35384577 Bushing, Nitrile 2
G 36892164 Standpipe Assembly, Return 1
H 95916532 Screw, Filister SLTD HD 5 10-32X.5
J 35322460 Union, Barbed Tube 1
K 95220851 Clamp, Hose 2
L 35363498 Hose, Fuel * 31" / *See Illstrn. for
Lengths
M 35296342 Clamp, Wormgear 6
N 36892172 Hose, Drain Connector 1
P 35225093 Clamp 3 1/2" Support
Q 35279025 Screw, Tapping 1 M08-1.25x20
R 36767051 Foam, Closed Cell 5
S 36845493 Filter, Fuel 1
T 92368687 Screw 1 M6 - 1.0 x 14
Book 22320717 (8/03) 97

22320717-30
REMOTE FILTERS COMPLETE
98 Book 22320717 (8/03)

22320717-30
REMOTE FILTERS COMPLETE

A 36897387 Oil Filter Assembly 1
36897445 Head, Filter
36897353 Element, Compressor Oil Filter 1
B 36534659 Element, Engine Fuel Filter 1
C 36881696 Element, Engine Oil Filter 1
D 36891968 Tube, Oil Fill 1
E 35294750 Elbow 2 90° 1-1/16" -12 JIC
F 22287189 Tube Assembly 1 -12 JIC
G 95951646 Tee 1 90° Long
H 36889350 Line 4 90° Fuel
J 35363498 Hose * 5/16" Fuel / See
Illustration for Length
K 35296342 Clamp, Worm Gear 6
L 36889947 Bulb, Fuel Primer 1
M 35323864 Hose Assembly 1 (-12 x 24)
N 36890895 Hose, Oil fill 1
P 35221662 Clamp, Hose 2
Q 36891109 Adapter, Engine Oil Fill 1
R 35114057 Clamp, Support 1 1.25
S 35376953 Screw, Hex 1 M10-1.50 x 20
T 36879195 Nut, Hex Flange 1 M10
V 36890168 Dipstick, Remote Mount 1
W 35114081 Clamp, Support 2 1.07
X 35300771 Screw, Tapping 1 M06-1.0 x 20
Y 96702055 Screw, Hex 2 M80-1.25 x 20
Z 95934998 Washer, Flat 2
A1 36894160 Gasket, Engine Oil Fill 1
A2 36895472 Connector, Fuel Filter 3
A3 22287262 Bracket, Oil Fill Support 1
A4 96702279 Screw 1 M10-1.5 x 20
A5 36895977 Reducer, Fuel Line 1
A6 35279025 Screw 2 M8-1.25 x 20
A7 96701479 Screw 4 M10-1.5 x 16
A8 35287556 Plug, Hex 1
Book 22320717 (8/03) 99

22320717-32
AIR & OIL PIPING
100 Book 22320717 (8/03)

22320717-32
AIR & OIL PIPING

NA 22313274 Air Oil Piping Complete
1 35356484 Tubing 0.38 OD
2 35324839 Valve, Ball .25 Npt
3 95953378 Elbow 90° 1.25 NPT
4 36923928 Nozzle, Sonic ORF
5 35369347 Conn. .25 NPT x .38 TBG
6 22287171 Tube Assy-Service Air
7 36781227 Tube Assy-Oil Scavenge
8 35370386 Elbow 90° .12 NPT x .38 TBG
9 35369354 Elbow 90° .25 NPT x .38 TBG
10 22287197 Tube - 16 JIC
11 36766756 Orifice 0.140
12 35279777 Elbow 90° .1.62-12 x -20 JIC
13 22287247 Tube Assy -16 JIC
14 95928230 Plug .25 NPT
15 95944690 Tee, Street .25 NPT
16 35373976 Tee Male Branch .25 NPT x .38 TBG
17 95431292 Elbow 90° 1.88-12 x -24 JIC
18 35246438 Hose Assy -24 x 21"
19 95219861 Elbow 90° 1.25 NPT x -20 JIC
20 35358662 Hose Assy -4 JIC
21 95916268 Nipple 1.25 x 8 LG
22 36840437 Inline Orifice/Check Valve
23 36766772 Orifice 0.062
24 54414420 Valve, Bypass
25 35322379 Valve Blowdown
26 35325224 Valve, Safety 150 PSI
27 36854149 Reg. Press 100 PSI
28 95944708 Tee Street .50 NPT
29 22287254 Tube Assy -16 JIC
30 35294750 Elbow 90° 1.06-12 x -12 JIC
31 54764964 Switch Shutdown W/O-Ring
32 35356468 Conn 1.60 -12 x -16 JIC
33 36891083 Oil Level Indicator
34 95992632 Elbow 45°
35 95935599 Coupling .12 NPT x 0.75
36 36890317 Sleeve Fitting
37 36881076 Valve, Service
38 35579630 Plug, Vented 1.62 -12 SAE
39 35279942 O-Ring
Book 22320717 (8/03) 101

22320717-34
AIR & OIL PIPING
102 Book 22320717 (8/03)

22320717-34
AIR & OIL PIPING

40 95944666 Elbow 90° Street 0.25 NPT
41 95954194 Tee
42 95667341 Nipple .25 NPT x .88 LNG
43 36891547 Elbow 90° .12 NPT x .12 TBG
44 36891562 Tubing .12 OD
45 35283506 Hose Assy -8 x 39
46 35285451 Bulkhead Union -8 JIC
47 95257325 Cap -8 JIC
48 35323864 Hose Assy -12 JIC x 34
49 22287189 Tube Assy -12 JIC
50 36897445 Head, Filter
51 35287556 Plug .56 -18 SAE
52 36897353 Element Oil Filter
53 95930301 Bushing .125 x .25 NPT
54 35291384 Elbow 90° 1.31 -12 x -16 JIC
55 35294750 Elbow 90° 1.06 -12 x -12 JIC
56 35283464 Elbow 90° 1/4 NPT x -4 JIC
57 96739693 Adapter 26 MM x -12
58 95951646 Tee -12 x -12 x -12
59 95986014 Union, Swivel Nut -4
60 93186278 Reducer -12 x -4 JIC
61 93481570 Tube Assy 5/16"
62 95989695 Adapter 12 MM x -5 JIC
63 35316587 Adapter, Barbed 1/8"
64 35377621 Clamp, Spring 1/4"
65 35282292 Tubing 1/8" x 14"
66 35323542 Adapter, Barbed 1/8"
67 55296409 Connector 1.88 - 12 x -24 JIC
68 22287221 Tube -24
69 95944906 Elbow, Union -24
71 95052387 Union -4 x -5
72 95644019 Reducer
73 35365774 Reducer -12 x -8
74 95955993 Connector
75 35114545 Tee 1/4 NPT
Book 22320717 (8/03) 103

22320717-36
INSTRUMENT/CONTROL PANEL WITHOUT START/RUN VALVE
104 Book 22320717 (8/03)

22320717-36
INSTRUMENT/CONTROL PANEL WITHOUT START/RUN VALVE

A 54749601 Frame, WW Instrument Panel 1
B 22171680 Panel, Instrument 1
C 22171698 Decal, WW Instrument Panel 1
D 54766704 Meter, Electronic Hour 1
E 22054159 Nut, Plastic 2 4-40
F 22127385 Switch, Ignition 1
G 35604065 Gauge 1 150 PSI Pressure
H 95935599 Coupling, Std 1 1/8" NPT x .75
J 36891547 Elbow 1 1/8" NPT x 1/8" Tube
K 22054167 Key, Removable Ignition 1
L 54774104 Key, Non- Removable Ignition 1
M 22107478 Hinge, Control Panel 1
N 36897380 Door, Instrument Panel 1
P 22070494 Screw, Plastic Tapping 8
Q 36920486 Rivet, Aluminum 6 3/16"
R 36877587 Rivet, Aluminum 4 3/16"
S 22058291 Gauge ASM. 1 4-IN -1
T 35607829 Eyebolt 2
U 95935029 Washer, Flat 2
V 36772028 Washer, Plastic 2
W 35607837 Spring 2
X 95923298 Nut, Hex 2 1/4" -20
Y 54774112 Module 1 2-Light Warning
Z 54774096 Gauge, Fuel 1
A1 22199079 Adapter, Switch 1
Book 22320717 (8/03) 105

22320717-38
BATTERY & MOUNTING
106 Book 22320717 (8/03)

22320717-38
BATTERY & MOUNTING

A 36844264 Battery 1
B 35516582 Cable, Positive Battery 1 (48")
C 36892685 Cable, Negative Battery 1 (37")
D 36853257 Angle 1
E 36890648 Tray, Battery 1
F 35130293 Screw, Tapping 1 3/8" -16 x 3/4"
G 36860005 J-Bolt 2
H 36853265 Washer, Plastic 2
J 35144492 Nut, Lock 2 1/4"-20
K 35225093 Clamp, Support 2 1/2"
L 36783488 Strap, Ground 1
M 35279025 Screw, Tapping 5 M08-1.25 x 20
Book 22320717 (8/03) 107

22320717-40
WIRING DIAGRAM
108 Book 22320717 (8/03)

22320717-40
WIRING DIAGRAM

B 36844264 Battery 1
CF1 36792083 Fuse 1 20A
D1 35676169 Diode 1
D3 35676169 Diode 1
D4 35676169 Diode 1
D5 35676169 Diode 1
D6 35676169 Diode 1
D7 35676169 Diode 1
G 36124881 Alternator 1
FG 54774096 Gauge, Fuel 1
FS 22058531 Sender, Fuel 1 Combined in1 Lamp
Module
H 54766704 Hourmeter 1
IL1 54774112 Low Oil Press Indicator Lamp 1 Combined in 2 Lamp
Module
IL2 54774112 Low Oil Press Indicator Lamp 1 Combined in 2 Lamp
Module
LFS 22058531 Switch, Low Fuel 1 Combined in1 Lamp
Module
M 36120649 Starter 1
PS1 54747935 Switch, Engine Oil Pressure 1
R2 54368048 Relay, Start Protect 1
R3 54368048 Relay, Start Inhibit 1
R4 54368048 Relay, Fuel Solenoid 1
R5 54368048 Relay, Fuel Shutdown 1
R6 54368048 Relay, Crank 1
R7 54368048 Relay, High Engine Temp 1
S1 92086719 Switch, Key 1
SV1 36125409 Solenoid, Fuel 1
TS1 54764964 Switch, A/E High Air Temp 1
TS2 54764956 Switch, Discharge High Air Temp 1
TS3 36893055 Switch, High Engine Temp 1
W1 22060321 Harness, Engine Control 1
22054167 Key, Removable
54774104 Key, Non- Removable
Book 22320717 (8/03) 109

22320717-42
WIRING DIAGRAM
110 Book 22320717 (8/03)

22320717-42
WIRING DIAGRAM

ATS 35372457 Airend Temp Sender
ETH 35367739 Manual Ether Start
35377266 Automatic Ether Start
ETS 35604180 Engine Temp Sender 3 Cyl.
35372457 Engine Temp Sender 4 Cyl.
GEN 36852622 Generator 4.5 KW
GL 36852622 Gauge Lights
35333236 Bulb, Incandescent
IL3 22061493 Low Oil Press Indicator Lamp Combined in 4 Lamp
Module
IL4 22061493 High Engine Temp Indicator Lamp Combined in 4 Lamp
Module
IL5 22061493 High A/E Temp Indicator Lamp Combined in 4 Lamp
Module
IL6 22061493 High A/E Temp Indicator Lamp Combined in 4 Lamp
Module
OPS 36870608 Oil Pressure Sender
PB1 * Push Button Switch Included in Option
SV2 * Tachometer Included in Option
TAC 22060198 Solenoid, Ether
TS4 * Switch, Block Temp. Ether Included in Option
VS1 36847838 Switch, Air Filter Restriction
VS2 36847838 Switch, Air Filter Restriction
W3 22074843 Harness, Gauge Illumination Option
W4 36842839 Harness, Air Filter Restr. Option
W5 36842821 Harness, Manual Cold Start Option
Book 22320717 (8/03) 111

22320717-44
ENCLOSURE COMPLETE
112 Book 22320717 (8/03)

22320717-44
ENCLOSURE COMPLETE

A 36890531 Stringer, Cab Side 1
B 36890549 Stringer, Bed Side 1
C 36890762 Panel, Roof CLR End 1
D 36891414 Channel, Roof Connector 1
E 36890838 Panel, Roof 1
F 36890739 Panel, Upper Engine Bed 1
G 36890721 Panel, Lower Engine Bed 1
H 36890812 Box, Air Inlet Bed 1
J 36890747 Panel, Filter End Bed 1
K 22287213 Bulkhead, Rear Bed 1
L 36890713 Panel, Cooler End Bed 1
M 36891745 Stringer, Lift Beam 1
N 36891729 Member, Lift Beam Rear 1
P 36891737 Member, Lift Beam Front 1
Q 36891760 Eye, Lift Beam 2
R 35368216 Foam * See Illustration for
Length
S 36890796 Bulkhead, Rear Cab 1
T 36890473 Orifice, Fan
U 36890705 Panel, Filter End Cab 1
V 36890770 Box, Air Inlet Cab 1
W 36892982 Spacer 1
X 92304450 Screw, Hex 1 M12-1.75 x 50
Y 36786218 Lanyard 2 1.6 x 355.6
Z 36890697 Panel, Upper Engine Cab 1
A1 36890689 Panel, Lower Engine Cab 1
A2 36890655 Panel, Cooler End Cab 1
A3 36895746 Nutsert, Hex 51 M08
A4 36877587 Rivet 15 3/16ÿ
A5 35279025 Screw Tapping 73 M08 - 125 x 20
A6 36892677 Latch, Trigger 4
A7 36861383 Hook 4 #9S
A8 35279413 Cover, Roof Access 1
A9 36879492 Screw, Hex Flange 5 M12 x 25
36881712 Screw, Hex Flange 2 1/2"-13X1.0
B1 36879203 Nut, Hex Flange 7 M12 - 1.75
B2 36877793 Screw, Hex Flange 4 M12-1.75 x 40
B3 36892206 Cap, Vinyl 4
B4 22095533 Bracket, Relay Mounting 1
B5 36797652 Screw 2 Tapping M06-1.0 x 12
B6 35271170 Screw 2 M8-1.25 x 40
Book 22320717 (8/03) 113

22320717-46
DECAL LOCATION
114 Book 22320717 (8/03)

22320717-46
DECAL LOCATION

A 54568779 Decal, Rotating Fan 2
B 54568761 Decal, Hot Press Fluid 1
C 54629902 Decal, Combination 3-part 1 3-part
E 54568787 Decal, Improper Operation 1
F 36514602 Decal, Noise Emission 1
Book 22320717 (8/03) 115

22320717-48
DECAL LOCATION
116 Book 22320717 (8/03)

22320717-48
DECAL LOCATION

A 22099311 Decal, Operating Instructions
B 22108617 Card, Standard Wiring 1
C 22108641 Card, Option Wiring 1
D 54568753 Decal, Battery Gas 1
E 54604970 Decal, Oil Fill
F 54568795 Decal, High Pressure Air 1
G 54629977 Decal, Central Drains 1
H 36523306 Plate, Serial Number 1
J 36794816 Rivet 2
Book 22320717 (8/03) 117

22320717-50
DECAL LOCATION
118 Book 22320717 (8/03)

22320717-50
DECAL LOCATION

A 54568779 Decal, Rotating Fan
B 54604962 Decal, Radiator Fill Hot 1
C 54625207 Decal, Diesel Fuel 1
Book 22320717 (8/03) 119

22320717-52
ACOUSTIC PANELS
120 Book 22320717 (8/03)

22320717-52
ACOUSTIC PANELS

A 22338529 Panel, Acoustic St. Door 1
B 22338511 Panel, Acoustic CRB Door 1
F 22338545 Panel, Acoustic Cab Cooler 1
G 22338552 Panel, Acoustic Cab Lwr Eng. 1
H 22338560 Panel, Acoustic Cab Upper Eng. 1
J 22338578 Panel, Acoustic Cab Fltr End 1
K 36892776 Panel, Acoustic Cab Air Box 1
L 22338586 Panel, Acoustic Bed Lwr Eng 1
M 22338545 Panel, Acoustic Bed Cooler End 1
N 22338602 Panel, Acoustic Bed Fltr End 1
P 36892834 Panel, Acoustic Bed Air Box 1
Q 22338610 Panel, Acoustic Bed Upper Eng 1
R 36892883 Panel, Acoustic Oil Cooler Top 1
S 36892909 Panel, Acoustic Center Roof 1
T 36892917 Panel, Acoustic End Roof 1
U 22287239 Panel, Acoustic BHD Bed Side 1
V 36892941 Panel, Acoustic BHD Ctr Upper 1
W 36892933 Panel, Acoustic BHD Cab Fltr 1
Y 36892891 Panel, Acoustic 1
Z 36892925 Panel, Acoustic BHD Cab eng 1
A1 22338636 Panel, Acoustic Exhaust Plenum 1
A2 22338628 Panel, Acoustic Fork Truck Plt 2
Book 22320717 (8/03) 121

This page intentionally left blank
NUMERICAL INDEX
COMM.NO. PAGE COMM.NO. PAGE COMM.NO. PAGE

22054159 ........................... 105 22338578 ............................121 35283506 ..............................87
22054167 ........................... 105 22338586 ............................121 .............................................89
.......................................... 109 22338602 ............................121 ...........................................103
22058291 ........................... 105 22338610 ............................121 35285451 ..............................89
22058531 ........................... 109 22338628 ............................121 ...........................................103
22060198 ........................... 111 22338636 ............................121 35287556 ..............................99
22060321 ........................... 109 22343529 ..............................71 ...........................................103
22061493 ........................... 111 22343537 ..............................71 35288448 ..............................77
22070494 ........................... 105 35088798 ..............................81 35289057 ..............................81
22074843 ........................... 111 35114057 ..............................99 35291384 ..............................75
22095533 ........................... 113 35114081 ..............................71 ...........................................103
22099311 ........................... 117 .............................................89 35294735 ..............................89
22107478 ........................... 105 .............................................99 35294750 ..............................75
22108617 ........................... 117 35114545 ..............................79 .............................................87
22108641 ........................... 117 .............................................85 .............................................89
22127385 ........................... 105 .............................................87 .............................................99
22171680 ........................... 105 ...........................................103 ...........................................101
22171698 ........................... 105 35130293 ............................107 ...........................................103
22199079 ........................... 105 35140409 ..............................71 35294768 ..............................75
22287122 ............................. 91 35144492 ............................107 35296342 ..............................75
22287130 ............................. 91 35165802 ..............................91 .............................................97
22287148 ............................. 91 35209048 ..............................73 .............................................99
22287155 ............................. 79 35221639 ..............................75 35296409 ..............................83
22287163 ............................. 87 35221662 ..............................75 35300771 ..............................99
22287171 ............................. 85 .............................................99 35304047 ..............................73
.......................................... 101 35225093 ..............................97 35314996 ..............................91
22287189 ............................. 83 ...........................................107 35316587 ..............................79
............................................ 99 35246438 ..............................87 ...........................................103
.......................................... 103 ...........................................101 35317197 ..............................81
22287197 ............................. 87 35271162 ..............................81 35317205 ..............................81
.......................................... 101 35271170 ............................113 35317213 ..............................81
22287205 ............................. 91 35278555 ..............................81 35317239 ..............................81
22287213 ........................... 113 35278589 ..............................81 35317599 ..............................79
22287221 ............................. 83 35279025 ..............................71 35318005 ..............................81
.......................................... 103 .............................................73 35318013 ..............................81
22287239 ........................... 121 .............................................75 35318914 ..............................81
22287247 ............................. 75 .............................................79 35321595 ..............................81
.......................................... 101 .............................................87 35321603 ..............................81
22287254 ............................. 75 .............................................89 35322379 ..............................87
.......................................... 101 .............................................91 ...........................................101
22287262 ............................. 99 .............................................97 35322460 ..............................97
22302046 ............................. 73 .............................................99 35322767 ..............................81
22313274 ........................... 101 ...........................................107 35323450 ..............................79
22319867 ............................. 71 ...........................................113 35323542 ..............................79
22329114 ............................. 71 35279413 ............................113 ...........................................103
22329122 ............................. 71 35279777 ..............................85 35323807 ..............................89
22329163 ............................. 71 ...........................................101 35323864 ..............................99
22331151 ............................. 71 35279942 ..............................85 ...........................................103
22333843 ............................. 71 .............................................87 35324839 ..............................85
22334874 ............................. 71 ...........................................101 ...........................................101
22334882 ............................. 71 35279959 ..............................81 35325224 ..............................87
22338511 ........................... 121 35282292 ..............................79 ...........................................101
22338529 ........................... 121 ...........................................103 35326032 ..............................95
22338545 ........................... 121 35283464 ..............................79 35327212 ..............................79
22338552 ........................... 121 ...........................................103 35328467 ..............................73
22338560 ........................... 121 35333236 ............................111
P250WJDU i-1
NUMERICAL INDEX

35356468 ............................. 75 36076784 ..............................73 36876423 ..............................95
.......................................... 101 36120649 ............................109 36876779 ..............................77
35356484 ........................... 101 36124881 ............................109 36877223 ..............................73
35358274 ............................. 79 36125409 ............................109 36877587 ..............................71
35358662 ........................... 101 36500197 ..............................73 ...........................................105
35360775 ............................. 75 36514602 ............................115 ...........................................113
35361849 ............................. 97 36523306 ............................117 36877793 ..............................87
35363498 ............................. 97 36534659 ..............................73 ...........................................113
............................................ 99 .............................................99 36878171 ..............................73
35365774 ............................. 87 36766756 ..............................79 36878221 ..............................75
............................................ 89 .............................................83 36879195 ..............................99
.......................................... 103 .............................................87 36879203 ............................113
35367739 ........................... 111 ...........................................101 36879492 ..............................91
35368216 ........................... 113 36766772 ..............................87 ...........................................113
35369347 ............................. 79 ...........................................101 36880839 ..............................73
............................................ 87 36767051 ..............................97 36880995 ..............................79
.......................................... 101 36769032 ..............................73 36881076 ..............................85
35369354 ............................. 87 36769289 ..............................79 ...........................................101
.......................................... 101 36769560 ..............................75 36881563 ..............................73
35370386 ........................... 101 36772028 ............................105 36881696 ..............................73
35372457 ........................... 111 36775690 ..............................73 .............................................99
35373976 ............................. 83 36781227 ..............................87 36881712 ............................113
.......................................... 101 ...........................................101 36881886 ..............................75
35374073 ............................. 91 36782019 ..............................77 .............................................91
35376953 ............................. 99 36783488 ............................107 36884948 ..............................75
35377266 ........................... 111 36785277 ..............................85 36885564 ..............................97
35377621 ............................. 79 36786218 ............................113 36888055 ..............................73
.......................................... 103 36786382 ..............................75 36889202 ..............................79
35379940 ............................. 77 36788172 ..............................77 36889350 ..............................99
35384577 ............................. 97 36792083 ............................109 36889608 ..............................91
35388883 ............................. 95 36793602 ..............................71 36889772 ..............................75
35388891 ............................. 95 36794816 ..............................71 36889780 ..............................75
35393669 ............................. 93 ...........................................117 36889939 ..............................97
35393677 ............................. 93 36796845 ..............................73 36889947 ..............................99
35393719 ............................. 93 36797652 ..............................71 36890168 ..............................99
35516582 ........................... 107 .............................................75 36890200 ..............................97
35579630 ............................. 87 ...........................................113 36890317 ..............................87
.......................................... 101 36840437 ..............................87 ...........................................101
35585009 ............................. 91 ...........................................101 36890457 ..............................71
35588193 ............................. 81 36842821 ............................111 36890465 ..............................71
35588300 ............................. 81 36842839 ............................111 36890473 ..............................75
35588318 ............................. 79 36844264 ............................107 ...........................................113
35588532 ............................. 79 ...........................................109 36890481 ..............................75
35591122 ............................. 81 36845493 ..............................97 36890499 ..............................71
35592435 ............................. 73 36847838 ............................111 36890507 ..............................71
35604065 ........................... 105 36852622 ............................111 36890515 ..............................71
35604180 ........................... 111 36853257 ............................107 36890523 ..............................71
35607829 ........................... 105 36853265 ............................107 36890531 ............................113
35607837 ........................... 105 36854149 ..............................87 36890549 ............................113
35613041 ............................. 75 ...........................................101 36890556 ..............................71
35676169 ........................... 109 36860005 ............................107 36890564 ..............................71
35833227 ............................. 81 36861383 ............................113 36890572 ..............................71
35836949 ............................. 81 36862829 ..............................91 36890580 ..............................71
35851377 ............................. 73 .............................................95 36890622 ..............................71
36076735 ............................. 91 36865293 ..............................71 36890648 ............................107
36076768 ............................. 75 36870608 ............................111 36890655 ............................113
i-2 P250WJDU
NUMERICAL INDEX

36890663 ............................. 71 36894160 ..............................99 54755087 ..............................79
36890671 ............................. 71 36894210 ..............................71 54755111 ..............................79
36890689 ........................... 113 36895472 ..............................99 54764956 ............................109
36890697 ........................... 113 36895746 ..............................71 54764964 ............................101
36890705 ........................... 113 .............................................75 ...........................................109
36890713 ........................... 113 ...........................................113 54766704 ............................105
36890721 ........................... 113 36895977 ..............................99 ...........................................109
36890739 ........................... 113 36896785 ..............................71 54774096 ............................105
36890747 ........................... 113 36897353 ..............................99 ...........................................109
36890762 ........................... 113 ...........................................103 54774104 ............................105
36890770 ........................... 113 36897380 ............................105 ...........................................109
36890796 ........................... 113 36897387 ..............................99 54774112 ............................105
36890812 ........................... 113 36897445 ..............................99 ...........................................109
36890838 ........................... 113 ...........................................103 55296409 ............................103
36890895 ............................. 99 36920486 ............................105 90544772 ..............................79
36891042 ............................. 89 36923928 ..............................85 92086719 ............................109
36891067 ............................. 89 ...........................................101 92304450 ............................113
36891083 ............................. 87 39317581 ..............................79 92368687 ..............................97
.......................................... 101 39831888 ..............................87 93186278 ..............................83
36891109 ............................. 99 54368048 ............................109 ...........................................103
36891141 ............................. 75 54390943 ..............................79 93481455 ..............................79
36891158 ............................. 75 54390950 ..............................79 93481570 ..............................83
36891208 ............................. 89 54413042 ..............................79 ...........................................103
36891414 ........................... 113 54414305 ..............................77 95022307 ..............................77
36891489 ............................. 87 54414420 ..............................75 95048914 ..............................85
36891547 ............................. 87 .............................................77 .............................................87
.......................................... 103 ...........................................101 95052387 ..............................83
.......................................... 105 54414677 ..............................77 ...........................................103
36891562 ........................... 103 54415393 ..............................93 95219861 ..............................85
36891588 ............................. 89 54425335 ..............................81 ...........................................101
36891729 ........................... 113 54429295 ..............................73 95220844 ..............................89
36891737 ........................... 113 54436845 ..............................79 95220851 ..............................89
36891745 ........................... 113 .............................................81 .............................................97
36891760 ........................... 113 54471057 ..............................79 95257325 ..............................89
36891810 ............................. 71 54471651 ..............................73 ...........................................103
36891968 ............................. 99 54471669 ..............................73 95332599 ..............................89
36892156 ............................. 97 54471685 ..............................79 95376943 ..............................79
36892164 ............................. 97 54471826 ..............................91 95431292 ..............................87
36892172 ............................. 89 .............................................93 ...........................................101
............................................ 97 54471834 ..............................93 95644019 ..............................75
36892206 ........................... 113 54471842 ..............................93 ...........................................103
36892461 ............................. 73 54479811 ..............................93 95667341 ............................103
36892479 ............................. 89 54568753 ............................117 95730172 ..............................89
36892677 ........................... 113 54568761 ............................115 95916268 ..............................85
36892685 ........................... 107 54568779 ............................115 ...........................................101
36892776 ........................... 121 ...........................................119 95916532 ..............................97
36892834 ........................... 121 54568787 ............................115 95923074 ..............................73
36892883 ........................... 121 54568795 ............................117 95923298 ............................105
36892891 ........................... 121 54604962 ............................119 95923322 ..............................73
36892909 ........................... 121 54604970 ............................117 95928230 ..............................87
36892917 ........................... 121 54625207 ............................119 ...........................................101
36892925 ........................... 121 54629902 ............................115 95929782 ..............................73
36892933 ........................... 121 54629977 ............................117 95930301 ..............................87
36892941 ........................... 121 54716360 ..............................75 ...........................................103
36892982 ........................... 113 54747935 ............................109 95934998 ..............................73
36893055 ........................... 109 54749601 ............................105 .............................................99
P250WJDU i-3
NUMERICAL INDEX

95935029 ........................... 105
95935052 ............................. 79
95935227 ............................. 73
95935599 ........................... 101
.......................................... 105
95944666 ............................. 79
............................................ 85
............................................ 87
95944690 ............................. 79
.......................................... 101
95944708 ............................. 87
.......................................... 101
95944906 ............................. 83
.......................................... 103
95951646 ............................. 83
............................................ 99
.......................................... 103
95953378 ............................. 85
.......................................... 101
95954194 ............................. 87
95955993 ............................. 87
.......................................... 103
95986014 ............................. 83
.......................................... 103
95989695 ............................. 83
.......................................... 103
95992632 ............................. 75
.......................................... 101
96701461 ............................. 73
96701479 ............................. 99
96701503 ............................. 79
96701750 ............................. 79
96702048 ............................. 79
96702055 ............................. 75
............................................ 99
96702279 ............................. 73
............................................ 99
96702287 ............................. 81
96702659 ............................. 77
96704630 ............................. 79
96708201 ............................. 79
96720545 ............................. 79
96721154 ............................. 73
96739693 ............................. 83
.......................................... 103
96739958 ............................. 73
i-4 P250WJDU
WORD INDEX
A Capscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 83, 103 Card, Option Wiring . . . . . . . . . . . . . . . . . . . . . . . 117
Adapter, Barbed . . . . . . . . . . . . . . . . . . . . . . 79, 103 Card, Standard Wiring . . . . . . . . . . . . . . . . . . . . . 117
Adapter, Engine Oil Fill . . . . . . . . . . . . . . . . . . . . . 99 Channel, Roof Connector . . . . . . . . . . . . . . . . . . 113
Adapter, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 91
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . 93 ClamP, Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Air Cleaner Assembly 8" . . . . . . . . . . . . . . . . . . . . 91 Clamp, Hose . . . . . . . . . . . . . . . . . . . . . . . 75, 89, 99
Air Intake Complete . . . . . . . . . . . . . . . . . . . . . . . 91 Clamp, Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Air Oil Piping Complete . . . . . . . . . . . . . . . . . . . . 101 Clamp, Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Airend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Clamp, Rubber Coated . . . . . . . . . . . . . . . . . . 71, 75
Airend Temp Sender . . . . . . . . . . . . . . . . . . . . . . 111 Clamp, Saddle . . . . . . . . . . . . . . . . . . . . . . . . . 73, 85
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Clamp, Spring . . . . . . . . . . . . . . . . . . . . . . . . 79, 103
Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Clamp, Support . . . . . . . . . . . . . . . . . . . . 97, 99, 107
Assy, Oil Temp Bypass valve . . . . . . . . . . . . . . . . 77 Clamp, Worm Gear . . . . . . . . . . . . . . . . . . . . . 89, 99
Automatic Ether Start . . . . . . . . . . . . . . . . . . . . . 111 Clamp, Wormgear . . . . . . . . . . . . . . . . . . . . . . . . . 75
Clamp, Wormgear . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cleaner Assembly - Air . . . . . . . . . . . . . . . . . . 91, 95
B
Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Clip - Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Band - Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 91
Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Conn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Connector . . . . . . . . . . . . . . . . . . . . . 75, 83, 87, 103
Battle, Coolant Recovery . . . . . . . . . . . . . . . . . . . 75
Connector, Bulkhead . . . . . . . . . . . . . . . . . . . . . . . 89
Bearing, Rod end . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connector, Fuel Filter . . . . . . . . . . . . . . . . . . . . . . 99
Blowdown Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Connector, Male . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Body - Air Cleaner . . . . . . . . . . . . . . . . . . . . . . 93, 95
Cooler, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Box, Air Inlet Bed . . . . . . . . . . . . . . . . . . . . . . . . 113
Cooling Complete . . . . . . . . . . . . . . . . . . . . . . . . . 75
Box, Air Inlet Cab . . . . . . . . . . . . . . . . . . . . . . . . 113
Corner, Vert Curb Bed . . . . . . . . . . . . . . . . . . . . . . 71
Bracket - Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . 91
Corner, Vert Curb Cab . . . . . . . . . . . . . . . . . . . . . 71
Bracket - Air Filter Mounting . . . . . . . . . . . . . . . . . 91
Corner, Vert Street Bed . . . . . . . . . . . . . . . . . . . . . 71
Bracket, A/E Mounting . . . . . . . . . . . . . . . . . . . . . 79
Corner, Vert Street Cab . . . . . . . . . . . . . . . . . . . . . 71
Bracket, A/e Support . . . . . . . . . . . . . . . . . . . . . . . 79
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 101
Bracket, Engine Oil/Fuel . . . . . . . . . . . . . . . . . . . . 71
Coupling, Std . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Bracket, Front Engine . . . . . . . . . . . . . . . . . . . . . . 73
Cover - Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 95
Bracket, Isolater . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Cover Assembly - Air Cleaner . . . . . . . . . . . . . . . . 93
Bracket, Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Cover, Bypass Valve, Machined . . . . . . . . . . . . . . 77
Bracket, Oil Bypass . . . . . . . . . . . . . . . . . . . . . . . . 75
Cover, Roof Access . . . . . . . . . . . . . . . . . . . . . . . 113
Bracket, Relay Mounting . . . . . . . . . . . . . . . . . . . 113
Cylinder, Pneumatic . . . . . . . . . . . . . . . . . . . . . . . 73
Bridge, Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Bulb, Fuel Primer . . . . . . . . . . . . . . . . . . . . . . . . . 99
Bulb, Incandescent . . . . . . . . . . . . . . . . . . . . . . . 111 D
Bulkhead Union . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Decal, Battery Gas . . . . . . . . . . . . . . . . . . . . . . . 117
Bulkhead, Rear Bed . . . . . . . . . . . . . . . . . . . . . . 113 Decal, Central Drains . . . . . . . . . . . . . . . . . . . . . 117
Bulkhead, Rear Cab . . . . . . . . . . . . . . . . . . . . . . 113 Decal, Combination 3-part . . . . . . . . . . . . . . . . . . 115
Bumper, Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Decal, Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . 119
Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Decal, High Pressure Air . . . . . . . . . . . . . . . . . . . 117
Bushing, Hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Decal, Hot Press Fluid . . . . . . . . . . . . . . . . . . . . . 115
Bushing, Nitrile . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Decal, Improper Operation . . . . . . . . . . . . . . . . . 115
Decal, Noise Emission . . . . . . . . . . . . . . . . . . . . 115
Decal, Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
C
Decal, Operating Instructions . . . . . . . . . . . . . . . 117
Cable, negative Battery . . . . . . . . . . . . . . . . . . . . 107
Decal, Rad Fill Hot . . . . . . . . . . . . . . . . . . . . . . . 119
Cable, Positibe Battery . . . . . . . . . . . . . . . . . . . . 107
Decal, Rotating Fan . . . . . . . . . . . . . . . . . . . 115, 119
Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Decal, WW Instrument Panel . . . . . . . . . . . . . . . 105
Cap - Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Cap, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Cap, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Dipstick, Remote Mount . . . . . . . . . . . . . . . . . . . . 99
Cap, Vinyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Door, Instrument Panel . . . . . . . . . . . . . . . . . . . . 105
Capnut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
P250WJDU ii - 1
WORD INDEX
E Harness, Gauge Illumination Option . . . . . . . . . . 111

Elbow . . . . 75, 79, 83, 85, 87, 89, 99, 101, 103, 105 Harness, Manual Cold Start Option . . . . . . . . . . . 111
Elbow - Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Head, Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Elbow 90° Street . . . . . . . . . . . . . . . . . . . . . . . . . 103 Head, Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Elbow, 45° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 High A/E Temp Indicator Lamp . . . . . . . . . . . . . . 111
Elbow, Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 High Engine Temp Indicator Lamp . . . . . . . . . . . 111
Elbow, Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Hinge, Control Panel . . . . . . . . . . . . . . . . . . . . . . 105
Element - Air Cleaner . . . . . . . . . . . . . . . . . . . . . . 95 Hinge, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Element - Primary Air Cleaner . . . . . . . . . . . . . . . 93 Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Element Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 103 Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87, 89, 99
Element, Compressor Oil Filter . . . . . . . . . . . . . . . 99 Hose - Engine Air Intake . . . . . . . . . . . . . . . . . . . . 91
Element, Engine Fuel Filter . . . . . . . . . . . . . . . . . . 99 Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Element, Engine oil Filter . . . . . . . . . . . . . . . . . . . 99 Hose Assy . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 103
Element, Separator . . . . . . . . . . . . . . . . . . . . . . . . 87 Hose, Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Element, Thermal . . . . . . . . . . . . . . . . . . . . . . . . . 77 Hose, Drain Connector . . . . . . . . . . . . . . . . . . . . . 89
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Hose, Drain Connector . . . . . . . . . . . . . . . . . . . . . 97
Engine Complete . . . . . . . . . . . . . . . . . . . . . . . . . 73 Hose, Engine Oil Drain . . . . . . . . . . . . . . . . . . . . . 89
Engine Temp Sender . . . . . . . . . . . . . . . . . . . . . 111 Hose, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Eye, Lift Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Hose, Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Eyebolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Hose, Radiator Bottom . . . . . . . . . . . . . . . . . . . . . 75
Hose, Radiator Top . . . . . . . . . . . . . . . . . . . . . . . . 75
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
F
Housing Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Housing, Oil Temp Bypass Valve . . . . . . . . . . . . . 77
Filter, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Fitting, Scavenge . . . . . . . . . . . . . . . . . . . . . . . . . 87
Flange, Unloader Inlet . . . . . . . . . . . . . . . . . . . . . . 79 I
Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 113 Inline Orifice/Chk Vlv . . . . . . . . . . . . . . . . . . . . . . 101
Foam, Closed Cell . . . . . . . . . . . . . . . . . . . . . . . . 97 Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Isolator, Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Frame, Door Lower . . . . . . . . . . . . . . . . . . . . . . . . 71
Frame, Door Upper . . . . . . . . . . . . . . . . . . . . . . . . 71 J
Frame, WW Instrument Panel . . . . . . . . . . . . . . . 105 J-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Front Louver Acoustical Foam . . . . . . . . . . . . . . . 71
K
Front Louver Assembly . . . . . . . . . . . . . . . . . . . . . 71
Key, Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Front Louver Crossmember . . . . . . . . . . . . . . . . . 71
Key, Non- Removable Ignition . . . . . . . . . . . . . . . 105
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Key, Non- Removable . . . . . . . . . . . . . . . . . . . . . 109
Key, Removable Ignition . . . . . . . . . . . . . . . . . . . 105
G Key, Removable . . . . . . . . . . . . . . . . . . . . . . . . . 109
Gage assembly, Oil level . . . . . . . . . . . . . . . . . . . 87
Gasket, A/e Discharge . . . . . . . . . . . . . . . . . . . . . 79
L
Gasket, Engine Oil Fill . . . . . . . . . . . . . . . . . . . . . 99
Lanyard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Gasket, Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . 97
Latch Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Gasket, Unloader . . . . . . . . . . . . . . . . . . . . . . . . . 79
Latch, Front Door . . . . . . . . . . . . . . . . . . . . . . . . . 71
Gasket, Unloader Inlet . . . . . . . . . . . . . . . . . . . . . 79
Latch, Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Gauge ASM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Low Oil Press Indicator Lamp . . . . . . . . . . . 109, 111
Gauge Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Gauge, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Gauge, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 M
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Manual Ether Start . . . . . . . . . . . . . . . . . . . . . . . 111
Grommet, Radiator Hose . . . . . . . . . . . . . . . . . . . 75 Member, Lift Beam Front . . . . . . . . . . . . . . . . . . . 113
Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Member, Lift Beam Rear . . . . . . . . . . . . . . . . . . . 113
Meter, Electronic Hour . . . . . . . . . . . . . . . . . . . . . 105
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
H
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Harness, Air Filter Restr Option . . . . . . . . . . . . . 111
Muffler, Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Harness, Engine Control . . . . . . . . . . . . . . . . . . . 109
ii - 2 P250WJDU
WORD INDEX
N Panel, Roof CLR End . . . . . . . . . . . . . . . . . . . . . 113

Nipple . . . . . . . . . . . . . . . . . . . . . . . 85, 87, 101, 103 Panel, Upper Engine Bed . . . . . . . . . . . . . . . . . . 113
Noz, Sonic ORF . . . . . . . . . . . . . . . . . . . . . . . . . 101 Panel, Upper Engine Cab . . . . . . . . . . . . . . . . . . 113
Nozzle Sonic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Pin Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Pipe, Exhaust Tail . . . . . . . . . . . . . . . . . . . . . . . . . 73
Nut Hex. Flange . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Piston Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Nut, Hex . . . . . . . . . . . . . . . . . . . . . . . . . 73, 79, 105 Piston Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Nut, Hex Flange . . . . . . . . . . . . . . . . . . . 75, 99, 113 Piston Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Nut, Hex Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Piston Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Nut, Hex Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Piston Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Nut, Hex Nyloc . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Piston Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Nut, Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Piston Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Nut, Nyloc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Plate, Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Nut, Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Plate, Serial Number . . . . . . . . . . . . . . . . . . . . . . 117
Nutsert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Plug . . . . . . . . . . . . . . . . . . . . . . 71, 81, 87, 101, 103
Nutsert, Hex . . . . . . . . . . . . . . . . . . . . . . . . . 75, 113 Plug, Hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87, 99
Plug, Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Plug, Vented . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
O
Pointer Assembly, rotating . . . . . . . . . . . . . . . . . . 87
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 99
Push Button Switch . . . . . . . . . . . . . . . . . . . . . . . 111
Oil Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . 101
Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . 111
Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 87, 101 R
Orifice, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 113 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Orifice, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 85, 87 Rear Fork Tube Cover . . . . . . . . . . . . . . . . . . . . . . 71
O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 81 Rear Louver Acoustical Foam . . . . . . . . . . . . . . . . 71
O-ring, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Rear Louver Assembly . . . . . . . . . . . . . . . . . . . . . 71
O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Rear Louver Crossmember . . . . . . . . . . . . . . . . . . 71
Reducer . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 87, 103
Reducer, Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . 99
P
Reg. Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Pan, Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Panel, Acoustic . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Relay, Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Panel, Acoustic Bed Cooler End . . . . . . . . . . . . . 121
Relay, Fuel Shutdown . . . . . . . . . . . . . . . . . . . . . 109
Panel, Acoustic Bed Lwr Eng . . . . . . . . . . . . . . . 121
Relay, Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . 109
Panel, Acoustic BHD Bed Side . . . . . . . . . . . . . . 121
Relay, High Engine Temp . . . . . . . . . . . . . . . . . . 109
Panel, Acoustic BHD Cab eng . . . . . . . . . . . . . . 121
Relay, Start Inhibit . . . . . . . . . . . . . . . . . . . . . . . . 109
Panel, Acoustic BHD Cab Fltr . . . . . . . . . . . . . . . 121
Relay, Start Protect . . . . . . . . . . . . . . . . . . . . . . . 109
Panel, Acoustic BHD Ctr Upper . . . . . . . . . . . . . 121
Repair Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Panel, Acoustic Cab Air Box . . . . . . . . . . . . . . . . 121
Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 113
Panel, Acoustic Cab Cooler . . . . . . . . . . . . . . . . 121
Rivet, Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . 105
Panel, Acoustic Cab Fltr End . . . . . . . . . . . . . . . 121
Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Panel, Acoustic Cab Lwr Eng. . . . . . . . . . . . . . . 121
Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Panel, Acoustic Cab Upper Eng. . . . . . . . . . . . . 121
Panel, Acoustic Center Roof . . . . . . . . . . . . . . . . 121
Panel, Acoustic CRB Door . . . . . . . . . . . . . . . . . 121 S
Panel, Acoustic End Roof . . . . . . . . . . . . . . . . . . 121 Safety Element - Air Cleaner . . . . . . . . . . . . . . . . . 93
Panel, Acoustic Exhaust Plenum . . . . . . . . . . . . 121 Screw . . . . . . . . . . . . . . . . . . 71, 75, 81, 97, 99, 113
Panel, Acoustic Fork Truck Plt . . . . . . . . . . . . . . 121 Screw Hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Panel, Acoustic St. Door . . . . . . . . . . . . . . . . . . . 121 Screw Hex. Head . . . . . . . . . . . . . . . . . . . . . . . . . 91
Panel, Cooler End Bed . . . . . . . . . . . . . . . . . . . . 113 Screw, Filister SlTD HD . . . . . . . . . . . . . . . . . . . . . 97
Panel, Cooler End Cab . . . . . . . . . . . . . . . . . . . . 113 Screw, Hex . . . . . . . . . . . . . . 73, 75, 79, 87, 99, 113
Panel, Filter End Bed . . . . . . . . . . . . . . . . . . . . . 113 Screw, Hex Flange . . . . . . . . . . . . . . . . . . . . 79, 113
Panel, Filter End Cab . . . . . . . . . . . . . . . . . . . . . 113 Screw, Hex Flange HD . . . . . . . . . . . . . . . . . . . . . 73
Panel, Instrument . . . . . . . . . . . . . . . . . . . . . . . . 105 Screw, Hex Head . . . . . . . . . . . . . . . . . . . . . . . . . 77
Panel, Lower Engine Bed . . . . . . . . . . . . . . . . . . 113 Screw, Plastic Tapping . . . . . . . . . . . . . . . . . . . . 105
Panel, Lower Engine Cab . . . . . . . . . . . . . . . . . . 113 Screw, Socket head . . . . . . . . . . . . . . . . . . . . . . . 79
Panel, Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Screw, Socket Set . . . . . . . . . . . . . . . . . . . . . . . . . 79
P250WJDU ii - 3
WORD INDEX
Screw, Sockethead . . . . . . . . . . . . . . . . . . . . . . . . 79 Tube, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Screw, Tapping . . . . . 71, 73, 75, 79, 87, 97, 99, 107 Tubing . . . . . . . . . . . . . . . . . . . . . . . 75, 79, 101, 103
ScrewTapping . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Seal, Door Long . . . . . . . . . . . . . . . . . . . . . . . . . . 71 U
Seal, Door Short . . . . . . . . . . . . . . . . . . . . . . . . . . 71 U-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Seal, Double Element . . . . . . . . . . . . . . . . . . . . . . 79 Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 103
Seal, Single Element . . . . . . . . . . . . . . . . . . . . . . . 79 Union, Barbed Tube . . . . . . . . . . . . . . . . . . . . . . . 97
Seal, U-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Union, Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Sender, Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . 97 Union, Swivel Nut . . . . . . . . . . . . . . . . . . . . . . . . 103
Sender, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Unloader Assembly . . . . . . . . . . . . . . . . . . . . . . . . 79
Sleeve Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Unloader Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Solenoid, Ether . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Unloader Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Solenoid, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Unloader Valve Assy. . . . . . . . . . . . . . . . . . . . . . . 81
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Spacer, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . 77, 81, 105 V
Standpipe Assembly, Pickup . . . . . . . . . . . . . . . . 97 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Standpipe Assembly, Return . . . . . . . . . . . . . . . . 97 Valve - Dust Ejector . . . . . . . . . . . . . . . . . . . . . . . . 93
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Valve - Vacuator . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Strap, Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Valve Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . 101
Stringer, Bed Side . . . . . . . . . . . . . . . . . . . . . . . . 113 Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Stringer, Cab Side . . . . . . . . . . . . . . . . . . . . . . . . 113 Valve, Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Stringer, Lift Beam . . . . . . . . . . . . . . . . . . . . . . . 113 Valve, Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Valve, Oil By-Pass . . . . . . . . . . . . . . . . . . . . . . . . . 75
Support, Air Cylinder . . . . . . . . . . . . . . . . . . . . . . . 73 Valve, Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Valve, Savety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Switch Shutdown W/O-Ring . . . . . . . . . . . . . . . . 101 Valve, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Switch, A/E High Air Temp . . . . . . . . . . . . . . . . . 109 Valve, WYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Switch, Air Filter Restriction . . . . . . . . . . . . . . . . 111
Switch, Block Temp. Ether . . . . . . . . . . . . . . . . . 111 W
Switch, Discharge High Air Temp . . . . . . . . . . . . 109 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Switch, Engine Oil Pressure . . . . . . . . . . . . . . . . 109 Washer Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Switch, High Engine Temp . . . . . . . . . . . . . . . . . 109 Washer, Flat . . . . . . . . . . . . . . . . . . . 73, 79, 99, 105
Switch, Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Washer, Plastic . . . . . . . . . . . . . . . . . . . . . . 105, 107
Switch, Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Washer, Snubber . . . . . . . . . . . . . . . . . . . . . . 73, 79
Switch, Low Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 109 Wrench, Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
T Z
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Panel, Acoustic Bed Air Box . . . . . . . . . . . . . . . . 121
Tank, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Panel, Acoustic Bed Fltr End . . . . . . . . . . . . . . . . 121
Tank, Separator . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Panel, Acoustic Bed Upper Eng . . . . . . . . . . . . . 121
Tee . . . . . . . . . . . . . . . . . . . . . . . 79, 83, 87, 99, 103 Panel, Acoustic Oil Cooler Top . . . . . . . . . . . . . . 121
Tee Male Branch . . . . . . . . . . . . . . . . . . . . . . . . . 101
Tee Street . . . . . . . . . . . . . . . . . . . . . . . . . . . 85, 101
Tee, Street . . . . . . . . . . . . . . . . . . . . . . . 79, 87, 101
Tee, Street NPT . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Tray, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Tube . . . . . . . . . . . . . . . . . . . . . . . . 83, 87, 101, 103
Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . 83, 99
Tube Assy . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 103
Tube Assy-Oil Scavenge . . . . . . . . . . . . . . . . . . 101
Tube Assy-Service Air . . . . . . . . . . . . . . . . . . . . 101
Tube, A/E Discharge . . . . . . . . . . . . . . . . . . . . . . . 83
Tube, Fuel Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Tube, Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Tube, Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Tube, Radiator Drain . . . . . . . . . . . . . . . . . . . . . . . 89
Tube, Scavenge . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ii - 4 P250WJDU
Portable Power Division
Ingersoll-Rand Company
P.O.Box 868 - 501 Sanford Ave.
Mocksville, N.C. 27028
©2003 Ingersoll-Rand Company, Printed in the USA

Manual Operacion, Mantenimienjto y Partes

Cargado por

Copyright:

Formatos disponibles

Manual Operacion, Mantenimienjto y Partes

Cargado por

Información del documento

Título original

Derechos de autor

Formatos disponibles

Compartir este documento

Compartir o incrustar documentos

Opciones para compartir

¿Le pareció útil este documento?

¿Este contenido es inapropiado?

Copyright:

Formatos disponibles

Manual Operacion, Mantenimienjto y Partes

Cargado por

Copyright:

Formatos disponibles

OPERATING, MAINTENANCE

AND PARTS MANUAL

This manual contains important safety information.

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2 Book 22320717 (8/03)

Book 22320717 (8/03) 3

Book 22320717 (8/03) 9

Safety Precautions machine safety valve rating.

10 Book 22320717 (8/03)

Book 22320717 (8/03) 11

The following substances may be produced

12 Book 22320717 (8/03)

! DANGER Indicates the presence of a hazard which WILL cause serious

! Indicates the presence of a hazard which CAN cause serious

! CAUTION Indicates the presence of a hazard which WILL or can cause

Indicates important set-up, operating or maintenance

Book 22320717 (8/03) 13

Do not operate without

14 Book 22320717 (8/03)

FUEL ONLY Relieve pressure before

FREE SAFETY DECALS!

Decal part numbers are on the bottom of each decal and

Book 22320717 (8/03) 15

16 Book 22320717 (8/03)

Book 22320717 (8/03) 17

1. The original air end is returned assembled and unopened.

2. Continued use of genuine Ingersoll-Rand parts, fluids, oil and filters.

3. Maintenance is performed at prescribed intervals.

18 Book 22320717 (8/03)

General Warranty Information

GENERAL WARRANTY Extended Coverage

Portable Genset 8KW, 11KW, Package 1 year/2000 hours None

Light Tower Package 1 year/2000 hours

NOTE: Actual warranty times may change. Consult the manufacturer’s

Book 22320717 (8/03) 19

Complete Machine Registration

NOTE: Completion of this form validates the warranty.

20 Book 22320717 (8/03)

Selling Distributor Servicing Distributor WARRANTY

 Construction-Heavy  Asphalt Contractor  Coal Mining  Other Mining

Model Unit S/N Engine S/N Date Delivered

Model Unit S/N Engine S/N Date Delivered

SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT

Book 22320717 (8/03) 21

22 Book 22320717 (8/03)

Book 22320717 (8/03) 23

This section pertains only to machines distributed within the United

Federal law prohibits the following acts or the causing thereof:

Compressor Noise Emission Control Information

24 Book 22320717 (8/03)

Noise Emission Control Maintenance Log

COMPRESSOR MODEL __________________________

UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM

Noise Emission Warranty

Book 22320717 (8/03) 25

deformed, such that their noise containment

C. Acoustic Materials H. Isolation Mounts

26 Book 22320717 (8/03)

Maintenance Record For Noise Emission Control And Extended Warranty

Construction-Heavy Asphalt Contractor Coal Mining Other Mining