7/20

P65
OPERATION AND MAINTENANCE MANUAL
Original Instruction

SERIAL No : 121001 −>

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

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
C.C.N. : 22311203 en
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
REV :H
Ingersoll-Rand Company and Doosan Company or the products of DATE : JANUARY 2010
Revised (10-12)
either.
Machine models represented in this manual may be used in various locations world−wide. Machines sold and shipped
into European Union Territories require that the machine display the CE Mark and conform to various directives. In
such cases, the design specification of this machine has been certified as complying with EC directives. Any
modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered
invalid. A declaration of that conformity follows:

SAMPLE
 CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to

the State of California to cause cancer, birth defects, and other
reproductive harm.
 CONTENTS & ABBREVIATIONS 1
1 CONTENTS ABBREVIATIONS & SYMBOLS

2 FOREWORD
#### Contact Ingersoll−Rand for serial number
3 WARRANTY −>#### Up to Serial No.
####−> From Serial No.
10 DECALS
* Not illustrated
16 NOISE EMISSION † Option
AR As required
20 MAINTENANCE RECORD FOR NOISE
EMISSION CONTROL AND EXTENDED HA High ambient machine
WARRANTY F.H.R.G. Fixed height running gear
21 SAFETY V.H.R.G. Variable height running gear

24 GENERAL INFORMATION bg Bulgarian

Dimensions cs Czech
Data da Danish
de German
26 OPERATING INSTRUCTIONS el Greek
Commissioning en English
Prior to starting es Spanish
Starting et Estonian
Stopping fi Finnish
Emergency stopping fr French
Re−starting hu Hungarian
Monitoring during operation it Italian
Decommissioning lt Lithuanian
lv Latvian, Lettish
30 MAINTENANCE mt Maltese
Routine maintenance nl Dutch
Lubrication no Norwegian
Speed & pressure regulation pl Polish
Torque settings table pt Portuguese
Compressor lubrication ro Romanian
ru Russian
sk Slovak
42 MACHINE SYSTEMS sl Slovenian
Electrical system sv Swedish
Piping & instrumentation system zh Chinese

46 FAULT FINDING

48 OPTIONS

Lubricator.
Safety.
General Information.
Operating Instructions.
Maintenance.
Fault Finding.

49 ENGINE INSTRUCTION MANUAL

7/20, P65
2 FOREWORD

The contents of this manual are considered to be proprietary and TABLE 1

confidential to Ingersoll Rand and should not be reproduced without the
prior written permission of Ingersoll Rand. Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
Nothing contained in this document is intended to extend any checks.
promise, warranty or representation, expressed or implied, regarding
the Ingersoll Rand products described herein. Any such warranties or Use of the machine outside the ambient temperature range
other terms and conditions of sale of products shall be in accordance specified in the GENERAL INFORMATION SECTION of this manual.
with the standard terms and conditions of sale for such products, which
are available upon request. This machine is not intended and must not be used in potentially
explosive atmospheres, including situations where flammable gases
or vapours may be present.
This manual contains instructions and technical data to cover all
routine operation and scheduled maintenance tasks by operation and Use of the machine fitted with non Ingersoll Rand approved
maintenance staff. Major overhauls are outside the scope of this components / lubricants / fluids.
manual and should be referred to an authorised Ingersoll Rand service
department.
Use of the machine with safety or control components missing or
disabled.
The design specification of this machine has been certified as
complying with EC directives. As a result: Use of the machine for storage or transportation of materials inside
or on the enclosure except when contained within the toolbox.
(a) Any machine modifications are strictly prohibited, and will invalidate
EC certification.

(b) A unique specification for USA/Canada is adopted and tailored to The company accepts no responsibility for errors in translation of
the territory. this manual from the original English version.

All components, accessories, pipes and connectors added to the © COPYRIGHT 2010
compressed air system should be:
. of good quality, procured from a reputable manufacturer and, DOOSAN COMPANY
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 / lubricants / fluids other than those included
within the Ingersoll Rand approved parts list may create hazardous
conditions over which Ingersoll Rand has no control. Therefore
Ingersoll Rand cannot be held responsible for equipment in which
non−approved repair parts are installed.

Ingersoll Rand reserves the right to make changes and

improvements to products without notice and without incurring any
obligation to make such changes or add such improvements to
products sold previously.

The intended uses of this machine are outlined below and examples
of unapproved usage are also given, however Ingersoll Rand cannot
anticipate every application or work situation that may arise.

IF IN DOUBT CONSULT SUPERVISION.

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

The use of the machine in any of the situation types listed in

table 1:−
a) Is not approved by Ingersoll Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll Rand.

7/20, P65
 WARRANTY 3
Ingersoll−Rand, through its distributor, warrants that each item of G. Ingersoll−Rand Platinum Drive Train Limited Extended
equipment manufactured by it and delivered hereunder to the initial Warranty − Platinum drive train refers to the Ingersoll−Rand
user will be free of defects in material and workmanship for a period of Engine and Airend combination. The earlier of sixty (60) months
three (3) months from initial operation or six (6) months from the date from shipment to, or the accumulation of 10,000 hours of
of shipment to the initial user, whichever occurs first. operation by the initial user. The starter, alternator, fuel injection
system and all electrical components are excluded from this
With respect to the following types of equipment, the warranty period extended warranty. The airend seal and drive coupling are
enumerated below will apply in lieu of the foregoing warranty period. included in the warranty but airend drive belts are excluded. This
limited extended warranty is automatically available when
meeting the following conditions are met:

1. The original airend is returned assembled and unopened.

A. Aftercoolers − The earlier of nine (9) months from date of
shipment to or six (6) months from start up by initial user.
2. Continued use of genuine Ingersoll−Rand parts, fluids, oil and
filters.
B. Portable Compressors, Portable Generator Sets −
9 Kva through to 550 Kva, Portable Light Towers and Air 3. Maintenance is performed at prescribed intervals by
Dryers − The earlier of twelve (12) months from shipment to or authorized and properly trained service engineers.
the accumulation of 2,000 hours of service by the initial user.

Ingersoll−Rand shall be provided with such information as it

2.5 Kva Through to 8 Kva − The earlier of twelve (12) months
requires to confirm that these conditions have been complied
from shipment to or the accumulation of 2,000 hours of operation
with.
by the initial user.

H1. Construction Tools, (Portable Power range only) − Twelve

Ingersoll−Rand will provide a new part or repaired part, at it’s sole (12) months from shipment to initial user. Ingersoll−Rand will
discretion, in place of any part which is found to be defective in provide a new part or repaired part, at it’s sole discretion, in place
material or workmanship during the period described above. of any part which is found to be defective in material or
Labor cost to replace the part is the responsibility of the initial workmanship during the period described above. Labor cost to
user. replace the part is the responsibility of the initial user.

C. Portable Compressor Air Ends − The earlier of twenty−four H2. Construction Tools Limited Extended Warranty, (Portable
(24) months from shipment to or the accumulation of 4,000 hours Power range only) − Thirty−six (36) months from shipment to
of service by the initial user. For Air Ends, the warranty against initial user. This extended warranty is automatically available
defects will include replacement of the complete Air End, only when the tool is registered with Ingersoll−Rand by
provided the original Air End is returned assembled and all completing and submitting the Warranty Registration form.
original seals are intact. Ingersoll−Rand will provide a new part or repaired part, at it’s sole
discretion, in place of any part which is found to be defective in
material or workmanship during the period described above.
C1. Portable Compressor Airend Limited Extended Warranty −
Labor cost to replace the part is the responsibility of the initial
The earlier of sixty (60) months from shipment to or the
user.
accumulation of 10,000 hours of operation by the initial user. This
extended warranty is limited to defects in design or defective
material or workmanship in rotors, housings, bearings and gears I. Spare Parts − Six (6) months from date of shipment to the initial
and provided all the following conditions are met: user.

The original air end is returned assembled and all original seals
are intact.
Ingersoll−Rand will provide a new part or repaired part, at its sole
discretion, in place of any part that is found to be defective in material
Continued use of genuine Ingersoll−Rand parts, fluids, oils and and workmanship during the period described above. Such parts will
filters. 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
Maintenance is performed at prescribed intervals by authorized authorized by Ingersoll−Rand. User must present proof of purchase at
and properly trained service engineers. the time of exercising warranty.

D. Generator Alternator − 9 Kva through to 550 Kva. The earlier The above warranties do not apply to failures occurring as a result of
of twenty−four (24) months from shipment to or the accumulation abuse; misuse, negligent repairs, corrosion, erosion and normal wear
of 4,000 hours of operation by the initial user. 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
2.5 Kva Through to 8 Kva − The earlier of twelve (12) months provided in the product’s operating and maintenance publications.
from shipment to or the accumulation of 2,000 hours of operation
by the initial user.
Accessories or equipment furnished by Ingersoll−Rand, but
manufactured by others, including, but not limited to, engines, tires,
E. Portable Light Tower Alternator − The earlier of twelve (12) batteries, engine electrical equipment, hydraulic transmissions,
months from shipment to or the accumulation of 2,000 hours of carriers, shall carry only the manufacturers warranty, which
operation by the initial user. Light Source model only, the earlier Ingersoll−Rand can lawfully assign to the initial user.
of twenty−four (24) months from shipment to or the accumulation
of 4,000 hours of operation by the initial user.
THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTHER
WARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT OF
F. Ingersoll−Rand Engines − The earlier of twenty−four (24) TITLE), AND THERE ARE NO WARRANTIES OF
months from shipment to or the accumulation of 4,000 hours of MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
operation by the initial user. PURPOSE.

7/20, P65
4 WARRANTY

GENERAL WARRANTY INFORMATION − ESA

COMMENTS

PORTABLE COMPRESSOR PACKAGE 12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,
HOURS RADIATOR, OIL COOLER, RECEIVER, PIPEWORK,
ELECTRICAL CIRCUIT ETC.

AIREND 24 MONTHS / 4,000 60 MONTHS / 10,000 HOURS. EXTENDED LIMITED

HOURS WARRANTY AVAILABLE ON MAJOR COMPONENTS.
REFER TO OPERATOR’S MANUAL.

ENGINE SEE BELOW

2.5kVA − 8kVA PACKAGE 12 MONTHS / 2,000 CONTACT IR NETWORK FOR WARRANTY (PARTS
GENERATORS HOURS ONLY NO LABOUR).

ALTERNATOR 12 MONTHS / 2,000 CONTACT IR NETWORK FOR WARRANTY (PARTS

HOURS ONLY NO LABOUR).

ENGINE SEE BELOW

9kVA − 550kVA PACKAGE 12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,
GENERATORS HOURS ELECTRICAL CIRCUIT ETC.

ALTERNATOR 24 MONTHS / 4,000 CONTACT IR NETWORK FOR WARRANTY.

HOURS

ENGINE SEE BELOW

LIGHT TOWER PACKAGE 12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,
HOURS ELECTRICAL CIRCUIT ETC.

ALTERNATOR 12 MONTHS / 2,000 EXTENDED WARRANTY OF 24 MONTHS / 4,000 HRS.

HOURS FOR LIGHTSOURCE INTRODUCED 8/16/99.

ENGINE SEE BELOW

ENGINES

MONTHS HOURS COMMENTS

CATERPILLAR 12 UNLIMITED EXTENDED WARRANTY PROVIDED VIA ENGINE

SUPPLIER’S OWN APPROVED NETWORK AT TIME OF
PURCHASE.

CUMMINS 24 2,000 EXTENDED WARRANTY PROVIDED VIA ENGINE

SUPPLIER’S OWN APPROVED NETWORK AT TIME OF
PURCHASE.

PERKINS 12 UNLIMITED IF UNDER 500 HOURS IN FIRST YEAR THEN BELOW

APPLIES.

24 1,000 ALL COMPONENTS COVERED EXCLUDING

INJECTORS.

JOHN DEERE 24 2,000 5 YRS/5,000 HRS USING OEM FLUIDS AND FILTERS
(IN COMPRESSORS) WITH $250 DEDUCTABLE

(IN GENERATORS) 24 2,000 24 MONTHS / 4,000 HRS. AVAILABLE FROM IR WITH

USE OF GENUINE IR PARTS AND OILS AT
PRESCRIBED SERVICE INTERVALS. CONTACT IR
NETWORK.

DEUTZ 0 − 12 UNLIMITED ALL COMPONENTS COVERED.

13 − 24 UNLIMITED MAJOR COMPONENTS COVERED. FURTHER

EXTENDED WARRANTY ON MAJOR COMPONENTS
PROVIDED VIA ENGINE SUPPLIER’S OWN APPROVED
NETWORK AT TIME OF PURCHASE.

INGERSOLL−RAND 24 4,000 EXTENDED WARRANTY OF 60 MONTHS / 10,000 HRS.

WHEN USING GENUINE INGERSOLL−RAND FLUIDS
AND PARTS ON MAJOR COMPONENTS.
7/20, P65
 WARRANTY 5
KUBOTA 24 4,000 EXTENDED WARRANTY OF 60 MONTHS / 10,000 HRS.
(7/20) WHEN USING GENUINE INGERSOLL−RAND FLUIDS
AND PARTS ON MAJOR COMPONENTS.

MITSUBISHI 24 2,000 NO EXTENDED WARRANTY AVAILABLE.

VOLVO 24 2,000 EXTENDED WARRANTY PROVIDED VIA ENGINE

SUPPLIER’S OWN APPROVED NETWORK AT TIME OF
PURCHASE.

HONDA 12 UNLIMITED WARRANTY PROVIDED VIA ENGINE SUPPLIERS’S

OWN APPROVED NETWORK.

YANMAR 12 UNLIMITED WARRANTY PROVIDED VIA ENGINE SUPPLIERS’S

OWN APPROVED NETWORK.

VANGUARD 24 UNLIMITED WARRANTY PROVIDED VIA ENGINE SUPPLIERS’S

OWN APPROVED NETWORK.

PARTS

MONTHS HOURS COMMENTS

INGERSOLL−RAND 6 UNLIMITED PARTS ONLY AVAILABLE FROM IR NETWORK.

AIREND EXCHANGE

MONTHS HOURS COMMENTS

AIREND 12 2,000 24 MONTHS / 4,000 HRS. AVAILABLE FROM IR

NETWORK.

CONSTRUCTION TOOLS

MONTHS HOURS COMMENTS

CONSTRUCTION TOOLS 12 N/A OPTIONAL 36 MONTHS EXTENDED WARRANTY

AVAILABLE FROM IR. ALL WARRANTY COVERS PARTS
ONLY REPLACEMENT.

NOTE: Actual warranty times may change.

Consult the Manufacturer’s warranty policy as shipped with each
new product.

7/20, P65
6 WARRANTY

Extended Limited Airend Warranty

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

All machines have the standard airend warranty, − The earlier of 24 months from shipment to, or the accumulation of 4000 hours of service by the
initial user.

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

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

1. The original airend is returned assembled and unopened.

2. Submissions of proof that Ingersoll−Rand fluid, filters and separators have been used. Refer to the Operation and Parts manual for the correct fluids,
filters and separator elements required.

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

WARRANTY TIME *BARE AIREND **AIREND COMPONENTS

STANDARD 2YRS / 4,000HRS 100% PARTS & LABOUR 100% PARTS & LABOUR
OPTIONAL 5YRS / 10,000HRS 100% PARTS & LABOUR 0%

*BARE AIREND − pertains to major airend parts (rotors, housings, gears and bearings).

**AIREND COMPONENTS − pertains to auxiliary attachments to the bare airend (seals, pumps, valves, tubes, hoses, fittings and filter housing).

Pro−Tec and XHP505 Compressor Fluids are available from your local Ingersoll−Rand branch or distributor.

For units operating within the USA & Canada, call the Statesville Product Support Department on 1−800−633−5206

1 XHP650/900/1070/1170 will continue to use XHP505 and will have the extended warranty when above conditions are met.

7/20, P65
 WARRANTY 7
WARRANTY REGISTRATION

FOR UNITS SOURCED FROM DUBLIN, IRELAND

Complete Machine Registration

To initiate the machine warranty, fill out the ”Warranty Registration” form 83242 11/99 supplied as part of the machine documentation, keep a copy for
your records and mail the original to:

Doosan Warranty Team

Doosan Trading Limited
Block B, Swords Business Campus
Swords
County Dublin
Ireland

Fax: (+353) 1 870 7404

Email: doosanwarranty@dii.doosan.com

Note: Completion of this form validates the warranty.

Engine Registration:
I−R powered machines do not require separate engine registration.

Deutz require a separate engine registration form to be completed and mailed direct to their Cologne office. The form is supplied as part of the machine
documentation for Deutz powered machines.

Caterpillar, Cummins and Perkins do not require a separate registration form but they stipulate that any new engine should be registered with their local
dealer to initiate warranty.

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

7/20, P65
8 WARRANTY

WARRANTY REGISTRATION
FOR UNITS SOURCED FROM STATESVILLE, USA
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:
Doosan International USA, Inc
1293 Glenway Drive
Statesville
North Carolina 28625−9218
Attn: Warranty Department
Note: Completion of this form validates the warranty.
Engine Registration:
I−R powered machines do not require separate engine registration.

John Deere requires a separate engine registration be completed and mailed direct to John Deere.

Separate engine registration material is included with this literature package for John Deere powered machines.

All other engine manufacturers do not require a separate engine registration.

You MUST present proof of in−service date at time of requesting engine warranty service.

7/20, P65
 WARRANTY 9

PORTABLE POWER
EXTENDED WARRANTY REGISTRATION FORM

Customer Details Service Provider Details

Company Name : Service Provider / Distributor :

Contact Name : Branch Office :

Signature :

Company Address : Machine Details

Product Type :

Model :

Serial Number :

SAMPLE
Engine Serial Number :

Engine Model Number :

Post / Zip Code : Airend Serial Number :

Country : Alternator Serial Number :

Phone Number : Date of start up :

Fax Number :

e−mail :

7/20, P65
10 DECALS

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING − Pressurised component or WARNING − Hot surface.
system.

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

WARNING − Pressurised vessel. WARNING − Hot and harmful exhaust gas. WARNING − Flammable liquid.

0C

X,X BAR

WARNING − Maintain correct tyre pressure. WARNING − Before connecting the tow bar WARNING − For operating temperature
(Refer to the GENERAL INFORMATION or commencing to tow consult the below 0C, consult the operation and
section of this manual). operation and maintenance manual. maintenance manual.

7/20, P65
 DECALS 11

WARNING − Do not undertake any

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

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

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

XX
km/h
Do not open the service valve before the
Do not exceed the trailer speed limit. No naked lights.
airhose is attached.

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

7/20, P65
12 DECALS

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

Read the Operation and Maintenance manual

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

Diesel fuel Rough Service Designation.

Parking brake.
No open flame. Wet Location Operation.

Replace any cracked protective shield. Oil drain.

7/20, P65
 DECALS 13
Look for these signs on machines shipped to markets in North America, which point out potential hazards
to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions.
If you do not understand, inform your supervisor.

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

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

DANGER WARNING
Trapped air pressure. Can
cause serious injury or
death.

Close service valve and

operate tool to vent trapped air
before performing any service.
Air discharged from this machine can contain
carbon monoxide or other contaminants which
will cause serious injury or death.
Do not breathe this air.

WARNING WARNING
Hot pressurized fluid. Rotating Fan Blade.
Can cause serious burns. CAN cause serious injury.

Do not open radiator while Do NOT operate with guard

hot. removed.

7/20, P65
14 DECALS

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

WARNING

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

Access Lifting Bail from inside machine.

WARNING

WARNING
High pressure air. Can
cause serious injury or
death.

Relieve pressure before

removing filler plugs/ Door under pressure CAN cause serious
caps, fittings or covers. injury.

Use both hands to open door when machine

is running.

7/20, P65
 DECALS 15

WARNING

WARNING
Collapsing propstand.
Can cause serious injury.
Excessive Towing Speed. CAN cause
Clamp propstand securely serious injury or death.
Do NOT Tow on Highway.
Excessive towing speed. Do NOT exceed 20 mph (32 km/h)
Can cause serious injury or
death.
Do NOT exceed 65 mph (105
km/hr)

For Highway Towable Units. For Non−Highway Towable Machines

FREE SAFETY DECALS!

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 Doosan Portable Power
EMEA Aftermarket 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.

7/20, P65
16 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:

1. Removal or rendering inoperative any of the following:

a. the engine exhaust system or parts thereof
b. the air intake system or parts thereof
c. enclosure or parts thereof

2. Removal of any of the following:

a. fan shroud
b. vibration mounts
c. sound absorption material

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

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 the 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.

7/20, P65
 NOISE EMISSION 17

NOISE EMISSION CONTROL

MAINTENANCE LOG

COMPRESSOR MODEL

SERIAL NO.

USER UNIT NO.

UNIT IDENTIFICATION DEALER OR DISTRIBUTOR

ENGINE MAKE & MODEL: FROM WHOM PURCHASED:
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 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 a 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. (40FR204.58−1).

7/20, P65
18 NOISE EMISSION
INTRODUCTION
The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air
Compressors.

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

MAINTENANCE SCHEDULE

ITEM AREA PERIOD

A. COMPRESSED AIR LEAKS AS DETECTED
B. SAFETY AND CONTROL SYSTEMS AS DETECTED
C. ACOUSTIC MATERIALS DAILY
D. FASTENERS 100 HOURS
E. ENCLOSURE PANELS 100 HOURS
F. AIR INTAKE & ENGINE EXHAUST 100 HOURS
G. COOLING SYSTEMS 250 HOURS
H. ISOLATION MOUNTS 250 HOURS
I. ENGINE OPERATION SEE OPERATOR’S MANUAL
J. FUELS & LUBRICANTS SEE OPERATOR’S MANUAL

7/20, P65
 NOISE EMISSION 19
A. COMPRESSED AIR LEAKS F. AIR INTAKE AND ENGINE EXHAUST

Correct all compressed air leaks during the first shutdown period Engine and compressor air intake and engine exhaust systems
after discovery. If severe enough to cause serious noise problems and should be inspected after each 100 hours of operation for loose,
efficiency loss, shut down immediately and correct the leak(s). damaged, or deteriorated components. Repairs or replacements
should be made before the next period of use.

B. SAFETY AND CONTROL SYSTEMS

G. COOLING SYSTEMS
Repair or replace all safety and control systems or circuits as
malfunction occurs. No compressor should be operated with either All components of the cooling systems for engine water and
system bypassed, disabled, or nonfunctional. compressor oil should be inspected every 250 hours of use. Any
discrepancies found should be corrected before placing the unit back
in operation. Unrestricted airflow over the radiator and oil cooler must
C. ACOUSTIC MATERIALS be maintained at all times during operation.
In daily inspections, observe these materials. Maintain all
acoustic material as nearly as possible in its original condition. Repair
or replace all sections that have: 1) sustained damage, 2) have partially H. ISOLATION MOUNTS
separated from panels to which they were attached, 3) are missing, or
Engine/airend isolation mounts should be inspected after each
have otherwise deteriorated due to severe operating or storage
250 hours of operation. Those mounts with cracks or splits in the
conditions. molded rubber, or with bent or broken bolts due to operation or storage
in severe environments, all should be replaced with equivalent parts.
D. FASTENERS

All fasteners such as hinges, nuts, bolts, clamps, screws, rivets I. ENGINE OPERATION
and latches should be inspected for looseness after each 100 hours of
operation. They should be retightened, repaired, or − if missing − Inspect and maintain engine condition and operation as
replaced immediately to prevent subsequent damage and noise recommended in the manuals supplied by the engine manufacturer.
emission increase.
J. FUELS AND LUBRICANTS
E. ENCLOSURE PANELS
Use only the types and grades of fuels and lubricants
Enclosure panels should also be inspected at 100 hour recommended in the Ingersoll−Rand Company and Engine
operational intervals. All panels that are warped, punctured, torn, or Manufacturer’s Operator and Maintenance Manuals.
otherwise deformed, such that their noise containment function is
reduced, should be repaired or replaced before the next operation
interval. Doors, access panels, and hatch closures especially, should
be checked and adjusted at this time to insure continuous sealing
between gasket or acoustic material and the mating frame.

7/20, P65
20 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY

MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY

ITEM NO. DESCRIPTION OF WORK OR HOURMETER MAINT/INSPECT LOCATION WORK DONE BY

COMMENTS READING DATE CITY/STATE (NAME)

7/20, P65
 SAFETY 21
WARNINGS WARNING: Under no circumstances should volatile liquids such
Warnings call attention to instructions which must be followed as Ether be used for starting this machine.
precisely to avoid injury or death.

CAUTIONS
Cautions call attention to instructions which must be followed
precisely to avoid damaging the product, process or its surroundings.
Never operate unit with guards, covers or screens removed. Keep
NOTES hands, hair, clothing, tools, blow gun tips, etc. well away from moving
Notes are used for supplementary information. parts.

General Information
Never operate unit without first observing all safety warnings and
carefully reading the operation and maintenance manual shipped from Compressed air
the factory with this machine.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
Ensure that the operator reads and understands the decals and system and that the machine cannot be started accidentally.
consults the manuals before maintenance or operation.
Ensure that the machine is operating at the rated pressure and that
Ensure that the Operation and Maintenance manual, and the the rated pressure is known to all relevant personnel.
manual holder, are not removed permanently from the machine.
All air pressure equipment installed in or connected to the machine
Ensure that maintenance personnel are adequately trained, must have safe working pressure ratings of at least the machine rated
competent and have read the Maintenance Manuals. pressure.

Make sure that all protective covers are in place and that the If more than one compressor is connected to one common
canopy/doors are closed during operation. downstream plant, effective check valves and isolation valves must be
fitted and controlled by work procedures, so that one machine cannot
accidentally be pressurised / over pressurised by another.
The specification of this machine is such that the machine is not
suitable for use in flammable gas risk areas. If such an application is
required then all local regulations, codes of practice and site rules must Compressed air must not be used for a direct feed to any form of
be observed. To ensure that the machine can operate in a safe and breathing apparatus or mask.
reliable manner, additional equipment such as gas detection, exhaust
spark arrestors, and intake (shut−off) valves may be required,
High Pressure Air can cause serious injury or death. Relieve
dependant on local regulations or the degree of risk involved.
pressure before removing filler plugs/caps, fittings or covers.

A weekly visual check must be made on all fasteners/fixing screws

securing mechanical parts. In particular, safety−related parts such as Air pressure can remain trapped in air supply line which can result
coupling hitch, drawbar components, road−wheels, and lifting bail in serious injury or death. Always carefully vent air supply line at tool
should be checked for total security. or vent valve before performing any service.

All components which are loose, damaged or unserviceable, must

be rectified without delay. The discharged air contains a very small percentage of compressor
lubricating oil and care should be taken to ensure that downstream
Air discharged from this machine may contain carbon monoxide or equipment is compatible.
other contaminants which will cause serious injury or death. Do not
breathe this air.
If the discharged air is to be ultimately released into a confined
space, adequate ventilation must be provided.
This machine produces loud noise with the doors open or service
valve vented. Extended exposure to loud noise can cause hearing loss.
Always wear hearing protection when doors are open or service valve When using compressed air always use appropriate personal
is vented. protective equipment.

Never inspect or service unit without first disconnecting battery All pressure containing parts, especially flexible hoses and their
cable(s) to prevent accidental starting. couplings, must be regularly inspected, be free from defects and be
replaced according to the Manual instructions.

Do not use petroleum products (solvents or fuels) under high Avoid bodily contact with compressed air.
pressure as this can penetrate the skin and result in serious illness.
wear eye protection while cleaning unit with compressed air to prevent
debris from injuring eye(s). The safety valve located in the separator tank must be checked
periodically for correct operation.

Rotating fan blade can cause serious injury. Do not operate without
guard in place. Whenever the machine is stopped, air will flow back into the
compressor system from devices or systems downstream of the
machine unless the service valve is closed. Install a check valve at the
Use care to avoid contacting hot surfaces (engine exhaust manifold machine service valve to prevent reverse flow in the event of an
and piping, air receiver and air discharge piping, etc.). unexpected shutdown when the service valve is open.

7/20, P65
22 SAFETY
Disconnected air hoses whip and can cause serious injury or death. DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY
Always attach a safety flow restrictor to each hose at the source of SINCE THIS MAY CAUSE IT TO EXPLODE.
supply or branch line in accordance with OSHA Regulation 29CFR
Section 1926.302(b).
Exercise extreme caution when using booster battery. To jump
battery, connect ends of one booster cable to the positive (+) terminal
Never allow the unit to sit stopped with pressure in the of each battery. Connect one end of other cable to the negative (−)
receiver−separator system. terminal of the booster battery and other end to a ground connection
away from dead battery (to avoid a spark occurring near any explosive
gases that may be present). After starting unit, always disconnect
cables in reverse order.

Materials
Radiator
The following substances may be produced during the operation of
this machine: Hot engine coolant and steam can cause injury. Ensure that the
. brake lining dust radiator filler cap is removed with due care and attention.
. engine exhaust fumes

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

Ensure that adequate ventilation of the cooling system and exhaust

gases is maintained at all times.
Transport
The following substances are used in the manufacture of this When loading or transporting machines ensure that the specified
machine and may be hazardous to health if used incorrectly: lifting and tie down points are used.

.. compressor lubricant
. engine lubricant When loading or transporting machines ensure that the towing
. preservative grease vehicle, its size, weight, towing hitch and electrical supply are all
. rust preventative suitable to provide safe and stable towing at speeds either, up to the
. diesel fuel legal maximum for the country in which it is being towed or, as specified
. battery electrolyte for the machine model if lower than the legal maximum.

AVOID INGESTION, SKIN CONTACT AND INHALATION OF

Ensure that the maximum trailer weight does not exceed the
FUMES
maximum gross weight of the machine (by limiting the equipment load),
limited by the capacity of the running gear.
Should compressor lubricant come into contact with the eyes, then
irrigate with water for at least 5 minutes.
Note:
Gross mass (on data plate) is for the basic machine and fuel only,
Should compressor lubricant come into contact with the skin, then excluding any fitted options, tools, equipment and foreign materials.
wash off immediately.
Before towing the machine, ensure that:−
Consult a physician if large amounts of compressor lubricant are
ingested. . the tyres and towing hitch are in a serviceable condition.
. the canopy is secure.
. all ancillary equipment is stored in a safe and secure manner.
Consult a physician if compressor lubricant is inhaled. . the brakes and lights are functioning correctly and meet necessary
road traffic requirements.
. break-away cables/safety chains are connected to the towing
Never give fluids or induce vomiting if the patient is unconscious or
vehicle.
having convulsions.

The machine must be towed in a level attitude in order to maintain

Safety data sheets for compressor and engine lubricants should be
correct handling, braking and lighting functions. This can be achieved
obtained from the lubricant supplier.
by correct selection and adjustment of the vehicle towing hitch and, on
variable height running gear, adjustment of the drawbar.
Never operate the engine of this machine inside a building without
adequate ventilation. Avoid breathing exhaust fumes when working on
To ensure full braking efficiency, the front (towing eye) section must
or near the machine.
always be set level.

This machine may include such materials as oil, diesel fuel, When adjusting variable height running gear:−
antifreeze, brake fluid, oil/air filters and batteries which may require
proper disposal when performing maintenance and service tasks.
Contact local authorities for proper disposal of these materials. Ensure front (towing eye) section is set level

When raising towing eye, set rear joint first, then front joint.

When lowering towing eye, set front joint first, then rear joint.
Battery
A battery contains sulphuric acid and can give off gases which are
corrosive and potentially explosive. Avoid contact with skin, eyes and
clothing. In case of contact, flush area immediately with water. After setting, fully tighten each joint by hand and then tighten further to
the next pin. Refit the pin.

7/20, P65
 SAFETY 23
When parking always use the handbrake and, if necessary, suitable Where brakes and safety chains are fitted:
wheel chocks.
a) Loop the chains onto the towing vehicle using the towing vehicle
Make sure wheels, tyres and tow bar connectors are in safe hitch as an anchorage point, or any other point of similar strength.
operating condition and tow bar is properly connected before towing.
b) Ensure that the effective chain length is as short as possible whilst
still allowing normal articulation of the trailer and effective operation of
the breakaway cable.

Safety chains / connections and their adjustment Where safety chains only are fitted:

The legal requirements for the joint operation of the breakaway

cable and safety chains are as yet unidentified by 71/320/EEC or UK a) Loop the chains onto the towing vehicle using the towing vehicle
regulations. Consequently we offer the following advice / instructions. hitch as an anchorage point, or any other point of similar strength.

b) When adjusting the safety chains there should be sufficient free

Where brakes only are fitted: length in the chains to allow normal articulation, whilst also being short
enough to prevent the towbar from touching the ground in the event of
an accidental separation of the towing vehicle from the trailer.
a) Ensure that the breakaway cable is securely coupled to the
handbrake lever and also to a substantial point on the towing vehicle.

b) Ensure that the effective cable length is as short as possible, whilst Disposal of contaminated fluids from bund
still allowing enough slackness for the trailer to articulate without the
handbrake being applied. Contaminated fluids removed from bund (where fitted), must be
disposed of to designated containers only.

7/20, P65
24 GENERAL INFORMATION

7/20 VARIABLE HEIGHT RUNNING GEAR

7/20 FIXED HEIGHT RUNNING GEAR

7/20, P65
 GENERAL INFORMATION 25
COMPRESSOR 7/20 INFORMATION ON AIRBORNE NOISE (‘W’ model)
Actual free air delivery. 1,84 m3 min−1 (65 CFM) − The A−weighted emission sound pressure level
Normal operating discharge pressure. 7 bar (100 PSI) . 84 dB(A), uncertainty 1 dB(A)
Maximum allowable pressure. 8,6 bar (125 PSI) − The A−weighted emission sound power level
Safety valve setting. 10 bar (145 PSI) . 97 dB(A), uncertainty 1 dB(A)
Maximum pressure ratio (absolute). 7,5 The operating conditions of the machinery are in compliance with ISO
3744:1995 and EN ISO 2151:2004
Operating ambient temperature.
Whisperised −10C TO +46C (14F TO 115F)
Standard −10C TO +52C (14F TO 126F) FIXED HEIGHT RUNNING GEAR
Unbraked version (KNOTT)
Maximum discharge temperature. 120C (248F)
Shipping weight. 430kg (948 lbs)
Cooling system. Oil injection
Maximum weight. 500kg (1102 lbs)
Oil capacity. 2,31 litres (0,61 GAL)
Maximum horizontal towing force. 725 kgf (1600 lbs)
Maximum oil system temperature. 120C (248F)
Maximum vertical coupling load
Maximum oil system pressure. 8,6 bar (125 PSI)
(nose weight). 75 kgf (165 lbs)

LUBRICATING OIL SPECIFICATION

(for the specified ambient temperatures). VARIABLE HEIGHT RUNNING GEAR
Unbraked version (KNOTT)
ABOVE −23C(−9_F)
Recommended: Pro−Tec Shipping weight. 445 kg (981lbs)
Approved: SAE 10W, API CF−4/CG−4 Maximum weight. 500 kg (1102lbs)
BELOW −23C(−9_F) Maximum horizontal towing force. 725 kgf (1600 lbs)
Mandatory: IR Performance 500
Maximum vertical coupling load
Ingersoll Rand Pro−TecTM compressor fluid is factory−fitted, for (nose weight). 75 kgf (165 lbs)
use at all ambient temperatures above −23C(−9F).
NOTE: Warranty may be extended only by continuous use of FIXED HEIGHT RUNNING GEAR
Pro−Tec and Ingersoll Rand oil filters and separators. Braked version (KNOTT)
No other oil/fluids are compatible with Pro−TecTM Shipping weight. 455kg (1003 lbs)
No other oils/fluids should be mixed with Pro−TecTM because the Maximum weight. 500kg (1102 lbs)
resulting mixture could cause damage to the airend.
Maximum horizontal towing force. 725 kgf (1600 lbs)
In the event that Pro−TecTM is not available and / or the end user
needs to use an approved single grade engine oil, the complete system Maximum vertical coupling load
including separator / receiver, cooler and pipework must be flushed (nose weight). 75 kgf (165 lbs)
clear of the first fill fluid and new Ingersoll Rand oil filters installed.
When this has been completed, the following oils are approved:
VARIABLE HEIGHT RUNNING GEAR
a) for ambient temperatures above −23C(−9F), Braked version (KNOTT)
SAE 10W, API CF−4/CG−4
Shipping weight. 470 kg (1036lbs)
b) for ambient temperatures below −23C(−9F),
IR Performance 500 only. Maximum weight. 500 kg (1102lbs)
Safety data sheets can be obtained on request from the lubricant Maximum horizontal towing force. 725 kgf (1600 lbs)
supplier.
Maximum vertical coupling load
For temperatures outside the specified ambient range, consult (nose weight). 75 kgf (165 lbs)
Ingersoll Rand.

WHEELS AND TYRES (KNOTT)

ENGINE
7/20, P65 Number of wheels. 2 x 41/2 J

Type/model. 7/20 D1005−EBB−EC−LT−1 Tyre size. 155 R13 82R AVON

P65 D1005−E3B−IRCZ Tyre pressure. 2,4 bar (35 PSI)
Number of cylinders. 3
Oil capacity. 5,1 litres (1,35 US GAL) Further information may be obtained by request through Ingersoll
Speed at full load. 3000 revs min−1 Rand customer services department.

Speed at idle. 2000 revs min−1

Electrical system. 12V negative earth
Power available at 2800 revs min−1 17,5kW (23,5 HP)
Fuel tank capacity 26 litres (6,87 US GAL)
Oil specification Refer engine section
Coolant capacity 4 litres (1,06 US GAL)

7/20, P65
26 OPERATING INSTRUCTIONS

COMMISSIONING Ensure that the correct fork lift truck slots or marked lifting / tie down
points are used whenever the machine is lifted or transported.
Upon receipt of the unit, and prior to putting it into service, it is
important to adhere strictly to the instructions given below in PRIOR TO
STARTING. When selecting the working position of the machine ensure that
there is sufficient clearance for ventilation and exhaust requirements,
observing any specified minimum dimensions (to walls, floors etc.).
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation.
Adequate clearance needs to be allowed around and above the
machine to permit safe access for specified maintenance tasks.
Ensure that the position of the emergency stop device is known and
recognised by its markings. Ensure that it is functioning correctly and
that the method of operation is known. Ensure that the machine is positioned securely and on a stable
foundation. Any risk of movement should be removed by suitable
means, especially to avoid strain on any rigid discharge piping.

Running gear drawbar − Machines are shipped to some areas with

the drawbar removed. Fitting involves four nuts / bolts to secure the Attach the battery cables to the battery(s) ensuring that they are
drawbar to the axle and two bolts to fit the drawbar to the front of the tightened securely. Attach the negative cable before attaching the
machine with the saddle and spacer block. positive cable.

Support the front of the machine, fit the wheel chocks to stop the
machine moving and attach the drawbar. Refer to the torque value table WARNING: All air pressure equipment installed in or connected
in the MAINTENANCE section of this manual for the correct torque to the machine must have safe working pressure ratings of at least
values. the machine rated pressure, and materials compatible with the
compressor lubricant (refer to the GENERAL INFORMATION
section).

CAUTION:
This is a safety critical procedure. Double check the torque settings
after assembly WARNING: If more than one compressor is connected to one
common downstream plant, effective check valves and isolation
valves must be fitted and controlled by work procedures, so that
one machine cannot accidentally be pressurised / over
Fit the propstand and coupling. Remove the supports and set the pressurised by another.
machine level.

WARNING: If flexible discharge hoses are to carry more than 7 bar

Before towing the unit, ensure that the tyre pressures are correct (100 psi) pressure then it is recommended that safety retaining
(refer to the GENERAL INFORMATION section of this manual) and wires are used on the hoses.
that the handbrake is functioning correctly (refer to the
MAINTENANCE section of this manual). Before towing the unit during
the hours of darkness, ensure that the lights are functioning correctly
(where fitted).

Ensure that all transport and packing materials are discarded.

7/20, P65
 OPERATING INSTRUCTIONS 27
A B C D

E F G

PRIOR TO STARTING CAUTION: When refueling:−

. switch off the engine.
A. Place the unit in a position that is as level as possible. The design . do not smoke.
of the unit permits a 15 degree lengthways and sideways limit on out . extinguish all naked lights.
of level operation. It is the engine, not the compressor, that is the limiting . do not allow the fuel to come into contact with hot surfaces.
factor. . wear personal protective equipment.

When the unit has to be operated out of level, it is important to keep

the engine oil level near the high level mark (with the unit level).
E. Open the service valve(s) to ensure that all pressure is relieved
from the system. Close the service valve(s).

CAUTION: Do not overfill either the engine or the compressor with oil.
F. CAUTION: Do not operate the machine with the canopy/doors in
the open position as this may cause overheating and operators to be
B. Check the engine lubrication oil in accordance with the operating exposed to high noise levels.
instructions in the Engine Operator’s Manual.

C. Check the compressor oil level (with the unit level). G. Check the radiator coolant level (with the unit level).

CAUTION: Fill oil up to the filler neck end. Check the air restriction indicator(s). Refer to the MAINTENANCE
section of this manual.

When starting or operating the machine in temperatures below or

D. Check the diesel fuel level. A good rule is to top up at the end of each approaching 0C, ensure that the operation of the regulation system,
working day. This prevents condensation from occurring in the tank. the unloader valve, the safety valve, and the engine are not impaired
by ice or snow, and that all inlet and outlet pipes and ducts are clear of
ice and snow.
CAUTION: Use only a No. 2−D diesel fuel oil with a minimum octane
number of 45 and a sulphur content not greater than 0,5%.

7/20, P65
28 OPERATING INSTRUCTIONS
0 1 2

STARTING THE MACHINE NOTE: As soon as the engine stops, the automatic blowdown valve will
relieve all pressure from the system.

WARNING: Under no circumstances should volatile liquids such

as Ether be used for starting this machine.
If the automatic blowdown valve fails to operate, then pressure must
be relieved from the system by means of the service valve(s).

All normal starting functions are incorporated in the key operated

switch.
CAUTION: Never allow the machine to stand idle with pressure in the
system.
. Turn the key switch to position 2 and hold for max 15 seconds to
allow the air inlet heater to reach working temperature.

. Turn the key switch to position 3 (engine start position). EMERGENCY STOPPING
In the event that the unit has to be stopped in an emergency, TURN
THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO
. Release to position 1 when the engine starts.
THE 0 (OFF) POSITION.

At temperatures below 0C (32F) or if there is difficulty starting first

time:
RE−STARTING AFTER AN EMERGENCY

. Open the service valve fully, with no hose connected. If the machine has been switched off because of a machine
malfunction, then identify and correct the fault before attempting to
re−start.
. Complete starting sequence above.
If the machine has been switched off for reasons of safety, then
. Close service valve as soon as engine runs freely. ensure that the machine can be operated safely before re−starting.

. Do not allow machine to run for long periods with service valve Refer to the PRIOR TO STARTING and STARTING THE UNIT
open. instructions earlier in this section before re−starting the machine.

. Allow the engine to reach operating temperature.

MONITORING DURING OPERATION
. At this point in the operation of the machine it is safe to apply full load Should any of the safety shut-down conditions occur, the unit will
to the engine. stop. These are:

. Low engine oil pressure

NOTE: Wear hearing protection at all times when the engine is started
with the service valve open and air is flowing from the valve. . High air discharge temperature

STOPPING THE MACHINE . High engine water temperature

. Close the service valve.
CAUTION: To ensure an adequate flow of oil to the compressor at low
. Allow the machine to run unloaded for a short period of time to temperature, never allow the discharge pressure to fall below 3,5 bar
reduce the engine temperature. (51psi).

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

7/20, P65
 OPERATING INSTRUCTIONS 29
DECOMMISSIONING
When the machine is to be permanently decommissioned or
dismantled, it is important to ensure that all hazard risks are either
eliminated or notified to the recipient of the machine. In particular:−

. Do not destroy batteries or components containing asbestos

without containing the materials safely.

. Do not dispose of any pressure vessel that is not clearly marked

with its relevant data plate information or rendered unusable by drilling,
cutting etc.

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

or drains.

. Do not dispose of a complete machine without documentation

relating to instructions for its use.

7/20, P65
30 MAINTENANCE

MAINTENANCE SCHEDULE
Initial. Hours Monthly / Hours
km Hours Daily Weekly
(miles) 200/400 1/− 3/250 6/500 12/1,000
850 50
(500)

Compressor Oil Level C

Engine Oil Level C
*Radiator Coolant Level C
Gauges/Lamps C
*Air Cleaner Service Indicators C
Fuel Tank (Fill at end of day) C
*Fuel/Water Separator Drain C
Oil Leaks C
Fuel Leaks C
Drain Water From Fuel Filters C
Coolant Leaks C
Header Tank Cap. C
Fan/Alternator Belts C
Battery Connections/Electrolyte C
Tire Pressure and Surface C
*Wheel Lug Nuts C
Hoses (Oil, Air, Intake, etc.) C
Automatic Shutdown System C
Air Cleaner System C
Compressor Oil Cooler Exterior C
*Engine Rad/Oil Cooler Exterior C
Fasteners, Guards C
Air Cleaner Elements R/WI

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

(1) or 3000 miles/5000km whichever is the sooner G = Grease
(2) or as defined by local or national legislation R = Replace
C = Check (adjust, clean or replace as necessary) T = Test
CBT = check before towing. W I =or when indicated if earlier.
CR = Check and report
Refer to specific sections of the operator’s manual for more
information.

7/20, P65
 MAINTENANCE 31
Initial. Hours Monthly / Hours
km Hours Daily Weekly
(miles) 200/400 1/− 3/250 6/500 12/1,000
850 50
(500)

*Fuel/Water Separator Element R

Compressor Oil Filter Element R
Compressor Oil R
Engine Oil Change R R/−
Engine Oil Filter R R/−
*Water Pump Grease. R
*Wheels (Bearings, Seals, etc.) C
*Engine Coolant C
Fuel Filter Element −/R
*Injection Nozzle Check C
Shutdown Switch Settings T
Scavenger Orifice & Related Parts C
Oil Separator Element R
*Feed Pump Strainer Cleaning. C
Coolant Replacement R
*Valve Clearance Check C
Lights (running, brake, & turn) CBT
Pintle Eye Bolts CBT
*Brakes C C
*Brake linkage C
Emergency stop T
Fasteners C
Running gear linkage G
Safety valve C
Running gear bolts(1) C
*Disregard if not appropriate for this particular machine. D = Drain
(1) or 3000 miles/5000km whichever is the sooner G = Grease
(2) or as defined by local or national legislation
R=Replace
C = Check (adjust, clean or replace as necessary)
T = Test
CBT =check before towing.
W I =or when indicated if earlier.
CR = Check and report
Refer to specific sections of the operator’s manual for more
information.

7/20, P65
32 MAINTENANCE
Initial. Hours Monthly / Hours
km Hours Daily Weekly
(miles) 200/400 1/− 3/250 6/500 12/1,000
850 50
(500)

Scavenge line C
Pressure system C
Engine breather element C
Pressure gauge C
Pressure regulator C
Separator tank (2) exterior CR
Lubricator (Fill) C

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

Airend drive belt. R

Safety valve C
Hoses R
Separator tank (2) interior C

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

(1) or 3000 miles/5000km whichever is the sooner G = Grease
(2) or as defined by local or national legislation R=Replace
C = Check (adjust, clean or replace as necessary) T = Test
CBT =check before towing. W I =or when indicated if earlier.
CR = Check and report Refer to specific sections of the operator’s manual for more
information.

7/20, P65
 MAINTENANCE 33
ROUTINE MAINTENANCE . loose clothing, jewelry, long hair etc. is made safe.
This section refers to the various components which require
periodic maintenance and replacement. . warning signs indicating that Maintenance Work is in Progress are
posted in a position that can be clearly seen.
The SERVICE/MAINTENANCE CHART indicates the various
components’ descriptions and the intervals when maintenance has to Upon completion of maintenance tasks and prior to returning
take place. Oil capacities, etc., can be found in the GENERAL the machine into service, ensure that:−
INFORMATION section of this manual.
. the machine is suitably tested.

For any specification or specific requirement on service or . all guards and safety protection devices are refitted.
preventative maintenance for the engine, refer to the Engine
. all panels are replaced, canopy and doors closed.
Manufacturer’s Manual.
. hazardous materials are effectively contained and disposed of.
Compressed air can be dangerous if incorrectly handled. Before PROTECTIVE SHUTDOWN SYSTEM
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally. Comprises:

If the automatic blowdown fails to operate, then pressure must be . Low engine oil pressure switch
gradually relieved by operating the manual blowdown valve. Suitable
. High discharge air temperature switch
personal protective equipment should be worn.
. High engine water temperature switch
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
Low engine oil pressure switch.

Prior to attempting any maintenance work, ensure that:− At three month intervals, test the engine oil pressure switch circuit
as follows:
. all air pressure is fully discharged and isolated from the system. If
the automatic blowdown valve is used for this purpose, then allow . Start the machine.
enough time for it to complete the operation. . Remove a wire from one terminal of the switch. The machine should
shutdown.
. the discharge pipe / manifold area is depressurised by opening the At twelve month intervals, test the engine oil pressure switch as
discharge valve, whilst keeping clear of any airflow from it. follows:
. Remove the switch from the machine.
. the machine cannot be started accidentally or otherwise, by posting
warning signs and/or fitting appropriate anti−start devices. . Connect it to an independent low pressure supply (either air or oil).
. The switch should operate at 1,0 bar (14.5 psi).
. all residual electrical power sources (mains and battery) are . Refit the switch.
isolated.

Prior to opening or removing panels or covers to work inside Temperature switch(es).

a machine, ensure that:− At three month intervals, test the temperature switch circuit(s) as
follows:
. anyone entering the machine is aware of the reduced level of . Start the machine.
protection and the additional hazards, including hot surfaces and
intermittently moving parts.
NOTE: Do not press the load button.
. the machine cannot be started accidentally or otherwise, by posting
warning signs and/or fitting appropriate anti−start devices.
. Disconnect each switch in turn. The machine should shutdown.
. Re−connect the switch.
Prior to attempting any maintenance work on a running
machine, ensure that:−
High discharge air temperature switch(es).
. the work carried out is limited to only those tasks which require the At twelve month intervals, test the air discharge temperature
machine to run. switch(es) by removing it from the machine and immersing in a bath
of heated oil. The switch should operate at 120C (248F). Refit the
switch.
. the work carried out with safety protection devices disabled or
removed is limited to only those tasks which require the machine to be
running with safety protection devices disabled or removed.
High water temperature switch

. all hazards present are known (e.g. pressurised components, At twelve month intervals, test the water temperature switch by
electrically live components, removed panels, covers and guards, removing it from the machine and immersing in a bath of heated
extreme temperatures, inflow and outflow of air, intermittently moving oil. The switch should operate at 115C (239F). Refit the switch.
parts, safety valve discharge etc.).
CAUTION: Never remove or replace switches when the machine
. appropriate personal protective equipment is worn. is running.

7/20, P65
34 MAINTENANCE
SCAVENGE LINE If, however, the element has to be replaced, then proceed as
follows:
The scavenge line runs from the combined orifice/drop tube in the
separator tank, to the orifice fitting located in the airend.
Removal
Examine the orifice, check valve and hoses at every service or in
the event of oil carryover into the discharge air.
WARNING: Do not remove the filter(s) without first making sure
It is good preventative maintenance to check that the scavenge line that the machine is stopped and the system has been completely
and tube are clear of any obstruction each time the compressor relieved of all air pressure. (Refer to STOPPING THE UNIT in the
lubricant is changed as any blockage will result in oil carryover into the OPERATING INSTRUCTIONS section of this manual).
discharge air.

COMPRESSOR OIL FILTER

Refer to the MAINTENANCE CHART in this section for the Disconnect all hoses and tubes from the separator tank cover plate.
recommended servicing intervals. Remove the drop−tube from the separator tank cover plate and then
remove the cover plate. Remove the separator element.

Removal
Inspection
Examine the filter element. Examine all hoses and tubes, and
WARNING: Do not remove the filter(s) without first making sure
replace if necessary.
that the machine is stopped and the system has been completely
relieved of all air pressure. (Refer to STOPPING THE UNIT in the
OPERATING INSTRUCTIONS section of this manual). Reassembly
Thoroughly clean the orifice/drop tube and filter gasket contact area
before reassembly. Install the new element.
Clean the exterior of the filter housing and remove the spin−on
element by turning it in a counter−clockwise direction.

Inspection
WARNING
Examine the filter element. Do not remove the staple from the anti−static gasket on the
separator element since it serves to ground any possible static
build−up. Do not use gasket sealant since this will affect electrical
CAUTION: If there is any indication of the formation of varnishes, conductance.
shellacs or lacquers on the filter element, it is a warning that the
compressor lubricating and cooling oil has deteriorated and that it
should be changed immediately. Refer to LUBRICATION later in this
section.
Reposition the cover plate, taking care not to damage the gasket,
Reassembly and replace the cover plate screws tightening in a criss−cross pattern
to the recommended torque (refer to the TORQUE SETTING TABLE
Clean the filter gasket contact area and install the new element by later in this section).
screwing in a clockwise direction until the gasket makes contact with
the filter housing. Tighten a further 1/2 to 3/4 of a revolution.
Engage the adaptor in the cover plate with the drop−tube integral
with the filter, reconnect all hoses and tubes to the separator tank cover
plate.
CAUTION: Start the machine (refer to PRIOR TO STARTING and
STARTING THE UNIT in the OPERATING INSTRUCTIONS section Replace the compressor oil (refer to LUBRICATION later in this
of this manual) and check for leakage before the machine is put back section).
into service.

COMPRESSOR OIL SEPARATOR ELEMENT

CAUTION: Start the machine (refer to PRIOR TO STARTING and
Normally the separator element will not require periodic STARTING THE UNIT in the OPERATING INSTRUCTIONS section
maintenance provided that the air and oil filter elements are correctly of this manual) and check for leakage before the machine is put back
maintained. into service.

7/20, P65
 MAINTENANCE 35
COMPRESSOR OIL COOLER AND ENGINE RADIATOR COOLING FAN DRIVE
When grease, oil and dirt accumulate on the exterior surfaces of the oil Periodically check that the fan mounting bolts in the fan hub have
cooler and radiator, the efficiency is impaired. It is recommended that not loosened. If, for any reason, it becomes necessary to remove the
each month the oil cooler and radiator be cleaned by directing a jet of fan or re−tighten the fan mounting bolts, apply a good grade of
compressed air, (carrying if possible a non−flammable cleaning commercially available thread locking compound to the bolt threads
solvent) over the exterior core of the cooler/radiator. This should and tighten to the torque value shown in the TORQUE SETTING
remove any accumulation of oil, grease and dirt from the exterior core TABLE later in this section.
of the cooler so that the entire cooling area can radiate the heat of the
lubricating and cooling oil/water into the air stream.
The fan belt(s) should be checked regularly for wear and correct
tensioning.

WARNING: Hot engine coolant and steam can cause injury. When FUEL SYSTEM
adding coolant or antifreeze solution to the engine radiator, stop
the engine at least one minute prior to releasing the radiator filler The fuel tank should be filled daily or every eight hours. To minimise
cap. Using a cloth to protect the hand, slowly release the filler cap, condensation in the fuel tank(s), it is advisable to top up after the
absorbing any released fluid with the cloth. Do not remove the machine is shut down or at the end of each working day. At six month
filler cap until all excess fluid is released and the engine cooling intervals drain any sediment or condensate that may have
system fully depressurised. accumulated in the tank(s).

FUEL FILTER WATER SEPARATOR

WARNING: Follow the instructions provided by the antifreeze
supplier when adding or draining the antifreeze solution. It is The fuel filter water separator contains a filter element which should
advisable to wear personal protective equipment to prevent skin be replaced at regular intervals (see the SERVICE/MAINTENANCE
and eye contact with the antifreeze solution. CHART).

HOSES
AIR FILTER ELEMENTS
All components of the engine cooling air intake system should be
The air filter should be inspected regularly (refer to the checked periodically to keep the engine at peak efficiency.
SERVICE/MAINTENANCE CHART) and the element replaced when
the restriction indicator shows red or every 6 Months (500 hours),
whichever comes first. The dust collector box(es) should be cleaned At the recommended intervals, (see the
daily (more frequently in dusty operating conditions) and not allowed to SERVICE/MAINTENANCE CHART), inspect all of the intake lines to
become more than half full. the air filter, and all flexible hoses used for air lines, oil lines and fuel
lines.

Removal
Periodically inspect all pipework for cracks, leaks, etc. and replace
immediately if damaged.
CAUTION: Never remove and replace element(s) when the machine
is running.
ELECTRICAL SYSTEM

WARNING: Always disconnect the battery cables before

Clean the exterior of the filter housing and remove the filter element performing any maintenance or service.
by releasing the nut.

Inspection Inspect the safety shutdown system switches and the instrument
panel relay contacts for evidence of arcing and pitting. Clean where
Check for cracks, holes or any other damage to the element by necessary.
holding it up to a light source, or by passing a lamp inside.

Check the mechanical action of the components.

Check the seal at the end of the element and replace if any sign of
damage is evident.
Check the security of electrical terminals on the switches and relays
i.e. nuts or screws loose, which may cause local hot spot oxidation.
Reassembly
Assemble the new element into the filter housing ensuring that the Inspect the components and wiring for signs of overheating i.e.
seal seats properly. discolouration, charring of cables, deformation of parts, acrid smells
and blistered paint.
Reset the restriction indicator by depressing the rubber diaphragm.
BATTERY
Assemble the dust collector box parts, ensuring that they are Keep the battery terminals and cable clamps clean and lightly
correctly positioned. coated with petroleum jelly to prevent corrosion.

Before restarting the machine, check that all clamps are tight. The retaining clamp should be kept tight enough to prevent the
battery from moving.

PRESSURE SYSTEM
VENTILATION
At 500 hour intervals it is necessary to inspect the external surfaces
Always check that the air inlets and outlets are clear of debris etc.
of the system (from the airend through to the discharge valve(s))
including hoses, tubes, tube fittings and the separator tank, for visible
signs of impact damage, excessive corrosion, abrasion, tightness and
chafing. Any suspect parts should be replaced before the machine is
CAUTION: NEVER clean by blowing air inwards. put back into service.

7/20, P65
36 MAINTENANCE
TYRES/TYRE PRESSURE The brake actuators must not be pre−tensioned − if necessary loosen
the brake linkage [7] on the brake equalisation assembly [8].
See the GENERAL INFORMATION section of this manual.
Check that brake actuators and cables [11] operate smoothly.
RUNNING GEAR/WHEELS
Check the wheel nut torque 20 miles (30 kilometres) after refitting 8
the wheels. Refer to the TORQUE SETTING TABLE later in this 5
section.

Lifting jacks should only be used under the axle.

10
The bolts securing the running gear to the chassis should be
checked periodically for tightness (refer to the
SERVICE/MAINTENANCE CHART for frequency) and re−tightened 9
where necessary. Refer to the TORQUE SETTING TABLE later in this
section.

BRAKES
Check and adjust the brake linkage at 500 miles (850Km) then
every 3000 miles (5000Km) or 3 months (whichever is the sooner) to 7 11
compensate for any stretch of the adjustable cables. Check and adjust
the wheel brakes to compensate for wear. 7 Brake linkage
8 Equalisation assembly
9 Compression spring
10 Equaliser plate
Adjusting the overrun braking system (KNOTT
11 Cable
Running Gear)
1: Preparation
CAUTION
Jack up the machine The compression spring [9] must only be lightly pre−tensioned and
when operating must never touch the axle tube.
Disengage the handbrake lever [1].
Never adjust the brakes at the brake linkage [7].
Fully extend the draw bar [2] on the overrun braking system.

2. Brake Shoe Adjustment

12

1
3 13

6
12 Adjusting screw
13 Cable entry
Width across flats of adjusting screw [12]
1 Handbrake lever
Brake size Key width
2 Draw bar and bellows 160x35 / 200x50 SW 17
250x40 SW 19
3 Handbrake lever pivot 300x60 SW 22
4. Spring sleeve complete.
5 Brake cable Tighten adjusting screw [12] clockwise until the wheel locks.
6 Breakaway Cable Loosen adjusting screw [12] anti−clockwise (approx. ½ turn) until the
wheel can be moved freely.
Slight dragging noises that do not impede the free movement of the
wheel are permissible.
Requirements:
This adjustment procedure must be carried out as described on both
During the adjustment procedure always start with the wheel brakes.
wheel brakes.
Always rotate the wheel in the direction of forward movement.
When the brake has been adjusted accurately the actuating distance
Ensure that an M10 safety screw is fitted to the handbrake pivot. is approximately 5−8mm on the cable [11]
7/20, P65
 MAINTENANCE 37
3: Compensator assembly adjustment Re−adjustment
Variable Height models The handbrake lever [1] should be engaged forcefully several times to
set the braking system.
Fit an M10 safety screw to the handbrake pivot. Check the setting of the brake equalisation assembly [8], which should
Disconnect the handbrake cable [5] at one end. be at right angles to the pulling direction.
Check the play in the brake linkage [7] again, ensuring that there is no
Pre−adjust brake linkage [7] lengthways (a little play is permissible) and play in the brake linkage and that it is adjusted without pre−tension
re−insert the cable [5], adjusting it to give a small amount of play. Check the position of the hand brake lever [1], cable [5] (with little play)
and the compression spring [9] (only slight pre−tension). The start of
Remove the M10 safety screw from the handbrake pivot. resistance of the handbrake lever should be approximately 10−15mm
All Models above the horizontal position.

Engage the handbrake lever [1] and check that the position of the
equaliser plate [10] is at right angles to the pulling direction. If Final test
necessary correct the position of the equaliser plate [10] on the cables
[11]. Check the fastenings on the transmission system (cables, brake
equalisation system and linkage)
The compression spring [9] must only be slightly pre−tensioned and
when engaged must not touch the axle tube. Apply the handbrake while rolling the machine forward, travel of the
handbrake lever up to 2/3 of maximum is allowed.
Check the handbrake cable [5] for a small amount of play and adjust if
4: Brake linkage adjustment necessary (Variable height only)
Adjust the brake linkage [7] lengthways without pre−tension.. Check the compression spring [9] for slight pre−tensioning.

CAUTION: Check the wheel nut torque 20 miles (30 kilometres) after
Readjustment
refitting the wheels (Refer to the TORQUE SETTING TABLE later in
Engage the handbrake lever [1] forcefully a number of times to set the this section).
brake.
Check the alignment of the equalisation assembly [8], this should be at
right angles to the pulling direction LUBRICATION
Check the play in the brake linkage [7] The engine is initially supplied with engine oil sufficient for a nominal
period of operation (for more information, consult the Engine section of
If necessary adjust the brake linkage [7] again without play and without
this manual).
pre−tensioning
There must still be a little play in cable [5] (Variable Height Only)
Check the position of the hand brake lever [1]. The start of resistance CAUTION: Always check the oil levels before a new machine is put into
should be approximately 10−15mm above the horizontal position. service.
Check that the wheels move freely when the handbrake is disengaged.

Final test If, for any reason, the unit has been drained, it must be re−filled with
new oil before it is put into operation.
Check the fastenings on the transmission system (cables, brake
equalisation system and linkage).
ENGINE LUBRICATING OIL
Check the handbrake cable [5] for a small amount of play and adjust if
necessary (Variable height only) The engine oil should be changed at the engine manufacturer’s
recommended intervals. Refer to the Engine section of this manual.
Check the compression spring [9] for pre−tensioning.

ENGINE LUBRICATING OIL SPECIFICATION

Test run Refer to the Engine section of this manual.
If necessary carry out 2−3 test brake actions.
ENGINE OIL FILTER ELEMENT
The engine oil filter element should be changed at the engine
Test brake action manufacturer’s recommended intervals. Refer to the Engine section of
Check the play in brake linkage [7] and if necessary adjust the length this manual.
of brake linkage [7] until there is no play. COMPRESSOR LUBRICATING OIL
Apply the handbrake while rolling the machine forward, travel of the Refer to the SERVICE/MAINTENANCE CHART in this section for
handbrake lever up to 2/3 of maximum is allowed. service intervals.

Re−adjusting the overrun braking system (KNOTT

NOTE: If the machine has been operating under adverse conditions,
Running Gear) or has suffered long shutdown periods, then more frequent service
Re−adjustment of the wheel brakes will compensate for brake lining intervals will be required.
wear. Follow the procedure described in 2: Brake Shoe Adjustment.
Check the play in the brake linkage [7] and re−adjust if necessary.
WARNING: DO NOT, under any circumstances, remove any drain
Important plugs or the oil filler plug from the compressor lubricating and
Check the brake actuators and cables [11]. The brake actuators must cooling system without first making sure that the machine is
not be pre−tensioned. stopped and the system has been completely relieved of all air
Excessive operation of the handbrake lever, which may have been pressure (refer to STOPPING THE UNIT in the OPERATING
caused by worn brake linings, must not be corrected by re−adjusting INSTRUCTIONS section of this manual).
(shortening) the brake linkage [7]
7/20, P65
38 MAINTENANCE
Completely drain the receiver/separator system including the piping COMPRESSOR OIL FILTER ELEMENT
and oil cooler by removing the drain plug(s) and collecting the used oil
in a suitable container. Refer to the SERVICE / MAINTENANCE CHART in this section for
service intervals.

Replace the drain plug(s) ensuring that each one is secure.

RUNNING GEAR WHEEL BEARINGS
Wheel bearings should be packed with grease every 6 months. The
NOTE: If the oil is drained immediately after the machine has been type of grease used should conform to specification MIL−G−10924.
running, then most of the sediment will be in suspension and will
therefore drain more readily.

CAUTION: Some oil mixtures are incompatible and result in the

formation of varnishes, shellacs or lacquers which may be insoluble.

NOTE: Always specify INGERSOLL RAND Pro−TecTM oil for use at

all ambient temperatures above −23C.

B A

SPEED AND PRESSURE REGULATION ADJUSTMENT Adjust the service valve on the outside of the machine to maintain
7 bar without the throttle arm moving from the full speed position. If the
Normally, regulation requires no adjusting, but if correct adjustment throttle arm moves away from the full speed position before 7 bar is
is lost, proceed as follows: attained, then turn the adjusting screw clockwise to increase the
pressure. Optimum adjustment is achieved when the throttle arm just
Refer to the diagram above. moves from its full speed position and the pressure gauge reads 7,2
bar.

A: Throttle arm
B: Adjusting screw Close the service valve. The engine will slow to idle speed.

Start the machine (Refer to STARTING INSTRUCTIONS in the

OPERATING INSTRUCTIONS section of this manual). CAUTION: Never allow the idle pressure to exceed 8,6bar on the
pressure gauge, otherwise the safety valve will operate.

Inspect the throttle arm on the engine governor to see that it is

extended in the full speed position when the engine is running at
full−load speed and the service valve is fully open. (Refer to the
GENERAL INFORMATION section of this manual).

7/20, P65
 MAINTENANCE 39
DRIVE BELT REPLACEMENT / ADJUSTMENT.

WARNING: DURING THE ADJUSTMENT / REPLACEMENT

PROCEDURE ALWAYS DISCONNECT BATTERY.

Remove drive belt guard.

Loosen securing screw M12 beside and above the Airend.
Loosen main pivot bolt M16.
Disconnect adjusting screw and pivot Airend towards engine to
slacken belt and remove belt from pulleys.
Fit new belt over pulleys, pivot Airend away from engine and
re−engage adjusting screw.
Adjust drive belt tightening by means of adjusting screw with M8
head socket screw.
Adjustment values:
New drive belt
105−115 Hz (35N−38N/5.9mm)
Run in drive belt
88−98 Hz (25N−28N/5.9mm)
1. Main pivot bolt. Tighten securing screw M12 beside and above the Airend.
2. Securing screw Tighten main pivot bolt M16 and secure by lock nut.
3. Adjusting screw Check belt adjustment.
4. Airend Install drive belt guard.

7/20, P65
40 MAINTENANCE
TORQUE VALUES

ft lbf Nm ft lbf Nm
Engine mounts to engine 29−35 39−47 Lifting bail to frame 29−35 39−47

Airend to pivot plate 29−35 39−47 Band clamp on oil pipes 71−88 96−119

Air filter to bracket 16−20 22−27 Radiator/Cooler to baffle 9−11 12−15

Autella clamp to exhaust 9−11 12−15 Running gear front to chassis 63−69 82−93

Baffle to frame 9−11 12−15 Running gear rear to chassis 63−69 82−93

Discharge manifold to frame 29−35 39−47 Running gear drawbar to axle 29−35 39−47

Pulley to flywheel 57−69 77−93 Main pivot bolt 106−133 143−180

Drop Leg 53−63 72−85 Pivot locking bolt 54−58 73−78

Engine/airend to chassis 54−58 73−78 Separator tank cover 40−50 54−68

Band clamp on discharge hose 58−67 78−91 Separator tank to frame 18−22 24−30

Exhaust flange to manifold 17−21 23−28 Band clamp on hose 106−133 143−180

Fan guard 9−11 12−15 Wheel nuts 50−80 67−109

Fan to hub 12−15 16−20

7/20, P65
 MAINTENANCE 41
COMPRESSOR LUBRICATION
RATED OPERATING PRESSURE
Portable Compressor Fluid Chart 100 − 300 PSI 350 PSI 500 PSI
125F
Refer to these charts for correct compressor fluid required. Note 50C
that the selection of fluid is dependent on the design operating
40C 104F IR IR IR
pressure of the machine and the ambient temperature expected to XHP505 XHP 1001 XHP1001
be encountered before the next oil change. 30C 86F

20C 65F
IR
PRO−TEC

Design Operating Ambient IR 10C 50F

Specification
PER FORMANCE
Pressure Temperature
500 0C 32F IR IR
PERFORMANCE XHP505
6.9bar − 20.7bar −10F to 125F IR Pro−Tec 500
(100 psi − 300 psi) (−23C to 52C) Mil –PRF 2104G −10C 14F
SAE 10W
10F
6.9bar − 20.7bar −40F to 125F IR Performance 500 −20C
(100 psi − 300 psi) (−40C to 52C) Mil−L−46167 −10F
−30C −22F
24.1bar −10F to 125F IR XHP 505
(350 psi) (−23C to 52C)
−40C −40F
65F to 125F (18C IR XHP1001 consult
to 52C) factory
−40F to 65F IR Performance 500
(−40C to 18C) Mil−L−46167

34.5bar 50F to 125F (10C IR XHP1001

Recommended Ingersoll Rand Fluids − Use of these fluids with
(500 psi) to 52C)
10F to 65F (−12C IR XHP 505 original IR filters can extend airend warranty. Refer to operator’s
to 18C) manual warranty section for details or contact your IR
below 10F (−12C) Consult Factory representative.

Recommended Fluid 3.8 Litre 19.0 Litre 208.2 Litre

IR Pro−Tec 36899698 36899706 36899714

IR XHP 505 35365188 35365170

IR Performance 500 35382928 35382936 35382944

IR XHP1001 35612738 35300516

7/20, P65
42 ELECTRICAL SYSTEM

KEY

B Battery 12V
CF1 Control fuse
D1−2 Diode, blocking
FP Fuel pump
G Alternator
GP Glowplugs
h Hourmeter
M Starter motor
NP1−4 Node point
PS1 Engine oil pressure switch
RT1 Relay, temperature switch
SO Key−switch
SV1 Solenoid, fuel
TS1 High air temperature switch (airend)
TS2 High water temperature switch (engine)

7/20, P65
 ELECTRICAL SYSTEM 43

SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM

KEY

1 Plug B Black
2 Light (right hand) G Green
3 Fog light K Pink
4 Light (left hand) N Brown
O Orange
P Purple
R Red
S Grey
U Blue
W White
Y Yellow

7/20, P65
44 ELECTRICAL SYSTEM

SCHEMATIC DIAGRAM FOR AMERICAN SAE LIGHTING SYSTEM

KEY

1 Stop / turn (left hand) B Black

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

7/20, P65
 PIPING AND INSTRUMENTATION SYSTEM 45
3 2 5
4

9 7

Air
Oil
Air/oil

KEY

1 Air discharge 6 Compressor

2 Sonic orifice (restricts flow) 7 Engine
3 Pressure gauge 8 Oil cooler
4 Separator tank 9 Oil filter
5 Safety valve

7/20, P65
46 FAULT FINDING

FAULT CAUSE REMEDY FAULT CAUSE REMEDY

Engine fails Low battery Check the fan belt tension, battery Engine Incorrect Check the throttle setting.
to start. charge. and cable connections. speed too throttle arm
low. setting.
Bad earth Check the earth cables, clean as
connection. required. Blocked fuel Check and replace if necessary.
filter.
Loose Locate and make the connection
connection. good. Blocked air Check and replace the element if
filter. necessary.
Fuel Check the fuel level and fuel
starvation. system components. Replace the Faulty Check the regulation system.
fuel filter if necessary. regulator
valve.
Relay failed. Replace the relay.
Premature Check the regulation and the
Engine control Check the speed cylinder and stop unloading. operation of the air cylinder.
not in ’run’ position.
position. Excessive Engine speed See ”Engine speed too low”
vibration. too low.
Engine Electrical fault Test the electrical circuits.
starts but
stalls when Low engine oil Check the oil level and the oil
the switch pressure. filter(s).
Refer also to the engine section of this manual.
returns to Faulty relay Check the relays.
position I.
Air Engine speed Check the air cylinder and air
Faulty Check the key−switch.
discharge too low. filter(s).
key−switch
capacity too
low. Blocked air Check the restriction indicators and
Engine Electrical fault. Test the electrical circuits.
cleaner. replace the element(s) if
starts but
Low engine oil Check the oil level and oil filter(s). necessary.
will not run
or engine pressure.
High pressure Check for leaks.
shuts down Safety Check the safety shut-down air escaping.
prematurely. shut-down switches.
system in Incorrectly set Reset the regulation system. Refer
operation. regulation to SPEED AND PRESSURE
system. REGULATION ADJUSTMENT in
Fuel Check the fuel level and fuel the MAINTENANCE section of this
starvation. system components. Replace the manual.
fuel filter if necessary.
Compressor Low oil level. Top up the oil level and check for
Switch failure. Test the switches. overheats. leaks.
High Check the compressor oil level and Dirty or Clean the oil cooler fins.
compressor oil oil cooler. Check the fan drive. blocked oil
temperature. cooler.
Water present Check the water separator and Incorrect Use Ingersoll Rand recommended
in fuel system. clean if required. grade of oil. oil.
Faulty relay. Check the relay in the holder and Recirculation Move the machine to avoid
replace if necessary. of cooling air. recirculation.
Engine Reduced Check the fan and the drive belts. Faulty Check the operation of the switch
Overheats. cooling air Check for any obstruction inside temperature and replace if necessary.
from fan. the cowl. switch.
Engine Incorrect Check the engine speed setting. Reduced Check the fan and the drive belts.
speed too throttle arm cooling air Check for any obstruction inside
high. setting. from fan. the fan cowl.
Faulty Check the regulation system.
regulator
valve.

7/20, P65
 FAULT FINDING 47
FAULT CAUSE REMEDY FAULT CAUSE REMEDY
Excessive oil Blocked Check the scavenge line, drop tube Oil is forced Incorrect Always employ the correct
present in scavenge line. and orifice. Clean and replace. back into the stopping stopping procedure. Close the
the air filter. procedure discharge valve and allow the
discharge Perforated Replace the separator element. used machine to run on idle before
air. separator stopping.
element.
Faulty inlet Check for free operation of the inlet
Pressure in Check the minimum pressure valve valve. valve(s).
the system is or sonic orifice.
too low. Faulty Remove the valve from the
discharge discharge pipe and check the
Safety valve Operating Check the setting and operation of check valve. operation.
operates. pressure too the regulator valve piping.
high. Machine Inlet valve set Refer to SPEED AND PRESSURE
goes to full incorrectly. REGULATION ADJUSTMENT in
Incorrect Adjust the regulator. pressure the MAINTENANCE section of this
setting of the when manual.
regulator. started.
Faulty Replace the regulator.
regulator. Machine fails Faulty load Replace the solenoid. Check the
Inlet valve set Refer to SPEED AND PRESSURE to load when solenoid. electrical circuit by feeling for
incorrectly. REGULATION ADJUSTMENT in the load movement whilst depressing the
the MAINTENANCE section of this button is load button.
manual. pressed.

Loose Check all pipe/hose connections.

pipe/hose
connections.
Faulty safety Check the relieving pressure.
valve. Replace the safety valve if faulty.
DO NOT ATTEMPT A REPAIR.

7/20, P65
48 OPTIONS

LUBRICATOR FAULT FINDING

SAFETY

WARNING: Ensure that the lubricator filler cap is re−tightened FAULT CAUSE REMEDY
correctly after replenishing with oil.
No oil flow. Incorrect Reverse the nylon tube
connection. connections to the lubricator.
WARNING: Do not replenish the lubricator oil, or service the
lubricator without first making sure that the machine is stopped
and the system has been completely relieved of all air pressure
(Refer to STOPPING THE UNIT in the OPERATING
INSTRUCTIONS section of this manual). BUNDED BASE
Description
CAUTION: If the nylon tubes to the lubricator are disconnected then
ensure that each tube is re−connected in its original location. This machine can be fitted with bund equipment to contain leakages
and spillages, which occur within the machine enclosure.
The bund will contain all fluids normally installed in the machine, plus
an additional 10%.
GENERAL INFORMATION When fitted with bund, the machine must only be operated within $ 3
degrees of level.
Oil capacity: 2 litres Drains for engine water & oil and compressor oil are located at the front
corner of the machine
Oil specification: The rear air intake is covered to prevent rainwater ingress. Ensure that
Refer to the Tool Manufacturer’s Manual. the cover is not prevented from moving
OPERATING INSTRUCTIONS Draining of contaminated fluids
COMMISSIONING Contaminated fluid must be removed by authorized personnel only.
Check the lubricator oil level and fill as necessary. Captured fluids can be drained from the bund by uncoupling the flexible
pipe secured at the rear / side. This pipe must be re−secured after
draining.
PRIOR TO STARTING
Drainage of machine fluids
Check the lubricator oil level and replenish as necessary.
During maintenance operations drain machine fluids using the drain
ports indicated
MAINTENANCE Remove fuel tank to drain.
Check the lubricator oil level and replenish as necessary. WARNING: Major leakages or spillages must be drained before
the machine is towed.

7/20, P65
 ENGINE INSTRUCTION MANUAL 49

KUBOTA D1005 − ENGINE

CONTENTS

50 FOREWORD
51 EXTERNAL VIEW
52 GENERAL INFORMATION
Main data and specifications
Engine identification
Ingersoll Rand engine after sales support
EMISSION CONTROL LABEL
54 FUEL, LUBRICANT, AND COOLANT
Fuel
Lubricant
Coolant
56 OPERATION
Check before operation
Check and operation after start− up
Operation and care of a new engine
60 MAINTENANCE SCHEDULE
62 PERIODICAL INSPECTION
AND MAINTENANCE
Lubricating system
Cooling system
Fuel system
Air intake system
Routine maintenance
68 TROUBLESHOOTING

7/20, P65
50 FOREWORD

The INGERSOLL RAND industrial diesel engines are a product of long years of experience, advanced technology, and up−to date production
facilities. INGERSOLL RAND takes great pride in the superior durability and operating economy of these engines.
In order to get the fullest use and benefit from your engine, it is important that you operate and maintain it correctly. This Manual is designed to help
you do this.
Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of trouble−free and
economical engine operation.
Should your engine require servicing, please contact your nearest INGERSOLL RAND branch or distributor.
All information, illustrations, and specifications contained in this Manual are based on the latest product information available at the time of
publication.
INGERSOLL RAND reserves the right to make changes in this Manual at any time without prior notice.

7/20, P65
 EXTERNAL VIEWS 51
DIESEL ENGINE Engine External View − Model

10 6 14 11

1. Intake manifold
2. Speed control12lever
19
3. Engine stop lever
4. Injection pump
1 5. Fuel feed pump
6. Cooling fan
2 7. Fan drive pulley15
8. Oil filter
4 cartridge
3 9. Water drain cock
10. Oil filler plug
11. Exhaust manifold
12. Alternator 8
16
13. Starter
14. Oil level gauge
15. Oil pressure
7 9
switch
16. Flywheel
17. Oil drain plug 13
18. Oil pan
19. Engine hook
5
17 18

1. Intake manifold 11.Exhaust manifold

2. Speed control lever 12.Alternator

3. Engine stop lever 13.Starter motor

4. Fuel injection pump 14.Dipstick (engine oil)

5. Fuel feed pump 15.Oil pressure switch

6. Cooling fan 16.Flywheel

17.Drain plug (engine oil)
7. Fan drive pulley
18.Oil pan
8. Engine oil filter
19.Lifting eye
9. Water drain cock
10.Filler port (engine oil)

7/20, P65
52 GENERAL INFORMATION

EPA CERTIFIED ENGINE DATA and SPECIFICATIONS

Model:
7/20 − KUBOTA D1005−EBB−EC−LT−1
P65 − KUBOTA D1005−E3B−IRCZ

Engine model name D1005−EBB−EC−LT−1 / D1005−E3B−IRCZ

Engine type Vertical inline water cooled diesel engine
Combustion type Spherical type (E−TVCS)
No. of cylinders − bore x stroke. mm 3−76x73.6
Engine displacement cm3 1,001
Compression ratio 23
Firing order 1−2−3
Exhaust emission control system Fuel injection nozzles, fuel injector pump
Governor Mechanical type
Injection nozzles Bosch MD Type mini pump
Specified fuel Diesel fuel No2 (ASTM D975)
Starter (V−kW) 12−1.0
Alternator (V−W) 12−360
Specified engine oil (API grade) (SAE grade) (CD,CF) (10W−30 or 15W−40)
Coolant volume (Engine only) L 4.0
Engine dry weight kg 89
Overall length mm 497.8
Engine dimensions Overall width mm 396
Overall height mm 608.7
Valve clearance (cold) mm 0.145−0.185
Nozzle injection pressure MPa 13.73
Injection timing B.T.D.C. at 2.5mm cam lift 19

ENGINE IDENTIFICATION INGERSOLL RAND ENGINE AFTER SERVICE

Serial No Location Please feel free to contact your Ingersoll Rand dealer for periodical
inspection and maintenance.
See illustration on page 53.
Ingersoll Rand Genuine Parts
Confirmation of Engine Number Genuine Ingersoll Rand parts are identical with those used in the
It is advisable to quote the engine serial number together with the engine production, and accordingly, they are warranted by Ingersoll
machine serial number, as it is required when you contact the Rand.
Ingersoll Rand branch or distributor for repair, service or parts
Genuine Ingersoll Rand parts are supplied by your Ingersoll Rand
ordering.
branch or distributor.
CAUTION: Conduct confirmation of engine serial number with the
Please ensure that only genuine Ingersoll Rand parts, lubricants and
engine stopped. To avoid being injured, do not check it, while the engine
fluids are used for service and/or repair.
is still hot.

7/20, P65
 EMISSION CONTROL LABEL 53
EC EMISSION CONTROL LABEL: ENGINE LABEL
Emission control label is attached on the “top of the rocker arm cover”

The following is the detail of a label required for engine emission control information, along with location.

(97/68/EC Directive label)

A. Label location
B. Serial No Location

7/20, P65
54 FUEL, LUBRICANTS, AND COOLANT

FUEL If refueling is done from an oil drum directly, ensure that it has been
kept stationary to allow any dust, sediment or water to settle at the
Fuel Selection bottom. Do not draw fuel direct from the bottom of the drum to prevent
pickup of any settled foreign material.
The following properties are required of the diesel fuel.
Always fully fill the fuel tank. Drain the sedimented particles in the
Must be free from minute dust particles. fuel tank frequently.
Must have adequate viscosity.
Must have high cetane value. Water in Fuel
Must have high cetane value., (45 or greater) During refueling, it is possible for water (and other contaminants) to be
Must have high fluidity at low temperature. pumped into your fuel tank along with the diesel fuel. This can happen
if a fuel provider does not regularly inspect and clean its fuel tanks, or
Must have low sulphur content. receives contaminated fuel from its supplier(s). To protect your engine
from contaminated fuel, there is a fuel filter system on the engine which
Must have little residual carbon. allows you to drain excess water.
It is strongly advisable to use ASTM D975 No. 2D (the general
automotive diesel engine purpose fuel oil) or equivalent which fully CAUTION: The water/diesel fuel mixture is flammable, and could be
meets the above requirements. hot. To avoid personal injury and/or property damage, do not touch the
fuel coming from the drain valve, and do not expose the fuel to open
flames or sparks.
Applicable Standard Recommendation
Be sure you do not overfill the fuel tank. Heat (such as from the engine)
JIS (Japanese Industrial Standard) K22O4 − 2 can cause the fuel to expand. If the tank is too full, fuel could be forced
out. This could lead to a fire and the risk of personal injury and/or
DIN (DEUTSCHE INDUSTRIE NORMEN) DIN 51601 equipment damage.
SAE (Society of Automotive Engineers) Based NO. 2−D
on SAE−J−313C Biocides
BS (BRITISH STANDARD) Based on Class A−1 or A−2 In warm or humid weather, fungus and/or bacteria may form in diesel
BS/2869−1970 fuel if there is water in the fuel.
NOTICE: Fungus or bacteria can cause fuel system damage by
ISO 8217 DMA
plugging the fuel lines, fuel filters or injector. They can also cause fuel
system corrosion.
FUEL REQUIREMENTS
If fungus or bacteria has caused fuel system problems, you should
Notice: the fuel injection pump, injector or other parts of the fuel system have your authorized dealer correct these problems. Then, use a diesel
and engine can be damaged if you use any fuel or fuel additive other fuel biocide to sterilize the fuel system (follow the biocide
than those specifically recommended by Ingersoll Rand. manufacturer‘s instructions). Biocides are available from your dealer,
service stations, parts stores and other automotive places. See your
NOTE: If any fuel other than the one specified is used, engine operation authorized dealer for advice on using biocides in your area and for
will be impaired. Engine failure or malfunction resulting from use of such recommendations on which biocides you should use.
improper fuel will not be warranted by Ingersoll Rand.

To help avoid fuel system or engine damage, please read the following: Smoke Suppressants
The use of a smoke suppressant additive is not allowed because of the
Do not use diesel fuel which has been contaminated with engine oil. greater possibility of stuck rings and valve failure, resulting from
Besides causing engine damage, such fuel can also affect emission
control. Before using any diesel fuel, check with the fuel supplier to see excessive ash deposits.
if the fuel has been mixed with engine oil.

Your engine is designed to use either Number 1−D or Number 2−D

diesel fuel. However, for better fuel economy, use Number 2−D diesel
fuel whenever possible. At temperatures less than −7C, (20F),
Number 2−D fuel may pose operating problems. At colder
temperatures, use Number 1−D fuel (if available) or use a “winterized”
Number 2−D (a blend of Number 1−D and Number 2−D). This blended
fuel is usually called Number 2−D also, but can be used in colder
temperatures than Number 2−D fuel which has not been “winterized.”

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

NOTICE: Do not use home heating oil or gasoline in your diesel

engine; either may cause engine damage.

Handling of the Fuel.

Any fuel containing dust particles or water might cause engine
failure .
Therefore, the following must be observed.
Take care to protect the fuel from ingress of dust particles or water
when filling the fuel tank.

7/20, P65
 FUEL, LUBRICANTS, AND COOLANT 55
LUBRICANT. NOTE

The quality of engine oil can affect engine performance, startability Using a mixture of different brands or quality of oils will adversely affect
and engine life. the original oil quality; therefore, never mix different brand or different
type oils.
Use of unsuitable engine oil will result in piston ring, piston and
cylinder seizure and accelerate surface wear causing increased oil Do not use API, CA, CB grade and reconstituted engine oil
consumption, lowered output and, finally engine failure. To avoid this, Engine damage due to improper maintenance, or using oil of the
use the specified engine oil.
improper quality and/or viscosity, is not covered by the warranty.
1) Engine Oil Selection

Pro Tec 
2) Oil Viscosity
Engine oil viscosity affects engine startability, performance, oil
consumption, wear and the potential for seizure, etc. Always ensure
that lubricants with the correct viscosity for the operating temperature
are used. Refer to fig 12.

Fig. 12

A. (Single − grade) IMPORTANT:

B. Ambient Temperature • Be sure to add Long Life Coolant Antifreeze (LLC) to soft water. In
cold season, the LLC is especially important. Without LLC, cooling
C. (Multi − grade) performance will decrease due to scale and rust in the cooling water
line. Without LLC, cooling water will freeze and expand to break the
cooling line.
COOLANT
• Be sure to use the mixing ratios specified by the LLC manufacturer
All Ingersoll Rand portable compressor engines are factory filled for your temperature range.
with a 50/50 Ethylene glycol base antifreeze/water mix. which provides
protection to −33C (−27F) • Do not mix different types (brand) of LLC, chemical reactions may
make the LLC useless and engine trouble could result
• Replace the cooling water every once a year

CAUTION:
When handling Long Life Coolant Antifreeze, wear protective
rubber gloves not to contact with it. If contact with the eyes or skin
should occur, wash with clean water

7/20, P65
56 OPERATION

ENGINE OPERATION When the belt is depressed 7 − 9 mm with the thumb (about 100 N
[10 kg] pressure) midway between the bottom pulley and alternator
Engine Exhaust Gas Caution (Carbon Monoxide) pulley, the belt tension is correct.
CAUTION If the belt tension is too high, it will result in alternator failure.
Do not breathe exhaust gas because it contains carbon monoxide, A loose belt will cause belt slippage which may result in a damaged
which by itself has no color or odor. Carbon monoxide is a dangerous belt, abnormal noise, poor battery charging and engine overheating.
gas. It can cause unconsciousness and can be lethal.
Do not run the engine in confined areas (such as garages or next to a
building). Keep the exhaust tailpipe area clear of snow and other
material to help reduce the buildup of exhaust gases under the 2
equipment. This is particularly important when parked in blizzard
conditions.

CHECK BEFORE OPERATION

CAUTION: For safety reasons, conduct the inspection with the engine
stopped. 2

Engine Oil Level.

Place the engine or the machine on a level surface
Remove the dipstick, wipe it with a cloth. Insert it fully and take it out
gently again.
Check the oil level against the marks on the dipstick. The oil level
must be between the upper level mark and the lower level mark as
illustrated. 1

A B

1. Fan belt

C 2. Bolt and nut

D
Coolant Level Check
The coolant level must be between “MAX COLD” and “MIN” marks on
the reserve tank depending on the temperature of the engine. Check
and ensure that the level is correct.

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

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

A. Filler cap Radiator Cap Condition

B. Dipstick After the replenishment of the coolant, install the radiator filler cap.
Make sure the cap is securely installed.
C. Upper limit

D. Lower limit

Remove filler cap on the rocker arm cover side of engine

Fill with engine oil up to the upper limit on the dipstick.
Manually tighten the filler cap. Do not use a tool such as pliers to tighten
it.

A certain period of time is required before the engine oil completely

flows down from the oil filler to the crankcase. Wait at least ten minutes
before checking the oil level.
NOTE: Take care to avoid engine oil being splashed on the fan drive
belt because it causes belt slippage or slackness.
CAUTION: When adding oil, take care not to spill it. If you spill oil on the
engine or equipment, wipe it properly, to prevent the risk of fire and
personal injury and/or equipment damage.

Fan Belt Check

Check the fan belt for tension and abnormalities.

7/20, P65
 OPERATION 57
Battery Cable Connection Fuel level

Check the battery cable connections for looseness or corrosion. A Check the remaining fuel oil level in the fuel tank and re−fuel if
loosened cable connection will result in hard engine starting or necessary.
insufficient battery charge. The battery cables must be tightened
securely. Never reverse “+” and “−” terminals when reconnecting
cables after disconnection. Even a short period of reverse connection When starting the engine after a long storage (of more than 3 months),
will damage the electrical parts. first set the engine stop lever to the “STOP” position and then activate
the starter for about 10 seconds to allow oil to reach every engine part.

A Battery cable D
A
B Connections

A. “ON”
Battery Electrolyte level
B. “OFF”
The amount of electrolyte in the batteries will be reduced after repeated
discharge and recharge. Check the electrolyte level in the batteries, C. Fuel filter lever
replenish with a commercially available electrolyte such as distilled
water, if necessary. The battery electrolyte level checking procedure D. Fuel filter pot
will vary with battery type. NOTICE: Do not replenish with dilute sulfuric
acid in the daily service.
1. Set the fuel lever to “ON”.

2. Place the engine stop lever in the START" position.

CAUTION:
When inspecting the batteries, be sure to stop the engine first.
As dilute sulphuric acid is used as electrolyte, be careful not to
contaminate your eyes, hands, clothes, and metals with the electrolyte.
If it gets in your eye, wash with a large amount of water at once, then
seek medical advice.

As highly flammable hydrogen gas is released from the batteries, do not A

create a spark or allow any naked flame near the batteries.

When handling such metallic articles as tools near the batteries, be B

sure not to contact the “+” terminal because the compressor body is “−”
and a dangerous short circuit might result. C

When disconnecting the terminals, start with “−” terminal. When

connecting them, connect the “−” terminal last. D

E F

A. “IDLE”

B. “OPERATION”

C. “START”

D. “STOP”

E. Speed control lever

F. Engine stop lever

7/20, P65
58 OPERATION

CHECKS AND OPERATION AFTER START−UP  Close the service valve to reduce the load.

Check after the Engine Start−up  Let the engine run at normal idle speed for two or three minutes. If
the engine coolant temperature does not start to drop, turn off the
Check the following items in the engine warming−up operation. engine and proceed as follows:
Engine noise and exhaust smoke color − CAUTION: To help avoid being burned −
Listen to the engine and, if any abnormal noise is heard, check to  Do not open the canopy or door if you see or hear steam or engine
determine the cause. coolant escaping. Wait until no steam or engine coolant can be seen or
Check the fuel combustion condition by observing the exhaust heard before opening the engine canopy or door.
smoke color. The exhaust smoke color after engine warm−up and at
no−load condition should be colorless or light blue.  Do not remove the radiator filler cap if the engine coolant in the
reserve tank is boiling. Also do not remove the radiator filler cap while
Black or white smoke indicates incorrect combustion. the engine and radiator are still hot. Scalding fluid and steam can be
blown out under pressure if either cap is taken off too soon.
Note: After start−up from cold the engine might be noisier and the
exhaust smoke color darker than when it has warmed up. However this If no steam or engine coolant can be seen or heard, open the canopy
condition will disappear after warm up. or door. If the engine coolant is boiling, wait until it stops before
proceeding. The engine coolant level should be between the “MAX
Leakage in the systems −
COLD” and “MIN” marks on the reserve tank.
Check the following items:
Make sure the fan belt is not broken, or off the pulley, and that the fan
Lubrication oil leakage − turns when the engine is started. If the engine coolant level in the
reserve tank is low, look for leaks at the radiator hoses and
Check the engine for oil leaks, paying particular attention to oil filter connections, radiator, and water pump. If you find major leaks, do not
and oil pipe joints. run the engine until these problems have been corrected. If you do not
find a leak or other problem, WAIT UNTIL THE ENGINE HAS COOLED
Fuel leakage −
DOWN then carefully add engine coolant to the reserve tank.
Check the fuel injection pump, fuel lines and fuel filter for leakage.
(Engine coolant is a mixture of ethylene glycol antifreeze and water.
Coolant leakage − Check the radiator and water pump hose See “Engine Care in cold season” for the proper antifreeze and
connections and the water drain cock on the cylinder block for leakage. mixture.)

Exhaust smoke or gas leakage CAUTION: To avoid being burned, do not spill antifreeze or engine
coolant on the exhaust system or hot engine parts. Under some
Checking coolant level conditions the ethylene glycol in engine coolant is combustible.
The coolant level could drop because any mixed air is expelled in about If the engine coolant level in the reserve tank is at the correct level but
5 minutes after the engine started. there is still an indication of an overheat condition and no cause was
found, please consult your local Ingersoll Rand branch or dealer.
Stop the engine, remove radiator cap, and add coolant.
CAUTION: Hot steam can rush out and you could get burnt if the Overcooling
radiator cap is removed when the engine is hot. Cover the radiator cap Operating the engine at low coolant temperature will not only increase
with a thick cloth and loosen the cap slowly to reduce the pressure, then the oil and fuel consumption but also will lead to premature parts wear
remove the cap. which may result in engine failure. Ensure that the engine reaches
normal operating temperature 75 to 85C (167 to 185F) within ten
minutes of starting.
OPERATION AND CARE OF A NEW ENGINE.
(3) Hourmeter
Your Ingersoll Rand engine is carefully tested and adjusted in the
factory, however, further run−in is necessary. Avoid any harsh engine This meter indicates the machine operation hours. Make sure that the
operation within the initial 100 operating hours. meter is always working during engine operation. Periodical machine
maintenance is scheduled on the operation hours indicated on the
Do not operate the unit at full load until the engine is warmed−up. hourmeter.
Do not allow the engine to run unloaded for extended periods so as to (4) Liquid and Exhaust Smoke Leakage
minimise the risk of cylinder bore glazing.
Make regular checks for lubricant, fuel, coolant and exhaust smoke
During operation, pay attention to the following points if the engine
leakage.
shows any sign of abnormalities.
(1) Engine Oil Pressure − The engine oil pressure is monitored by a (5) Abnormal Engine Noise
switch that will stop the engine if the pressure falls below a pre−set In the event of any abnormal engine noise, please consult your local
value.
Ingersoll Rand branch or dealer.
(2) Coolant Temperature − The engine performance will be adversely
affected if engine coolant temperature is too hot or too cold. The normal (6) State of the Exhaust Smoke
coolant temperature is 75 to 85C (167 to 185F). Check for any abnormal exhaust smoke color.
Overheating

CAUTION: ENGINE STOPPING

If you see or hear escaping steam or have other reason to suspect (1) Close service valves.
there is a serious overheat condition, stop the engine immediately. (2) Before stopping the engine, cool down the engine by operating it at
If the Engine Coolant Temperature gage (where fitted) shows an reduced load about three minutes. In this period, check the engine
overheat condition, or you have reason to suspect the engine may be noise for abnormalities.
overheating, take the following step:

7/20, P65
 OPERATION 59
LONG TERM STORAGE
If the equipment is to be out of operation for an extended period, it
should be started at least once per week and run on load for about 15
minutes after it has reached normal operating temperature.
If this is not possible,
 Do not drain the cooling water
 Clean dust or oil from the engine extension
 Either fill completely or drain the fuel tank
 Grease accelerator joints and electrical connections
 Disconnect the negative battery terminal

7/20, P65
60 ENGINE MAINTENANCE SCHEDULE

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

IMPORTANT:
Establish a periodic check plan according to the operating conditions and make sure to conduct checks at specified intervals. Otherwise,
malfunctioning may occur to shorten the engine life.
As special knowledge and skill are required for items marked with , consult your local Ingersoll Rand branch or distributor.

: Check : Replace : Contact your dealer

Periodic inspection interval

System Check item Daily Every 50 Every 200 Every 400 Every 800 Every
hours hours hours hours 2000
hours
Fuel Fuel tank level check and refill 
Cleaning fuel tank 
Draining from fuel / water separator 
Cleaning fuel / water separator 
Fuel filter replacement 
Engine oil level 

Engine
g oil Engine oil replacement  
1st time 2nd &
Engine oil filter replacement after
Check & addition cooling 
Radiator fin checking & cleaning 
Cooling fan V−belt checking, adjusting &   
replacement 1st time 2nd &
after
Cooling water
Cooling water replacement 
or every 1
yr
Cooling water path flushing & maintenance 
or every 2
yrs
Fuel & cooling water pipe replacement 
Rubber hoses or every 2
yrs
Operating Governor lever & accelerator check & adjust  
system
Intake and Air cleaner element cleaning & replacement  
exhaust
Electrical Battery electrolyte check and recharging 
equipment
Adjust intake I exhaust valve clearance 
Cylinder head
Lapping intake I exhaust valve seats 

Fuel valve Check fuel injection valve pressure & adjust 

pump * Check & adjust fuel injection pump 

* The specific emissions related parts for the EPA/ARB regulations

EPA allows to apply Maintenance schedule for Emission related parts as follows.

− Check Fuel Valve Nozzle and clean Adjust, cleaning and repair of fuel injection Pump
and fuel valve nozzle

kW x 130 1500 hours of use and at 1500−hour intervals 3000 hours of use and at 3000−hour intervals
thereafter thereafter

7/20, P65
 ENGINE MAINTENANCE SCHEDULE 61
Note:
 This is a recommended maintenance. The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior
to the completion engine useful life. Ingersoll Rand, however, urges that recommended maintenance service is performed at the indicated intervals.

EXPLANATION OF MAINTENANCE SCHEDULE

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

1. Oil level. Check that the oil level is between the max. and the min. level marks.
Add oil to the max. level mark if it is below the min. level.
If it is above the max. level mark, drain oil until the max. level is reached.
2. Engine oil replacement Change at 200 hours or 6 months, whichever comes first.
3. Oil filter element replacement Change at 200 hours or 6 months, whichever comes first.
4. Fuel leakage Replace any damaged or malfunctioning parts which could cause leakage.
5. Draining water in fuel Drain off water in the fuel filter/separator bowl.
filter/separator.
6. Fuel filter element Replace both primary (filter/separator) and secondary elements at 400 hours or 6 months whichever come
replacement first.
7. Injection nozzle check Check injection opening pressure and spray condition. (This is a recommended maintenance item ).
Consult your local Ingersoll Rand branch or distributor.
8. Coolant level. Check coolant level and add coolant if necessary.
9. Coolant leakage check Replace any damaged or malfunctioning parts which could cause leakage.
10. Radiator filler cap fitting The radiator cap must be installed tightly and sealing correctly.
condition
11. Fan belt tension check Check and adjust fan belt deflection. Look for cracks, fraying and wear. Replace if necessary.
12. Coolant temperature Normal running temperature is 75 to 85C (167 to 185F). Check and repair the cooling system if temperature
is abnormal.
13. Coolant replacement Change coolant at intervals of 800 hours or 12 months, whichever comes first.
14. Radiator external face Check monthly. Clean at intervals of 200 hours or 3 months, whichever comes first. In very dusty
cleaning environments, more frequent cleaning might be necessary.
15. Cooling system circuit Clean at intervals of 2000 hours or 24 months, whichever comes first.
cleaning
16. Radiator filling cap function Check radiator pressure cap periodically for proper operation. Consult your local Ingersoll Rand branch or
check distributor.
17. Battery electrolyte level Replenish with distilled water if necessary.
check
18. Battery cleaning Clean the terminals
19. Battery charge condition If cranking speed is too slow to start the engine, charge the battery.
20. Air filter element replacement Change element at 400 hrs or sooner if the restriction indicator shows red.
21. Cylinder compression Consult your Ingersoll Rand dealer or distributor
pressure
22. Valve clearance check Check and adjust every 800 hours. Consult your Ingersoll Rand dealer or distributor

7/20, P65
62 PERIODICAL INSPECTION AND MAINTENANCE.

Inspection after initial 50 hours operation

(1) Replacing the engine oil and engine oil filter (1st time)
When the engine oil is still hot, be careful with a splash of engine oil
which may cause burns. Cool the engine to replace engine oil until the
engine oil becomes warm. It is most effective to drain the engine oil
while the engine is still warm.
In early period of use, the engine oil gets dirty rapidly because of the
initial wear of internal parts. Replace the engine oil earlier.
Engine oil filter should also, be replaced when the engine oil is replaced.

A
Engine oil and engine oil filter replacing procedures are as follows.
Remove the oil filler cap to drain easily while draining the engine oil.
B
1) Prepare a waste oil container collecting waste oil.
2) Loosen the drain plug using a wrench (customer procured) to drain
the engine oil.
3) Securely tighten the drain plug after draining the engine oil.
4) Turn the engine oil filter counter−clockwise using a filter wrench
(customer procured) to remove It.
5) Clean the engine oil filter mounting face.
6) Moisten the new engine oil filter gasket with the engine oil and install
the new engine oil filter manually turning it clockwise until it comes into
contact with the mounting surface, and tighten it further to 3/4 of a turn
with the filter wrench.
Tightening torque: 19.623.5Nm (2.02.4kgfm)

Applicable engine oil filter Part No.

CCN 22355481 C

7) Fill with the new engine oil until it reaches the specified level as
explained in OPERATION section.

A. Oil pan
IMPORTANT:
Do not overfill the oil pan with engine oil. Be sure to keep the specified B. Drain plug
level between upper and lower limit on the dipstick. C. Engine oil filter

8) Warm up the engine by running for 5 minutes while checking any oil
leakage.
9) Stop the engine after warming up and leave it stopping for about 10
minute to recheck the engine oil level with dipstick and replenish the
engine oil. If any oil is spilled, wipe it away with a clean cloth.

7/20, P65
 PERIODICAL INSPECTION AND MAINTENANCE. 63
(2) Checking and adjusting cooling fan V−belt
When there is not enough tension in the V−belt, the V−belt will slip
making it impossible for the alternator to generate power and cooling
water pump and cooling fan will not work causing the engine to
overheat. Check and adjust the V−belt tension (deflection) in the
following manner.
1) Press the V−belt down with your thumb [approx. 100N(10.2kgf)]. at
the middle of the V−belt span to check the tension (deflection).
The specified deflection should be as follows.

A
79mm

(Adjusting the V−belt tension)

A. Adjust the V−belt tension by prying with a wooden bar

B. Alternator
C. Adjusting bracket

Use of genuine Ingersoll Rand fan belt

Always use genuine Ingersoll Rand fan belts as they provide high
driving ability and long operating durability. Use of non−Ingersoll Rand
fan belts could result in premature belt wear or belt elongation leading
to engine overheating or excessive belt noise.

D. Radiator fan CAUTION:

To help avoid being injured, check and adjust the fan belt tension with
E. Set bolt engine stopped.
F. Alternator
G. Deflection
H. Press with thumb
I. Crankshaft V−pulley
J. V−belt

2) If necessary, adjust the V−belt tension (deflection). To adjust the

V−belt tension, loosen the set bolt and move the alternator to tighten the
V−belt.
3) Visually check the V−belt for cracks, oiliness or wear. If any , replace
the V−belt with new one.

7/20, P65
64 PERIODICAL INSPECTION AND MAINTENANCE.

Inspection every 50 hours operation  If the engine cranking speed is so slow that the engine does not start
up, recharge the battery.

(1) Inspection of battery  If the engine still will not start after charging, replace the battery.

Fire due to electric short−circuit  Remove the battery from the battery mounting of the machine unit
after daily use if letting the machine unit leave in the place that the
ambient temperature could drop at −15C or less. And store the battery
 Make sure to turn off the battery switch or in a warm place until the next use the unit to start the engine easily at
disconnect the negative cable (−) before low ambient temperature.
inspecting the electrical system. Failure to do so
could cause short−circuiting and fires.
 Always disconnect the (−) Negative battery
cable first before disconnecting the battery cables
from battery. An accidental “Short circuit” may
cause damage, fire and or personnel injury.

And remember to connect the (−) Negative battery cable (back onto the
battery) LAST.

Proper ventilation of the battery area

Keep the area around the battery Well ventilated,

paying attention to keep away any fire source.
During operation or charging, hydrogen gas is
generated from the battery and can be easily OPTION
ignited.

Do not come in contact with battery electrolyte Follow the instructions an precautions in the manual from the battery
maker.
Pay sufficient attention to avoid your eyes. or skin
A. Battery fluid
from being in contact with the fluid. The battery
electrolyte is dilute sulfuric acid and causes burns. B. Lower limit
Wash it off immediately with a large amount of
fresh water if you get any on you. C. Upper limit

 Clean the battery terminals Inspection every 200 hours operation

 Check the level of fluid in the battery. (1) Draining and cleaning of the fuel tank
When the amount of fluid nears the lower limit, fill with battery fluid
(available in the market) to the upper limit. If operation continues with 1) Prepare a waste oil container.
insufficient battery fluid, the battery life is shortened, and the battery
2) Take off the fuel tank.
may overheat and explode.
3) Remove the cap of the fuel tank to drain (water, dust ,etc.) from the
 Battery fluid tends to evaporate more quickly in the summer, and the
fluid level should be checked earlier than the specified limes. fuel tank bottom.

4) Drain fuel and clean fuel tank.

5) Put back the fuel tank.

(2) Cleaning The Fuel Filter Pot.

Clean the fuel filter in a clean place to prevent dust intrusion.

1) Close the fuel filter lever.

2) Remove the top cap, and rinse the inside with diesel fuel.

3) Take out the element, and rinse it with diesel fuel.

4) After cleaning, reinstall the fuel filter, keeping out of dust and dirt.

5) Air−bleed the injection pump.

7/20, P65
 PERIODICAL INSPECTION AND MAINTENANCE. 65
(4) Checking and cleaning radiator fins.

Beware of dirt from air blowing

A Wear−protective equipment such as goggles to

protect your eyes when blowing compressed air.
C Dust or flying debris can hurt eyes.

Dirt and dust adhering on the radiator fins reduce the cooling
performance, causing overheating. Make it a rule to check the radiator
fins daily and clean as needed.
D B
 Blow off dirt and dust from fins and periphery with compressed air
[0.19MPa (2kgf/cm2) or less] not to damage the fins with compressed
A. “OFF” air.
B. “ON”  If contaminated heavily, apply detergent, thoroughly clean and rinse
with tap water shower.
C. Fuel filter lever

D. Fuel filter pot

NOTE:
Entrance of dust and dirt can cause a malfunction of the fuel
injection pump and the injection nozzle. Wash the fuel filter cup
periodically.

Fuel System Air Bleeding

The entry of air into the fuel system will cause difficult engine starting
or engine malfunction.
When carrying out service procedures such as emptying the fuel tank,
draining the filter/separator, and changing the fuel filter element be sure
to bleed air from the fuel system.
A. Dust, dirt.
To activate the “automatic air−bleeding system”, turn the key switch to
B. Radiator fins
the “ON” position and energize the electromagnetic pump” to bleed the
air. C. Air blow

Air bleeding method: IMPORTANT:

Never use high pressure water or air from close by fins or never attempt
When the “starter switch” is set to the “ON” position to activate the
to clean using a wire brush. Radiator fins can be damaged.
electromagnetic pump, fuel is forced to the fuel valve of each injection
pump and then to the leak−off pipe of each injector nozzle, so that any
air in the fuel system bleeds off automatically to the fuel tank.
(5) Checking the governor lever and accelerating device.
The governor lever and accelerating devices (accelerating lever, pedal.
NOTE: etc.) of the machine unit are connected by a fixed linkage to a
Although the fuel system can bleed air automatically when the key pneumatic actuator. If the linkage becomes loose, the deviation in the
switch is in the “ON” position, air can also be manually bled by use of position may result and make operation unsafe. Check the linkage
the primer pump facility in the filter/separator assembly. connections for excess play. For adjustment of linkage see
By unscrewing the plastic primer pump head ‘A’ and stroking it up and compressor operation section.
down, any air bubbles in the system will be purged back to the fuel tank.
When this has been completed, the pump head must be screwed back
into the filter/separator assembly. Governor Control Seals
As the governor is precisely adjusted, most of the controls are sealed,
Start the engine and visually check the fuel system for leaks. please do not break them. Should any adjustment be necessary,
contact your local Ingersoll Rand branch or distributor.

(3) Replacing the engine oil and engine oil filter (2nd time and
after) NOTE: Ingersoll Rand will not accept any warranty claim on an
engine with broken governor seals.
Replace the engine oil every 200 hours operation from 2nd time and on.
Replace the engine oil filter at the same time.

7/20, P65
66 PERIODICAL INSPECTION AND MAINTENANCE.
(6) Air cleaner element inspection (1) Checking and adjusting cooling fan V−belt (2nd time and after)
Check and adjust the cooling fan V−belt tension every 200 hours
AIR INTAKE SYSTEM operation from 2nd time and on.

Air cleaner
Inspection every 400 hours operation
Engine performance and life vary with the air intake conditions.
(1) Replacing the air cleaner element
A dirty air cleaner element reduces the amount of intake air, causing
reduced engine output and possible engine damage. Replace the air cleaner element periodically even if it is not damaged
or dirty. When replacing the element, clean the inside air cleaner case
Also, a damaged element leads to abrasion of cylinders and valves, at the time. If having the air cleaner with double elements, do not
resulting in increased oil consumption, reduced output and shortened remove the inner element. If the engine output is still not recover (or the
engine life. dust indicator still actuates if having the air cleaner with a dust indicator)
even though the outer element has replaced with new one, replace the
inner element with new one.
INSPECT THE CONDITION OF THE ELEMENT.

Inspection every 800 hours operation

(1) Replacing cooling water
Cooling water contaminated with rust or water scale −reduces the
3 cooling effect. Even when antifreeze agent (LLC) is mixed, the cooling
water gets contaminated due to deteriorated ingredients. Replace the
cooling water at least Once a year.
1) Remove the header tank cap.
1
2) Remove the radiator drain plug of the radiator and drain the cooling
water.
4
2
3) After draining the cooling water, put the drain plug back.
4) Fill radiator and engine with cooling water via the header tank.
A B
Beware of scalding by hot water
Wait until the temperature goes down before draining the Cooling water.
Otherwise, hot water may splash to cause scalding.
A Normal
B Clogged
1 Indicator
2 Window
3 “RESET” button
4 Red signal

Air cleaner with dust indicator

This indicator is attached to the air cleaner. When the air cleaner
element is clogged, air intake resistance becomes greater and the dust
indicator signal turns to red indicating the element needs to be
changed.
When the signal turns to red, replace the element. Then press the dust
indicator button to reset the indication.

7/20, P65
 PERIODICAL INSPECTION AND MAINTENANCE. 67
(2) Checking and adjusting the fuel injection valve
As the adjustment requires specialized knowledge and skill, .consult
your Ingersoll Rand dealer. This adjustment is needed to obtain the
optimum injection pattern for full engine performance.

(3) Adjusting intake / exhaust valve clearance

As this adjustment requires specialized knowledge and skill, consult
your Ingersoll Rand dealer. The adjustment is necessary to maintain
the correct timing for the opening and closing of valves. Neglecting the
adjustment will cause the engine to run noisily and result in poor engine
performance and other damage.

Inspection every 2000 hours operation

(1) Flushing the cooling system and checking the
cooling system parts
As this maintenance requires specialized knowledge and skill, consult
your Ingersoll Rand dealer. Rust and water scale will accumulate in the
cooling system through many hours of operation. This lowers the
engine cooling effect.
(2) Checking and replacing fuel hoses and cooling water hoses
As this maintenance requires specialized knowledge and skill, consult
your Ingersoll Rand dealer. Regularly check the rubber hoses of the
fuel system and cooling water system. If cracked or degraded, replace
them with new one. Replace the rubber hoses at least every 2 years.
(3) Lapping the intake and exhaust valves
As this maintenance requires specialized knowledge and skill, consult
your Ingersoll Rand dealer. The adjustment is necessary to maintain
proper contact of the valves and seats.
(4) Checking and adjusting the fuel injection timing
As this maintenance requires specialized knowledge and skill, consult
your Ingersoll Rand dealer.

Checking and adjusting the EPA emission related parts.

The inspection and servicing require specialized knowledge and
techniques. Consult your Ingersoll Rand dealer or distributor.
EPA allows to apply maintenance schedule for emission related parts
as follow.

− Check Fuel Valve Adjust, cleaning and

Nozzle and clean repair of Fuel injection
Pump and Fuel Valve
Nozzle.
kW x 130 1500 hours of use 3000 hours of use
and at 1500−hour and at 3000−hour
intervals thereafter intervals thereafter

7/20, P65
68 ENGINE TROUBLESHOOTING

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

Engine does not start Battery discharged

Starter does not turn. Bad cable connections.

Starter or starter switch failure.

Safety relay failure.

Engine stop solenoid malfunction.

No fuel in the fuel tank.

No fuel injection. Clogged fuel filter element.

Air in the fuel system.

Starter turns but engine does not Control rack is stuck at no fuel
fire. position.

Incorrect preheating operation.

Faulty air heater.

Fuel is injected but engine does not Incorrect injection timing.

fire.

Low cylinder compression

pressure.

Engine stop solenoid not fully

returned.

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

Incorrect low idle speed adjustment.

7/20, P65
 ENGINE TROUBLESHOOTING 69
Unstable engine running Crack in injection pipe.

Injection nozzle failure.

Unstable low idling Engine stop solenoid return failure.

Uneven compression pressure between cylinders.

Incorrect high idle speed Incorrect control lever adjustment.

adjustment.

Governor internal malfunction.

Engine hunting in medium speed Governor spring deteriorated.

range.

Air in the fuel system

Insufficient fuel supply. Clogged fuel filter element

Piping failure (squeezed/restricted

etc.)

Engine malfunction in high speed Uneven fuel injection amount between cylinders.
range.

Deteriorated governor spring.

Incorrect valve clearance adjustment.

Deteriorated valve spring.

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

Engine overheat. Insufficient coolant volume.

Fan belt slippage.

Cooling system defect Thermostat malfunction.

Radiator filler cap malfunction.

Cooling system interior fouled.

Radiator clogged.

Engine over−loaded.

Improper servicing Air cleaner element clogged.

Insufficient airflow/restriction.

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

Low oil pressure Lack of oil Oil leakage

High oil consumption

Wrong oil Wrong type and viscosity.

High coolant temperature. Over heat.

Clogged filter and strainer.

Worn bearings and oil pump.

Faulty relief valve.

7/20, P65
70 ENGINE TROUBLESHOOTING

Low engine output Incorrect injection timing Too far advanced.

Too far retarded.

Injection nozzle malfunction Incorrect injection pressure.

Incorrect spray condition.

Incorrect injection pump adjustment Lack of fuel in tank.

Insufficient fuel supply to the Air in injection pump.

injection pump

Fuel filter clogged.

Overflow valve malfunction.

Governor malfunction Incorrect engine control

adjustment.

Deteriorated governor spring.

Incorrect valve clearance

adjustment.

Cylinder compression leakage Injector nozzle misalignment.

Low cylinder compression pressure Cylinder bore wear.

Insufficient air intake volume. Air cleaner clogged.

Restricted air flow.

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

Too much oil quantity.

Engine burning oil Faulty piston rings/damaged cylinder bores.

Faulty valve stem seal.

Damaged seal / Damaged turbocharger seal

Oil leakage Loose joints/gaskets.

Improper installation of filter and piping.

Fuel leakage Damaged seals.

Excessive fuel consumption Improper component installation or tightening.

Excessive injection volume. Injection pump defective.

Excessive mechanical loads

7/20, P65
 ENGINE TROUBLESHOOTING 71
Improper exhaust Clogged air cleaner.

Damaged injector nozzle.

Excessive black smoke Wrong injector nozzle.

Injection timing incorrect.

Excessive injection volume.

Incorrect fuel.

Water mixing in fuel

Excessive white smoke Low compression pressure.

Injection timing incorrect.

Low coolant temperature

Faulty turbocharger

Battery over discharge Low electrolyte level Crack in battery body.

Natural consumption.

Charging failure Loose or damaged belt.

Faulty alternator.

Damaged wiring or contact failure.

Excessive electrical loads Insufficient battery capacity for the application.

7/20, P65