OPERATION and MAINTENANCE

MANUAL

AIRSOURCE-IR AIRSOURCE PLUS-IR

This manual contains important safety information.

Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.

501 Sanford Ave

Mocksville, N.C. 27028

Book 22498711 (12-15-06)

 CALIFORNIA
Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the
State of California to cause cancer, birth defects, and other reproduc-
tive harm.
 TABLE OF CONTENTS

TITLE PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hazardous Substance Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

WARRANTY REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Complete Machine Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Complete the Applicable Blocks Owner / User Type of Business (check one only) . . . . . . . . . . 1-22

NOISE EMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

This section pertains only to machines distributed within the United States. . . . . . . . . . . . . . . . . . . 3-26
Compressor Noise Emission Control Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Noise Emission Control Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
A. Compressed Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
B. Safety and Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
C. Acoustic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
D. Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
E. Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
F. Air Intake and Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
G. Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
H. Isolation Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
I. Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
J. Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Unit Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
RUNNING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
UNITS MEASUREMENTS WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
EXPENDABLE SERVICE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

SECTION 5 - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

BEFORE TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

SETTING UP (ALL UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

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TITLE PAGE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
STANDARD CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Machine has shutdown and sensors as follows: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
After Starting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Compressor Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Compressor Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Receiver-Separator Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Exterior Finish Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Field Repair of Texture Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
FIELD REPLACEMENT OF CANOPY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57

Trouble Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Action Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
A. Think Before Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
B. Do The Simplest Things First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
C. Double Check Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
D. Find And Correct Basic Cause. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
Bold Headings depict the COMPLAINT - Subheadings indicate CAUSES . . . . . . . . . . . . . . . . 8-59

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SECTION 9 - 4IRY3N-4IRY3T ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66
Servicing of the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66
Names of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67
Pre-Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
Checks During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69
Radiator Cooling Water (Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
Color of Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
Immediately Stop the Engine If; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
Reversed Engine Revolution and Remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71
How to Tell When the Engine Starts Running Backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71
Remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-72
Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-73
Periodic Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-75
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-75
Fuel Level Check and Refueling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-75
Air Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-77
Air Bleeding Procedure 77
Checking the Fuel Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-79
Cleaning the Fuel Filter Pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-80
Fuel Filter Cartridge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-81
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82
Checking Oil Level and Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82
Changing Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-84
Replacing the Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-85
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-86
Checking Coolant Level, Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-87
Changing Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-89
Remedies for Quick Decrease of Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-89
Checking Radiator Hoses and Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-89
Precaution at Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90
Cleaning Radiator Core (Outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90
Anti-Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-91
Radiator Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-92
Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-93
Adjusting Fan Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-93
Carriage and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-96
When it is difficult to start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-96
When output is insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-97
When engine suddenly stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-98
When color of exhaust is especially bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-98
When engine must be stopped immediately. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-99
When engine overheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-99
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-100

1-3
 TABLE OF CONTENTS

TITLE PAGE

1-4
FOREWORD

3
 FOREWORD

4
FOREWORD FOREWORD

Foreword
Nothing contained in this document is intended to extend any promise, warranty or representation,
expressed or implied, regarding the Ingersoll-Rand products described herein. Any such warranties or
other terms and conditions of sale of products shall be in accordance with the standard terms and
conditions of sale for such products, which are available upon request.
This manual contains instructions and technical data to cover all routine operation and scheduled
maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorized Ingersoll-Rand service department.
All components, accessories, pipes and connectors added to the compressed air system should be:

• of good quality, procured from a reputable manufacturer and, wherever possible, be of a type
approved by Ingersoll-Rand.
• clearly rated for a pressure at least equal to the machine maximum allowable working
pressure.
• compatible with the compressor lubricant/coolant.
• accompanied with instructions for safe installation, operation and maintenance.
Details of approved equipment are available from Ingersoll-Rand Service departments. The use of
repair parts other than those included within the Ingersoll-Rand approved parts list may create
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.
This machine has been designed and supplied for above ground operation to be used for compression
of normal ambient air containing no additional gases, vapors or particles within the ambient temperature
range specified in the general data section of this manual.
This machine should not be used:

1. For direct or indirect human consumption of the compressed air.

B. Outside the ambient temperature range of minus 20°F to 115°F.
C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors
exists.
D. With other than Ingersoll-Rand approved components.
E. With guards, or controls or switches missing or disabled.
F. For storage or transportation of materials inside or on the enclosure.
This company accepts no responsibility for errors in translation of this manual from the original English
version.

5
 FOREWORD

To Convert From Shipping Position to Towing Position

Following Tools are required Hardware Included

Ratchet (4) 12mm bolts with pre-applied thread lock
13mm socket to fit ratchet (2) 8mm Taptite Bolts
Torque wrench set to 68 foot pounds (9.4 (2) Washers
kg-meters)
16mm socket to fit torque wrench (2) Safety Chains
12 inch extension for torque wrench

1. Remove hardware box from compressor toolbox.

2. Open box and remove the bag containing hardware, safety chains and assembly
instructions.

3. Raise the front of the unit 50 that the legs are approximately 1" above the ground and
support front of unit.

4. Remove the temporary retaining bolts from both sides of the frame at the drawbar
connection. (See Figure 1).

5. Carefully lower drawbar to the Level Position.

6
FOREWORD FOREWORD

6. Install the four bolts (with pre-applied thread lock} to the four points inside the
enclosure and torque to 68 ft. Ibs. (9.4 kg-m}. (See Figure 1).

7. Install safety chains by sliding the second link of one chain into the slot in drawbar
plate. Fasten chain to plate using taptite and washer. Repeat for the other chain.
(See Figure 2).
Support the Drawbar at the Pintle Eye:

8. Pull the pin out of the jack located at the front of the enclosure. Remove the jack by
sliding it off the mounting tube. Relocate and install the jack to the mounting tube on
the side of the drawbar.

7
 FOREWORD

8
Section 1 - Safety

9
 Operating & Maintenance Manual Safety

Safety Precautions

General one common downstream plant, effective

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

10
Safety Operating & Maintenance Manual

Exercise extreme caution when using (engine exhaust manifold and piping, air
booster battery. To jump battery, connect receiver and air discharge piping, etc.).
ends of one booster cable to the positive (+)
Ether is an extremely volatile, highly
terminal of each battery. Connect one end of
flammable gas. USE SPARINGLY! DO NOT
other cable to the negative (-) terminal of the
use ETHER if unit has GLOW Plug starting
booster battery and other end to a ground
aid. Engine damage will result.
connection away from dead battery (to avoid
a spark occurring near any explosive gases Never allow the unit to sit stopped with the
that may be present). After starting unit, pressure in receiver-separator system. As a
always disconnect cables in reverse order. precaution, open manual blowdown valve.
High Pressure Air can cause serious injury or Never operate unit with guards, covers or
death. Relieve pressure before removing screens removed. Keep hands, hair,
filler plugs/caps, fittings or covers. clothing, tools, blow gun tips, etc. well away
from moving parts.
Air pressure can remain trapped in air supply
line which can result in serious injury or Make sure wheels, tires and tow bar
death. Always carefully vent air supply line at connectors are in safe operating condition
tool or vent valve before performing any and tow bar is properly connected before
service. towing.
This machine produces loud noise with doors Steps for determining correct load limit -
open or service valve vented. Extended
exposure to loud noise can cause hearing 1. Locate the statement “The weight of cargo
loss. Always wear hearing protection when should never exceed xxx kg or xxx lbs” on
doors are open or service valve is vented. your vehicle’s placard.
Never inspect or service unit without first 2. This figure equals the available amount of
disconnecting battery cable(s) to prevent cargo and luggage load capacity.
accidental starting.
3. Determine the combined weight of
Do not remove the pressure cap from a HOT luggage and cargo being loaded on the
radiator. Allow radiator to cool down before vehicle. That weight may not safely exceed
removing pressure cap. the available cargo and luggage load
capacity.
Do not use petroleum products (solvents or
fuels) under high pressure as this can Whenever the machine is stopped, air will
penetrate the skin and result in serious flow back into the compressor system from
illness. devices or systems downstream of the
machine unless the service valve is closed.
Wear eye protection while cleaning unit with
Install a check valve at the machine service
compressed air to prevent debris from
valve to prevent reverse flow in the event of
injuring eye(s).
an unexpected shutdown when the service
Disconnected air hoses whip and can cause valve is open. Stop machine to add fuel.
serious injury or death. Always attach a
safety flow restrictor to each hose at the
source of supply or branch line in accordance
with OSHA Regulation 29CFR Section
1926.302(b).
Rotating fan blade can cause serious injury.
Do not operate without guard in place.
Use care to avoid contacting hot surfaces

11
 Operating & Maintenance Manual Safety

Hazardous Substance Precaution

The following substances are used in the
manufacture of this machine and may be
hazardous to health if used incorrectly.
Avoid ingestion, skin contact and breathing
fumes for the following substances:
Antifreeze, Compressor Oil, Engine
Lubricating Oil, Preservative Grease, Rust
Preventative, Diesel Fuel and Battery
Electrolyte.

12
 Operating & Maintenance Manual Safety

Look for these signs on machines. They 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
DANGER (Red Background) indicates the
presence of a hazard which will cause
werious injury, death or property damage
if ignored.

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

! CAUTION
CAUTION (Yellow Background) indicates
indicates the presence of a hazard which
will or can cause serious injury or
property damage if ignored.

NOTICE
NOTICE (Blue Background) indicates
important set-up, operating or
maintenance information.

12
Safety Operating & Maintenance Manual

13
 Operating & Maintenance Manual Safety

14
Safety Operating & Maintenance Manual

Table 1:

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 Mocksville Parts
Service Department. The no charge order should contain only Safety Decals. Help
promote safety! Assure that decals are present on the machines. Replace decals that
are not readable.

15
 Operating & Maintenance Manual Safety

16
Section 1 - WARRANTY

17
 Operating & Maintenance Manual WARRANTY

WARRANTY
Ingersoll-Rand, through its distributors, warrants to the initial user that each portable air
compressor manufactured by it, will be free of defects in material and workmanship for a
period of the earlier of twelve (12) months from shipment to or the accumulation of 2,000 hours
of service by the initial user.
Portable compressor airends will be free of defects in material and workmanship for a period
of the earlier of twenty four months from shipment to or the accumulation of 4,000 hours of
service by the initial user. The warranty against defects will include replacement of the
complete airend, provided the original airend is returned assembled and unopened.
Portable Compressor Airend Limited Optional Warranty - The earlier of sixty (60) months
from shipment to or the accumulation of 10,000 hours of service. The optional warranty is
limited to defects in rotors, housings, bearings and gears and is automatically available when
meeting the following conditions:

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

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

3. Maintenance is performed at prescribed intervals.

Oil-Free airends are fee-based and may require a maintenance agreement. Formal
enrollment is required.
Ingersoll-Rand engines will be free of defects in material and workmanship for a period of
the earlier of twenty four months from shipment to or the accumulation of 4,000 hours of
service by the initial user.
Ingersoll-Rand Platinum Drive Train Warranty (Optional) – Platinum drive train (Ingersoll-
Rand Engine and Airend combination) will be free of defects in material and workmanship for
a period of the earlier of sixty (60) months from shipment to, or the accumulation of 10,000
hours of service. The starter, alternator, fuel injection system and all electrical components are
excluded from the extended warranty. The airend seal and drive coupling are included in the
warranty (airend drive belts are not included). The optional warranty is automatically available
when meeting the following conditions:

1. The original airend is returned assembled and unopened.

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

3. Maintenance is performed at prescribed intervals.

It is the obligation of the user to provide verification that these conditions have been satisfied
when submitting warranty claims.
Limited Corrosion Warranty (Optional) - The earlier of sixty (60) months from shipment to
or the accumulation of 10,000 hours of service. The optional warranty is limited to corrosion of
canopy, exterior sheet metal (sidewalls) and belly pans. The Corrosion warranty is available
at an additional fee, only for models AirSource and AirSource Plus. Consult the authorized
Sales or Service representative for availability and pricing. Formal enrollment is required.

18
WARRANTY Operating & Maintenance Manual

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

19
 Operating & Maintenance Manual WARRANTY

WARRANTY REGISTRATION

Complete Machine Registration

Machines shipped to locations within the United States do not require a warranty registration
unless the machine status changes (i.e. change of ownership).

Machines shipped outside the United States require notification be made to initiate the
machine warranty.

Fill out the Warranty Registration Form in this section, keep a copy for your records and
mail form to:
Ingersoll-Rand Company
Portable Compressor Division
P.O. Box 868
Mocksville, North Carolina 27028
Attn: Warranty Department

NOTE: Completion of this form validates the warranty.

20
WARRANTY Operating & Maintenance Manual

21
 Operating & Maintenance Manual WARRANTY

Selling Distributor Servicing Distributor WARRANTY

REGISTRATION
Name _________________ Name _________________ Owner/User Name _________
Address ________________ Address ________________ Address _________________
City ___________________ City ___________________ City_____________________
County _________________ County _________________ County __________________
State _________________ State ___________________ State __________________
Zip Code _______________ Zip Code _______________ Zip Code_________________
Telephone ______________ Telephone ______________ Telephone _______________

Complete the Applicable Blocks Owner / User Type of Business (check one only)

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

(highway, excavation, etc.)
† Construction-Light † Government † Quarry † Shallow Oil & Gas
(carpentry, plumbing, (municipal, state,
pools, mason, etc.) county, etc.)
† Rental (rental center, † Building Contractor † Waterwell † Utility Company
rental fleet, etc.)
† Industrial (plant use) † Other specify † Exploration † Utility Contractor

Model Unit S/N Engine S/N Date Delivered

Model Unit S/N Engine S/N Date Delivered

SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT

1. The Purchaser has been instructed and/or has read the manual and understands
proper preventative maintenance, general operation and safety precautions.
2. The warranty and limitation of liability has been reviewed and understood by the owner/
user.
3. In the event that this unit is to be used within a nuclear facility, the owner/user shall
notify Ingersoll-Rand of such use so that Ingersoll-Rand may arrange for appropriate
nuclear liability protection from the owner-licensee of the facility.
4. Ingersoll-Rand reserves the right to make design changes or modifications of Ingersoll-
Rand products at anytime without incurring any obligation to make similar changes or
modifications on previously sold units.

22
WARRANTY Operating & Maintenance Manual

23
 Operating & Maintenance Manual WARRANTY

24
Section 3 - NOISE EMISSION

25
 Operating & Maintenance Manual NOISE EMISSION

Noise Emission

This section pertains only to machines distributed within the United

States.

! WARNING
Tampering with Noise Control System Prohibited

Federal law prohibits the following acts or the causing thereof:

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

Compressor Noise Emission Control Information

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

26
NOISE EMISSION Operating & Maintenance Manual

Noise Emission Control Maintenance Log

COMPRESSOR MODEL __________________________

SERIAL NO. ___________________________________
USER UNIT NO. ________________________________

UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM

WHOM PURCHASED:
Engine Make & Model: ________________ __________________________________
Serial No.: _________________________ __________________________________
Purchaser or Owner: _________________ __________________________________
Address: __________________________ Date Purchased: ____________________

The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control
system of any compressor manufactured and sold under the above regulations, specifically
the following acts or the causing thereof:
(1) the removal or rendering inoperative by any persons, other than for purposes of
maintenance, repair, or replacement, of any device or element of design incorporated into new
compressor for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use; or (2) the use of the compressor after such device or element
of design has been removed or rendered inoperative by any person.

Noise Emission Warranty

The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this
air compressor was designed, built and equipped to conform at the time of sale to the first retail
purchaser, with all applicable U.S. EPA Noise Control Regulations.
This warranty is not limited to any particular part, component, or system of the air compressor.
Defects in the design, assembly or in any part, component, or system of the compressor
which, at the time of sale to the first retail purchaser, caused noise emissions to exceed
Federal Standards are covered by this warranty for the life of the air compressor.

Introduction
The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for
Noise Emissions, applicable to Portable Air Compressors.
The purpose of this book is to provide (1) the Maintenance Performance Schedule for all
required noise emission controls and (2) space so that the purchaser or owner can record what
maintenance was done, by whom, where and when. The Maintenance Schedule and detailed
instructions on the maintenance items are given on following page.

27
 Operating & Maintenance Manual NOISE EMISSION

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

A. Compressed Air Leaks

Correct all compressed air leaks during the first shutdown period after discovery. If severe
enough to cause serious noise problems and efficiency loss, shut down immediately and
correct the leak(s).

B. Safety and Control Systems

Repair or replace all safety and control systems or circuits as malfunction occurs. No
compressor should be operated with either system bypassed, disabled, or nonfunctional.

C. Acoustic Materials
In daily inspections, observe these materials. Maintain all acoustic material as nearly as
possible in its original condition. Repair or replace all sections that have: 1) sustained damage,
2) have partially separated from panels to which they were attached, 3) are missing, or have
otherwise deteriorated due to severe operating or storage conditions.

D. Fasteners
All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be
inspected for looseness after each 100 hours of operation. They should be retightened,
repaired, or if missing, replaced immediately to prevent subsequent damage and noise
emission increase.

E. Enclosure Panels
Enclosure panels should also be inspected at 100 hour operational intervals. All panels that
are warped, punctured, torn, or otherwise deformed, such that their noise containment
function is reduced, should be repaired or replaced before the next operation interval. Doors,
access panels, and hatch closures especially, should be checked and adjusted at this time to
insure continuous seating between gasket or acoustic material and the mating frame.

F. Air Intake and Engine Exhaust

Engine and compressor air intake and engine exhaust systems should be inspected after each
100 hours of operation for loose, damaged, or deteriorated components. Repairs or
replacements should be made before the next period of use.

G. Cooling Systems
All components of the cooling system for engine water and compressor oil should be inspected

28
NOISE EMISSION Operating & Maintenance Manual

every 250 hours of use. Any discrepancies found should be corrected before placing the unit
back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at
all times during operation.

H. Isolation Mounts
Engine/airend isolation mounts should be inspected after each 250 hours of operation. Those
mounts with cracks or splits in the molded rubber, or with bent or broken bolts due to operation
or storage in severe environments, all should be replaced with equivalent parts.

I. Engine Operation
Inspect and maintain engine condition and operation as recommended in the manuals
supplied by the engine manufacturer.

J. Fuels and Lubricants

Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand
Company and Engine Manufacturer’s Operator and Maintenance Manuals.

29
 Operating & Maintenance Manual NOISE EMISSION

Maintenance Record For Noise Emission Control And Extended Warranty

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

30
Section 4 - GENERAL DATA

31
 Operating & Maintenance Manual GENERAL DATA

General Data

Unit Model:

UNIT MODEL Air Source Air Source

Plus

CFM 160 185

Engine Speed - RPM (Full Load) 2600 2500
Engine Speed - RPM (No Load) 1700 1700
COMPRESSOR
Rated Operating Pressure - psi (kPa) 100 (689) - - -(861)
Safety Valve Setting - psi (kPa) 150 (1034) 150 (1034)
Net Weight (less fuel) pounds 1700 1700
ENGINE (Diesel)
Manufacturer Ingersoll-Rand
Model 4IRX3N 4IRX3T
Electrical System 12VDC 12VDC

FLUID CAPACITIES
Compressor Lubricant...............................................10 quarts (9.5 litres)
Engine Crankcase Lubricant ....................................10.0 quarts (9.5 litres)
Fuel Tank .................................................................20 U.S gal. (76 litres)
Radiator ....................................................................2.5 U.S. gal. (9.5 litres)

RUNNING GEAR
Tire Size....................................................................205/75D15
Inflation Pressure (Cold) ...........................................50 psi
Towing Speed (Maximum) ........................................65 mph (105 km/hr)

UNITS MEASUREMENTS WEIGHTS

Overall Length...........................................................11.0 feet (5.2 meters)
Overall Height ...........................................................4.9 feet (2.3 meters)
Overall Width ...........................................................5.6 feet (2.6 meters)
Track Width...............................................................4.5 feet (2.1 meters)

32
GENERAL DATA Operating & Maintenance Manual

Weight (with fuel) ......................................................1850 lbs

Weight (less fuel) ......................................................1700 lbs

EXPENDABLE SERVICE PARTS

Compressor Oil FIlter Element..................................Part No. 22436323
Compressor Oil Separator Element ..........................Part No. 22436331
Air Cleaner Element (Compressor) primary ..............Part No. 35393685
Air Cleaner Element (Engine) primary ......................Part No. 35393685
Air Cleaner Element (Compr) secondary - optional ..Part No. 35393651
Air Cleaner Element (Engine) secondary - optional .Part No. 35393651
Engine Oil Filter Element .........................................Part No. 22496905
Fuel Water Separator Element .................................Part No. 22532378
Fuel/Water Filter Assembly .......................................Part No. 22528228
In-Line Fuel Filter ......................................................Part No. 36845493
Protec Compressor Fluid (1 gal) ...............................Part No. 36899698
500 hour Maintenance Kit (without fluids).................Part No. 36096170
500 hour Maintenance Kit (with fluids)......................Part No. 36096188
1000 hour Maintenance Kit (without fluids) ...............Part No. 36096196
1000 hour Maintenance Kit (with fluids)....................Part No. 36096204

! WARNING
Modification or alteration of this machine. Can result in severe injury or
death. Do not modify or alter without the express written consent of
Ingersoll-Rand Company.

33
 Operating & Maintenance Manual GENERAL DATA

34
SECTION 5 - OPERATION

35
 Operating & Maintenance Manual SECTION 5 - OPERATION

BEFORE TOWING towing.

SETTING UP (ALL UNITS)

! WARNING • Position as level as possible. The
design of these units permits a 15
Failure to follow these instructions degree sidewise limit on out-of-level
CAN cause severe injury or death. operation.

• Assure tow vehicle has towing • When the unit is to be operated out-
capacity for weight of this unit as of-level, it is important:
stated on general data decal.
• Position the tow vehicle to align its 1. To keep the engine crankcase oil level
hitch with the pintle eye or coupler of near the high level mark (with the unit
the compressor. level).
2. To have the compressor oil level gauge
• Engage the parking brake and chock show no more than mid-scale. Do not
the tires of the tow vehicle. overfill either the engine crankcase or
the compressor lubricating oil system.
• Stand to the side and ensure pin is
FULLY inserted (secure) in tube of 3. The canopy must be closed to maintain
jack. . a cooling air path and to avoid
recirculation hot air.
• Crank jack to seat pintle eye or
coupler onto hitch. Latch and lock TOWING
hitch. Cross safety chain(s) under
drawbar. Attach to vehicle

• Crank jack to raise pad off the ! WARNING

ground. Pull pin from tube of jack.
Failure to follow these instructions
• Fold jack handle down and forward.
CAN cause severe injury or death.
Swing up jack tube and FULLY insert
pin in tube.
• Ensure that tires, wheels and running
gear are in good condition and
• Remove tire chocks.
secure, and ensure hat tires are
• Test brakes, if so equipped. inflated to 50 psi.

• Test lights (running, stop, and turn • Do not tow this unit in excess of 65
signals). mph (104 km/hr).

• Use a tow vehicle whose towing

capacity is greater than the gross
weight of this unit.
! WARNING
Always raise (or remove) jack for
maximum ground clearance before

36
SECTION 5 - OPERATION Operating & Maintenance Manual

DISCONNECT

• Engage tow vehicle parking brake.

• Chock tires of compressor.

• Set the vehicle parking brake. Chock

wheels of unit.

• Standing to the side, remove pin from

tube of jack.

• Disconnect safety chains. Crank jack

to raise eye or coupler from hitch.
Tow vehicle can be moved.

UTILITY PACKAGE SET-UP (no

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

37
 Operating & Maintenance Manual SECTION 5 - OPERATION

STANDARD CONTROL PANEL

Instruments & Controls

1. Discharge Pressure Gauge - Indicates pressure in receiver tank, psi (kPa).

2. Hourmeter - Records running time for maintenance.
3. Start/Run Valve -

4. Key Start Switch -

38
SECTION 5 - OPERATION Operating & Maintenance Manual

OPTION PANEL

1. Fuel Level - Indicates fuel level

1A. Low fuel level shutdown indicator light
2. Discharge Pressure Gauge
3. Tachometer - Indicates engine speed
4. Airend Temp Gauge
4A. High A/E temperature shutdown indicator light
5. Hourmeter - Records running time for maintenance
6. Engine Water Temperature - Indicates coolant temperature with normal operating range
from 180°F (82°C) to 210°F (99°C).
6A. High engine water temperature shutdown indicator light
7. Start/Run Valve - N
8. Voltmeter - Indicates battery condition
8A. Low accelerator output indicator light
9. Ignition Switch
10. Engine Oil Pressure Gauge
10A. Low engine oil pressure shutdown indicator light.

39
 Operating & Maintenance Manual SECTION 5 - OPERATION

Before Starting to loud noise can cause hearing loss.

Wear hearing protection when doors
• Open service valve(s) to ensure pressure or valve (s) are open.
is relieved in receiver-separator system.
Close valve(s) in order to build up full air • Close all doors to maintain a cooling air
pressure and ensure proper oil path and to avoid recirculation of hot air.
circulation. This will maximize the life of the engine
and compressor and protect the hearing
• Check battery for proper connections and of surrounding personnel.
condition.
• Be sure no one is IN or ON the
• Check battery for proper connections and compressor unit.
condition.

• Check engine coolant level.

! WARNING
! WARNING Unrestricted air flow from a hose will
result in a whipping motion of the
hose which can cause severe injury or
Do not remove pressure cap from death. A safety device must be
a HOT radiator. Allow radiator to attached to the hose at the source of
cool down before removing supply to reduce pressure in case of
pressure cap. Use extreme care hose failure or other sudden pressure
when removing a pressure cap release. Reference: OSHA regulation
from a liquid cooling system for 29 CFR Section 1926.302 (b).
the engine. The sudden release of
pressure from a heated cooling
system can result in a loss of Starting
coolant and possible severe
personal injury. • Turn the POWER switch to “ON”.

• Turn Power switch to “START”

• Check the engine oil level. Maintain per
position to crank engine. Hold switch
marks on dipstick.
in “START” position for
• Check the fuel level. Add only CLEAN approximately 5 seconds after engine
DIESEL fuel for maximum service from starts.
the engine.

• Check the compressor lubricating fluid

level between bottom and midway of the
sight glass on the separator tank.

! WARNING
This machine produces loud noise
with doors open. Extended exposure

40
SECTION 5 - OPERATION Operating & Maintenance Manual

each battery. Then connect

one end of the other cable

NOTICE to the negative (-) terminal

of the booster battery and
the other end to the engine
Do not operate the starter block. NOT TO THE
motor for more than 10 NEGATIVE (-) TERMINAL
seconds without allowing OF THE WEAK BATTERY.
at least 30 seconds cooling
time between start Stopping
attempts.

Release Power Switch (it will automatically

move to the “ON” position) when the engine
starts and sustains running.
NOTICE
• Allow engine to warm up 5 to 10 Whenever the machine is
minutes. stopped, air will flow back
into the compressor
• If so equipped, press the “Service Air system from devices or
Button”. Open air service valve(s). systems downstream of the
machine unless the service
valve is closed. Install a
Cold Weather Starting check valve at the machine
service valve to prevent
a. Turn power switch to the glow reverse flow in the event of
plug position and hold 8 seconds. an unexpected shutdown
Then turn to start. when the service valve is
open.

NOTICE
Engine is equipped with
glow plugs for cold starting
aid. Do not use ETHER/
starting fluid. Engine
damage can occur.

NOTICE
Exercise extreme caution
when using a booster
battery to start. To jump
start: Connect the ends of
one booster cable to the
positive (+) terminals of

41
 Operating & Maintenance Manual SECTION 5 - OPERATION

Compressor Air/Oil Temperature:

Close air service valves.
• At the airend outlet.
• Allow the unit to run at idle for 3 to 5
minutes to reduce the engine
• In separator tank.
temperatures.
• Low fuel level shutdown only with
• Turn Power Switch to “OFF” position. optional controls and instruments.
• When the engine stops, automatic Units with Optional Controls and
blowdown valve should relieve Instrument Panel
system air pressure. If automatic
The optional control and instrument panel
blow-down valve malfunction is
provides an added shutdown feature for low
suspected, open manual blowdown
fuel level. This option also includes shutdown
valve.
indicator lights adjacent to gauges.
• Never allow unit to sit under pressure In a shutdown situation, the function of the
when engine is not running. lights is to indicate what specific failure
caused the unit to shut down. These lamps
will remain illuminated until the Power Switch
! WARNING is turned “OFF”.
Test the lights by turning the ignition switch
“ON”. All lights should be OFF during
Since the service valve is closed,
machine operation.
air downstream of the valve may
be trapped. A vent hole in the
service valve will slowly bleed air
from the hose. Do not disconnect
hoses until all pressure has been
vented.

NOTICE
Do NOT wire around or bypass a
shutdown sensor or switch.

Machine has shutdown and sensors

as follows:

• Low Engine oil pressure, in the

engine.

• High engine coolant temperature, in

the engine.

42
SECTION 5 - OPERATION Operating & Maintenance Manual

Speed and Pressure Regulator Adjusting Instructions

The engine idle and full speed settings are After Starting Unit
set and sealed at the factory, and should not
be adjusted. Serious injury may result if the 4. If equipped, push the SERVICE AIR
full speed is increased. Removal of the seals button on the control panel, making
without authorization could affect the certain the button does not pop back out.
warranty. If speed settings are lost due to The unit should speed up and then
engine fuel pump service or other repairs, the unload (and drop back to IDLE). With the
speed settings can be reset as follows: unit unloaded, turn the adjusting screw
on the pressure regulator clockwise until
the discharge pressure gauge indicates
Before Starting
125-130 psi. Tighten the pressure
regulator jam nut. Replace cover.
1. At the Pressure Regulator (on service
pipe near receiver tank), remove the 5. With the service valve closed, adjust
cover to expose the adjusting screw. IDLE speed (*). Adjust speed using
Loosen the jam nut and turn screw adjusting rod (D). Tighten jam nut (H).
counterclockwise until tension is no
6. Open the service valve and adjust the
longer felt at the screw. Then, turn screw
discharge pressure to 100 psi (700 kPa).
clockwise one full turn.
Now turn adjusting rod (C) until the
2. Close service valve(s). proper engine FULL speed setting (*) is
reached. Tighten jam nuts (B & J).
3. Inspect throttle arm (G) on engine
governor to see the arm is resting against 7. To obtain maximum CFM at any pressure
the governor stop. Loosen jam nut on air between 80 psi (550kPa) and maximum
actuating cylinder (A) and then turn pressure rating (*), make adjustment at
cylinder rod (D) until throttle arm (G) is the pressure regulator to obtain desired
forced against the governor stop. discharge pressure at FULL engine
speed. Lock adjusting screw and replace
cover.
* See General Data Specifications.

43
 Operating & Maintenance Manual SECTION 5 - OPERATION

44
Section 6 - MAINTENANCE

45
 Operating & Maintenance Manual MAINTENANCE

Maintenance
for repair. Preventive maintenance is the
easiest and the least expensive type of
! CAUTION maintenance. Maintaining your unit and
keeping it clean at all times will facilitate
Any unauthorized modification or servicing.
failure to maintain this equipment may
make it unsafe and out of factory
warranty. Scheduled Maintenance
The maintenance schedule is based on
If performing more than visual
normal operation of the unit. This page can
inspections, disconnect battery
be reproduced and used as a checklist by the
cables and open manual blowdown
service personnel. In the event unusual
valve.
environmental operating conditions exist, the
schedule should be adjusted accordingly.
Use extreme care to avoid contacting
hot surfaces (engine exhaust manifold
and piping, air receiver and air Compressor Oil Level
discharge piping, etc.).
Check the compressor fluid level when the
Never operate this machine with any machine is not operating. Maintain the fluid
guards removed. level between bottom and midway of the
sight glass on the separator tank.
Inch and metric hardware was used in
the design and assembly of this unit.
Consult the parts manual for Air Cleaner
clarification of usage.
Weekly, squeeze the rubber valve
(precleaner dirt dump) on each air cleaner
NOTICE housing to ensure that they are not clogged.
The air filters restricted sensor will
Disregard any maintenance pertaining automatically reset after the main power
to components not provided on your switch is turned to “OFF.”
machine. To service the air cleaners on all units
proceed as follows:

General 1. Loosen clips and remove with cover.

Remove Element.
In addition to periodic inspections, many of 2. Inspect air cleaner housing for any
the components in these units require condition that might cause a leak and
periodic servicing to provide maximum correct as necessary.
output and performance. Servicing may
consist of pre-operation and post-operation 3. Wipe inside of air cleaner housing with a
procedures to be performed by the operating clean, damp cloth to remove any dirt
or maintenance personnel. The primary accumulation, especially in the area
function of preventive maintenance is to where the element seals against the
prevent failure, and consequently, the need housing.

46
MAINTENANCE Operating & Maintenance Manual

4. Install new elements in the reverse order Tires

to the above. Tighten wing nut firmly. A weekly inspection is recommended. Tires
5. Inspect to ensure that end cap seals that have cuts or cracks or little tread should
tightly 360° around air cleaner body. be repaired or replaced. Monthly check the
wheel lug nuts for tightness.
In addition, the air cleaner system (housing
and piping) should be inspected every month
for any leakage paths or inlet obstructions. Fasteners
Make sure the air cleaner mounting bolts and
clamps are tight. Check the air cleaner Visually check entire unit in regard to bolts,
housing for dents or damage which could nuts and screws being properly secured.
lead to a leak. Inspect the air transfer tubing Spot check several capscrews and nuts for
from the air cleaner to the compressor and proper torque. If any are found loose, a more
the engine for leaks. thorough inspection must be made. Take
Make sure that all clamps and flange joints corrective action.
are tight. Table 1:

Gauges Wheel Torque Chart

The instruments or gauges are essential for M12 Bolts Torque (Ft-Lbs)
safety, maximum productivity and long 13” wheel 60-70
service life of the machine. Inspect the
gauges and test any diagnostic lamps prior to 1/2” lug nuts
start-up. During operation observe the
gauges and any lamps for proper functioning. 13” wheel 80-90
Refer to Operating Controls, for the normal 15” wheel 105-115
readings.
16” wheel 105-115

Fuel Tank 16.5” wheel 105-115

5/8” lug nuts
CLEAN fuel in the fuel tanks is vitally
important and every precaution should be 16” wheel 190-210
taken to ensure that only clean fuel is poured
or pumped into the tank. 17.5” wheel 190-210

When filling the fuel tank on this unit, by

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

Battery NOTICE
Keep the battery posts-to-cable connections
clean, tight and lightly coated with a grease. The use of water alone in this engine
Also the electrolyte level in each cell should can result in major engine failure.
cover the top of the plates. If necessary, top- Refer to engine section for coolant
up with clean distilled water. recommendation.

47
 Operating & Maintenance Manual MAINTENANCE

Hoses the 3/8 inch O.D. tubing; 1/8 inch for the 0.25
inch O.D. tubing. This will ensure that tubing
Each month it is recommended that all of the is fully engaged in the sealing mechanism.
intake lines to and from the air cleaners, the
engine cooling system hoses and all of the
flexible hoses used for air, oil, and fuel be Compressor Oil Filters
inspected. The oil filter must be replaced every 500
To ensure freedom from air leaks, all rubber hours of operation or six (6) months,
hose joints and the screw-type hose clamps whichever comes first.
must be absolutely tight. Regular inspection To service oil filters it will first be necessary
of these connections for wear or deterioration to shut the unit down. Wipe off any external
is necessary. dirt and oil from the exterior of the filter to
Premature wear of both the engine and minimize any contamination from entering
compressor is ASSURED whenever dust- the lubrication system. Proceed as follows:
laden air is permitted to enter the engine’s
combustion chamber or compressor intake.
The flexible hoses used in the fuel, oil and air ! WARNING
lines on these units are primarily used for
their ability to accommodate relative
High pressure air can cause severe
movement between components. It is
injury or death from hot oil and flying
important they be periodically inspected for
parts. Always relieve pressure before
wear and deterioration. It is also important
removing caps, plugs, covers or other
the operator does not use the hoses as
parts from pressurized air system.
convenient hand hold or steps. Such use can
cause early cover wear and hose failure. 1. Open the service air valve(s) to ensure
that system is relieved of all pressure.
Close the valve(s).
2. Turn the spin-on filter element
NOTICE counterclockwise to remove it from the
filter housing. Inspect the filter.

Some of the airlines are nylon tubing. 3. Inspect the oil filter head to be sure the
The associated fittings are “push-in” gasket was removed with the oil filter
design. Features are as follows: element. Clean the gasket seal area on
the oil filter head.
Pulling on the tubing will cause the inner
sleeve to withdraw and compress, thus
tightening the connection. The tubing can be
withdrawn only while holding the sleeve NOTICE
against the fitting. The tubing can be
removed and replaced numerous times Installing a new oil filter element when
without losing its sealing ability. the old gasket remains on the filter
To install the nylon tubing, make a mark (with head, will cause an oil leak and can
tape or grease pencil) approximately 7/8 inch cause property damage.
from the end of the tubing. Insert the tubing
into the sleeve and “push-in” past the first 4. Lubricate the new filter gasket
resistance to the bottom. The mark should be with the same oil being used
approximately 1/16 inch from the sleeve, for in the machine.

48
MAINTENANCE Operating & Maintenance Manual

5. Install new filter by turning the Receiver-Separator Systems

element clockwise until
gasket makes initial contact.
Tighten an additional 1/2 to 3/
4 turn. ! WARNING
6. Start unit and allow to build up
to rated pressure. Check for High pressure air can cause severe
leaks before placing unit back injury or death from hot oil and flying
into service. parts. Always relieve pressure before
removing caps, plugs, covers or other
parts from pressurized air system.
Compressor Oil Cooler
• Open service valve at end of machine.
The compressor lubricating and cooling oil is
cooled by means of the fin and tube-type oil • Ensure pressure is relieved, with BOTH:
cooler, located beside the radiator. The — Discharge air pressure gauge reads
lubricating and cooling oil, flowing internally zero (0).
through the core section, is cooled by the air
stream from the cooling fan flowing past the — No air discharging from service valve.
core section. When grease, oil and dirt Remove plug near bottom of separator tank
accumulate on the exterior surfaces of the oil to drain compressor oil.
cooler, its efficiency is impaired.
When adding oil, remove and replace (make
Each month it is recommended that the oil tight) plug on top of separator tank.
cooler be cleaned by directing compressed
air which contains a nonflammable, non- The life of the oil separator element is
caustic safety solvent through the core of the dependent upon the operating environment
oil cooler. This should remove the (soot, dust, etc.) and should be replaced
accumulation of grease, oil and dirt from the every twelve months or 1000 hours. To
exterior surfaces of the oil cooler core so that replace the element proceed as follows:
the entire cooling area can transmit the heat • Ensure the tank pressure is zero.
of the lubricating and cooling oil to air stream.
• Unscrew separator element from manifold.
In the event foreign deposits, such as sludge
and lacquer, accumulate in the oil cooler to • Install new element.
the extent that its cooling efficiency is
impaired, a resulting high discharge air
temperature is likely to occur, causing shut
Scavenge Line
down of the unit. To correct this situation it
will be necessary to clean it using a cleaning
compound in accordance with the
manufacturer’s recommendations.
! WARNING
High pressure air can cause severe
Compressor Oil injury or death from hot oil and flying
parts. Always relieve pressure before
The lubricating and cooling oil must be removing caps, plugs, covers or other
replaced every 500 hours of operation or six parts from pressurized air system.
(6) months, whichever comes first. Refer to
warranty section about extended warranty. The scavenge line originates at the manifold
and terminates at the compressor air-end

49
 Operating & Maintenance Manual MAINTENANCE

near the oil filter element. An orifice check Field Repair of Texture Paint
valve is located on the scavenge tube.
Once a year or every 1000 hours of 1. The sheet metal should be washed and
operation, whichever comes first, replace the clean of foreign material and then
separator element and clean the scavenge thoroughly dried.
orifice/check valve. 2. Clean and remove all grease and wax
NOTE: Excessive oil carry-over may be from the area to be painted using
caused by an oil-logged separator element. Duponts 3900S Cleaner prior to sanding.
Do not replace element without first 3. Use 320 grit sanding paper to repair any
performing the following maintenance scratches or defects necessary.
procedure:
4. Scuff sand the entire area to be painted
1. Check oil level. Maintain as indicated with a red scotch brite pad.
earlier in this section. 5. Wipe the area clean using Duponts
2. Thoroughly clean scavenge line, any 3900S.
orifice and check valve. 6. Blow and tack the area to be painted.
3. Assure minimum pressure valve/orifice is 7. Apply a smooth coat of Duponts 1854S
operational. Tuffcoat Primer to all bare metal areas
4. Run unit at rated operating pressure for and allow to dry.
30 to 40 minutes to permit element to 8. Apply 2 medium - wet coats of Duponts
clear itself. 222S Adhesion Promoter over the entire
area to be painted, with a 5 minute flash
in between coats.
Exterior Finish Care
9. To apply the texture coat, use Duponts
This unit was painted and heat cured at the 1854S Tuffcoat Primer. The proper
factory with a high quality, thermoset technique to do this is to spray the
polyester powder coating. The following care Tuffcoat Primer using a pressure pot and
will ensure the longest possible life from this use about 2-5 pounds of air pressure.
finish. This will allow the primer to splatter
causing the textured look.
1. If necessary to remove dust, pollen, etc.
from housing, wash with water and soap NOTE: You must be careful not to put
or dish washing liquid detergent. Do not too much primer on at one time, this
scrub with a rough cloth, pad, etc. will effect the amount of texture that
you are trying to achieve. Allow the
2. If grease removal is needed, a fast texture coat to flash for 20 minutes or
evaporating alcohol or chlorinated until dry to touch.
solvent can be used. Note: This may
cause some dulling of the paint finish. 10. Apply any of Duponts Topcoat Finishes
such as Imron™ or Centari™ according
3. If the paint has faded or chalked, the use to the label instructions.
of a commercial grade, non-abrasive car
wax may partially restore the color and NOTE: To re-topcoat the textured surfaces
gloss. when sheet metal repairs are not necessary,
follow steps 1, 2, 4, 5, 6, 8 and 10.

50
MAINTENANCE Operating & Maintenance Manual

FIELD REPLACEMENT OF CANOPY DECALS

1. The decal area should be

wiped with 70% isopropyl
alcohol and a lint free cloth, in
a well ventilated area.

2. Allow sufficient time for

drying, but not enough time
for dust to resettle on surface.

3. Align decals prior to removing

the backing.

4. Peel (1) section of backing

from decal, while still aligned,
and squeegy decal from
center the the edges, to
remove air.

5. Remove the remaining

backing and repeat squeegy
process.

6. Repeat squeegy process over

entire decal surface to assure
a tight bond, allow 24 hours
for permanent bond.

7. Any air bubbles may be

removed by pricking the
bubble center with a pin and
squeegy air toward the hole.

51
 Operating & Maintenance Manual MAINTENANCE

MAINTENANCE SCHEDULE

Daily Weekly Monthly 3 MOS. 6 MOS. 12 MOS.

250 hours 500 hours 1000 hours
Compressor Oil Level C
Engine Oil Level C
Radiator Coolant Level C
Gauges/Lamps C
Air Cleaner Service Indicators C
Fuel Tank (fill at end of day) C DRAIN
Fuel Water Separator (Drain) C
Oil Leaks C
Fuel Leaks C
Drain Water From Fuel Filters DRAIN
Coolant Leaks C
Radiator Filler Cap C
Air Cleaner PreCleaner Dumps C
Fan/Alternator Belts C
Battery Connections/Electrolyte C
Tire Pressure and Surface C
Wheel Lug Nuts C
Hoses (oil, air, intake, etc) C
Automatic Shutdown System Test C
Air Cleaner System Visual C
Compressor Oil Cooler Exterior C CLEAN
Engine Radiator Exterior C CLEAN
Fasteners, Guards C
Air Cleaner Elements R
Fuel/Water Separator Element R
Compressor Oil Filter Element R
Compressor Oil R
Engine Oil Change (initial change @ 50 hrs) R -non IR R*
fluids
Engine Oil Filter (initial change @ 50 hrs) R - non IR R*
fluids
Wheels (bearings, seals, etc) C
Engine Coolant Test C R
Fuel Filter Element R
Injection Valve Pressure C
Shutdown Switch Settings Test C
Scavenge Orifice & related parts CLEAN
Oil Separator Element R
Injection Pump (check & adjust) C@ 3000hrs
Valve Clearance Check C@ 800 hrs
Adjust Intake and Exhaust Valves C@ 800 hrs
Lights (running, brake, & turn) CBT
Pintle Eye Bolts CBT

R=replace, C=check Engine Fluid

(adjust if necessary)
CBT = check before
towing.
* Applies only when using IR Protec™

52
Section 7 - LUBRICATION

53
 Operating & Maintenance Manual LUBRICATION

Lubrication
Portable Compressor Fluid
Chart
Refer to these charts for correct compressor
fluid required. Note that the selection of fluid
is dependent on the design operating
pressure of the machine and the ambient
temperature expected to be encountered
before the next oil change.

NOTE: Fluids listed as “preferred” are

required for extended warranty.

Compressor oil carryover (oil

consumption) may be greater with the use
of alternative fluids.

Design
Ambient
Operating Specification
Temperature
Pressure
100 psi to -100F to 1250F Preferred:
300 psi IR Pro•Tec™
(-230C to 520C)
Alternate:
ISO Viscosity Grade 46 with rust
and oxidation inhibitors, designed Preferred Ingersoll-Rand Fluids - Use of
for air compressor service. these fluids with original I-R filters can extend
350 psi (-230C to 520C) Preferred: airend warranty. Refer to operator’s manual
IR XHP 605
-100F to 1250F warranty section for details or contact your IR
Alternate: representative.
IR XHP405
ISO Viscosity Grade 68 Group 3
or 5 with rust and oxidation
inhibitors designed for air
compressor service.
650F to 1250F Preferred:
(-18°C to 52°C) XHP605
IR XHP1001

Ingersoll-Rand
1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Litre)
Preferred Fluids
Preferred:
IR Pro-Tec™ 36899698 36899706 36899714 36899722
IR XHP605 - 22252076 22252050 22252068
IR XHP1001 - 35612738 35300516 -
XHP405 - 22252126 22252100 22252118
Engine Oil 54480918 36875938 36866903

54
LUBRICATION Operating & Maintenance Manual

55
 Operating & Maintenance Manual LUBRICATION

56
Section 8 - Trouble Shooting

57
 Operating & Maintenance Manual Trouble Shooting

Trouble Shooting B. Do The Simplest Things First

Most troubles are simple and easily
corrected. For example, most complaints are
Introduction “low capacity” which may be caused by too
low an engine speed or “compressor over-
Trouble shooting for a portable air
heats” which may be caused by low oil level.
compressor is an organized study of a
particular problem or series of problems and Always check the easiest and most obvious
a planned method of procedure for things first; following this simple rule will save
investigation and correction. The trouble time and trouble.
shooting chart that follows includes some of
the problems that an operator may encounter NOTE: For trouble shooting electrical
during the operation of a portable problems, refer to the Wiring Diagram
compressor. Schematic found in Parts List Section.
The chart does not attempt to list all of the
troubles that may occur, nor does it attempt C. Double Check Before Disassembly
to give all of the answers for correction of the
problems. The chart does give those The source of most compressor troubles can
problems that are most apt to occur. To use be traced not to one component alone, but to
the trouble shooting chart: the relationship of one component with
another. Too often, a compressor can be
A. Find the “complaint” depicted as a bold partially disassembled in search of the cause
heading. of a certain trouble and all evidence is
destroyed during disassembly. Check again
B. Follow down that column to find the to be sure an easy solution to the problem
potential cause or causes. The causes
has not been overlooked.
are listed in order (1,2,3 etc.) to suggest
an order to follow in trouble shooting.
D. Find And Correct Basic Cause

Action Plan After a mechanical failure has been

corrected, be sure to locate and correct the
cause of the trouble so the same failure will
A. Think Before Acting not be repeated. A complaint of “premature
breakdown” may be corrected by repairing
Study the problem thoroughly and ask
any improper wiring connections, but
yourself these questions: something caused the defective wiring. The
cause may be excessive vibration.
1. What were the warning signals that
preceded the trouble?
2. Has a similar trouble occurred before?
3. What previous maintenance work has
been done?
4. If the compressor will still operate, is it
safe to continue operating it to make
further checks?

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Trouble Shooting Operating & Maintenance Manual

Trouble Shooting Chart

Bold Headings depict the COMPLAINT - Subheadings indicate CAUSES

NOTE: Subheadings suggest sequence to follow troubleshooting.

Table 1: Unit Shutdown

Cause Corrective Action
Out of Fuel Add CLEAN diesel Fuel
Compressor Oil Level Too Low Add correct oil
Compressor Oil Temp. Too High See Table 10
Engine Water Temp. Too High Check coolant level. If necessary, Add.
Loose Wire Connection Check all connections. Make repairs.
Low Fuel Level Shutdown Switch Replace switch.
Defective Discharge Air Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Replace switch.
Broken Engine Fan Belt Replace fan belt.
Engine Oil Pressure Too Low See Table 3 and Table 4.
Defective Shutdown Solenoid Replace solenoid.
Malfunctioning Relay Replace relay.
Blown Fuse Replace fuse/Check for Short.
* < 10 Volts at Shutdown Solenoid Check battery and alternator. Make repairs.
Engine Malfunctioning See Trouble Shooting in Engine Section.
Airend Malfunctioning See Table 10.

Table 2: Won’t Start/Run:

Cause Corrective Action
Out of Fuel Add CLEAN diesel Fuel
Clogged Fuel Filters Service filters.
Compressor Oil Level Too Low Add corrected oil
Loose Wire Connection Repair or replace connection.
Low Battery Voltage Check electrolyte level. Check connections.
* <10 Volts at Shutdown Solenoid Charge battery and alternator. Make repairs.
Defective Alternator Replace/Repair Alternator
Engine Water Temp. Too High Check fluid level. If necessary, Add.
Malfunctioning Start Switch Replace switch.
Defective D2 Diode Replace D2 Diode.
Blown Fuse Replace fuse/Check for Short.
Engine Oil Pressure Too Low See Table 3 and Table 4.
Compressor Oil Temp. Too High See Table 10.
Defective Discharge Air Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Replace switch.
Defective Shutdown Solenoid Replace solenoid.

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 Operating & Maintenance Manual Trouble Shooting

Defective Engine Temp. Switch Replace Switch

Defective Separator Tank Temp Switch Replace Switch
Defective Low Fuel Shutdown Switch Replace Switch
Malfunctioning Relay Replace relay.
Engine Malfunctioning See Trouble Shooting in Engine Section.
Airend Malfunctioning See Table 10.

Table 3: Engine Temperature Lamp Stays On:

Complaint Corrective Action
Dirty Cooler Clean exterior of cooler.
Operating Pressure Too High Reduce pressure to spec.
Recirculation of Cooling Air Close all doors.
Dirty Operating Conditions Move unit to cleaner environment.
* Out of Level >15 degrees Relocate or reposition unit.
* Ambient Temp. >125°F (52°C) Above spec limit.
Loose Wire Connection Repair or replace.
Broken Engine Fan Belt Replace fan belt set.
Malfunctioning Controller Replace Controller.

Table 4: Engine Oil Pressure Lamp Stays On:

Complaint Corrective Action
Low Oil Level Add oil.
Clogged Oil Filter Element(s) Replace element(s).
Out of Level >15 degrees Relocate or reposition.
Loose Wire Connection. Repair or replace.
Wrong Lube Oil See Engine Oil Spec. Change oil.
Malfunctioning Controller Replace Controller.
Engine Malfunctioning See Trouble Shooting in Engine Section.

Table 5: Engine Temperature Lamp Stays Off:

Complaint Corrective Action
Bulb Burned Out Replace Controller.
Shorted Wire (Hot) Repair short.
Malfunctioning Controller Replace Controller.

Table 6: Engine Oil Pressure Lamp Stays Off:

Complaint Corrective Action
Bulb Burned Out Replace Controller.
Shorted Wire (Hot) Repair short.
Malfunctioning Controller Replace Controller.

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Trouble Shooting Operating & Maintenance Manual

Table 7: Alternator Lamp Stays On:

Complaint Corrective Action
Low Battery Voltage Check electrolyte level. Add if necessary.
Check connectors. Clean & tighten.
Recharge battery.
Loose or Broken Belts Tighten or replace belt set.
Malfunctioning Alternator Repair or replace alternator.
Shorted wire (ground) Repair short.

Table 8: Alternator Lamp Stays Off:

Complaint Corrective Action
Bulb Burned Out Replace Controller.
Loose Wire Connection Repair or replace connector.
Malfunctioning Controller Replace Controller.

Table 9: Unit Fails To Shutdown:

Complaint Corrective Action
Defective Low Fuel Shutdown Switch Pull wire off shutdown solenoid. Replace switch.
Defective Discharge Air Temperature Switch Pull wire off. Replace switch.
Defective Sep. Temp. Switch Replace switch.
Defective Engine Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Pull wire off. Replace switch.
Defective Shutdown Solenoid Carefully block air inlet to stop engine.
Malfunctioning Relay Replace relay.
Defective Start Switch Pull wire off shutdown solenoid. Replace Start Switch.
Wire Shorted Hot Repair short.

Table 10: Excessive Compressor Oil Temperature:

Complaint Corrective Action
Dirty Cooler Clean exterior surfaces.
Low Oil Level Add oil. Look for any leaks.
Clogged Oil Filter Elements Replace elements. Change oil.
Operating Pressure Too High Reduce pressure to spec.
Dirty Operating Conditions Move unit to cleaner environment.
Ambient Temp. > 125°F (52°C) Above spec limit.
Out of Level > 15 degrees Relocate or reposition unit.
Wrong Lube Oil Check spec in this manual.
Recirculation Of Cooling Air Close all doors. Replace belly pan if missing.
Malfunctioning Thermostat Replace thermostat in bypass valve.
Loose or Broken Belts Tighten or replace belt set.
Defective Oil Cooler Relief Valve Replace valve.
Defective Minimum Pressure Valve Repair or replace valve.
Malfunctioning Fan Check fan belt tension. Tighten or replace belt set.
Blocked or Restricted Oil Lines Clean by flushing or replace.

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 Operating & Maintenance Manual Trouble Shooting

Airend Malfunctioning See Tables 11, 12, 13, 15, 16 or 18.

Table 11: Engine RPM Down

Complaint Corrective Action
Clogged Fuel Filter Clean primary filter. Replace final filter. Drain tanks.
Add CLEAN fuel.
Dirty Air Filter Clean or replace elements.
Wrong Air Filter Element Install correct element.
Operating Pressure Too High Reduce pressure to spec limit.
Incorrect Pressure Regulator Adjustment Adjust regulator.
Malfunctioning Pressure Regulator Replace regulator.
Incorrect Linkage Adjustment Adjust linkage.
Malfunctioning Air Cylinder Replace air cylinder and adjust.
Defective Separator Element Install new element.
Engine Malfunctioning See Trouble Shooting in Engine Section.
Airend Malfunctioning Consult Dealer.

Table 12: Excessive Vibration

Complaint Corrective Action
Dirty Fuel/Filters Replace filters/fuel.
Engine idle speed too low. Raise “No Load” speed by adjusting air cylinder.
Rubber Mounts, Loose or Damaged Tighten or replace.
Anti-rumble valve not working. Repair or Replace.
Drive Coupling Defective Replace coupling.
Defective Fan Replace fan.
Engine Malfunctioning See Trouble Shooting in Engine Section.
Airend Malfunctioning See Table 15 and 17.

Table 13: Low CFM

Complaint Corrective Action
Engine RPM too Low Adjust RPM
Malfunctioning Air Cylinder Replace air cylinder.
Incorrect Linkage Adjustment Adjust linkage.
Malfunctioning Inlet Unloader Inspect valve.
Dirty Air Filter Clean or replace elements.
Wrong Air Filter Element Install correct element.
Incorrect Pressure Regulator Adjustment Adjust linkage.
Malfunctioning Pressure Regulator Replace regulator.
Defective Separator Element Install new element.
Defective Minimum Pressure Valve Repair or replace valve.

Table 14: Short Air Cleaner Life

Complaint Corrective Action
Inadequate Element Cleaning Install new element.
Dirty Operating Conditions Move unit to cleaner environment.

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Trouble Shooting Operating & Maintenance Manual

Incorrect Stopping Procedure Read procedure in this manual.

Wrong Air Filter Element Install proper element.

Table 15: Excessive Oil In Air

Complaint Corrective Action
High Oil Level Read procedure in this manual.
Clogged Scavenge Orifice Remove scavenge orifice. Clean and Replace.
Incorrect Oil Replace by spec. in this manual.
Defective Scavenge Check Valve Remove check valve. Replace with new valve.
Out of Level > 15 degrees Relocate or reposition unit.
Defective Separator Element Remove element. Install new.
Scavenge Tube Blocked Remove scavenge tube. Clean and Replace.
Sep. Tank Blow Down Too Quickly Allow unit to blow down automatically.
Defective Minimum Pressure Valve Remove valve. Repair valve and replace.

Table 16: Oil Seal Leak

Complaint Corrective Action
Contaminated Lube Oil Drain and flush system. Add new CLEAN oil.
Replace seal.
Blocked or Restricted Oil Line(s) Remove, clean and replace line(s). Replace seal.
Malfunctioning Seal Consult dealer. Replace seal.
Scored Shaft See instructions in new seal kit.

Table 17: Will Not Unload

Complaint Corrective Action
Incorrect Pressure Regulator Adjustment Adjust regulator.
Leak in Regulator Piping Find and repair leak(s).
Malfunctioning Pressure Regulator Replace regulator.
Malfunctioning Inlet Valve Unloader Inspect valve. Repair/Replace.
Defective Separator Element Remove element. Install new.
Ice in Regulation Lines/Orifice Apply heat to line(s) and or orifice.

Table 18: Oil In Air Cleaner

Complaint Corrective Action
Incorrect Stopping Procedure Read Procedure in this manual.
Malfunctioning Unloader Repair/Replace.

Table 19: Safety Valve Relieves

Complaint Corrective Action

Operating Pressure Too High Reduce pressure to spec limit.
Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual.
Malfunctioning Pressure Regulator Replace regulator.
Leak In Regulator Piping Repair leak(s).

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 Operating & Maintenance Manual Trouble Shooting

Malfunctioning Inlet Unloader Inspect valve. Repair/Replace.

Defective Separator Element Remove element. Install new.
Defective Safety Valve Replace safety valve.
Ice in Regulation Lines/Orifice Remove ice.

64
Section 9 - 4IRY3N-4IRY3T Engine

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Engine

Servicing of the Engine

Your dealer is interested in your new engine and has the desire to help you get the most value
from it. After reading this manual thoroughly, you will find that you can do some of the regular
maintenance yourself.
However, when in need of parts or major service, be sure to see your dealer.
For service, contact the Ingersoll-Rand Dealership from which you purchased your engine or
your local IR dealer. When in need of parts, be prepared to give your dealer the engine serial
number.
Locate the serial number now and record them in the space provided.

Machine Serial No.

Engine Serial No.

Date of Purchase

(1) Engine serial number

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Names of Parts

(1) Intake manifold (10) Oil filler plug

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

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Pre-Operation Check

Break-in
During the engine break-in period, observe the following by all means:

1. Change engine oil and oil filter cartridge after the first 50 hours of operation
(See "ENGINE OIL" in Periodic Service Section).
2. When ambient temperature is low, operate the machine after the engine has
been completely warmed up.

Daily Check
To prevent trouble from occurring, it is important to know the conditions of the engine well.
Check it before starting.

! CAUTION
To avoid personal injury:

Be sure to install shields and safeguards attached to the engine when

operating.

Stop the engine at a flat and wide space when checking.

Keep dust or fuel away from the battery, wiring, muffler and engine to
prevent a fire.

Check and clear them before operating everyday. Pay attention to the
heat of the exhaust pipe or exhaust as so that it can not ignite trash.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Checks During Operation

While running, make the following checks to see that all parts are working correctly.

Radiator Cooling Water (Coolant)

! WARNING
To avoid personal injury:

Do not remove radiator cap until coolant temperature is well below its
boiling point. Then loosen cap slightly to the stop position, to relieve any
pressure, before removing cap completely.

When the engine overheats and hot coolant overflows through the radiator and hoses, stop
the engine immediately and make the following checks to determine the cause of trouble:
Check item

1. Check to see if there is any coolant leak;

2. Check to see if there is any obstacle around the cooling air inlet or outlet;
3. Check to see if there is any dirt or dust between radiator fins and tube;
4. Check to see if the fan belt is too loose;
5. Check to see if radiator water pipe is clogged; and
6. Check to see if anti-freeze is mixed to a 50/50% mix of water and anti-freeze.

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Fuel

! CAUTION
To avoid personal injury:

Fluid escaping from pinholes may be invisible. Do not use hands to

search for suspected leaks; Use a piece of cardboard or wood, instead. If
injured by escaping fluid, see a medical doctor at once. This fluid can
produce gangrene or a severe allergic reaction.

Check any leaks from fuel pipes or fuel injection pipes. Use eye
protection when checking for leaks.

Be careful not to empty the fuel tank. Otherwise air may enter the fuel system, requiring fuel
system bleeding. (See "FUEL" in Maintenance Section).

Color of Exhaust
While the engine is run within the rated output range:

• The color of exhaust remains colorless.

• If the output slightly exceeds the rated level, exhaust may become a little colored with
the output level kept constant.
• If the engine is run continuously with dark exhaust emission, it may lead to trouble
with the engine.

Immediately Stop the Engine If;

• The engine suddenly slow down or accelerates.

• Unusual noises suddenly appear.
• Exhaust fumes suddenly become very dark.
• The oil pressure lamp or the water temperature alarm lamp lights up.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Reversed Engine Revolution and Remedies

! CAUTION
To avoid personal injury:

Reversed engine operation can make the machine reverse and run it
backwards. It may lead to serious trouble.

Reversed engine operation may make exhaust gas gush out into the
intake side and ignite the air cleaner; It could catch fire.

Reversed engine revolution must be stopped immediately since engine oil circulation is cut
quickly, leading to serious trouble.

How to Tell When the Engine Starts Running Backwards

1. Lubricating oil pressure drops sharply. Oil pressure warning light, if used, will
light.
2. Since the intake and exhaust sides are reversed, the sound of the engine
changes, and exhaust gas will come out of the air cleaner.
3. A louder knocking sound will be heard when the engine starts running
backwards.

Remedies

1. Immediately set the engine stop lever to the "STOP" position to stop the engine.
2. After stopping the engine, check the air cleaner, intake rubber tube and other
parts and replace parts as needed.

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Maintenance

! CAUTION
To avoid personal injury:

Be sure to conduct daily checks, periodic maintenance, refueling or

cleaning on a level surface with the engine shut off and remove the key.

Before allowing other people to use your engine, explain how to operate,
and have them read this manual before operation.

When cleaning any parts, do not use gasoline but use regular cleanser.

Always use proper tools, that are in good condition. Make sure you
understand how to use them, before performing any service work.

When installing, be sure to tighten all bolts lest they should be loose.
Tighten the bolts by the specified torque.

Do not put any tools on the battery, or battery terminals may short out.
Severe burns or fire could result. Detach the battery from the engine
before maintenance.

Do not touch muffler or exhaust pipes while they are hot; Severe burns
could result.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Service Intervals
Observe the following for service and maintenance.
The lubricating oil change intervals listed in the table below are for Classes CF, CE and CD
lubricating oils of API classification with a low-sulfur fuel in use. If the CF-4 or CG-4 lubricating
oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals than
recommended in the table below depending on the operating condition.

Interval Item

Every 50 hours Check of fuel pipes and clamp bands @

See NOTE Change of engine oil (depending on the oil pan) #
Every 100 hours Cleaning of air cleaner element *1 @
Cleaning of fuel filter
Check of battery electrolyte level
Check of fan belt tightness
Every 200 hours Check of radiator hoses and clamp bands
Replacement of oil filter cartridge, using standard oil pan #
Check of intake air line @
Every 400 hours Replacement of oil filter cartridge, using standard oil pan #
Replacement of fuel filter cartridge @
Every 500 hours Removal of sediment in fuel tank
Cleaning of water jacket (radiator interior)
Replacement of fan belt
Every one or two months Recharging of battery
Every year Replacement of air cleaner element *2 @
Every 800 hours Check of valve clearance
Every 1500 hours Check of fuel injection nozzle injection pressure *3 @
Every 3000 hours Check of turbo charger *3 @
Check of injection pump *3 @
Every two years Change of radiator coolant (L.L.C.)
Replacement of battery
Replacement of radiator hoses and clamp bands
Replacement of fuel pipes and clamp bands *3 @
Replacement of intake air line *4 @

Important

• The jobs indicated by # must be done after the first 50 hours of operation.
*1 Air cleaner should be cleaned more often in dusty conditions than in normal
conditions.
*2 After 6 times of cleaning.

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

*3 Consult your local dealer for this service.

*4 Replace only if necessary.
• When the battery is used for less than 100 hours in a year, check its electrolyte
yearly. (for refillable battery's only)
• The items listed above (@ marked) are registered as emission related critical parts
in the U.S. EPA non-road emission regulation. As the engine owner, you are
responsible for the performance of the required maintenance on the engine
according to the above instruction.

NOTE: Changing interval of engine oil

Ingersoll-Rand Engine Oil

1 gallon 34480918
5 gallon 36875938
55 gallon 36866903

• With Ingersoll-Rand Engine Oil - 500 hrs

• With non-Ingersoll-Rand Engine Oil - 200 hrs

NOTE: Lubricating oil

With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been
developed for use of a low-sulfur fuel on on-road vehicle engines. When an off-road vehicle
engine runs on a high-sulfur fuel, it is advisable to employ the CF, CD or CE lubricating oil with
a high total base number. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel,
change the lubricating oil at shorter intervals.

• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is

employed.
O : Recommendable X : Not recommendable

Lubricating Fuel
Remarks
oil class Low-sulfur High-sulfur
CF O O TBN ≥10
CF-4 O X
CG-4 O X

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Periodic Service

Fuel

! CAUTION
To avoid personal injury:

Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an
explosion.

Be careful not to spill fuel during refueling. If fuel should spill, wipe it off
at once, or it may cause a fire.

Do not fail to stop the engine before refueling. Keep the engine away from
the fire.

Be sure to stop the engine while refueling or bleeding and when cleaning
or changing fuel filter or fuel pipes. Do not smoke when working around
the battery or when refueling.

Check the above fuel systems at a well ventilated and wide place.

When fuel and lubricant are spilled, refuel after letting the engine cool off.

Always keep spilled fuel and lubricant away from engine.

Fuel Level Check and Refueling

1. Check to see that the fuel level is above the lower limit of the fuel level gauge.
2. If the fuel is too low, add fuel to the upper limit. Do not overfill.
No.2-D is a distillate fuel oil of lower volatility for engines in industrial and heavy mobile service.
(SAE J313 JUN87)
Grade of Diesel Fuel Oil According to ASTM D975

Water and Carbon Residue

Flash Point,
Sediment, on, 10 percent Ash, Weight
°C
volume Residuum, %
(°F)
% %

Min Max Max Max

52
0.05 0.35 0.01
(125)

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Distillation
Viscosity Kinematic Viscosity
Temperatures,
cSt or Saybolt,
°C (°F)
mm /s at SUS at
90%
40° C 37.8° C (100° F)
Point

Min Max Min Max Min Max

282 338
1.9 4.1 32.6 40.1
(540) (640)

Sulfur, Copper
Cetane
weight Strip
Number
% Corrosion

Max Max Min

0.50 No. 3 40

The cetane number is required not to be less than 45.

IMPORTANT:

• Be sure to use a strainer when filling the fuel tank, or dirt or sand in the fuel may
cause trouble in the fuel injection pump.
• For fuel, always use diesel fuel. You are required not to use alternative fuel, because
its quality is unknown or it may be inferior in quality. Kerosene, which is very low in
cetane rating, adversely affects the engine. Diesel fuel differs in grades depending
on the temperature.
• Be careful not to let the fuel tank become empty, or air can enter the fuel system,
necessitating bleeding before next engine start.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Air Bleeding the Fuel System

! CAUTION
To avoid personal injury:

Do not bleed a hot engine as this could cause fuel to spill onto a hot
exhaust manifold creating a danger of fire.

Air bleeding of the fuel system is required if;

• after the fuel filter and pipes have been detached and refitted;
• after the fuel tank has become empty; or
• before the engine is to be used after a long storage.
Air Bleeding Procedure

1. For fuel tanks that are lower than the injection pump. The fuel system must be
pressurized by the fuel system electric fuel pump.
2. If an electric fuel pump is not used, you must manually actuate the pump by
lever to bleed.
3. The primary fuel filter must be on the pressure side of the pump if the fuel tank
is lower than the injection pump.
4. Open the air vent cock on top of the fuel injection pump.
5. Turn the engine, continue it for about 10 seconds, then stop it, or move the fuel
feed pump lever by hand (optional).
6. Close the air vent cock on top of the fuel injection pump.
IMPORTANT:

• Tighten air vent plug of the fuel injection pump except when bleeding, or it may stop
the engine suddenly.

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

[Tank Below Injection Pump System]

(1) Fuel tank below injection pump

(2) Pre-filter

(3) Electric or Mechanical pump

(4) Main Filter

(5) Injection pump

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Checking the Fuel Pipes

! CAUTION
To avoid personal injury:

Check or replace the fuel pipes after stopping the engine. Broken fuel
pipes can cause fires.

Check the fuel pipes every 50 hours of operation. When if;

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

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

(1) Clamp band

(2) Fuel pipe

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Cleaning the Fuel Filter Pot

Every 100 hours of operation, clean the fuel filter in a clean place to prevent dust intrusion.

1. Close the fuel filter lever.

(1) Fuel filter lever (A) "OFF"

(2) Fuel filter pot (B) "ON"

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.
IMPORTANT:

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

(1) O-Ring (4) Filter bowl

(2) Filter element (5) Screw ring

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

(3) Spring

Fuel Filter Cartridge Replacement

1. Replace the fuel filter cartridge with a new one every 400 operating hours.
2. Apply fuel oil thinly over the gasket and tighten the cartridge into position by
hand-tightening only.
3. Finally, vent the air.
IMPORTANT:

• Replace the fuel filter cartridge periodically to prevent wear of the fuel injection pump
plunger or the injection nozzle, due to dirt in the fuel.

(1) Fuel filter cartridge

(2) Air vent plug

(3) O-Ring

(4) Pipe joint

(5) Cover

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Engine Oil

! CAUTION
To avoid personal injury:

Be sure to stop the engine before checking and changing the engine oil
and the oil filter cartridge.

Do not touch muffler or exhaust pipes while they are hot; Severe burns
could result. Always stop the engine and allow it to cool before
conducting inspections, maintenance, or for a cleaning procedure.

Contact with engine oil can damage your skin. Put on gloves when using
engine oil. If you come in contact with engine oil, wash it off immediately.

NOTE: Be sure to inspect the engine, locating it on a level place. If placed

on gradients accurately, oil quantity may not be measured.

Checking Oil Level and Adding Engine Oil

1. Check the engine oil level before starting or more than 5 minutes after stopping
the engine.
2. Remove the oil level gauge, wipe it clean and reinstall it.
3. Take the oil level gauge out again, and check the oil level.

(1) Oil level gauge [Lower end of oil level gauge]

(A) Engine oil level within this

range is proper.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

4. If the oil level is too low, remove the oil filler plug, and add new oil to the
prescribed level.
5. After adding oil, wait more than 5 minutes and check the oil level again. It takes
some time for the oil to drain down to the oil pan.
Engine oil quantity: 9.5 L (2.51 U.S. gal)
IMPORTANT:

• Use Ingersoll-Rand Engine oil or engine oil should be MIL-L-2104C or have

properties of API classification CD grades or higher.

• When using oil of different brands from the previous one, be sure to drain all the
previous oil before adding the new engine oil.

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Changing Engine Oil

! CAUTION
To avoid personal injury: Be sure to stop the engine before draining
engine oil. When draining engine oil, place some container underneath
the engine and dispose of it according to local regulations.

Do not drain oil after running the engine. Allow engine to cool down
sufficiently.

1. Change oil after the initial 50 hours of operation and every 500 hours thereafter.

• API service classification: above CD grade

• Ambient temperature: below 35° C (95° F)
2. Remove the drain plug at the bottom of the engine, and drain all the old oil.
Drain oil will drain easier when the oil is warm.

(1) Oil drain plug

3. Add new engine oil up to the upper limit of the oil level gauge.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Replacing the Oil Filter Cartridge

! CAUTION
To avoid personal injury:

Be sure to stop the engine before changing the oil filter cartridge.

Allow engine to cool down sufficiently, oil can be hot and cause burns.

1. Replace the oil filter cartridge. Oil filter cartridge should be replaced every 500
hours. Use Oil Filter Element 22496905.
2. Remove the old oil filter cartridge with a filter wrench.
3. Apply a film of oil to the gasket for the new cartridge.
4. Screw in the cartridge by hand. When the gasket contacts the seal surface,
tighten the cartridge enough by hand. Because, if you tighten the cartridge with
a wrench, it will be tightened too much.

(1) Oil filter cartridge

(2) Remove with a filter wrench (Tighten with your hand)

5. After the new cartridge has been replaced, the engine oil level normally
decreases a little. Thus, run the engine for a while and check for oil leaks
through the seal before checking the engine oil level. Add oil if necessary.

NOTE: Wipe off any oil sticking to the machine completely.

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Radiator
Coolant will last for one day's work if filled all the way up before operation start. Make it a rule
to check the coolant level before every operation.

! WARNING
To avoid personal injury:

Do not stop the engine suddenly, stop it after about 5 minutes of

unloaded idling.

Work only after letting the engine and radiator cool off completely (more
than 30 minutes after it has been stopped).

Do not remove the radiator cap while coolant is hot. When cool to the
touch, rotate cap to the first stop to allow excess pressure to escape.
Then remove cap completely.

If overheat should occur, steam may gush out from the radiator or reserve
tank; Severe burns could result.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Checking Coolant Level, Adding Coolant

1. Remove the radiator cap, after the engine has completely cooled, and check to
see that coolant reaches the supply port.

(1) Radiator pressure cap

2. Check the coolant level of the reserve tank. When it is between the "FULL" and
"LOW" marks, the coolant will last for one day's work.

(1) Reserve tank (A) "FULL"

(B) "LOW"

3. When the coolant level drops due to evaporation, add water only up to the full
level.
4. Check to see that two drain cocks; one is at the crankcase side and the other

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is at the lower part of the radiator as figures below.

(1) Coolant drain cock

IMPORTANT:

• If the radiator cap has to be removed, follow the caution and securely retighten the
cap.
• If coolant should be leak, consult your local KUBOTA dealer.
• Make sure that muddy or sea water does not enter the radiator.
• Use clean, fresh water and 50% anti-freeze to fill the recovery tank.
• Do not refill reserve tank with coolant over the "FULL" level mark.
• Be sure to close the radiator cap securely. If the cap is loose or improperly closed,
coolant may leak out and decrease quickly.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Changing Coolant

1. To drain coolant, always open both drain cocks and simultaneously open the
radiator cap as well. With the radiator cap kept closed, a complete drain of
water is impossible.
2. Remove the overflow pipe of the radiator pressure cap to drain the reserve
tank.
3. Prescribed coolant volume is 8.1L (2.14 U.S.gallons)
4. An improperly tightened radiator cap or a gap between the cap and the seat
quickens loss of coolant.
5. Coolant (Radiator cleaner and anti-freeze)

Season Coolant

Pure water and radiator

Summer
cleaner

Winter (when temperature Pure water and anti-freeze (See

drops below 0° C (32° F) or "Anti-freeze" in RADIATOR
all season Section)

Remedies for Quick Decrease of Coolant

1. Check any dust and dirt between the radiator fins and tube. If any, remove them
from the fins and the tube.
2. Check the tightness of the fan belt. If loose, tighten it securely.
3. Check the internal blockage in the radiator hose. If scale forms in the hose,
clean with the scale inhibitor or its equivalent.

Checking Radiator Hoses and Clamp

! CAUTION
To avoid personal injury:

Be sure to check radiator hoses and hose clamps periodically. If radiator

hose is damaged or coolant leaks, overheats or severe burns could
occur.

Check to see if radiator hoses are properly fixed every 200 hours of operation or 6 months,
whichever comes first.

1. If hose clamps are loose or water leaks, tighten hose clamp securely.
2. Replace hoses and tighten hose clamps securely, if radiator hoses are swollen,

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

hardened or cracked.
Replace hoses and hose clamps every 2 years or earlier, if checked and found that hoses are
swollen, hardened or cracked.

Precaution at Overheating
Take the following actions in the event the coolant temperature is nearly or more than the
boiling point, what is called "Overheating". Take these actions:

1. Stop the engine operation in a safe place and keep the engine unloaded idling.
2. Do not stop the engine suddenly. Stop it after about 5 minutes of unloaded
idling.
3. If the engine stalls within about 5 minutes of running under no load, immediately
leave and keep yourself away from the machine. Do not open the hood and any
other part.
4. Keep yourself and others well away from the engine for further 10 minutes or
while the steam blown out.
5. Checking that there gets no danger such as burn, get rid of the causes of
overheating according to the manual, see "Troubleshooting" section. And then,
start again the engine.

Cleaning Radiator Core (Outside)

If dust is between the fin and tube, wash it away with running water.
IMPORTANT:

• Do not clean radiator with firm tools such as spatulas or screwdrivers. They may
damage specified fin or tube. It can cause coolant leaks or decrease cooling
performance.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Anti-Freeze

! CAUTION
To avoid personal injury:

When using anti-freeze, put on some protection such as rubber gloves

(Anti-freeze contains poison).

If should drink anti-freeze, throw up at once and take medical attention.

When anti-freeze comes in contact with the skin or clothing, wash it off
immediately.

Do not mix different types of anti-freeze. The mixture can produce

chemical reaction causing harmful substances.

Anti-freeze is extremely flammable and explosive under certain

conditions. Keep fire and children away from anti-freeze.

When draining fluids from the engine, place some container underneath
the engine body.

Do not pour waste onto the grounds, down a drain, or into any water
source.

Also, observe the relevant environmental protection regulations when

disposing of anti-freeze.

If it freezes, coolant can damage the cylinders and radiator. If the ambient temperature falls
below 0° C (32° F) or before a long-term storage, let out cooling water completely, or mix fresh
water with long-life coolant and fill the radiator and reserve tank with the mixture.

1. Long-life coolant (hereafter LLC) comes in several types. Use ethylene glycol
(EG) type for this engine.
2. Before employing LLC-mixed cooling water, fill the radiator with fresh water and
empty it again. Repeat this procedure 2 or 3 times to clean up the inside.
3. Mixing the LLC
Put the LLC in cooling water in the percentage (%) for a target temperature.
When mixing, stir it up well, and then fill into the radiator.
4. The procedure for the mixing of water and anti-freeze differs according to the
make of the anti-freeze and the ambient temperature. Refer to SAE J1034
standard, more specifically also to SAE J814c.

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

IMPORTANT:

• When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be
less than 50%.

Freezing Point Boiling Point *

Vol %
Anti-freeze
°C °F °C °F

40 -24 -12 106 222

50 -37 -34 108 226

*At 1.013X105 Pa (760 mm Hg) pressure (atmospheric). A higher boiling point is

obtained by using a radiator pressure cap which permits the development of
pressure within the cooling system.
5. Adding the LLC

1. Add only water if the mixture reduces in amount by evaporation.

2. If there is a mixture leak, add the LLC of the same manufacturer and type
in the same mixture percentage.
*Never add any long-life coolant of different manufacturer. (Different brands
may have different additive components, and the engine may fail to perform as
specified.)
6. When the LLC is mixed, do not employ any radiator cleaning agent. The LLC
contains anti-corrosive agent. If mixed with the cleaning agent, sludge may
build up, adversely affecting the engine parts.
7. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to
change the coolant every 2 years.

NOTE: The above data represent industry standards that necessitate a

minimum glycol content in the concentrated anti-freeze.
When the coolant level drops due to evaporation, add water only to keep
the anti-freeze mixing ratio less than 50%. In case of leakage, add anti-
freeze and water in the specified mixing ratio before filling into the
radiator.

Radiator Cement
As the radiator is solidly constructed, there is little possibility of water leakage. Should this
happen, however, radiator cement can easily fix it. If leakage is serious, contact your local
dealer.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

Fan Belt

Adjusting Fan Belt Tension

! CAUTION
To avoid personal injury:

Be sure to stop the engine and remove the key before checking the belt
tension.

Be sure to reinstall the detached safety shield after maintenance or

checking.

A deflection of between 7 to 9 mm (0.28 to 0.35 in.) when

Proper fan belt tension
the belt is pressed in the middle of the span.

1. Stop the engine and remove the key.

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

• If belt is loosen or damaged and the fan is damaged, it could result in overheats or
insufficient charging. Correct or replace belt.

(1) Fan belt (A) 7 to 9 mm (0.28 to 0.35 in.)

(2) Bolt and nut (under load of 10 kgf (22.1 lbs))

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Carriage and Storage

Carriage

! CAUTION
To avoid personal injury:

Fix the engine securely not to fall during operation.

Do not stand near or under the engine while carrying it.

The engine is heavy. In handling it, be very alert not to get your hands and
body caught in.

1. Use carrier such as crane when carrying the engine, or hurt your waist and
yourself. Support the engine securely with rope not to fall while carrying it.
2. When lifting the engine, put the hook securely to metal fittings attached to the
engine. Use strong hook and fittings enough to hang the engine.

Storage

! CAUTION
To avoid personal injury:

Do not clean the machine with engine running.

To avoid the danger of exhaust fume poisoning, do not operate the

engine in a closed building without proper ventilation.

When storing the engine just after running, let the engine cool off.

Before storing the engine for more than a few months, remove any dirt on the machine, and:

1. Drain the coolant in the radiator. Open the cock at the bottom of the radiator,
and remove the pressure cap to drain water completely. Leave the cock open.
Hang a note written "No water" on the pressure cap. Since water may freeze
when the temperature drops below 0° C (32° F), it is very important that no
water is left in the machine.
2. Remove dirty engine oil, fill with new oil and run the engine for about 5 minutes
to let the oil penetrate to all the parts.
3. Check all the bolts and nuts, and tighten if necessary.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

4. Remove the battery from the engine, adjust the electrolyte level, and recharge
it. Store the battery in a dry and dark place.
5. When the engine is not used for a long period of time, run it for about 5 minutes
under no load every 2 to 3 months to keep it free from rust. If the engine is
stored without any running, moisture in the air may condense into dew over the
sliding parts of the engine, resulting in rust there.
6. If you forget to run the engine for longer than 5 to 6 months, apply enough
engine oil to the valve guide and valve stem seal and make sure the valve
works smoothly before starting the engine.
7. Store the engine in a flat place and remove the key from engine.
8. Do not store the engine in a place where has flammable materials such as dry
grass or straw.
9. When covering the engine for storage, let engine and muffler cool off
completely.
10. Operate the engine after checking and repairing damaged wirings or pipes, and
clearing flammable materials carried by mouse.

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

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

When it is difficult to start the engine

Cause Countermeasures

*Check the fuel tank and fuel filter.

Fuel is thick and doesn't *Remove water, dirt and other impurities.
flow. *As all fuel will be filtered by the filter, if there should be water or
other foreign matters on the filter, clean the filter with kerosene.

*If air is in the fuel filter or injection lines, the fuel pump will not work
properly. To attain proper fuel injection pressure, check carefully for
Air or water mixed in fuel loosened fuel line coupling, loose cap nut, etc.
system
*Loosen joint bolt stop fuel filter and air vent screws of fuel injection
pump to eliminate all the air in the fuel system.

*This is caused when water or dirt is mixed in the fuel. Clean the
Thick carbon deposits on nozzle injection piece, being careful not to damage the orifice.
orifice of injection nozzle. *Check to see if nozzle is working properly or not. If not, install a new
nozzle.

Valve clearance is not as *Adjust valve clearance to 0.18 to 0.22 mm (0.007 to 0.0087 in.)
specified. when the engine is cold.

Leaking valves *Grind valve.

Fuel injection timing is not as *Check injection timing

specified. *The injection timing 0.19 rad(11) before top dead center.

Engine oil becomes thick in

cold weather and engine *Change grade of oil according to the weather (temperature.)
cranks slow.

*Bad valve or excessive wear of rings, pistons and liners cause

Low compression
insufficient compression. Replace with new parts.

*Charge battery.
Battery is discharged and the
engine will not crank. *In winter, always remove battery from machine, charge fully and
keep indoors. Install in machine at time of use.

NOTE: If the cause of trouble cannot be found or if you cannot adjust by

yourself, contact your IR dealer.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

When output is insufficient

Cause Countermeasures

*Clean orifice and needle valve, being very careful not to damage the
Carbon stuck around nozzle orifice.
orifice of nozzle piece
*Check nozzle to see if good. If not, replace with new parts.

Compression is *Bad valve and excessive wear of rings, pistons and liners cause
insufficient. Leaking insufficient compression. Replace with new parts.
valves *Grind valves.

Fuel is insufficient. *Check fuel system.

*Check lubricating oil system.

*Check to see if lubricating oil filter is working properly.
*Filter element deposited with impurities would cause poor lubrication.
Overheating of moving Change element.
parts
*Check the clearance of bearing are within factory specs.
*Check injection timing.
*Check timing 0.19 rad(11°) before top dead center.

Valve clearance is not as *Adjust to proper valve clearance of 0.18 to 0.22 mm

specified. (0.007 to 0.0087 in.) with engine cold.

Air cleaner is dirty *Clean the element every 100 hours of operation.

*Check injection pressure.

Fuel injection pressure is
1st Stage 18.6 MPa (190 kgf/cm2; 2702 psi)
not as specified.
2nd Stage 22.6 MPa (230 kgf/cm2; 3271 psi)

*Do not use poor quality fuel as it will cause wear of the pump. Only use
No. 2-D diesel fuel.
Injection pump wear
*Check the fuel injection pump element and delivery valve assembly
and replace as necessary.

NOTE: If the cause of trouble cannot be found or if you cannot adjust by

yourself, contact your IR dealer.

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

When engine suddenly stops

Cause Countermeasures

*Check the fuel tank and refill the fuel, if necessary.

Lack of fuel
*Also check the fuel system for air or leaks.

Bad nozzle *If necessary, replace with a new nozzle.

*Check amount of engine oil with oil level gauge.

Moving parts are
overheated due to *Check lubricating oil system.
shortage of lubrication oil *At every 2 times of oil change, oil filter cartridge should be replaced.
or improper lubrication.
*Check to see if the engine bearing clearances is within factory specs.

NOTE: When the engine has suddenly stopped, turn the engine lightly by
pulling on the fan belt. If the engine turns easily without abnormalities,
the cause of the trouble is usually lack of fuel or bad nozzle.

When color of exhaust is especially bad

Cause Countermeasures

Fuel governing device bad *Contact dealer for repairs.

Fuel is of extremely poor *Select good quality fuel.

quality.
Use No. 2-D diesel fuel only.

Nozzle is bad. *If necessary, replace with new nozzle.

*Cause is poor atomization, improper injection timing, etc. Because of

trouble in injection system or in poor valve adjustment, or
Combustion is incomplete. compression leakage, poor compression, etc.
Check for the cause.

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Section 9 - 4IRY3N-4IRY3T Engine Operating & Maintenance Manual

When engine must be stopped immediately

Cause Countermeasures
Engine revolution suddenly
*Check the adjustments, injection timing and the fuel system.
decreases or increases.
Unusual sound is heard
*Check all moving parts carefully.
suddenly.
Color of exhaust suddenly
*Check the fuel injection system, especially the fuel injection nozzle.
turns dark.
Bearing parts are
*Check the lubricating system.
overheated.
*Check the lubricating system.
*Check, if the engine bearing clearances are within factory specs.
Oil lamp lights up during
*Check the function of the relieve valve in the lubricating system.
operation.
*Check pressure switch.
*Check filter base gasket.

When engine overheat

Cause Countermeasures
Engine oil insufficient *Check oil level. Replenish oil as required.
Fan belt broken or
*Change belt or adjust belt tension.
elongated
Coolant insufficient *Replenish coolant.
Excessive concentration of
*Add water only or change to coolant with the specified mixing ratio.
antifreeze
Radiator net or radiator fin
*Clean net or fin carefully.
clogged with dust
Inside of radiator or coolant
*Clean or replace radiator and parts.
flow route corroded
Fan or radiator or radiator
*Replace defective parts.
cap defective
Thermostat defective *Check thermostat and replace if necessary.
Temperature gauge or
*Check temperature with thermometer and replace if necessary.
sensor defective
Overload running *Reduce load.
Head gasket defective or
*Replace parts.
water leakage
Incorrect injection timing *Adjust to proper timing.
Unsuitable fuel used *Use the specified fuel.

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

Specifications

Model 4IRY3N 4IRY3T

Type Vertical, water-cooled, 4-cycle diesel engine
Number of cylinders 4
Bore and stroke mm (in.) 87 x 102.4
3
Total displacement cm (cu.in.) 4-98x110 (148.53)
Combustion chamber Re-entrant Type (Direct Injection)
SAE NET Intermittent kW/rpm 36.6/2600
H.P (SAE J1349) (HP/rpm) (49.1/2600)
SAE NET Continuous 31.8/2600
H.P (SAE J1349) (HP/rpm) (42.6/2600)
Maximum Bare Speed - RPM 2800
Order of firing 1-3-4-2
Direction of rotation Counter-clockwise (viewed from flywheel side)
Injection pump Bosch "K" Type mini pump
1st Stage 18.6 Mpa (190 kgf/cm2, 2702 psi)
Injection pressure
2nd Stage 22.6 Mpa (230 kgf/cm2, 3271 psi)
Injection timing (Before T.D.C.) 0.113 rad (6.5°)
Compression ratio 20
Fuel Diesel Fuel No.2-D or No.2-DLS
Lubricant (API classification) above CD grade
Dimension mm (in.) 667.1 X 507.1 X 635.0 667.1 X 507.1 X 698.3
(length X width X height) (26.3 X 20.0 X 25.0) (26.3 X 20.0 X 27.5)
Dry weight (BB Spec.) kg (lbs.) 184 (406)
Starting system Cell starter (with glow plug)
Starting motor 12 V, 2.0 kW
Charging generator 12 V, 480 kW
Recommended battery capacity 12 V, 100 to 120 AH

NOTE: Specifications are subject to change without notice.

100
 **Always use Ingersoll-Rand Replacement parts!**

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 Operating & Maintenance Manual Section 9 - 4IRY3N-4IRY3T Engine

102
 WORD INDEX

A P
Acoustic Materials . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Portable Compressor Fluid Chart . . . . . . . . . . . . 7-54
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Air Intake and Engine Exhaust . . . . . . . . . . . . . . 3-28 R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
B Receiver-Separator Systems . . . . . . . . . . . . . . . 6-49
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 RUNNING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
BEFORE TOWING . . . . . . . . . . . . . . . . . . . . . . . 5-36 S
Safety and Control Systems . . . . . . . . . . . . . . . . 3-28
C Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-10
Compressed Air Leaks . . . . . . . . . . . . . . . . . . . . 3-28 Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Compressor Oil Filters . . . . . . . . . . . . . . . . . . . . 6-48 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . 6-46
Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . 6-46 SETTING UP (ALL UNITS) . . . . . . . . . . . . . . . . . 5-36
CONTROL PANE . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Speed and Pressure Regulator Adjusting Instructions
Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 5-43
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
D Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
T
E Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . 3-28 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
EXPENDABLE SERVICE PARTS . . . . . . . . . . . 4-33 Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . 8-59
Exterior Finish Care . . . . . . . . . . . . . . . . . . . . . . 6-50
U
F UNITS MEASUREMENTS WEIGHTS . . . . . . . . 4-32
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . 3-28, 6-47 UNITS WITH DIAGNOSTIC LAMPS . . . . . . . . . . 5-42
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . 4-32
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 W
Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . 3-29 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
WARRANTY REGISTRATION . . . . . . . . . . . . . . 1-20
G WATER COOLED ENGINE . . . . . . . . . . . . . . . . 5-37
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

H
Hazardous Substance Precaution . . . . . . . . . . . 1-11
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

I
Ingersoll-Rand Preferred Fluids . . . . . . . . . . . . . 7-54
Isolation Mounts . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

L
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

N
Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
WORD INDEX
©2004 Ingersoll-Rand Company, Printed in the USA