INGERSOLL-RAND. OPERATING, MAINTENANCE, PARTS MANUAL COMPRESSOR MODELS VHP400 WCU HP450 WCU XP525 WCU P600 WCU Code A This manual contains important safety information. Do not destroy this manual. This manual must be available to the personnel who operate and maintain this machine. INGERSOLL-RAND. AIR COMPRESSORS Portable Ais Compressor Division P.O. Box 868 - 501 Sanford Ave Mocksville, N.C. 27028 Book 35392893 (5/00) ()QUALITY POLICY We will supply products and services that consistently meet the requirements of our customers and each other. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Book 35392893 (5/00)Foreword Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European common market countries requires that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE certfication and marking being rendered invalid. A declaration of that conformity follows: Declaration of Conformity WITH EC DIRECTIVE 98/37/EC Ingersoll-Rand Company We Ingersoll-Rand Company Limited Portable Compressor Division Standard Products Division P.O. Box 868 Represented InEC By: Swan Lane Hindley Green 501 Sanford Avenue Wigan WN2 4Ez Mocksville, North Carolina 27028 United Kingdom Declare that, under our sole responsibility for manufacture and supply, the product(s) HP1@00WCU —- VHP25WCU —-XHPSOOWCAT = VHP7S0WCAT ~—XHP 10700AT. XP1400WCU —- HPSSEWCU = XHPESOWCAT == VHP8SOWCAT ——yxpy300WCU P1600WCU —-XP1050WCU ——XHP750WCAT — HP9O0WCAT. XP9OOWCU —-HP825WCU = XHPB25WCAT XP 1000WCAT ‘To which this declaration relates, is (are) in conformity with the provisions of the above directives using the following principal standards. EN1012-1, EN29001, EN202, EN60204-1 PNBNTC2, EN 50081, EN50082 Issued at Mocksville on 1-1-95 EE : Hee ‘Seddon, G.A. Manager Ric Lfinstord Manager of Quality Contro! Book 35392893 (5/00) (3)Nothing contained in this documents 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 andwithout 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: ‘A. For direct or indirect human consumption of the compressed air. Outside the ambient temperature range specified in the general data section of this manual When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists. With other than Ingersoll-Rand approved components. With guards, or controls or switches missing or disabled. mmoo® For storage or transportation of materials inside or on the enclosure. ‘This company accepts no responsibilty for errors in translation of this manual from the original English version. Book 3639289 (5/00) (4)TABLE OF CONTENTS SECTION 1...........-.45 SAFETY SECTION 2..............- WARRANTY/REGISTRATION SECTION 3............005 NOISE EMISSION SECTION 4.............05 GENERAL DATA SECTION 5.. . OPERATION SECTIONG.............45 MAINTENANCE SECTION 7...........0005 LUBRICATION SECTION S.............45 TROUBLESHOOTING SECTIONY...........-06 PARTS ORDERING SECTION 10... . PARTS LIST SECTION 11.............. OPTIONS-PARTS LIST SECTION 12.............. ENGINE O&M Book 35392893 (6/00) (5)SECTION 1- ‘SAFETY PRECAUTIONS General Information Ensure that the operator reads and understands the decals and consults the manuals before mainte- nance or operation. Ensure that the Operation and Maintenance manu- al, and the manual holder if equipped, are not re- moved permanently from the machine Ensure that maintenance personnel are adequately trained, competent and have read the manuals. ‘Make sure that all protective covers are in place and that the canopy/doors are closed during operation. The specification of this machine is such that the ‘machine is not suitable for use in flammable gas risk areas. If such an application is required then alllocal regulations, codes of practice and site rules must be observed. To ensure that the machine can operate ina safe and reliable manner, additional equipment such as gas detection, exhaust spark arrestors, and. intake (shut-off) valves may be required, depen- dent on local regulations or the degree of risk in- volved. Ar discharged from this machine may contain car- bon monoxide or other contaminants. which will ‘cause serious injury or death. Do not breathe this air, ‘Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure, that all pressure is vented from the system and that the machine cannot be started accidentally Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel. Allair pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine safety vaive rating, If more than one compressor is connected to one ‘common downstream plant, effective check valves andisolation valves mustbe fitted and controlled by work procedures, so that one machine cannot acci- Book 36392893 (5/00) (6) SAFETY dentally be pressurized or over pressurized by another. Compressed air must not be used for a feed to any form of breathing apparatus or mask. ‘The discharged air contains a very small percent- ‘age of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible. It the discharged air is to be ultimately released into confined space, adequate ventilation mustbe pro- vided. When using compressed air, always use ap- propriate personal protective equipment. All pressure containing parts, especially flexible hoses and their couplings, must be regularly in- spected, be free from detects and be replaced ac- cording to the Manual instructions. ‘Avoid bodily contact with compressed ai ‘The safety valve located in the separator tark must be checked periodically for correct operation. Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. Never operate the engine of this machine inside a building without adequate ventilation. Avoid breath- ing exhaust fumes when working on or near the ma- chine. Do not alter or modify this machine, ‘A battery contains sulfuric acid and can give off gases which are corrosive and potentially explo- sive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water. Exercise extreme caution when using booster bat- tery. To jump battery, connect ends of one booster able to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After starting unit, always dis- connect cables in reverse order.Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with, this machine. This machine may include such materials as oll, die- sel uel, antifreeze, brake fluid, oii fiters and bat- teries which may require proper disposal when per- forming maintenance and service tasks. Contact local authorities for proper disposal of these materi- als. Ar discharged from this machine may contain car- bon monoxide or other contaminants which will cause serious injury or death. Do not breathe this ai. Never operate the engine of this machine inside a building without adequate ventilation. Avoid breath- ing exhaust fumes when working on or near the ma- chine, A battery contains sulfuric acid and can give off gases which are corrosive and potentially explo- sive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water. High Pressure Air can cause serious injury or death. Relieve pressure before removing filler plugs/caps, fittings or covers, Air pressure can remain trapped in air supply line which can result in setious injury or death. Always ‘carefully vent air supply line at too! or vent valve be- fore performing any service. This machine produces loud noise with the doors ‘open or service valve vented. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open or service valve is vented. Never inspect or service unit without first discon- necting battery cable(s) to prevent accidental start- ing. Do not remove the pressure cap from a HOT radia- tor. Allow radiator to cool down before removing pressure cap. Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result in serious ilness. wear eye protection while cleaning unit wth compressed air to prevent debris from injuring eye(s). Disconnect air hoses whip and can cause serious injury or death. Always attacha safety flowrestrictor to each hose at the source of supply or branch line Book 35392893 (5/00) (7) in accordance with OSHA Regulation 20FR Sec- tion 1926.902(b). Hot pressurized fluid can cause serious burns. Do not open radiator while hot Rotating fan blade can cause serious injury. Do not, operate without guard in place. Use care to avoid contacting hot surfaces (engine ‘exhaust manifold and piping, air receiver and air discharge piping, ete). Ether is an extremely volatile, highly flammable gas. USE SPARINGLY! If too much is injected, it may resutt in costly damage to the engine. Never allow the unit to sit stopped with pressure in the receiver-separator system. As a precaution, open the manual blowdown valve. Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, blow gun tips, etc. well away from moving parts. Make sure wheels, tires and tow bar connectors are in safe operating condition and tow bar is properly connected before towing. Whenever the machine is stopped, air wil flew back into the compressor system from devices or systems downstream of the machine unless the service vaive is closed. Install a check valve at the machine service valve to prevent reverse iow inthe event of an unexpected shutdown when the service valve is open. Hazardous Substance Precaution The following substances are used in the ‘manufacture of this machine and may be hazardous to health if used incorrectly. Precaution: 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. ‘The following substances may be produced during the operation of this machine and may be hazardous to health: ‘Avoid build-up of Engine Exhaust Fumes in confined spaces. Avoid breathing Exhaust Fumes. Avoid breathing Brake Lining Dust during mainte- nance.SAFETY LABELS Look for these signs on machines shipped to international markets outside North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform you supervisor. Corrosion risk Hot Surface Lifting point (P) | | WARNING: Electrical shock risk. Parking Brake No open flame Diesel Fuel. No open flame. Do not operate the machine Lifting point without guard being fitted. ® WARNING - Flammable liquid. When parking use prop stand, handbrake and wheel chocks. _—_Alir/gas flow or Air discharge. WARNING - Hot and harmful exhaust gas. Tie down point Do not breathe the compressed air from this machine, Book 35392893 (5/00) (8)© Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken. BARI WARNING - Maintain correct tire pressure. (Refer to the GENERAL INFORMATION section of this manual) WARNING: Consult the operation and maintenance manual before performing any maintenance. 1.5m. 67 154 Rough Service Designation Wet Location Operation Do not stack Replace any cracked Do not use fork lift truck from this side protective shield. Off (power). Do not operate with the doors or enclosure ‘open. WARNING - Before connecting the tow bar or when preparing to tow, consult the operation and maintenance manual. Emergency stop. Book 35392893 (5/00) (9)Sha a Oil Drain © Do not exceed the speed limit. 4 § CS | WARNING - For operating temperature below °C, consult the operation and maintenance man AN AN © WARNING - Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure Is totally relieved. @>e& Ee Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken Do not remove the Operating and Maintenance manual and manual holder from this machine. A oe A Pressurized vessel. Book 35392893 (5/00) (10) Use fork lift truck from this side only. Pressurized component or system.Look for these signs on machines shipped to markets in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform you supervisor. NGER Indicates the presence of a hazard which WILL cause A serious injury, death or property damage, it ignored. (Red Background) Indicates the presence of a hazard which CAN. WG ARNING cause serious injury, death or property damage, ifignored, (Orange Background) CAUTION Indicates the presence of a hazard which WILL or ‘can cause injury or property damage, if ignored. (Yellow Background) NOTICE Incase Important set-up, operating or maintenance (Blue Background) DANGER RRA ‘Trapped air pressure. Can cause serious injury or death, Ae Acrecharped|,wom)this | machine} cat Close service valve and operate tool to vent contain eicarbon a monenide mormother) trapped air before performing any service. contaminants which will cause serious eee ey injury or death. Do not breathe this air. WARNING WARNING 2 6 | High pressure air. Can cause serious Hot pressurized fluid. Injury or death. [Can cause serious burns. ; Relieve pressure before removing filler Do not open radiator while hot. Flager caps: ftings or eovere Book 35392893 (5/00) (11)Improper operation of this equipment. CAN cause serious injury or death. Read Operator's Manual supplied with this machine before operation or servicing, Modification or alteration of this machine. CAN cause serious injury or death. Do NOT ater or modity this machine without the express written consent of the manufacturer. Collapsing jack stand. Will cause serious wr Insert locking pin —\I completely. Rotating Fan Blade. CAN cause serious injury. Do NOT operate with guard removed, WARNING Falling off machine. CAN cause serious injury or death. Access Lifting Bail from inside machine. Book 35392896 (5/00) Excessive towing speed. Can cause serious injury or death. Do NOT exceed 50 mph (80 Rh y > For Highway Towable Units Excessive Towing Speed. CAN cause serious injury or death. Do NOT Tow on Highway. Do NOT exceed 20 mph (32 km/h) For Non-Highway Towable Machines PINAL) Door under pressure CAN cause serious injury. Use both hands to open door when machine is running, (2)Disconnected Air Hoses Whip. CAN cause serious injury or death. Combustible Gas. CAN cause serious. When using air tools attach safety device burns, blindness or death. (OSHA Valve) at source of air supply for Keep sparks and open flames away from each tool batieries FREE SAFETY DECALS! To promote communication of Safety Warnings on products manufactured by the Portable Compressor Division in Mocksville, N.C., Safety Decals are available free of charge. Safety decals are identified by the decal heading: DANGER, WARNING or CAUTION. Decal part numbers are on the bottom of each decal and are also listed in the compressor’s parts manual. Submit orders for Safety Decals to the Mocksville Parts Service Department. The no charge order should contain only Safety Decals. Help promote product safety! Assure that decals are present on the machines. Replace decals that are not readable. Book 35392893 (5/00) (13)SECTION 2 - Warranty Ingersoll-Rand, through its distributor, warrants, that each item of equipment manufactured by itand delivered hereunder tothe initial user will be free of defects in material and workmanship for a period of three (3) months from initial operation or six (6) months from the date of shipment tothe initial user, whichever occurs frst With respect to the following types of equipment, the warranty period enumerated below will apply in ligu of the foregoing warranty period. A. Aftercoolers - The earlier of rine (9) Months from date of shipment to or six (6) months from star up by intial user. B. Portable Compressors, Portable Genera- tor Sets (GENSET), Portable Light Towers and Air Dyers - The earlior of twelve (12) ‘months from shipment to or the accumula tion of 2,000 hours of service by the initial user. C. Portable Compressor Air Ends - The earlier of twenty-four (24) months from shipment to (r the accumulation of 4,000 hours of service by the initial user. For Air Ends, the warranty against defects will include replacement of the complete Air End, provided the original Air End is returned assembled and un- opened. C.1 Portable Compressor Airend Limited Op- tional Warranty - The earlier of sity (60) months from shipment to or the accumulation of 10,000 hours of service. The optional war- ranty is limited to defects in rotors, housings, bearings and gears and provided ali the follow- ing conditions are met: ‘The original airend is returned assembled and unopened. Continued use of genuine Ingersoll-Rand Parts, fluids, oils and fiters. Maintenance is performed at prescribed inter- vals. D. Genset Generators - The earlier of twenty- four (24) months from shipment to or the accu- ‘mulation of 4,000 hours of service by the initial user. Book 35392893 (5/00) (14) E. Portable Light Tower Generators - The ear- lier of twelve (12) months from shipment to or the accumulation of 2,000 hours of service by the intial user. Light Source model only, the eartior of twenty-four (24) months from ship- ment to or the accumulation of 4,000 hours of service. Ingersoll-Rand Engines - The earlier of twenty-four (24) months from shipment to or the accumulation of 4,000 hours of service. Ingersoll-Rand Platinum Drive Train War- ranty (Optional) - Platinum drive train per- tains to the Ingersoll-Rand Engine and Airend combination. The earlier of sixty (60) months from shipment to, or the accumulation of 10,000 hours of service. The starter, alterna- tor, fuel injection system andall electrizal com- ponents are excluded from the extended war- ranty. The airend seal and drive coupling are lncluded in the warranty (airend drive belts are ‘not included). The optional warranty is auto- ‘matically available when meeting the following conditions: ‘The original airend is returned assembled and unopened. Continued use of genuine Ingersoll-Rand Parts, fluids, oil and fiters. Maintenance is performed at prescribed inter- vals. Its the obligation of the user to provide verifi- cation that these conditions have been satis- fied when submitting warranty claims, Spare Parts — Six (6) months from date of shipment.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 with- ‘out 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 In- gersoll-Rand. User must present proof of purchase atthe time of exercising warranty. ‘The above warrantees do not apply to failures oc- curring as a result of abuse; misuse, negligent re- pairs, 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 inthe product's operating and maintenance publica- tions. ‘Accessories or equipment furnished by Ingersoll- Rand, but manufactured by others, including, but not limited to, engines, ties, batteries, engine elec- trical equipment, hydraulic transmissions, carriers, shall carry whatever warranty the manufacturers have conveyed to Ingersoll-Rand and which can be passed on to the initial user. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, (EX- CEPT THAT OF TITLE),AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. Book 35392893 (5/00) (1s)CALIFORNIA EMISSION CONTROL WARRAN- TY STATEMENT EMISSION RELATED SYSTEM DEFECT WAR- RANTY Ingersoll-Rand Company warrants to the initial owner and subsequent owner of a certified non- road diesel engine (powering non-road machines. and equipment), that the engine is: 1. Designed, built, and equipped so as to conform, at the time of sale, with all applicable regula- tions adopted by the United States Environ- mental Protection Agency (EPA) and the Cali- fornia Air Resource Board, 2. Free from defects in materials and workman- ship in specific emission related parts for a peri- od of five (5) years or 3,000 hours of operation whichever occurs first, after date of delivery to the initial owner. I an emission related part fails during the warranty period, it willbe repaired or replaced. Any such part repaired or replaced under warranty is warranted for the remainder of the warranty period. During the term of this warranty, Ingersoll-Rand ‘Company will provide repair or replacement of any warranted part at no charge to the non-road engine owner. In an emergency, repairs may be performed at any service establishment, or by the owner, using any replacement part. Ingersoll-Rand Company will reimburse the owner for their expenses, including diagnostic charges for such emergency repair. These expenses shall not ‘exceed Ingersoll-Rand Company suggested retail price for all warranted parts replaced, and labor charges based on Ingersoll-Rand Company rec- ‘ommended time allowance for the warranty repair ‘and the geographically appropriate hourly labor rate. Apart not being available within 30 days constitutes an emergency. ‘As a condition of reimbursement, replaced parts and receipted invoices must be presented ata place of business of Ingersoll-Rand Company or other establishment authorized by Ingersoll-Rand Com- pany. This warranty covers the following emission related parts and components. + Charge Air Cooling System (if Equipped) Book 35392893 (5/00) (16) Fuel Injection System + Intake Manifold + Exhaust Manifold ‘Turbocharger System + Miscellaneous hoses, clamps, connectors and sealing devices used in the above systems. If failure of one of these components results in fail- ture of another part, both willbe covered by this war- ranty. Any Replacement part may be used for mainte- nance or repairs. The owner should ensure that such parts are equivalent in design and durability to genuine INGERSOLL-RAND parts. Use of non-genuine INGERSOLL-RAND parts does not invalidate the warranty. However, Ingersoll-Rand Company is not lable for parts which are not genuine INGERSOLL-RAND parts. LIMITATIONS AND RESPONSIBILITIES ‘These warranties are subject to the following: INGERSOLL-RAND COMPANY RESPONSI- BILITIES During the emission warranty period, if a defect in material or workmanship of a warranted part or ‘component is found, Ingersoll-Rand Company will provide: *+ New, Remanufactured, or repaired parts and! of components required to correct the defect. Note: Items replaced under this warranty become the property of Ingersoll-Rand Company + Labor, during normal working hours, required to make the warranty repair. This includes diagnosis and labor to remove and install the engine, if necessary. OWNER RESPONSIBILITIES During the emission warranty period, the owner is responsible for: + The performance of all required maintenance. ‘Awarranty claim will not be denied because the scheduled maintenance was not performed. However, if the lack of required maintenance \was the reason for the repair, then the claim will be denied. + Premium of overtime labor costs. * Costs to investigate complaints which are not caused by a defect in Ingersoll-Rand Compa- ‘ny material or workmanship. + Providing timely notice of a warrantable failure and promptly making the product available for repairLIMITATIONS. Ingersoll-Rand Company is not responsible for re- sultant damages to an emission related part or ‘component resulting from: ‘+ Any application or installation Ingersoll-Rand ‘Company deems improper as explained in the Instruction Manual. + Attachments, accessory items, of parts not au- thorized for use by Ingersoll-Rand Company + Improper off-road engine maintenance, repair, or abuse, + Owner's unreasonable delay in making the product available after being notified of a po- tential product problem. This warranty isin addition to Ingersoll-Rand Com- pany standard warranty, applicable to the off-road engine product involved. Remedies under this warranty are limited to the provision of material and services as specified herein. Ingersoll-Rand Company is not responsi- ble for incidental or consequential damages such ‘as downtime or loss-use of engine powered equip- ment, CALIFORNIA EMISSION CONTROL WARRAN- ‘TY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGA- TIONS ‘The Califomia Air Resources Board (CARB) and Ingersoll-Rand Company are please to explain the ‘emission control system warranty on your 1996 and later certified heavy duty off-road engine._ In California, new heavy-duty off-road engines must be designed, built and equipped to meet the state's stringent anti-smog standards. Ingersoll-Rand Company must warrant the emission control sys- tem on your engine for the periods of time listed be- low provided there has been no abuse, neglect, or improper maintenance of your engine. Book 35392893 (5/00) a7) Your emission control system may include parts such as the fuel injection system, air induction sys- tem. Also included may be hoses, belts, connec- tors and other emission-related assemblies. ‘Where a warrantable condition exists, an autho- rized INGERSOLL-RAND Dealer will repair the heavy-duty off-road engine at no cost to the owner including diagnosis, parts and labor. MANUFACTURER'S WARRANTY COVERAGE: ‘The 1996 and later heavy-duty off-road engines ate warranted for a period of five (6) years, or 3000 hours of operation which ever occurs first. If any emission-related part on your engine is detective, the part will be repaired or replaced by an autho- tized INGERSOLL-RAND Dealer. OWNER’S WARRANTY RESPONSIBILITIES: + Asthe heavy-duty off-road engine owner, you are responsible for the performance of the re- Quired maintenance listed in owner's manual (Instruction Manual). Ingersoll-Rand Compa- ry recommends that you retain all receipts and records covering the maintenance on your en- gine, but Ingersoll-Rand Company cannot deny warranty solely for the lack of receipts and records of for your failure to ensure the performance of all scheduled maintenance, + Asthe heavy-duty off-road engine owner, you should however be aware that Ingersoll-Rand Company may deny you warranty coverage if your heavy-duty off-road engine, or part has ‘ailed due to abuse, neglect, improper mainte- nance, or unapproved modifications. + Your engine s designed to operate on commer- cial diesel fuel only. Use of any other fuel may result in our engine no longer operation in com- pliance with California's emission require- ments, + You are responsible for initiating the warranty process. The CARB suggests that you present your heavy-duty off-road engine to an autho- rized INGERSOLL-RAND Dealer as soon asa problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. Ifyou have any questions regarding your warranty rights and responsibilities, you should contact In- gersoll-Rand Company, at P.0. Box 868, Mock- sville, NC 27028 or the State of California Air Re- sources Board, Mobile source Operation Division, PO. Box 8001, at El Monte, CA 91731-2690.MAINTENANCE RECOMMENDATION: ‘Some Ingersoll-Rand Company non-road engines. are certified by the United States Environmental Protection Agency and California Air Resource Board to comply with smoke and gaseous emission standards prescribed by Federal laws at the time of manufacture. ‘The engine is certified ifithas a special certification label. An INGERSOLL-RAND Dealer can also in- form you if the engine is certified. Efficiency of emission control and engine perfor- ‘mance depends on adherence to proper operation and maintenance recommendations and use of recommended fuels and lubrication oils. It is rec- ‘ommended that major adjustments and repair be made by your authorized INGERSOLL-RAND Dealer. Various chemical fuel additives, which claim to re- duce visible smoke, are available commercially. Al- though additives have been used by individuals to solve some isolated smoke problems in the field, they are not recommended for general use. Federal smoke regulations require that engines be certified without smoke depressants. The corrective steps taken immediately on discov- ‘ery of worn parts, which may affect emission levels, will help assure proper operation of emission con- trol systems. The use of genuine INGERSOLL- RAND parts is recommended. Suppliers of non- INGERSOLL-RAND parts must assure the owner that the use of such parts will not adversely affect emission levels. Regular maintenance intervals, along with special ‘emphasis on the following items, are necessary to keepexhaust emissions within acceptable limits for the useful Ife of the engine. Refer to the Mainte- nance Section of this manual. Ifthe engine is oper- ating under severe conditions, adjust the mainte- nance schedule accordingly. See your authorized INGERSOLL-RAND Dealer to help analyze your specific application, operating environment and maintenance schedule adjustments, ‘The following is an explanation of maintenance for emission-related components, ‘See the Maintenance Schedule for the specific in- terval forthe following items. Book 35392893 (5/00) (as) FUEL INJECTION PUMPS OR NOZZLES — Fuel injection pumps or nozzles are subject to tp wear ‘aS a result fuel contamination. This damage can ‘cause an increase in fuel consumption, the engine to emit black smoke, misfire or run rough. Inspect, test and replace if necessary. Fuel injectionpumps can be tested by an authorized INGERSOLL- RAND Dealer. ‘TURBOCHARGER — Check for any unusual sound or vibration in the turbocharger. Inspect inlet and exhaust piping and connections. Check bearing condition and perform maintenance as described in the Maintenance Schedule. ‘Slow engine response and low power may indicate a need for adjustment or repair. Your INGER- ‘SOLL-RAND Dealer is equipped with the neces- sary tools, personnel, and procedures to perform this service. ‘Owner is encouraged to keep adequate mainte- ‘nance records, but the absence of such, in and of ‘itself, will not invalidate the warranty. The machine or equipment owner may perform routine maintenance, repairs and other non-war- ranty work or have it done at any repair faci. ‘Such non-warranty workneed note performed at a dosignatad warranty station in order tor the waeran- ty to remain in force. CUSTOMER ASSISTANCE — EMISSION CON- ‘TROL SYSTEM WARRANTY: Ingersoll-Rand Company aims to ensure that the Emission Control Systems Warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Systems War- ranty, call or write: Ingersoll-Rand Company P.O. Box 868 Mocksville, NC 27028 Tel.: 336-751-3561 Authorized Dealers are recommended for major ‘maintenance and repair work as they are staffed with trained personnel, proper tools and are aware of the latest maintenance methods and proce- dures. Owners and others who desire to perform their own work should purchase a Service Manual and obtain current service information from their INGERSOLL-RAND Dealer.GENERAL WARRANTY INFORMATION (GENERAL WARRANTY Extended Coverage Portable Compressor _| Package *Tyeari2000 hours Airend 2 years/4000 hours | 5 years/10,000 hours: Limited warranty, major ‘components (refer to operator's manual, Portable Genset Package 7 year/2000 hours [Generator 2 years/4000 hours Light Tower Package 7 year/2000 hours Generator 7 year/2000 hours 2 years/4000 hours, for Lightsource introduced 8/16/99. ENGINES Caterpilar Months Hours Extended Coverage 2 No Limit Available at dealer Cummins 24 [2000 Major components 3 yrs/10,000 hours = available at dealer John Deere 24 [2000 ‘Available at dealer Deutz 24 [2000 ‘Available at dealer Kubota 24 2000 ‘Major components 36 ‘months/3000 hours = parts only Ingersoll-Rand 24 r4000 '5 years/10,000 hours when using genuine In- gersoll-Rand fluids and parts. Refer to opera- tor's manual [PARTS Months Hours (Coverage Ingersoll-Rand é No Limit Parts Only [AIREND EXCHANGE Months Hours Extended Coverage Airend 72 '2000 hours 2 years/4000 hours ~ available from IR. Note: Actual warranty times may change. Consut the manufacturer's warranty policy as shipped wih each new product. Book 35392893 (5/00) (9)Extended Limited Airend Warranty Ingersoll-Rand Portable Compressor Division is pleased to announce the availabilty of extended limited air- ‘end warranty. Announcement ofthe extended warranty coincides with the introduction of PRO*TEC™ Com- pressor Fluid, PRO*TEC™ Compressor Fluids an amber colored fluid specially formulated for Portable Com- pressors and is being provided as the factory filled fluid fr all machines except 1 XHP650/900/1070 models. ‘Allmachines have the standard airend warranty - The earlier of 24 months from shipment to, or the accumula- tion of 4000 hours of service. ‘The warranty against defects will include replacement of the complete airend, provided the original airené is returned assembled and unopened. ‘The optional limited warranty is the earlier of 60 months from shipmentto, or the accumulation of 10,000 hours of service. The optional warranty is limited to defects in major components (rotors, housings, gears, bear- ings), and is automatically available when the following three conditions are met: 1. The original airend is returned assembled and unopened. 2, Submissions of proof that Ingersoll-Rand fluid, fiters and separators have been used. Refer to the Operation and Parts manual forthe correct fluids, fers and separator elements required. 3. Submission of proof that maintenance intervals have been followed. WARRANTY TIME *BARE AIREND ** AIREND COMPONENT: STANDARD | 2yrs/4000 hrs | 100% parts and labor 100% parts and labor OPTIONAL | Syrs/10,000 hrs | 100% parts and labor 0% * Bare Airend ~ pertains to major airend parts (rotors, housings, gears and bearings) ™* Airend Components - pertains to auxiliary attachments to the bare alrend (drive coupling, seals, pumps, valves, tubes, hoses, fittings and fiter housing). PRO-TEC™ and XHP505 Compressor Fluids are available from the Mocksville Product Support department by calling 1-800-633-5206, ' XHP650/900/1070 will continue to use XHP5OS and will have the extended warranty when above conditions. are met. Book 35392893 (5/00) (20)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. John Deere requires a separate engine registration be completed and mailed direct to John Deere. Separate engine registration material is included with this literature package for John Deere powered ma- chines. All other engine manufacturers do not require a separate engine registration. You MUST present proof of in-service date at time of requesting engine warranty service. Book 35392893 (5/00) 1)WARRANTY REGISTRATION (Owner/User Name Address City city County State County State —_________ Zp Coe Zip Code Telephone Telephone Complete the Applicable Blocks Owner/User Type of Business (check one only) 0 Construction-Heavy D Asphalt Contractor =O fee ea pt Coal Mining 0 other Mining 1 Construction-Light DD Government (carpentry, plumbing, pools, (municipal, state, mason, etc.) county, etc.) O auany O Shallow oil & Gas OO Rental Building Contractor []_ Waterwell i (Fetal center, ental fet, etc) 1 Bulting 0 unity company (gas, electric, water, etc.) C1 Industrial (plant use) 1 Other D Exploration o ctor omer Uility Contractor Model Unit S/N, Engine S/N Date Delivered Airend S/N Truck S/N Truck Engine S/N ‘SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT ‘The Purchaser has been instructed and/or has read the manual and understands proper preventative maintenance, general operation and safety precautions. ‘The warranty and limitation of liability has been reviewed and understood by the owner/user. In the event that this unit is to be used within a nuclear faciity, the owner/user shall notify Ingersoll-Rand of such] Use so that Ingersoll-Rand may arrange for appropriate nuclear liabilty protection from the owner-licensee of the| facility. Ingersoll-Rand reserves the right to make design changes or modifications of Ingersoll-Rand products at anytime ‘without incurring any obligation to make similar changes or modifications on previously sold. units. Book 35392893 (5/00)queuedeg Aueuey, :uonueny 8ZOLZ BUIJO1eD YUION ‘oII/ASY2OW 898 X08 ‘Od uorsiaiq 1ossesduiog eqeuod ‘Aueduiog puey -/0ss06u) Book 36392893 (5/00) 3)SECTION 3 - NOISE EMISSION This section pertains only to machines distributed within the United States. ‘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: 4. 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 5, Removal of any of the following: a. fan shroud b. vibration mounts c. sound absorption material 6. Operation of the compressor with any of the enclosure doors open. ion Control Information ‘A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of design incorporated into this compressor in compliance with the ‘noise control act; B. The use of this compressor after such device or element of design has been removed or rendered inoperative. Note: the above information applies only to units that are built in compliance with the U.S. 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. Book 35392893 (5/00) 4)NOISE EMISSION CONTROL MAINTENANCE LOG le [COMPRESSOR MODEL SERIAL NO. USER UNIT NO. UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM Engine Make & Model: WHOM PURCHASED: ‘Serial No... Purchaser or Owner: Address: Date Purchased: ‘The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any com- pressor 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, of replacement, of any device or element of design incorporated into new compressor for the purpose of noise Control prior toits sale or delivery to the ultimate purchaser or while it isin 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 uitimate purchaser and each subsequent purchaser that this air compres- sor was designed, buit and equipped to conform atthe time of sale tothe first retal purchaser, wth allapplica- ble U.S. EPA Noise Control Regulations This warranty isnot limited to any particular part, component, or system of the ait compressor. Defects in the design, assembly or in any part, component, or system of the compressor which, atthe time of sale to the first retail purchaser, caused noise emissions to exceed Federal Standards are covered by this warranty for the life ofthe 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 emis- sion controls and (2) space so that the purchaser or owner can record what maintenance was done, ty whom, where and when. The Maintenance Schedule and detailed instructions on the maintenance items ere given ‘on following page. Book 35392893 (5/00) @5)MAINTENANCE SCHEDULE ITEM ‘AREA PERIOD ry ‘Compressed Air Leaks [As Detected B. Safety and Control Systems | As Detected c. Acoustic Materials Daily D. Fasteners, 100 hours, E Enolosure Panels, 100 hours F Air Intake & Engine Exhaust | 100 hours G Cooling Systems 250 hours H. Isolation Mounts 250 hours p Engine Operation )See Operator's Manual u 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 Mater Indally Inspections, observe these materials. Main- tain all acoustic material as nearly as possible ints original condition. Repair or replace all sections that, have: 1) sustained damage, 2) have partially sepa- rated from panels to which they were attached, 3) are missing, or have otherwise deteriorated due to, severe operating or storage conditions, D. Fasteners Al 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, re- placed 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, tom, or otherwise deformed, such that their noise containment function is re- duced, should be repaired or repiaced before the ‘next operation interval. Doors, access panels, and hatch closures especially, should be checked and adjusted at this time to insure continuous seating Book 3539289 (5/00) (26) between gasket or acoustic material and themating frame. F. Air Intake and Engine Exhaust Engine and compressor air intake and engine ex- haust systems should be inspected after each 100 hours of operation for loose, damaged, or deterio- rated components. Repairs or replacements should be made before the next period of use. G. Cooling Systems All components ofthe cvuling systern for engine we ter and compressor oll should be inspected every 250 hours of use. Any discrepancies found should be corrected before placing the unit back in opera- tion. Unrestricted airflow over the radiator and oil cooler must be maintained at alltimes during opera- tion. 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 sterage in severe environments, all should be replaced with ‘equivalent parts |. Engine Operation Inspect and maintain engine condition and opera- tion as recommended in the manuals supplied by the engine manufacturer. J. Fuels and Lubricants Use only the types and grades of fuels and lubri- cants recommended in the Ingersoll-Rand Compa- nny and Engine Manufacturer's Operator and Main- tenance Manuals.MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY TTEMNO. DESCRIPTION OF WORK HOURMETER READING MAINT) INSPECT DATE LOCATION cry ‘STATE WORK DONE BY (NAME) Book 35392893 (5/00) 7)SECTION 4 - GENERAL DATA Unit Models VHP400WCU _HP450WCU___XPS25WCU __ P6DOWCU COMPRESSOR Free air delivery-cfm (L per sec.) 400 (189) 450 (212) 525 (247) | 600 (283) Rated operating press. psig (bars) 200(13.8) | 150(103) | 125 (86) | 100 (69) Pressure range psig 80 to 200 80 to 150 8010125 | 80to 100 (bars) (6510138) | (65t0103) | (65t08.6) | (65t06.9) Air discharge outlets (Qty) size in, (1) 2° NPT (y2npt | (1) 2NPT (1) 2NPT Engine Speed - RPM (Full Load) secs cence 2200 = RPM (No Load) ...... vote e tees eeteeereeeces 1400 ENGINE (Diesel) Manufacturer .......ce.e. coe ttteteee tenes Cummins: Modal B5.9-174 Electrical System ..... 24. VOC FLUID CAPACITIES - U.S. gallons (litres) Compressor Lubricant, refill oo. ..ecececeeseteeesteesetsereeteeetteeeseerteese ss 82 (5) Engine Crankease Lube (including fer) .........6.cccceeeeeeeseees 43 (16.4) Fuel Tank (Use clean DIESEL fuel) ; vette etetee eee e ees 65 (246) Engine Coolant (Radiator)... seeeseeseeeteeeeesssteeteseteessesesesesceese s+, 6,63 (25) UNITS MEASUREMENTS/WEIGHTS Overall Length - inches(mm) 179 14547) Overall Height - inches (mm) 71 (1803) Overall Width - inches(mm) 64 (1626) Track Width - inches(mm) 52 (1321) Weight, ready to run-Ib. (kg) $5200 (2360) RUNNING GEAR Tie Size/Load Range - 8.75 x 16.5/E Inflation Pressure (COld) ......sececessceetevsessssteesecssssceeseeses 75 psi (620 KPa) Towing Speed (MaxIMUM) ..........eceeecereeee ‘50 mph (80 krn/tr) Book 35392893 (5/00) (28)SECTION 5 - OPERATION BEFORE TOWING WARNING ] Failure to follow these instructions can cause severe injury or death. CAUTION ) = Position the tow vehicle to align its hitch with the pintle eye or coupler of the compressor. = Engage the parking brake and chock the wheels of the tow vehicle. Stand tothe side and ensure pinis FULLY inserted (secure) in tube of jack. Crank jack to seat pintle eye. or coupler onto hitch. Latch and lock hitch. Cross safety chain(s) under drawbar. Attach to vehicle. = Crank jack to raise pad off the ground. Pull pin from tube of jack. Fold jack handle down and forward. Swing up jack tube and FULLY insert pin in tube Units equipped with hydraulic brakes: = Check brake fluid level. Top off as required with DOT 3 brake fluid. = Check condition of brake lines, hoses and cables. Repair or replace damaged parts. ~ Attach brake actuator break-a-way chain above hitch or towing vehicle. ‘SETTING - UP + Place the unit in an open, well-ventilated area. Position as level as possible. The design of these Units permits a 15 degree limit on out-of-level operation. When the unitis to be operated out-of-level, itis important: (1) to keep the engine crankcase ol evel near the high level mark (with the unit level), and (2) to have the compressor cil level gauge show no more than mid-scale (with the unit running at full load). Do not overfil either the engine crankcase or the compressor lubricating oil system. Book 35392893 (5/00) 9) TOWING Failure to follow these instructions can cause severe injury or death. ~ Ensure that tires, wheels and running gear are in ‘good condition and secure. ~ Ensure that tires are inflated to 75 psi (520kPa) = Do not tow this unit in excess of 50 mph (80 kh), = Use a tow vehicle whose towing capacity is greater than the gross weight of this unit. DISCONNECT ~ Set the vehicle parking brake. Chock wheels of unit ~ Standing tothe side, remove pin from tube of jack. AAs jack tube swings down, FULLY insert pin in the tube. - Disconnect safety chains. Crank jack to raise eye or coupler from hitch. Tow vehicle can be moved, TING Do not connect the air discharge on this unit into a ‘common header with any other unit of any description, or any other source of compressed air, without first making sure a check valve is used between the header and the unit. If this unit is ‘connected in parallel with another unit of higher discharge pressure and capacity, a safety hazard ‘could occur in a back-flow condition. Unrestricted alr flow from a hose will result in a whipping motion of the hose which can cause severe injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure in case of hose failure or other sudden pressure release. Reference: OSHA regulation 29 CFR Section 1926.302 (b.+ Open manual blowdown valve to ensure pressure is relieved in receiver-separator system. Close valve in order to build up full air pressure and ensure proper oil circulation, * Check battery for proper connections and condi- tion, + Check the compressor lubricating oil level. The proper cil level is mid-way on the sight gauge. Add Oilf the level falls to the bottom of the sight gauge. Do not overfill. + Check the engine lubricating oll level. Addl flow on dipstick. Do not remove the cap from a HOT engine radiator. The sudden release of pressure froma heated cooling system can cause severe injury or death. “The use of water alone in this engine can result in major engine failure. + At overtiow reservoir ( plastic bottle ) check coolant level and, if necessary, top off to “cold” mark. * Check the fuel level. Add only CLEAN DIESEL fuel for maximum service from the engine. Note: To minimize condensation (water) in the fuel tank, fill the tank at the end of each day. This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve (s) are open. Close the side doors to maintain a cooling ait path and to avoid recirculation of hot air. This will maximize the life of the engine and compressor and. protect the hearing of surrounding personnel. Be sure no one is IN or ON the compressor unit. Book 35392883 (6/00) 0) STARTING WARNING J Do NOT operate machine with guards removed. CAUTION ) Do NOT operate machine with safety shutdown switches by-passed. In freezing weather and if so equipped, flio HEAT- ERS switch "On" and wait sixty (60) seconds. This applies heat to the control system components for easier starting. Leave this switch “On" while oper- ating at these temperatures. Flip the POWER switch to"On". All DIAGNOSTICS lamps will light (glow) for two (2) seconds. Then all lamps should go off except for ALTERNATOR NOT CHARGING and LOW ENGINE OIL PRESSURE. Ether is an extremely volatile, highly flammable gas. Use sparingly! If too much Is injected, the uncontrolled explosion may result in costly damage to the engine. Incold weather, open manual blow down valve and, if So equipped, press the ETHER INJECT button ‘once and release. Then, while cranking, press re- ease button once every five (5) seconds. This in- jects a measured amount of ether to the engine. Press both the START and the BY PASS buttons to crank the engine. DO NOT OPERATE THE STARTER MOTOR FOR MORE THAN TEN (10) SECONDS WITHOUT ALLOWING AT LEAST ONE MINUTE COOLING TIME BETWEEN START ATTEMPTS. Release the START button when the engine starts land sustains running. If the engine does not start after a couple of attempts, refer to Trouble Shooting Section. Release the BYPASS button after two (2) to three (8) seconds.‘All Diagnostic lamps should be off. If not, stop the machine and investigate. If opened above, close manual blowdown valve. ‘Observe the gauges while the unit warms up for five ©) toten (10) minutes or until the coolant tempera- ture reaches 140 degrees F (60°C), Push the SERVICE AIR button. The engine should {90 to full speed and the discharge pressure rise to slightly over rated pressure. The compressor will Unload (intake be throttled or closed) and the engine speed will drop to the idle speed. Compressor is now ready to furnish air when the service valve is opened. STOPPING + Close air service vaive (s). + Allow the unit to run at “no load” for 3 to § minutes to reduce the engine temperatures. + Flip all toggle switches to “Off. Note: Once the engine stops, the automatic blowdown vaive will begin to relleve all pres- sure from the receiver-separator system. Never allow the unit to sit stopped with pressure in the receiver-separator system. As a precaution, after the automatic blowdown period (2 minutes), ‘open the manual blowdown valve. EQUIPMENT PROTECTION Note: Do NOT wire around or bypass a shut- down sensor or switch. This unit is protected by five (5) sensors or switches at the following locations: Book 3539289 (5/00) G1) (1) High engine COOLANT temperature in the en- gine. (2) Low engine oil pressure, in the engine. (9) Low Fuel Level. High Discharge AIR Temperature - (4) At the airend outlet (6) In the safety valve connection on the separator tank. AUTOMATIC SHUTDOWN / DIAGNOSTICS ‘Should any of these problem situations ocour, the Unit will automatically shutdown and stop. BE FORE restarting the unit or flipping the POWER ‘switch to *Off", check the DIAGNOSTICS area on. the instrument panel ‘The upper four (4) lamps are electronically “latched” to only respond to the first or primary signal for a shutdown. In other words, if the automatic shut- down is the resutt of one of these four problems, only that particular problem lamp willbe it. And the lamp will remain lit as long as the batteries provide power. Refer to OPERATING CONTROLS AND INSTRU- MENTS, for the various problem signal criteria (*, psi, etc.). The indicated problem area should be in- sspected for a physical cause (low fluid, broken fan belt, evidence of excessive heat, etc.) and correc- tions made. The shutdown will automatically reset when the problem condition is corrected. Other possible causes for an unexpected shutdown are listed on the Trouble Shooting ChartControl Panel © © OO Operating Controts/instruments (Standard) 1. Compressor Discharge Pressure Gauge - Indicates pressure in receiver tank, psi (KPa), 2. Discharge Air Temp. Gauge (Optional) - Indicates in °F and °C. Normal operating range: 185°F/85° to 248°F/120°C. 3. Engine Oil Pressure Gauge (Optional) - Indicates engine oll pressure (psi (kPa). 4. Engine Speed Gauge (Optional) - Indicates engine speed. 5. Hourmeter - Records running time for maintenance. 6. Fuel Level Gauge - Indicates amount of fue! in tank. 7. Engine Water Temp. Gauge (Optional) - Indicates coolant temperature, with normal operat- ing range frm 180°F (82°C) to 210°F (99°C). 8 Voltmeter (Optional) - Indicates battery condition. Book 35392893 (5/00) (2) DIAGNOSTICS/AUTO SHUTDOWN 9, High Compressor Temperature - 248°F (120°C) or more, 10. Low Engine Oil Pressure - 12 psi or less 11. High Engine Temperature - Coolant above 220°F (104°C). 12. Low Fuel Level - Must add fue! to operate. 13. Alternator Not Charging - needs attention, 14, Low Coolant Level - ‘Must add coolant 15. Air Filters Restricted - Needs servicing, CONTROLS 16. Power Switch - Flip “ON' to activate systems prior to Starting. Flip “Off to stop engine. 19. Service Air Button ~ After warm up, PUSH. Provides full air pressure at the service outlet. 21. Start Button - PRESS to crank engine. Release when engine sus- tains fring. 22. Bypass Button - PRESS while engine is starting, Release after 2-3 seconds. OPTIONAL CONTROLS 17. Lights Switch - Operates Lamps within Gauges. 18. Heaters Switch - ‘Activates control system heaters for operaton be- low 32°F (°C). 20. Ether inject Button - Injects a measured shot. USE SPARINGLY.Before Starting Unit: 1. Adjust jam nut (D) on throttle spring rod (E) to relieve tension on two compression springs (F). 2, Atop separator cover at pressure regulator (PR) loosen locknut (G) counterclockwise. Turn adjusting screw (H) counterclockwise one fulltur. After Starting Unit: 3. Allow unitto warm up, then push “Service Air” button on control panel. 4. Open and adjust service valve on outside of [9 the unit to obtain the rated operating pressure on the discharge pressure gauge. Note: If the rated operating pressure cannot be ‘maintained with engine at full load speed and rod (M) fully extended, turn regulator adjusting screw (H) clockwise until throttle arm (A) just begins to move. us 5. Insure the pressure is maintained at rated pressure, then turn regulator adjusting screw (H) ‘clockwise until throttle arm (A) just begins to move. 6. Close service valve (engine wil slow tonoload or idle speed). Loosen jam nut (L) at air cylinder (AC) shaft. Rotate air cylinder shaft (M) to adjust speed to no load rpm, if unable to obtain no load ‘pm, loosen nuts (C) and rotate throttle arm (A) as required. Moving throttle arm (A) clockwise in- creases idle speed. Tighten nuts (C) and, if neces- sary, fine adjust idle speed by rotating air cylinder shaft (M). Then tighten jam nut (L), 7. I necessary, repeat steps 4, 5 and 6. 8. Limit full load engine speed by adjusting the collar (N) on the end of the throttle spring rod (€). 9. Adjust jam nut (D) on throttle spring rod (E) un- Book 35392893 (5/00) 63) ‘SPEED AND PRESSURE REGULATION ADJUSTING INSTRUCTIONS. osetia til distance "x" between spring mount (J) end rod Quide (K) is 1.75 in. (45 mm). 10. At pressure regulator (PR) tighten looknut (G). 11. To obtain maximum CFM at any pressure be- ‘tween 80 PSI (550KPa) and the rated operating pressure, tum adjusting screw (H) of the pressure regulator (PR) to obtain desired discharge pressure at full load engine speed. Always lock and protect pressure setting of adjusting screw (H) with ocknut ©. 12. Insure unloader solenoid (US) acts to hold pres- sure in inlet unloader (IU) after shutdown. After start-up, a pressure switch will open unloader sole- noid (US).SECTION 6 - MAINTENANCE CAUTION J ‘Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty. WARNING J It performing more than visual inspections, disconnect battery cables and open manual blowdown valve. Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). Never operate this machine with any guards removed, Inch and metric hardware was used in the design and assembly of this unit. Consult the parts manual for clarification of usage. GENERAL In addition to periodic inspections, many of the ‘components in this unit requires periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and post-operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need for repair. Preventive maintenance isthe easiest and the least expensive type of maintenance. Maintaining your unit and keeping it clean at all times wil facilitate servicing ‘SCHEDULED MAINTENANCE The maintenance schedule is based on normal operation of the unit. In the event unusual environmental operating conditions exist, the ‘schedule should be adjusted accordingly Book 35992893 (5/00) (4) COMPRESSOR OIL LEVEL The oil level should be checked before the unit is, started. The optimum operating level is midway of the sight tube on the side of the receiver tank. See the decal beside the sight tube. Ifthe il level is not in the "OK" range, make appropriate corrections (Add or Drain). A totally filed sight tbe in which the level is not visible indicates an over-full condition and requires that oil be drained. AIB.CLEANER This unit is equipped with an AIR FILTERS RESTRICTED lamp on the instrument panel, covering both the engine and the compressor. This should be checked daily during operation. Ifthe lamp glows (red) with the unit operating at full speed, servicing of the cleaner element is necessary, ‘Also weekly squeeze the rubber valve (precleaner dirt dump) on each air cleaner housing to ensure that they are not clogged. The air filtors restricted eeneor will automatically reset after the main power switch is turnedto “OFF.” To service the air cleaners proceed as follows: 4. Loosen outer wing nut and remove with cover. Remove Element, 2. Inspect air cleaner housing for any conaition that might cause a leak and correct as necessary. 3. Wipe inside of air cleaner housing with a clean, damp cloth to remove any dirt accumulation, especially in the area where the element seals against the housing. 4. Inspect element by placing a bright light inside and rotating slowly. If any holes or tears are found in the paper, discard this element. If no ruptures are found, the element can be cleaned. 5, Ifanewairfitter element is to be used check. it closely for shipping damage.6 Install cleaned or new elements in the reverse order to the above. Tighten wing nut firmly. 7. Inspect to ensure that the end cap seals tightly 360 degrees around the air cleaner body. In the event that the fiter element must be reused immediately, compressed air cleaning (as follows) is recommended since the element must be thoroughly dry. Direct compressed air through the ‘element in the direction opposite to the normal air flow through the element. Move the nozzle up and down while rotating the element. Be sure to keep the nozzle at least one inch (25.4 mm) from the pleated paper. NOTE: To prevent damage to the element, never exceed a maximum alr pressure of 100 psi (700 kPa). In the event the element is contaminated with dry dirt, cilorgreasy dirtdeposits, and anew element is, not available, cleaning can be accomplished by washing, using the air cleaner element manufactur- er's recommendations. NOTE: Itisrecommended that replacement ele- ments be installed inthe unit. The elements just removed for cleaning can be washed and stored as future replacement elements. In addition, the air cleaner system (housing and piping) should be inspected every month for any leakage paths or inlet obstructions. Make sure the air cleaner mounting bolts and clamps are tight. ‘Check the air cleaner housing for dents or damage which could lead to a leak. Inspect the air transfer tubing from the air cleaner to the compressor and the engine for leaks. Make sure thatll clamps and flange joints are tight. Book 3539289 (5/00) (5) GAUGES: ‘The instruments or gauges are essential for safety, maximum productivity and long service life of the machine. Inspect the gauges and test any diagnostic amps priorto start-up. During operation observe the gauges and any lamps for proper functioning. Refer to Operating Controls, for the normal readings. EVEL TANK CLEAN fuel inthe fuel tanks is vitally important and every precaution should be taken to ensure that only clean fuel is poured or pumped into the tank. ‘When filing the fuel tank on this unit, by methods other than a pump and hose, use a CLEAN ‘non-metallic funnel, BATTERY Keep the battery posts-to-cable connections clean, tight and lightly coated with a grease. Also the electrolyte level in each cell should coverthe top of the plates. If necessary, top-off with clean distilled water. TIRES ‘A weekly inspection is recommended. Tires that have cuts or cracks oritle tread should be repaired or replaced. Monthly check the wheel lug ruts for tightness.COMPRESSOR OIL COOLER ‘The compressor lubricating and cooling oilis cooled by means of the fin and tube-type oil cooler. The lubricating and cooling oi, flowing internally through the core section, is cooled by the air stream from the cooling fan flowing past the core section. When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler, its efficiency is impaired. Each monthit isrecommended that the oilcooler be cleaned by directing compressed air which contains a nonflammable, non-caustic safety solvent through the core of the oil cooler. This should remove the accumulation of grease, oll and dit from the exterior surfaces of the ollcooler core so that the entire cooling area can transmit the heat of the lubricating and cooling cil to the air stream. In the event foreign deposits, such as sludge and lacquer, accumulate in the oll cooler to the extent that its cooling efficiency is impaired, a resulting high discharge air temperature is likely to occur, causing shut down of the unit. To correct this situation it will be necessary to clean it using a leaning compound in accordance with the ‘manufacturer's recommendations. HOSES Each month itis recommended that all of the intake. lines to and from the air cleaners, the engine cooling system hoses and all ofthe flexible hoses used for air, oil, and fuel be inspected. To ensure freedom from ai leaks, all rubber hose joints and the screw-type hose clamps must be absolutely tight. Regular inspection of these connections for wear or deterioration is necessary. Premature wear of both the engine and compressor is ASSURED whenever dust-laden air is permitted to enter the engine's combustion chamber or the compressor intake. Book 35392893 (5/00) (G6) ‘The flexible hoses used in the fuel, oll and ait lines. ‘on these units are primarily used for their ability to accommodate relative movement between ‘components. It is important they be periodically inspected for wear and deterioration. It is also important the operator does not use the heses as convenient handhold or steps. Such use cancause early cover wear and hose failure. NOTICE Piping systems operating at less than 150 psi (1050 kPa) may use a special nylon tubing. The associated fittings are also of a speci “push-in” design. Iso, features are as follow: Pulling on the tubing will cause the inner sleeve to withdraw and compress, thus tightening the ‘connection. The tubing can be withdrawn ony while holding the sleeve against the fitting. The tubing can be removed and replaced numerous times without losing its sealing ability. To install the nylon tubing, make a mark (withtape or grease pencil) approximately 7/8 inch from the end of the tubing. Insert the tubing into the sleeve and “push-in" past the first resistance to the bottom. The mark should be approximately 1/16 inch from the sleeve, for the 3/8 inch O.D. tubing; 1/8 inch for the 0.25 inch O.D. tubing. This will ensure that the tubing is fully engaged in the sealing mechanism. NOTICE The oil filter must be replaced every 500 hours, of operation or three (3) months, whichever comes first. On new or overhauled units, re- place the element after the first 50 and 150 hours of operation; thereafter, service the oll fil ter every 500 hours. To service the oil fiters it will frst be necessary to shut the unit down. Wipe off any external dir and oil from the exterior of the filter to minimize any contamination from entering the lubrication system. Proceed as follows:High pressure air can cause severe injury or death from hot oll and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. 1. Open the service air valve(s) to ensure that system is relieved of all pressure. Close the vaive(s) 2. Turn the spin-on filter element counterclockwise to remove it from the filter housing. Inspect the fier. NOTICE If there is any indication of formation of var- nishes, shellacs or lacquers on the oil filter ele- ‘ment, itisa warning the compressor lubricating oil has improper characteristics and should be Immediately changed. 3. Inspect the oil fter head to be sure the gasket was removed with the oil fiter element. Clean the gasket seal area on the oil fter head. Book 35392898 (5/00) 67) NOTICE Installing a new oil filter element when the old gasket remains on the filter head, will cause an oil leak and can cause property damage. 4. Lubricate the new filter gasket with the same oil being used in the machine. 5. Install new fiter by turning element clockwise Until gasket_makes initial contact. Tighten an additional 1/2 to 3/4 turn 6. Start unit and allow to build up to rated pressure. Check for leaks before placing unit back into service, FASTENERS Visually check entire unitin regard to bolts, nuts and screws being properly secured. Spot check several capscrews and nuts for proper torque. If any are found loose, a more thorough inspection must be made. Take corrective action. COMPRESSOR OIL ‘The lubricating and cooling oll must be replaced every 1000 hours of operation o six (6) months, whichever comes first. RUNNING GEAR Every month or 500 miles, tighten the wheel lug nuts to 85 - 95 Ibs.-ft. Every six months the wheel bearings, grease seals and axle spindles should be inspected for damage (corrosion, etc.) or excessive wear. Replace any damaged or worn parts. Repack wheel bearings. Use a wheel bearing grease conforming to specification MIL~G-10924 and suitable for all ambient temperatures. Grease can be replaced in a wheel bearing using a special fixture or by hand as follows. Before installing bearing, place a light coat of grease on the bearing cups which are pressed in the hub,Place a spoonful of grease in the palm of one hand and take the bearing in the other hand. Push a segment of the wider end of the bearing down into the outer edge of the grease pile closest to the thumb. Keep lifting and pushing the bearing down into the edge of the grease pile until grease oozes ‘out both from the top and from between the rollers. Then rotate the bearing to repeat this operation on the next segment. Keep doing this until you have the entire bearing completely filled with grease. NOTICE Excessive grease in the hub or grease cap ‘Serves no purpose due to the fact that there is no way to force the grease into the bearing. The manufacturer's standard procedure is to thoroughly pack the inner and outer bearing with grease and then to apply only a very small amount of grease into the grease cap. If bearing adjustment is required or the hub has been removed for any reason, the following procedure must be followed to ensure a correct bearing adjustment of 0.001 to .012 free play. 1. While rotating hub slowly to seat the bearings, tighten’ spindle nut to approximately 15 Ibs.-ft. Grasp the tire at the top and bottom and rock, in and out ‘There should be no evidence of looseness {free play) at the bearing 2. Loosen nut to remove preload torque. Do not rotate hub. 3. Finger tighten nut untiljust snug. Loosen nut Until the first nut castellation lines up with cotter pin hole in spindle. Insert cotter pin. 4. Ensure a definite but minimal amount of free play by rocking the tire. 6. _Nutshould be free to move with only restraint being the cotter pin Book 35392893 (5/00) G8) RECEIVER-SEPARATOR SYSTEMS. High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. + Open service valve at end of machine. + Ensure pressure is relieved, with BOTH: - Dischargeair pressure gaugereads zero (0). = No air discharging from service valve. ‘When draining oil, remove plug from bottom of separator tank. ‘When adding oil, remove and replace (make tight) plug on side of separator tank. In the compressor lubricating and cooling system, ‘separation of the oil from the compressed air takes place in the receiver-separator tank. As the ‘compressed air enters the tank, the change in velocity and direction drop out most of the oll from the air. Additional separation takes place in the oil separator element which is located in the top of the tank. Any oil accumulation in this separator elerient is continuously drained off by means of a scavenge tube which returns the accumulated oil to the system,The life of the oil separator element is dependent Upon the operating environment (soot, dust, etc.) and should be replaced every twelve months or 2000 hours. To replace the element proceed as follows: + Ensure the tank pressure is zero. + Disconnect the hose from the scavenge tube. + Remove scavenge tube from tank cover. + Disconnect service line from cover. + Remove cover mounting screws. + Remove cover and element. + Remove any gasket material lefton cover or tank. + Install new element. NOTICE Donot remove staples from th connection. [—— STRAIGHTEDGE f + Place a straightedge across top of element and measure from bottom of straightedge to bottom of element (See Fig. 4.1). + Replace scavenge tube in cover (cover is still off of tank). + Measure from bottom of cover to end of scavenge tube. Measurement shouldbetrom 1/8" to 1/4" less than the element measurement. If not, cut to size. ‘+ Remove scavenge tube. + Reposition cover (use care not to damage gaskets). + Replace cover mounting screws: tighten in a crisscross pattern. + Reconnect service line. Replace scavenge tube. Reconnect hose. * Close service valve. Start unit and look for leaks. When replacing the element, the scavenge lines, orifice, filter, and check valve should be thoroughly cleaned and the oil changed. TANK TOP Oo} tie t aeven ee 1 J] stowoseser To we eee ELEMENT MEASUREMENT = — SEPARATOR TANK cay, Book 35392893 (5/00) (9)High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. The scavenge line originates atthe receiver-separator tank cover and terminates at the compressor airend near the oilfiter element. An orifice check valve is located on the scavenge tube. Once a year or every 2000 hours of operation, Whichever comes first, replace the separator element and clean the scavenge ofifice/check valve. NOTE: Excessive oil carry-over may be caused by an oll-logged separator element. Do not re- place element without first performing the fol- lowing maintenance procedure: 4. Check oil level. Maintain as indicated earlier in this section. 2. Thoroughly clean scavenge line, any orifice and check valve. 3. Assute minimum pressure valveforfice is operational 4, Run unit at rated operating pressure for 30 to 40 minutes to permit element to clear itself, EXTERIOR FINISH CARE This unit was painted and heat cured at the factory with a high quality, thermoset polyester powder coating. The following care will ensure the longest possible life from this finish, 1. Ifnecessary to remove dust, pollen, etc. from housing, wash with water and soap or dish washing liquid detergent. Do not scrub with a rough cloth, pad, etc. 2. If grease removal is needed, a fast evaporating alcohol or chlorinated solvent can be used. Note: This may cause some dulling of the paint finish. Book 35392893 (5/00) (40) 3. Ifthe paint has faded or chalked, the use. ‘of a commercial grade, non-abrasive car wax may partially restore the color and gloss, Field Repair 1. The sheet metal should be washed and clean of foreign material and then thoroughly dried. 2, Clean and remove all grease and wax from the area to be painted using Duponts 3900S Cleaner prior to sanding. 3. Use 920 grit sanding paper to repair any scratches or defects necessary. 4. Scuff sand the entire area to be painted with a red scotch brite pad. 5. Wipe the area clean using Duponts 3900S. 6. Blow and tack the area to be painted. 7. Apply a smooth coat of Duponts 1854S Tuffcoat Primer to all bare metal areas and allow to dry. 8 Apply 2 medium - wet coats of Duponts 2288 Adhesion Promoter over the entire area to be painted, with a § minute flash in between coats. 9. To apply the texture coat, use Duponts 1854S Tuffcoat Primer. The proper technique to do this is to spray the Tuffooat Primer using a pressure pot and us2 about 2-5 pounds of air pressure. This will allow the primer to splatter causing the taxtured look. Note: yournust be careful not tc puttoo much primer on at one time, this wil effect the amount of texture that you are trying to achieve. Allow the texture coat to flash for 20 minutes or until dry to touch. 10. Apply any of Duponts Topcoat Finishes such ‘as Imron™ or Centari™ according to the label instructions. Note: To re-topcoat the textured surfaces when sheet metal repairs are not necessary, follow steps 1, 2, 4, 5, 6, 8 and 10.MAINTENANCE SCHEDULE Daily Weekly Monthly [3MOS. 250 hrs. 6MOS. 500 hrs 12M0S, 1000 hrs. Compressor Oi Level Engine Oi Lever "Radiator Coolant Laval Gaugesitamps Fue Tank (iat ood of day) RAN *FualWalor Separator Bran apa] a] of of oy ‘A Gleaner Prectoaner Dumps FaniAtemnator Bats Battery ConnectonsjElecroie Tie Pressure and Surface apapey a} aathost Log Nats Hoses (0 ate, ee) ‘Rutorabe Shutdown System Test ‘i Cleaner Syston Visual Gornpressor 01 Coater Eccl (CLEAN "Engine Radiol Goater Exoror of ay of of of oy (CLEAN Fastonors, Guards ir Cleaner Elements FueifWater Separator Element Compressor Oi Fiter Eioment Compressar OF Wools (bearings, seal, ot) Engine Godan Test ape] a} a] a] = Shutdown Switch Setings Test [Scavenger Orlice & Related Parts CLEAN (Oi Separator Elomont Tis (running, brake, & tan) car Pirie Eye Bats car [Engine (Ol changes, ters, et) Refer 1o Engine Operator Manual this Book *Disregard if not appropriate for this particular machine. replace, C=check (adjust if necessary), WI=OR when indicated, CBT = Refer to specific sections of the operator's manual for more information. Book 35392893 (5/00) (4) heck before towing.SECTION 7 - LUBRICATION GENERAL INFORMATION. Lubrication is an essential part of preventive main- tenance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit require more frequent lubri- cation than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency of their application be explicitly fol- lowed. Periodic lubrication of the moving parts re- duces to a minimum the possibility of mechanical failures. ‘The Preventive Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed. A regular service program should be developed to include all items and fluids. These intervals are based on average operating conditions. In the event of extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than, specified may be necessary. Details concerning lubrication of the running gear are in Maintenance Section. All fiters and fiter elements for air and compressor lubricant must be obtained through Ingersoll-Rand to assure the proper size and fitration for the com- pressor. (COMPRESSOR OIL CHANGE ‘These units are normally furnished with an initial supply of ol sufficient to allow operation of the unit, for approximately 6 months or 1000 hours, whichev- ercomes fist. Ifa.unithas been completely drained of alll, it must be refilled with new oil before it is Placed in operation. Refer to specifications in Lu- brication Table NOTICE ‘Some oil types are incompatible when mixed and result inthe formation of varishes, shellacs, or lac- ‘quers which may be insoluble. Such deposits can cause serious troubles including clogging of the fi- ters. Where possible, do NOT mix oils of different types and avoid mixing different brands. A type or brand change is best made atthe time of a complete il drain and refill. Book 35392883 (5/00) (#2) If the unit has been operated for the time’ hours ‘mentioned above, it should be completely drained fool, Ifthe unit has been operated under adverse conditions, or after long periods in storage, an earl er change period may be necessary as oil deterio- rates with time as well as by operating conditions. High pressure air can cause severe injury or death from hot oil and flying parts. Always re- lieve pressure before removing caps, plugs, covers or other parts from pressurized air sys- tem. Ensure the following conditions are met: = Discharge air pressure gauge reads zero (0). = No air discharging from an “open” manual blowdown valve. ‘An oil change is good insurance against the accu- mulation of dit, sludge, or oxidized oll products. Completely drain the receiver- separator, piping, and oil cooler. Ifthe ollis drained immediately after the unit has been run for some time, most of the sediment will be in suspension and, therefore, will drain more readily. However, the fluid willbe not and care must be taken to avoid contact with the skin or eyes. ‘Atter the unit has been completely drained cf all old, oil, lose the drain valve, Add oil in the specified quantity atthe filer plug. Tighten the filer pug and run the machine to circulate the oil. Check the oil level WHEN RUNNING AT FULL LOAD. If not near the middle of the sight tube, stop the unit and make corrections. DO NOT OVERFILL, NOTICE Ingersoll-Rand provides compressor oil specifically formulated for Portable Compressors and requires the use of these fluids in order to obtain extended limited airend warranty.SECTION 7 - COMPRESSOR RATED OPERATING PRESSURE 100 = s00 Psi tae 35081 ____|s0 psi LUBRICATION so 1 awcttionr ng bin Portable Compressor Fluid Chart H] ee oe or ! Refer to these charts for correct compressor wr tl fluid required. Note that the selection of fluid is aT | ¥ dependent on the design operating pressure a ! of the machine and the ambient temperature t expected to be encountered before the next oil nt on change. PeRronMAICE | spss wr 1 wor ! Yt [Design Operatir “Ambient 10°F Pressure” | Temperature ‘Specification -2°F | 100 psito 300 psi | -10°F to 125°F IF Pro-Tec r ri! conta (-29°01052°C) ji-PRF 21046 SAE 10H factory 100 psito 200s |-40°Ft0126°F | ip Peromance S00 (40°C 1082°6) | Mi-L-46167 scopes | -10rFto125°F | i xHP 505 (29°01 60°0) esr to125°F | mn xnPr001 (19°C1052°0) 40°F 1965" | 1m Peiomance 500 (-aorot0 18-0) | MicL-soter soorsi | sorrtoras:r | inxHProot (0"c152-0) rorrtoes:F | in xnesos (12°C 10 18°C) Recommended Ingersoll-Rand Fluids - Use of these fluids wit original I-R fiters can extend airend warran- (below 10°F ‘Consult Factory ty. Refer to operator's manual warranty section for de- (20) tals or contact your I-R representative Recommended Fluid | _1 Gal. (38 Litre) 5 Gal, (19.0 Litre) 55 Gal, (208.2 Litre) IR Pro-Tec™ 36899698 IR XHP 505 IR Performance 500 35982928 IR XHP1001, 196899706 35965188 ‘95382936 35612738 36899714 35365170 35982944 35300516 Book 3539289 (5/00) (3)SECTION 8 - Trouble Shooting INTRODUCTION Trouble shooting for a portable air compressor is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction, The trouble shooting chart that follows includes some of the problems that an operator may encounter during the operation of a portable compressor. The chart does not attempt to list all of the troubles that may occur, nor does it attempt to ive all of the answers for correction of the problems. The chart does give those problems that are most aptto ocour. To usethe ‘rouble shooting chart: ‘A. Find the “complaint” depicted as a bold heading, Follow down that column to find the po- tential cause or causes. The causes are listed in order (1,2,3 etc.) to suggest an order to follow in trouble shooting. ACTION PLAN A. Think Before Acting Study the problem thoroughly and ask yourself these questions: (1) What were the warning signals that preceded the trouble? Has a similar trouble occurred before? What previous maintenance work has been done? Ifthe compressor wil still operate, isit safe to continue operating itto make further checks? Book 35392893 (5/00) B. Do The Simplest Things First Most troubles are simple and easily corrected. For ‘example, most complaints are “low capacity” which may be caused by too low an engine speed or “compressor over- heats” which may be caused by low oil level. ‘Always check the easiest and most obvious things first; following this simple rule will save time and trouble. Note: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in Parts List Section, C. Double Check Before Disassembly ‘The source of most compressor troubles can be traced not to. one component alone, but to the relationship of one ‘component with another. Too often, a compressor can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly. Check again to be sure an easy solution to the problem hhas not been overlooked. D. Find And Correct Basic Cause ‘After a mechanical failure has been corrected, be sure to locate and correct the cause of the trouble so the same failure will not be repeated. A complaint of “premature breakdown” may be corrected by repairing any improper wiring connections, but something caused the defective wiring, The cause may be excessive vibration. (4)TROUBLE SHOOTING CHART Bold Headings depict the COMPLAINT - Subheadings suggest the CAUSE lo 1. Unit Shutdown: Out of Fuel ‘Compressor Oil Temp. Too High Engine Water Temp. Too High Engine Oil Pressure Too Low Broken Engine Fan Belt ‘Loose Wire Connection Low Fuel Level Shutdown Switch Detective Discharge Air Temp. Switch Detective Engine Oil Pressure Switch Defective Shutdown Solenoid Maifunctioning Relay + < 16 Volts at Shutdown Solenoid Biown Fuse Engine Malfunctioning Airend Malfunctioning 2. Won't Start/Run: Low Battery Voltage + <16 Volts at Shutdown Solenoid Blown Fuse Matfunctioning Start Switch Defective Safety Bypass Switch Clogged Fuel Fitters Out of Fuel Compressor Oil Temp. Too High Engine Water Temp. Too High Engine Oil Pressure Too Low Loose Wire Connection Defective Discharge Air Temp. Switch Defective Engine Oil Pressure Switch Defective Shutdown Solenoid Malfunctioning Relay Engine Matfunctioning Arend Malfunctioning 3. Engine Temperature Lamps Stays On: Broken Engine Fan Belt Matfunctioning Circuit Board » Ambient Temp. >125°F (52°C) Dirty Operating Conditions. Dirty Cooler * Out of Level >15 degrees Operating Pressure Too High Recirculation of Cooling Air Loose Wire Connection Matfunctioning circuit board, yeater than, < = less than Book 35392893 (5/00) Note: Subheadings suggest sequence to follow troubleshooting. Corrective Action ‘Add CLEAN diesel Fuel ‘See Complaint 10 ‘Check coolant level. necessary, Add. ‘See Complaint 3 and Complaint 4. Replace fan belt Wiggle wires at switches & connector blocks. Make repairs. Replace switch. Replace switch Replace switch. Replace solenoid. Repiace relay. Check battery and alternator. Make repairs. Replace fuse. See Trouble Shooting in Engine Manual See Complaint 10. Check electrolyte level. Check connections. Charge battery and alternator. Make repairs. Replace fuse. Replace switch. Replace swith. Service fiters. See Engine Operator's Manual Add CLEAN fuel. See Complaint 10, Check fluid level. if necessary, Add. See Complaint 3 and Complaint 4. Repair or replace connection Replace switch. Replace switch. Replace solenoid. Replace relay. See Trouble Shooting in Engine Manual See Complaint 10. Replace fan belt set. Replace circuit board. ‘Above spec limit. Move unit to cleaner environment. Clean exterior of cooler. Relocate or reposition unit Reduce pressure to spec. Close side doors. Repair or replace. Replace circut board, @s)6. Engine Oil Pressure Lamp Stays On: Low Oil Level Out of Level >15 degrees ‘Wrong Lube Oil Clogged Oil Filter Element(s) Engine Malfunctioning Loose Wire Connection. Malfunctioning circuit board Engine Temperature Lamps Stays Off: Bulb Burned Out Malfunctioning circuit board Engine Oil Pressure Lamp Stays Off: Bulb Burned Out Malfunctioning circuit board Alternator Lamp Stays On: Loose or Broken Belts Loose Wire Connection Low Battery Voltage Matfunctioning Alternator Matfunctioning circuit board Alternator Lamp Stays Off: Bulb Burned Out Loose Wire Connection Malfunctioning circuit board Unit Fails To Shutdown: Defective Low Fuel Shutdown Switch Detective Discharge Air Temperature Switch Detective Engine Oil Pressure Switch Detective Shutdown Solenoid Matfunctioning Relay Detective Safety Bypass Switch Book 35392893 (5/00) (46) Corrective Action ‘Add oil. Relocate or reposition. See Engine Oil Spec. Change oi Replace element(s). See Trouble Shooting in Engine Manual Repair or replace. Replace circut. Replace circuit board. Replace circuit board. Replace circuit board, Replace circuit board, Tighten or replace belt set. Repair or replace connection, heck electrolyte level. Add if necessary, ‘Check connectors. Clean & tighten. Recharge battery. Repair or replace alternator. Replace circuit board Replace circuit board. Repair or replace connector. Replace circuit board. Pull wire off shutdown solenoid, Replace switch Pull wire off. Replace switch, Pull wire off. Replace switch, Carefully biock air inlet to stop engine. Replace solenoid. Pull wire off shutdown solenoid. Replace relay. Pull wire off shutdown solenoid. Replace defective iter10. Excessive Compressor Oil Temperature: ‘Ambient Temp. > 125°F (52°C) Out of Level > 15 degrees Low Oil Level Wrong Lube Oil Dirty Cooler Dirty Operating Conditions Clogged Oil Filter Elements Loose or Broken Belts Operating Pressure Too High Recirculation Of Cooling Air Malfunctioning Thermostat Malfunctioning Fan Defective Oil Cooler Relief Valve Defective Minimum Pressure Valve Blocked or Restricted Oil Lines Airend Malfunctioning 11. Engine RPM Down: Clogged Fuel Fiter Operating Pressure Too High Incorrect Pressure Reguiator Adjustment Malfunctioning Pressure Regulator Incorrect Linkage Adjustment Dirty Air Fitter Malfunctioning Air Cylinder Wrong Air Filter Element Defective Separator Element Engine Matfunctioning Arend Matfunctioning 12. Excessive Vibration: Rubber Mounts, Loose or Damaged Defective Fan Drive Coupling Defective Engine Malfunctioning Arend Matfunctioning ‘Anti-rumble valve not working. Engine idle speed too low. 13, Low Cem: Dirty Air Fitter Incorrect Linkage Adjustment Incorrect Pressure Regulator Adjustment ‘Matfunctioning Pressure Regulator Malfunctioning Inlet Unloader/Buttertly Valve Malfunctioning Air Cylinder Defective Minimum Pressure Valve Defective Separator Element Wrong Air Filter Element Book 35392893 (5/00) (47) i ‘Above spec limit Relocate or reposition unit. ‘Add oil. Look for any leaks. Check spec in this manual. lean exterior surfaces. Move unit to cleaner environment. Replace elements. Change oil. Tighten or replace bett set. Reduce pressure to spec. Close side doors. Replace belly pan. Replace thermostat in bypass valve. Check fan belt tension. Tighten or replace belt set. Replace valve. Repair or replace valve. Clean by flushing o replace. See Complaint 11, 12, 13, 15, 16 or 16. Clean primary fiter. Replace final fier. Drain tanks. ‘Add CLEAN fuel. Reduce pressure to spec limit. ‘See Section 6 in this manual. Replace regulator. ‘See Section 6 in this manual. Ciean or replace elements. Replace air cylinder and adjust per Section 6 Install correct element. Install new element per page 21 ‘See Trouble Shooting in Engine Manual. Refer to Airend Rebuild Manual. Tighten or replace. Replace fan. Replace coupling. ‘See Trouble Shooting in Engine Manual ‘See Complaint 15 and 17. Repair or Replace. Raise "No Load” speed per Section 6. Clean or replace elements. ‘See Section 6 in this manual. ‘See Section 6 in this manual. Replace regulator. Inspect valve, Make adjustment per Section 6. Replace air cylinder. Repair or replace valve. Install new element per Page 21 Install correct element14, Short Air Cleaner Life: Dirty Operating Conditions Inadequate Element Cleaning Incorrect Stopping Procedure Wrong Air Filter Element ll Pump Drive Coupling 15. Excessive Oil in Air: High Oil Level Out of Level > 15 degrees Clogged Scavenge Orifice ‘Scavenge Tube Blocked Defective Scavenge Check Valve Sep. Tank Blow Down Too Quickly Defective Minimum Pressure Valve 16. oi! Seal Leak: Contaminated Lube Oil Blocked or Restricted Oil Line(s) Malfunctioning Seal ‘Scored Shaft 17, WiILNot Unioad: Leak in Regulator Piping Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Malfunctioning Inlet Butterfly Valve Ice in Regulation Lines/Orifice 18, Oil in Air Cleaner: Incorrect Stopping Procedure il Pump Drive Coupling Discharge Check Valve Faulty 19. safety Valve Relieves: Operating Pressure Too High Leak in Regulator Piping Incorrect Pressure Regulator Adjustment Malfunctioning Pressure Regulator Malfunctioning Inlet Unloader/Butterfly Valve Defective Safety Valve Detective Separator Element Ice in Regulation Lines/Orifice Book 35392893 (5/00) (a Corrective Action Move unit to cleaner environment. Install new element. Read procedure in this manual. Install proper element. Inspect coupling. If necessary, replace coupling. Read procedure in this manual. Relocate or reposition unit. Remove scavenge orifice. Clean and Replace. Remove scavenge tube. Clean and Replace. Remove check valve. Replace with new valve. Allow unit to blow down automatically Remove valve. Repair valve and replace. Drain and flush system. Add new CLEAN oil Remove, clean and replace line(s). Refer to Airend Rebuild Manual ‘See instructions in new seal kit. Find and repair leak(s). Refer to Section 6 in this manual. Replace regulator. Inspect valve fit. Readjust per Section 6. Apply heat toline(s) and or orifice. Read Procedure in this manual. Inspect coupling. Replace if necessary. Replace. Reduce pressure to spec limit. Repair leak(s). Refer to Section 6 in this manual. Replace regulator. Inspect vaive fit. Readjust per Section 6. Replace safety valve. Remove element, Install new. Apply heat to lines and/or orifice. 8)SECTION 9 - PARTS ORDERING GENERAL This publication, which contains an illustrated parts breakdown, has been prepared as an aid in locating those parts which may be required in the mainte- nance of the unit. All of the compressor parts, listed in the parts breakdown, are manufactured with the ‘same precision as the original equipment. For the greatest protection always insist on genuine Inger- soll-Rand Company parts for your compressor. NOTICE Ingersoll-Rand Company can bear no responsibil ity for injury or damages resulting directly from the Use of non-approved repair parts. Ingersoll-Rand Company service facilities and parts are available worldwide. There are Ingersoll- Rand Company Construction Equipment Group Sales Offices and authorized distributors located in the principal cities of the United States. In Canada ‘our customers are serviced by the Canadian Inger- soll-Rand Company, Limited. Thereare also Inger- soll-Rand International autonomous companies and authorized distributors located in the principal Cities throughout the free world Special order parts may not be included in this ‘manual, Contact the Mocksville Parts Department with the unit serial number for assistance with these special parts, DESCRIPTION ‘The illustrated parts breakdown ilustrates and lists the various assemblies, subassemblies and detailed parts which make up this. particular machine. This covers the standard models and the ‘more popular options that are available. ‘Aseries ofillustrations show each part distinetlyand in location relative to the other parts in the Book 35392893 (5/00) (49) assembly. The part number, the description of the part and the quantity of parts required are shownon eachillustration or on adjacent page. The quantities specified are the number of parts used per one assembly and are not necessatily the total number of parts used in the machine, Where no quantity is specified the quantity is assumed to be one. Each description of a partis based upon the “noun first” method, e., the identifying noun or item name is always the first part of the description. The noun ame is generally followed by a single descriptive modifier. The descriptive modifier may be followed by words or abbreviations such as upper, lower, inner, outer, front, rear, RH, LH, etc. when they are essential. In referring to the rear, the front or to either side of the unit, always consider the drawbar end of the Unit as the front. Standing at the rear of the unit facing the drawbar (front) will determine the right and left sides. FASTENERS Both SAE/inch and |SO/metric hardware have been used in the design and assembly of these units. In the disassembly and reassembly of parts, extreme care must be taken to avoid damaging threads by the use of wrong fasteners. In order to clarify the proper usage and for exact replacement parts, all standard fasteners have been identified by part number, size and description. This will erable a customer to obtain fasteners locally rather than ordering from the factory. These parts are identified in tables that will be found at the rear of the parts illustrations. Any fastener that has not been identified by both part number and size's a specially engineered part that must be ordered ty part number to obtain the exact replacement part.NOTICE Do not paint over safety warnings or instruc- tional decals. If safety warning decals become legible, immediately order replacements from the factory. Part numbers for original individual decals and their mounting locations are shown within Parts List Section. These are available as long as a particular model is in production, Afterwards, service sets of exterior decals and current production safety warning decals are available. Contact the Product Support Group at Mocksville for your particular needs and availabilty, HOW TO USE PARTS LIST a. Turnto Parts List. b. Locate the area or system of the compressor in which the desired partis used and find ilus- tration page number. ©. Locate the desired part on the illustration by vi- sual identification and make note of part num- ber and description. HOW TO ORDER ‘The satisfactory ordering of parts by a purchaser is greatly dependent upon the proper use of all available information. By supplying your nearest sales office, autonomous company or authorized distributor, with complete information, you will enable them to fill your order correctly and to avoid any unnecessary delays. In order that all avoidable errors may be eliminated, the following instructions are offered as a guide to the purchaser when ordering replacement parts a. Always specify the model number of the unit ‘as shown on the general data decal attached to the unit. b. Always specify the serial number of the unit THIS IS IMPORTANT. The serial number of the unit will be found stamped on a plate at- Book 35392893 (5/00) 0) ‘ached to the unit. (The serial number on the Unit is also permanently stamped in the metal of the frame side rail) ©. Always specify the number of the parts list Publication. d. Always specify the quantity of parts required. 2. Always specify the part number, as well as the description of the part, or parts, exactly as it is given on the parts list ilustraton. Inthe event parts are being returnedto your nearest sales office, autonomous company or authorized distributor, for inspection or repair, itis important to include the serial number of the unit from which the parts were removed. ‘TERMS AND CONDITIONS ON PARTS ORDERS Acceptance: Acceptance of an offer is expressly limited to the exact terms contained herein. If pur- chaser’s order form is used for acceptance of an of- for, itis expressly understood and agreed that the terms and conditions of such order form shall not apply unless expressly agreed to by Ingersoll-Rand Company (‘Company’) in writing, No additional or contrary terms will be binding upon the Company Unless expressly agreed to in writing ‘Taxes: Any tax or other governmental charge now or hereafter levied upon the production, sale, use or shipment of material and equipment orderedor sold is not included in the Company's price and will be ‘charged to and paid for by the Purchaser. Shipping dates shall be extended for delays due to acts of God, acts of Purchaser, acts of Goverment, fires, floods, strikes, rot, war, embargo, transporta- tion shortages, delay or default on the part of the Company's vendors, or any other cause beyond the Company's reasonable control. Should Purchaser request special shipping instruc- tion, such as exclusive use of shipping facilities, cluding air freight when common carrier has been ‘quoted and before change order to purchase order ‘can be received by the Company, the additional charges will be honored by the Purchaser.Warranty: The Company warrants that parts man- Ufactured by it will be as specified and will be free from defects in materials and workmanship. The Company's liability under this warranty shall be lim- ited to the repair or replacement of any part which was defective at the time of shipment provided Pur- chaser notifies the Company of any such defect promptly upon discovery, but in no event later than three (8) months from the date of shipment of such part by the Company. The only exception to the pre- vious statement is the extended warranty as it ap- plies to the special airend exchange program. Repairs and replacements shall be made by the ‘Company F.0.B. point of shipment. The Company shall not be responsible for costs of transportation, removal or installation. Warranties applicable to material and equipment supplied by the Company but wholly manufactured by thers shall be limited to the warranties extended tothe Company by the manufacturer which are able to be conveyed to the Purchaser. Delivery: Shipping dates are approximate. The Company will use best efforts to ship by the dates specified; however, the Company shall not be liable for any delay or failure in the estimated delivery or shipment of material and equipment orfor any dam- ages suffered by reason thereof. The company makes no other warranty or repre- sentation of any kind whatsoever, expressed or im- plied, except that of tte, and all implied warranties, including any warranty of merchantability and fit- ness for a particular purpose, are hereby dis- claimed. Book 35392893 (6/00) (1) Limitation of Liability: ‘The remedies of the Purchaser set forth herein are: exclusive, and the total liability of the Compeny with respect to this order whether based on contract, warranty, negligence, indemnity, strict liability or otherwise, shall not exceed the purchase price of the part upon which such liability is based. ‘The Company shall in no event be liable to the Pur- chaser, any successors in interest or any beneficia- ry ofthis order for any consequential, incidental, in- direct, special or punitive damages arising out of this order or any breach thereof, or any defect in, or failure of, or maifunction of the parts hereunder, whether based upon loss of use, lost profits or reve- ‘ue, interest, lost goodwill, work stoppage, impair- ment of other goods, loss by reason of shutdown or ‘non- operation, increased expenses of operation or claims of customers of Purchaser for service inter- ruption whether or not such loss or damage is based on contract, warranty, negligence, indemnity, strict liabilty or otherwise.AIREND EXCHANGE PROGRAM Your Ingersoll-Rand Company Construction Equip- ment Group Sales Offices and authorized distribu- tors as well as Ingersoll-Rand International autono- mous companies and authorized distributors now have an airend exchange program to benefit porta- ble compressor users. On the airend exchange program the exchange price is determined by the age and condition of the airend and may be classified by one of the following categories. Category “A”: The airend must not be over two years old and must have reusable rotor housing(s) and rotor(s) Category “B”: The airend must be between two and five years old and returned with two or more re- usable major castings. Category “C: The airend must be over five years. old. Book 35392893 (5/00) (52) Your nearest sales office, autonomous company or authorized distributor must first contact the Parts Service Department at the factory at which your portable air compressor was manufactured for an airend exchange number. The airend must be tagged with this preassigned number and returned to the factory prepaid. The airend must be intact, with no excluded parts, otherwise the exchange agreement may be cancelled. The warranty on an ‘exchange or factory rebuilt airend is 365 days. Airends being returned to the factory in con- nection with a WARRANTY CLAIM must be pro- cessed through the Customer Service Depart- ment. If returned without a Warranty MRR (Material Return Request) Number, no warranty claim will be considered.SECTION 10 - PARTS LIST CONTENTS Frame & Running Gear Drawbar Complete Running Gear Complete Electric Brake Wiring Electric Brake Shoes Engine Complete Liquid Cooling Complete Airend Complete Airend Assembly Unloader Assembly Exhaust Complete Air Service Complete Seperator Tank Complete Minimum Pressure Valve Fuel Tank Complete Air Intake Complete Air Cleaner Assembly Engine Air Cleaner Assembly Battery Assembly Air Piping Oil Piping Wiring Diagram 2 Tail Light Wiring Diagram Inst/Control Panel Enclosure Complete Foam Insulation Complete Decal Location Book 35392898 (4/01) 5CPN. ary DESCRIPTION 36888071 36723048 36799724 35284074 96730395 36887545 35304047 35369313 35374834 95934899 36769743 36844710 36793040 36879211 36779791 36765121 95935052 95148071 35145234 35148204 36880995 36879195 195935003 c D E F G H J K L M N Pp Q R s T U v w x Book 35392898 (4/01) FRAME RUNNING GEAR RUNNING GEAR w/ ELECTRIC BRAKES TIRE AND WHEEL ASSY. ‘SCREW, HEX HD M12-2.5 X50 ‘SUPPORT, RADIATOR BOTTOM NUT, HEX NYLOC M12 FOLDING STEP SCREW WASHER NUT LIFTING BAIL SCREW NUT LIFTING EYE SCREW WASHER TIRE WHEEL VALVE STEM ‘SCREW, HEX FLANGE M10-150 NUT, HEX FLANGE M10 WASHER, FLAT 35 PRIOR TO S/N 320787 BEGIN with S/N 320787 TNGERSOLL-RAND COMPANY 95392893-03 FRAME & RUNNING GEAR 4fo1_H.TNGERSOLL-RAND COMPANY 35392893-04 |3/97_A Book 35392898 (4/01) aoaCPN. ary DESCRIPTION vow» E FE G H J K L M N 36843803 36763670 35356526 96752228 84443577 35609544 36757284 39179072 36879211 196700885 35605187 35376094 35610377 38372432 Book 35392898 (4/01) DRAWBAR, SCREW NUT JACK ASSEMBLY JACK ASSEMBLY QUICK RELEASE PIN MOUNTING PLATE SCREW, M16 X 50 NUT, HEX FLANGE M16 NUT PINTLE EYE SCREW SAFETY CHAIN COUPLING LINK Ts {PRIOR TO S/N 309681} {BEGIN WITH S/N 309681} TNGERSOLL-RAND COMPANY .95392893-05 DRAWBARwa DRAWBAR END RUNNING GEAR COMPLETE PART NO. 36723948 DEXTER 8-LUG PRIOR TO S/N 320787 Book 35392898 (4/01)3 a 2 CPN. DESCRIPTION A B ° D E F G H J K L M N Pp Q R s Fr U v w x Y 36316850 95315126 36316959 35316868 36316876 95316884 36770709 35316900 36316918 35315209 95815217 95315225 96316926 95316967 95315258 95361898 96315274 35326958 35315340 35315357 35326966 35315365 95318373 Book 35392898 (4/01) AXLE SPRING U-BoLT GREASE SEAL BEARING CONE BEARING CUP HUB: BEARING CUP BEARING CONE SPINDLE WASHER SPINDLE NUT COTTER PIN GREASE CAP TIE PLATE NUT WHEEL STUD WHEEL NUT FRONT HANGER SHACKLE BOLT SHACKLE NUT REAR HANGER, KEEPER BOLT KEEPER NUT = RUNNING GEAR COMPLETE PART NO. 36723948 DEXTER 8-LUG PRIOR TO S/N 320787 TNGERSOLL-RAND COMPANY 35392893-07 RUNNING GEAR COMPLETE.wa DRAWBAR END 35392893-06 Book 35392898 (4/01) ~~3 a 2 CPN. DESCRIPTION 36316850 AXLE 95315126 SPRING 36136959 U-BoLT 36865962 GREASE SEAL 36316876 BEARING CONE 95316884 BEARING CUP 35388669 HUB: 35316900 BEARING CUP 36316918 BEARING CONE 95315209 SPINDLE WASHER 95815217 SPINDLE NUT 95893792 GREASE CAP 95916967 TIE PLATE 35315258 NUT 35361898 WHEEL STUD 95315274 WHEEL NUT 95326958 FRONT HANGER 35315340 ‘SHACKLE BOLT 35315357 SHACKLE NUT 35326966 REAR HANGER, 95315365 KEEPER BOLT 95315373 KEEPER NUT 36855377 LH BRAKE ASSEMBLY 36855385 RH BRAKE ASSEMBLY 95315225 PIN, COTTER 95391135 PLUG, EZ LUBE A B ° D E F G H J K L M N Pp Q R s Fr U v w x Y BEGIN with S/N 320787 TNGERSOLL-RAND COMPANY ELEC BRAKE AXLE. Peoowou | 35392893-07 |4/01_B Book 35392898 (4/01) nol* USE (2) EXISTING GROWMETS TNGERSOLL-RAND COMPANY ELEC BRK w/2-UIGHTASSY Feoowcu | 9599280008 Book 35392898 (4/01) ~o-3 a 2 CPN. QTY _DESCRIPTION 36788081 TAIL LIGHT 96895282 HARNESS, ELECTRIC BRAKE 36787968 GROMMET 36896264 HARNESS, TAIL LIGHT 38375427 ‘TERMINAL, SNAP 96315944 ‘SWITCH, BREAKAWAY 35287572 TERMINAL, SPLICE 35346337 TERMINAL, LUG 35253038 CLAMP, 3/8 36799724 GEAR, ELEC BRAKE w/ RUNNING 92368687 ‘SCREW, TAPPING M06-100 X 14 36794774 GROMMET, SCREW 36789261 HARNESS, 6 CONDUCTOR CABLE (STD LENGTH DRAWBAR) 36787216 HARNESS, 6 CONDUCTOR CABLE (EXTENDED LENGTH DRAWBAR) 35225093 CLAMP, 1/2 35252451 SCREW, LOCK 1/4-20X 1 35144492 NUT, LOCK 1/4-20 35225077 CLAMP, 5/8 ‘36895860 LIGHT, LICENSE 36782637 ‘SCREW, HEX SHT METAL #10 X 1 zZzerxcronmooar Pp Q R s Fr uU TNGERSOLL-RAND COMPANY ELEC BRK w/2-UIGHTASSY Peoowcu | 35392893-09 |4/01_C| Book 35392898 (4/01) neali) SECTION A - A 35392893-10 Book 35392898 (4/01) csCPN. QTY _DESCRIPTION 36393859 LH BACKING PLATE ASSEMBLY 95393867 RH BACKING PLATE ASSEMBLY 36895803 BRAKE SHOE KIT 36895811 MAGNET KIT 36390913 PARKING BRAKE LEVER 35393726 ADJUSTING SCREW KIT 35391069, ADJUSTING SLOT PLUG 36895829 LH PARK BRAKE LEVER KIT 36895837 RH PARK BRAKE LEVER KIT TNGERSOLL-RAND COMPANY ELEC BRAKE SHOE Peoowou | 35392893-11_|4/01_B Book 35392898 (4/01) eala z i ac 4 S z a a a Book 35392898 (4/01)3 a 2 CPN. QTY _DESCRIPTION 36881688 ENGINE 36887578 LEVER, EXT ENG SPEED 35322445 GUIDE, ROD / SPRING 36763688 SCREW, HEX M12-175 X 35 95934931 WASHER, FLAT 36840254 NUT, FLANGE HD M12 195279527 ELBOW 96710488 SCREW M10-1.50 X 80 195935037 WASHER, FLAT 36887578 BRACKET, AIR CYLINDER MOUNTING 35929721 ‘SPRING, COMPRESSION 35322411 SPRING, COMPRESSION 35322437 MOUNT, SPRING 95594225 CYLINDER, 9923082 NUT, HEX JAM 3/8-24 35922635 BALL JOINT, 1/4-28 35922429 ROD, SPRING THROTTLE 35300532 BEARING, ROD END 7/16-20 35322452 BUSHING, ROD END BEARING 35374669 FUEL ELEMENT WITH WATER SEPARATOR 35974677 ‘SECONDARY FUEL ELEMENT 36387489 OIL FILTER ELEMENT 36845410 FAN 35145242 ‘SCREW, LOCK 1/4-20.X 1 1/4 36288885 BUSHING, 3/8 X 5/8 36761476 ‘SCREW, SHOULDER SOC HD 195923314 NUT, HEX LOCK 5/16-18 195923108 NUT, HEX JAM 3/4-16 35924664 COLLAR, 3/8 195925939 NUT, HEX LOCK 1/4-28 195926028 NUT, HEX JAM &/16-20 35144492 NUT, LOCK WASHER HD 1/4-20 35307818 ‘SCREW, HEX M06-100 X 10 195935029 WASHER, FLAT A B c D E F G H J K L M N Pp Q R s T uU v w x Y Zz AL a2 AB eeeReaE TNGERSOLL-RAND COMPANY ENGINE COMPLETE 35392893-13 |3/97_G Book 35392898 (4/01) molBook 35392898 (4/01)CPN. 3 DESCRIPTION 36887644 36842953 36888063 35140409 36843044 36843951 36887552 36887560 36887602 36843993 36887610 38360775 92368687 36846350 195935029 35144336 35252600 35221662 35222017 36845600 35360775 35222538 35296342 36846723 96702055 195934998, 35279025 36763704 95935003 96700877 96700869 RADIATOR: OIL COOLER PLATE, BAFFLE FOAM, 1/4 X 3/4 (2 PCS) RADIATOR SUPPORT OIL COOLER SUPPORT TOP FAN SHROUD BOTTOM FAN SHROUD RADIATOR INLET HOSE FAN SHROUD RADIATOR OUTLET HOSE HOSE SCREW FAN GUARD WASHER, SCREW NUT CLAMP, 34mm - 57mm, CLAMP, 2 1/4 - 3 OVERFLOW TANK HOSE CLAMP, SUPPORT CLAMP FAN SHROUD BRACKET ‘SCREW, HEX Mo8-125 X 20 WASHER, FLAT 3/8 SCREW, TAPPING Mo8-125 X 20 ‘SCREW, HEX M12-175 x 30 WASHER, FLAT 1/2 NUT, HEX M12 NUT, HEX Mos BIN Q R 8 F u TNGERSOLL-RAND COMPANY [AIR SERVICE COMPLETE 35392893-29 |5/99_H Book 35392898 (4/01) 5CPN. QTY _DESCRIPTION 54466701 SEPARATOR TANK (P600, HP450,XP525 ONLY) 54466735, ‘SEPARATOR TANK (VHP400 ONLY) 36845469 ELEMENT 36794147 SCAVENGE TUBE 36329309 LENZ FITTING 23A7S8 BUSHING 36840411 CHECK VALVE 36795680 BALL VALVE 35826636 SAFETY VALVE (P-600WCU) 38596972 ‘SAFETY VALVE (VHP-400WCU) 36784114 SAFETY VALVE (HP-450WCU) 36784114 SAFETY VALVE (XP-525WCU) 36824649 GASKET 23781221 BUSHING 36860468 FITTINGS, 92121532 SIGHT GLASS 38356500 CONNECTOR 35A2D3272Z1 SCREW 35279942 O-RING 35579630 PLUG 35305275 STREET TEE 35279777 ELBOW 67A7MEZt ELBOW (VHP-400 ONLY) xeZO™MIOD L M N Pp Q R s T u v w TNGERSOLL-RAND COMPANY ‘SEP TANK COMPLETE 35392893-31 |7/00_G Book 35392898 (4/01) ~85-TNGERSOLL-RAND COMPANY MIN PRESS VALVE 35392893-32 |3/97_A Book 35392898 (4/01) nealCPN. ary DESCRIPTION eratmmooay 35367333 36367317 35367358 36367325 36367374 36367366 1150621 35367390 35367341 35598770 Book 35392898 (4/01) MIN PRESS VALVE BODY CV ASSEMBLY SPRING PISTON O-RING SPRING WASHER, INSERT CAP MIN PRESS VALVE ASSEMBLY “a TNGERSOLL-RAND COMPANY MIN PRESS VALVE 35392893-33wa DRAWBAR END AD ROM TNGERSOLL-RAND COMPANY Book 35392898 (4/01)36843746 FUEL TANK 36845550 FUEL TANK CUSHION 35279934 JIC ELBOW, 90 DEGREE 36282995 SUPPLY HOSE 35282078 RETURN HOSE 35322668 ELBOW BARBED 35296342 CLAMP 35369347 TANK CONNECTOR 95956484 HOSE, VENT 35369330 SILENCER CONNECTOR 35322395, SILENCER 35253038 CLAMP 96845543 REAR FUEL TANK CUSHION 38225077 TUBE CLAMP 36279025 SCREW, HEX M08-1.25 X 20 36845402 FUEL LEVEL SENDER 36842102 SCREW 36845014 FUEL FILLER CAP 36845022 FUEL TANK STRAINER CPN. QTY _DESCRIPTION 1 1 1 1 36852606 BRACKET 95974834 ‘SCREW, HEX Mo8-1.25 X 20 36901396 WASHER, FLAT Mos 96700869 NUT, HEX Mos 36890093 CONDUIT, CONVOLUTED 35190487 BRACKET, HOSE CLAMP. 35225077 clamp 35144336 SCREW, LOCKING 5/16-18 X 3/4” ‘35252600 NUT, LOCKING 5/16-18 95972204 ‘SCREW, HEX 7/16-20 X 1” A B c D E F G H J K L M N P Q R s T u v w x Y Zz Al AQ Ag AA AS > TNGERSOLL-RAND COMPANY FUEL TANK COMPLETE 95392893-35 |6/98_E Book 35392898 (4/01) “S= DRAWBAR END PRIOR TO S/N 320381 TNGERSOLL-RAND COMPANY NAIR INTAKE COMPLETE 35392893-36 Book 35392898 (4/01) -90-DRAWBAR END = BEGIN with S/N 320381 TNGERSOLL-RAND COMPANY NAIR INTAKE COMPLETE 35392893-36 Book 35392898 (4/01) ~~CPN. QTY _DESCRIPTION 36789543 ENGINE AIR CLEANER 36845873 ENG AIR CLEANER BRKT 36845881 ‘SPRT ENG AIR CLEANER BRKT 35135300 ELBOW 36791226 TUBE 36845907 ELBOW 36849487 TUBE 35287358 HOSE, HUMP, 35820844 MOUNTING BANDS 35374834 SCREW, HEX MO8-125 X 25 95934998 WASHER , FLAT 196700869 NUT, HEX Mos 36279025 ‘SCREW, TAP MoB-125 X 20 36845890 AE AIR CLEANER 35803147 MOUNTING BANDS 96844728 AE AIR CLEANER BRKT 96701495 SCREW, M12-1.75 X 25 195935003 WASHER, FLAT 1/2 35274703 REDUCING ELBOW 36279553 4.5 CLAMP 36161025 5.5 CLAMP 195956199 ELBOW, 45() 1/8 NPT 36847838 SWITCH, VAC 36273408 SCREW, HEX M08-1.25 X 20 36881886 NUT, FLANGE HD Mo8-1.25 A B ° D E F G H J K L M N P Q R 8 = u v w x Y Zz A PRIOR TO S/N 320381 TNGERSOLL-RAND COMPANY "AIR INTAKE COMPLETE 35090080-97 Book 35392898 (4/01) ~92-CPN. ary DESCRIPTION A B ° D E F G H J K L M N P Q R 8 T u v w x Y Zz A 36789543 36845873 36845881 36136300 36791226 36845907 96849487 35287358 35820844 35374834 95934998 196700869 36279025 36845890 35803147 84733647 35274703 36279553 36161025 195956199 36847838 36273408 36881886 Book 35392898 (4/01) ENGINE AIR CLEANER ENG AIR CLEANER BRKT ‘SPRT ENG AIR CLEANER BRKT ELBOW TUBE ELBOW TUBE HOSE, HUMP, MOUNTING BANDS SCREW, HEX MO8-125 X 25 WASHER , FLAT NUT, HEX Mos ‘SCREW, TAP MoB-125 X 20 AE AIR CLEANER MOUNTING BANDS AVE AIR CLEANER BRKT REDUCING ELBOW 4.5 CLAMP 5.5 CLAMP ELBOW, 45() 1/8 NPT SWITCH, VAC SCREW, HEX M08-1.25 X 20 NUT, FLANGE HD Mo8-1.25 BEGIN with S/N 320381 TNGERSOLL-RAND COMPANY NAIR INTAKE COMPLETE 95392803-37 ~ 03©) orriona. LK) AJE AIR CLEANER ASSEMBLY 36845899 TNGERSOLL-RAND COMPANY ‘AE AIR CLEANER ASSY. 95392893-38_|3/97_B Book 35392898 (4/01) LSCPN. QTY _DESCRIPTION 35384601 AIR CLEANER BODY 35384619 ELEMENT 35384635 COVER 35380823 VAGUATOR VALVE 35380815 NUT ASSEMBLY 95984650 GASKET 35980856 WING NUT 35380864 WING NUT RETAINER 35984627 SAFETY ELEMENT (OPTION) 35384643 NUT ASSEMBLY A B i) D E F G H J K AJE AIR CLEANER ASSEMBLY 36845899 TNGERSOLL-RAND COMPANY 'NE AIR CLEANER ASSY. 35392893-39 |3/97_B Book 35392898 (4/01) 5©) orriona. LK) ENG AIR CLEANER ASSEMBLY 36789543 TNGERSOLL-RAND COMPANY ENG AIR CLEANER ASSY. 35392893-40 |3/97_C Book 35392898 (4/01) calCPN. QTY _DESCRIPTION 35380765 ‘AIR CLEANER BODY 36300375 ELEMENT 35380799 COVER 35380823 \VACUATOR VALVE 35380815 NUT ASSEMBLY 35380849 GASKET 35380856 WING NUT 35380864 WING NUT RETAINER 35300383 SAFETY ELEMENT (OPTION) 35380807 NUT ASSEMBLY Reranmoaa> ENG AIR CLEANER ASSEMBLY 36789543 TNGERSOLL-RAND COMPANY ENG AIR CLEANER ASSY, 95392893-41 Book 35392898 (4/01) aowa DRAWBAR END TNGERSOLL-RAND COMPANY BATTERY ASSEMBLY 35392893-42 |3/97_C Book 35392898 (4/01) aaCPN. DESCRIPTION 36844975 BATTERY, 12 VDC 36853232 BATTERY TRAY 96853257 ANGLE 36853240 J-BOLT 35512425 POSITIVE BATTERY CABLE 35587088 NEGATIVE BATTERY CABLE 36853265 WASHER 35144492 NUT 192368687 SCREW wee678 CLAMP 35258789, JUMPER CABLE 35293075 GROUND STRAP 34M2AB461M3 SCREW 12A5D6Z1 WASHER 36130301 SCREW 12ASD3Z1 WASHER TNGERSOLL-RAND COMPANY BATTERY ASSEMBLY 35392893-43 |3/97_C Book 35392898 (4/01) aoa~pisoHaRGe PRESSURE = e f a a 4 4 enne TNGERSOLL-RAND COMPANY ounces ‘AIRPRING 95392893-44 |6/98_E Book 35392898 (4/01) ~ 100 -CPN. DESCRIPTION THARZGETS 5260241 95602473 1947525921 135598770 95395128 35322379 35280472 36766756 ‘35288038 35001225 ‘6240883 136757573 2aarsizi 136845220 ‘36045212 35256500, ‘35581792 yaa7Zi 3082088 95968827 35248145 as200147 ‘5280092 35279026 35298853 ‘8279827 6347952 "35950090 36896892 ‘35204082 95282946 35310908 5270998 35283468 5531642 35308687 35022346 7aa7Mz2 s9A7S221 ‘ATSIZ) ‘35282920 2aa7S221 yea7ss2i 35965600 ‘ea4ost 35298701 35202124 2aarsszs ‘5907973 135306091 ‘35906100 35283050 sa7a06s 35987919 ELBOW9q) 562-18 TO ~4 JIG W/O-FING HOSE ASSY -4 X14" LG VALVE, BALL 2° NPT NIPPLE, 2¢ NPT X 120016 VALVE, NIN PRESS ST. CONN 2.0 NPT TO -32IC VALVE, BLOWDOWN ST. CONN 26 NPT TO -4 JIC COFIF/MUFE 140° HOSE ASSY 4X97" LG ELBOW, 80) 125 FNPT TO -4 IC SOLENOID VALVE 24 voc ‘STARTER PROTECTION. RED, BUSHING 25 NPT 70.125 NPT TUBE ASSY - BOTTOM TUBE ASSY - TOP ST. CONN, 250-12 X -92 JIG W/O-RING VALVE, BALL 50 NIPPLE, 60 NPT X 1.126. ELBOW, 9] 500 NET TO -6 IC SST. CONN SW NUT .972 NPT TO -6 JIC VALVE, CHECK 25 NPT ST. CONN 275 NPT TO -6 JIC TEE, BRANCH SW. NUT -6 IC ELBOW, s/] 275 NPT TO ~6 JIC ELBOW, 90) SW. NUT.25 NPT TO -6 ELBOW, off 562-18 X ~6 JIC W/O-FING REGULATOR (PeCgWCU & XPS25WCU) REGULATOR (HP4S0WCU) REGULATOR (VHP¢00WCU) ST. CONN 25 NPT TO -6 HOSE ASSY -8X9.5°LG HOSE ASSY -8 X 39° LG ELBOW, 90) 25 NET TO -8I ELBOW. 99] 25 NPT TO -4.IC HOSE ASSY “4 X59" LG ELBOW, 901.125 NPT TO -4 JIC ORIFICE 156 CROSS 25 NPT NIPPLE, 25 NPT X 88 LG PLUG, 25 NPT HOSE ASSY -4 x9" LG RED, GUSH 975 NPT X 1.00LG NIPPLE, 2 NPT X 1.50 LG. BR TEE 25NPT (CHECK VALVE HOSE ASSY -6 X97" LG TEE, SW FUN, -4IC RED BUSHNG 50 NPT TO 25 NPT STREET TEE 50 NPT REDUCER, -8 JIOX -4 JIC NUT, TUBE -BuIC TEE, RUN 1/4 NPT -6.IC REPAIR KIT BLOWDOWN VALVE REPAIR KI” REGULATOR, Book 35392898 (4/01) 101 TNGERSOLL-RAND COMPANY ’AIR PIPING 95392803-45 9/99 _HNote: SEE SHT 9 FOR MATCH POINTS [Al [B ONSN oesy Z Book 35392898 (4/01) vHeocivas TNGERSOLL-RAND COMPANY ‘OIL PIPING 95392893-46_|3/97_E TTITEM C.PN. DESCRIPTION DESCRIPTION {96846061 ST. CONN. 1.625-12 WIO-ING 96844963 TUBE ASSY-UPFER, 26844371 TUBE ASSY-LOVIER 98279777 ELB. CONN. 1.625-12 WiO-RING 95958682 HOSE ASSY 6640411 | CHECK VALVE 96798147 TUBE ASSY 3582900 LENZ FITTING 96037446 RED. BUSH 3/4 NPT - 98 NET ‘36926696 VALVE SAFETY (600) ‘96784114 VALVE SAFETY (HP4SO & XPS28) 95596972 VALVE SAFETY (VHP400) 95005275 ST. TEE 1.0NPT 96940060 RED. BUSH 1.0N°T - SONPT 26065756 SW. SHUTDOWN ‘26060468 SIGHT TUBE FITTING 95824649. GASKET 92121882 TUBE, SIGHT 35579630 PLUG, VENTED 1.625 95279942 O-RING ‘98576570 GASKET {96798680 VALVE BALL, .75 NPT X 1.08-12 ‘96108608 HOSE ASSY 95289191 ELBOW, 4801.6 P25, HP450) {95219861 ELBOW, 90() 1.25 NPT X -20 JIG (VHP-400) ‘96871689 VALVE BYPASS 95278876 ELBOW, 90() 437-20 W/0-RING 12 WIO-RING (P600, HOSE ASSY SW. SHUTDOWN * RELIEF VALVE REPAIR KIT 35388024 ELEMENT REPAIR KIT 35388032 O-RING REPAIR KIT 35388040 Book 35392898 (4/01) 96765121 ‘95095082 96700885 e7es068 se40mn6s 96848281 195940060 ese70667 95983709 5290158 95983211 95944732 6066846 292143 95094683 35291640 95957976 95575570 ‘35642160 35975285 936880596 36897246 35279959 Ts SOREWM 16-2X1G, 45 (4 REQD) WASHER 68 (4 REQ'D) NUTM 16 (4 REGO) SCREW M 16-2X701G. (¢ REGD) O-RING GASKET RED BUSH 1.0 NPT - 50 NPT (xP525, HPaso) VALVE, CHECK, 1.28 NPT (VHP400) NIP, CLOSE 1.25 NPT (VHP400) (CONN, 1.625-12 X 1.25 NPTF (VHPaQ9) ELBOW, GO[ ST, 1.25 NPT (VHP400) ELBOW, 90() 250-12 W/ O-RING HOSE Assy FLANGE HALF (2 REQD) WASHER. 562 (4 REG'D ) SCREW M14-2 X40LG. (4 REQD ) O-RING GASKET Leow SCREWM 16-2 4016, (4FEQD) ELEMENT OILFILTER {PRIOR TOSIN 300624) ELEMENT OIL FILTER {BEGIN WITH SiN 300624) O-RING TNGERSOLL-RAND COMPANY ‘OIL PIPING 35392893-47 |5/99_FNore: SEE SHT 1 FOR MATCH POINTS [A] [B) TNGERSOLL-RAND COMPANY ‘OIL PIPING 95392893-48_|3/97_D Book 35392898 (4/01) adITEM C.PN. DESCRIPTION ITEM CPN. DESCRIPTION asere82r 96795482 35278843 ‘96646087 36846095 5286401 96846111 6846129 96846103 95008622 6846145 95278876 96846137 ‘assoze0s 95976168 ELBOW, 90[ 1.625-12 X -16 JIC W/O-FING we27se HOSE ASSY 96645154 OIL MANIFOLD EXPANDER 497-20 X. 562-18 W/O-RING 38270959 95278571 Book 35392898 (4/01) Boe ELBOW, 90() 562-18 W/O- RING TUBE ASSY TEE BRANCH 562-18 WO-RING TUBE ASSY EXPANDER 75-16 X 875-14 WIO-RING ELBOW, 901) 875-140N/0-FING. TUBE ASSY TEE BRANCH 75-14 WiO-RING TUBE ASSY ELBOW, 901).75-16X -10 JIC WIO-RING TUBE ASSY ELBOW, 200) 437-20 W/O-RING. TUBE ASSY SST. CONN 437-20 X -8 JIG WIO-FING ELBOW, 901] SW NUT 1.312-12X 16 JIC O-RING O-RING TNGERSOLL-RAND COMPANY ‘GIL PIPING 35392893-49_|11/97 Fyosirs STANDARD Dara TNGERSOLL-RAND COMPANY [STD WIRING DIAGRAM 95392893-50 Book 35392893 (4/01) = 106—CPN. DESCRIPTION 96844942 STARTER 36844975 BATTERY 36844975 BATTERY 35376169 DIODE 35376169 DIODE 36376169 DIODE 95376169 DIODE 36376169 DIODE 35376169 DIODE 36793651 25AFUSE 36782464 15AFUSE 96782654 SAFUSE 38577873 START RELAY 35586130 RELAY 38586130 RELAY 35586130 RELAY 95586130 RELAY 36878361 RELAY * FUEL SOLENOID 36840841 START/RUN SOLENOID 36840841 UNLOADER SOLENOID 36841245 HOURMETER 36337435 TOSGLE SWITCH 35255561 PUSH BUTTON SWITCH 35255553 PUSH BUTTON SWITCH 36596436 TEMPERATURE SWITCH 96757581 PRESSURE SWITCH 95327691 TEMPERATURE SWITCH 35255561 PUSH BUTTON SWITCH 36843423 ENG OIL PRESSURE SWITCH 36757573 PRESSURE SWITCH 36865756 THERMAL SENSOR 96771434 DIAGNOSTIC MODULE 96887313 TINER MODULE 36844744 CHASSIS HARNESS 36844769 CONTROL BOX HARNESS. 96887362 ADAPTER HARNESS * FURNISHED BY ENGINE MANUFACTURER, TNGERSOLL-RAND COMPANY 'STO WIRING DIAGRAM 95392803-51 |3/97_F Book 35392898 (4/01) aeDOAN STONED POSW TNGERSOLL-RAND COMPANY ‘STD WIRING DIAGRAM 95392893-52_|5/97_E Book 35392893 (4/01) SLsCPN. DESCRIPTION 35363472 4A FUSE 36844934 ALTERNATOR 35604065 DISCHG PRESS GAGE (P-600WCU) 35612233 DISCHG PRESS GAGE (VHP-400WCU) 36891216 DISCHG PRESS GAGE (HP-450WCU) 36891216 DISCHG PRESS GAGE (xP-525WCU) 35604099 FUEL LEVEL GAGE 35356709 COOLANT PROBE 36774198 RESISTOR 36774198 RESISTOR 36841146 RESISTOR / BULB KIT ‘35968992 RESTRICTION INDICATOR SWITCH ‘35968992 RESTRICTION INDICATOR SWITCH 36845402 FUEL LEVEL MODULE 195356781 COOLANT MODULE 36844744 CHASSIS HARNESS 36844769 CONTROL BOX HARNESS TNGERSOLL-RAND COMPANY ‘STD WIRING DIAGRAM 95392893-53_|12/97 H Book 35392898 (4/01) BoeDss - ps4 RFT CLEARANCE LIGHT RR CLEARANCE LIGHT pst RIGHT TAIL LIGHT Ds3 LICENSE PLATE LIGHT ps2 LEFT TAIL LIGHT Ds7 pss LFT CLEARANCE LIGHT LR CLEARANCE LIGHT NOTE: TNGERSOLL-RAND COMPANY WHITE WIRE MAY BE FRAME GROUND. ison ‘STD WIRING DIAGRAM 35392893-54 |1/98_A Book 35392898 (4/01) ~Ti0-ITEM CPN. DESCRIPTION DS1 36788081 LAMP ASSEMBLY Ds2 36788081 LAMP ASSEMBLY Dss 36895860 LIGHT, LICENSE Ds4 35367044 LAMP, RED CLEARANCE DSs 35367051 LAMP, YELLOW CLEARANCE DSé 35367044 LAMP, RED CLEARANCE DS7 35367051 LAMP, YELLOW CLEARANCE We 36895852. HARNESS, 2-LIGHT SYSTEM AVAILABLE FROM I-R: PLUG SOCKET 35288760 95288752 NOTE: STANDARD MACHINE IS SUPPLIED WITHOUT PLUG ON LIGHT HARNESS. PLUG / SOCKET WIRING CONNECTIONS. 1 YELLOW - LEFT TURN AND STOP-LIGHT 2 BROWN - TAIL LIGHTS 3 WHITE - GROUND 4 GREEN- RIGHT TURN AND STOP-LIGHT TNGERSOLL-RAND COMPANY ‘STD WIRING DIAGRAM 35392893-55_|1/98_A Book 35392898 (4/01) TiTNGERSOLL-RAND COMPANY INSTRUMENT PANEL 95392893-56_|3/97_B Book 35392898 (4/01) “TiCPN. QTY _DESCRIPTION 36844595 PANEL COVER 36845304 INSTR PNL DOOR 36845733 DOOR HINGE 35356617 RIVET 35144328 SCREW 35144492 NUT 36842656 INSTRUMENT PANEL 36845725 PANEL HINGE 35365386 SCREW weee78 CLAMP 35255561 BY-PASS SWITCH 36771434 DIAGNOSTIC MODULE 36775484 RIVET 35337435 TOGGLE SwiTcH 35604065 DISCHG PRESS GAGE (P-600WCU) 35612233 DISCHG PRESS GAGE (VHP-400WCU) 36891216 DISCHG PRESS GAGE (HP-450WCU) 36891216 DISCHG PRESS GAGE (XP-525WCU) 36841245 HOURMETER 35604099 FUEL GAGE 35255553 PUSH BUTTON SWITCH 36844124 sTUD 35369180 RETAINER 35314582 RECEIPTACLE 35327303 EYE BOLT 14A5D3Z1 WASHER 95927811 SPRING 67A4C2Z1 NUT 35356781 COOLANT MODULE 92368687 SCREW 35586130 RELAY 36785905 RIVET 35577873 MAGNETIC SWITCH 36797652 SCREW 35603349 DOOR HOLDER 11A5D4Z1 WASHER 35273366 NUT 36767440 PLUG Ovz=rxAcrTOmmoaa> R 8 F u v w x Y Zz At a2 AS Aa AS > TNGERSOLL-RAND COMPANY INSTRUMENT PANEL 95392893-57_|12/97 E Book 35392898 (4/01) “3wa DRAWBAR END TNGERSOLL-RAND COMPANY ENCLOSURE COMPLETE 35392893-58 |1/98_C Book 35392898 (4/01) srs3 a 2 CPN. QTY _DESCRIPTION 36844256 36896249 36896256 36844173 36844827 36794774 96844553 36708378 36793602 96844355 36755742 36895860 36797652 36794816 92368687 35337328 12A5D3Z1 14A5C65Z1 1eMasC22M3 36788081 36787968 36893634 3567051 35367044 36894616 36894608 ROOF SIDE PIECE FRONT END CAP REAR END CAP. REAR SIDE PANEL SIDE GRILLE LICENSE PLATE NUT SIDE DOOR, HINGE SLAM LATCH GAS SPRING STRIP CONNECTOR LIGHT, LICENSE SCREW RIVET SCREW BALL STUD FLAT WASHER LOCK WASHER, NUT LIGHT, TAIL, GROMMET GROMMET, CLEARANCE LIGHT LIGHT, YELLOW CLEARANCE LIGHT, RED CLEARANCE REFLECTOR, AMBER REFLECTOR, RED HURRAH OSODROG* RAN HHH HAAN A B ° D E F G H J K L M N Pp Q R s Fr U v w x Y Zz AL A2 TNGERSOLL-RAND COMPANY ENCLOSURE COMPLETE 95392893-59_|1/98_D Book 35392898 (4/01) “3= DRAWBAR END RSKTY TNGERSOLL-RAND COMPANY ENCLOSURE COMPLETE 35090080-00 Book 35392898 (4/01) ~116—ITEM CPN. ary DESCRIPTION A B c D E F G H J K L M N Pp a R s Fe u v w x Y Zz At a2 36844835 36844868 36797652 36844850 36848208 36844843 12102414221 12ASD2Z1 1GA4C1Z1 96846715 35278720 36845667 96851483 36845642 92368687 35279413 35256452 36256429 35256445 35296508 35130707 35374834 11A5D3Z1 36769743 36851475 36851467 Book 35392898 (4/01) FRONT ROOF REAR ROOF SCREW LIFTING BAIL COVER ROOF CHANNEL RADIATOR FILL DOOR SHOULDER SCREW FLAT WASHER NUT RAD FILL DOOR BRKT QUICK RELEASE PIN REAR BELLY PAN MID BELLY PAN FRONT BELLY PAN SCREW COVER RECEPTACLE CLIP STUD RETAINER REAR DRAIN COVER HAND HOLD SCREW FLAT WASHER NUT. BOX ASSEMBLY BELLY PAN “- TNGERSOLL-RAND COMPANY ENCLOSURE COMPLETE 95392893-61wa DRAWBAR END TNGERSOLL-RAND COMPANY TENCLOSUFE COMPLETE 35392893-62 |3/97_C Book 35392898 (4/01) “TinCPN. QTY _DESCRIPTION 96844900 1 RH FRONT INTAKE BAFFLE 92368687 38 SCREW 36844884 RH INTAKE BAFFLE 36844876 LH INTAKE BAFFLE 36848315 LH FRONT INTAKE BAFFLE 36844892 BRACE BAFFLE 36847259 BRACE BAFFLE 36845345 OIL COOLER BAFFLE 36887743 COOLER TOP BAFFLE 36845352 OIL COOLER BAFFLE 36757652 SCREW 36757652 SCREW 36848704 BRACKET 36847317 MUFFLER BAFFLE 36851715 BAFFLE 36849644 STREET INLET DUCT 36849636 STREET INLET DUCT 36849628 CURB INLET DUCT 36851707 SUPPORT 36852580 COOLER BAFFLE BRACKET 36852788 BRACKET N THGERSOLL-RAND COMPANY TENCLOSUFE COMPLETE 35392893-63_|3/97_D Book 35392898 (4/01) “-= DRAWBAR END TNGERSOLL-RAND COMPANY FOAM LOCATION 35090080-64 Book 35392898 (4/01) 120ITEM CPN. ary DESCRIPTION 96849123 36849131 36849149 36849222 36849248 36849230 36849362 36849396 96849156 96849164 96849255 96851863 36851855, Book 35392898 (4/01) ROOF ACST PANEL CENTER ROOF ACST PNL REAR ROOF ACST PNL FRONT END ACST PNL RT FRT END ACST PNL LF FRT END ACST PNL INST PNL ACST PNL MUFFLER ACST PNL UPPER DOOR ACST PNL LOWER DOOR ACST PNL SIDE ACST PNL TOP REAR ACST PNL. BOT REAR ACST PNL TNGERSOLL-RAND COMPANY 35392893-65 FOAM LOZATION.wa DRAWBAR END TNGERSOLL-RAND COMPANY FOAM LOCATION 35392893-66_|3/97_B Book 35392898 (4/01)ITEM CPN. ary DESCRIPTION 36849362 36519289 36849271 36849297 36849347 36849339 36849313 36849321 36851749 36851756 96851731 36849750 36849842 36849867 36849800 36851764 36849768 684818 36849784 36849834 36849859 36849743 36849776 36849792 36849826 A B c D E F G H J K L M N Pp a R s Fe u v w x Y Zz AL A2 3 Book 35392898 (4/01) INST PNL ACST PNL BAFFLE ACST PNL BAFFLE ACST PNL BAFFLE ACST PNL. BAFFLE ACST PNL BAFFLE ACST PNL BAFFLE ACST PNL BAFFLE ACST PNL BOX SIDE ACST PNL BOX REAR ACST PNL BOX TOP ACST PNL WHEEL WELL ACST PNL. OUTSIDE CURB ACST PNL BAFFLE CURB ACST PNL BAFFLE TOP ACST PNL. REAR BAFFLE ACST PNL BAFFLE ACST PNL BOT BAFFLE ACST PNL FR ACST PNL FAN SHROUD ACST PNL (CROSSMEMBER ACST PNL OUTSIDE ACST PNL FR ACST PNL RAD SUPPORT ACST PNL FRAME ACST PNL TNGERSOLL-RAND COMPANY FOAM LOCATION 95392893-67_|3/97_BAN A\ WARNING 4) DANGER 4\ WARNING Z\ WARNING - BE Book 35392898 (4/01) A & {\WARNING A\WARNING 95392803-68CPN. DESCRIPTION A B ° D E F G H J K 96518744 36519924 54568779 54568761 84568803 64629902 54625207 36522290 36847861 54568787 GENERAL DATA DECAL OPERATING INSTRUCTIONS WARNING ROTATING FAN WARNING HOT FLUID DECAL 2-PART 65MPH DANGER/WARNING DECAL DIESEL FUEL DECAL SAFETY CARD CABLE TIE IMPROPER OPERATION Book 35392898 (4/01) TNGERSOLL-RAND COMPANY 35392893-69 (DECAL LOCATION 12/00 FA\WARNING A\WARNINGITEM CPN. 54604962 54568779 36522118, 54568753 36530715 54604970 36502995 54568795 Book 35392898 (4/01) DESCRIPTION RADIATOR FILL DECAL WARNING ROTATING FAN WIRING DIAGRAM WARNING BATTERY ADJUSTING INSTRUCTIONS OIL FILL DECAL, FOLDING STEP DECAL WARNING HIGH PRESSURE TNGERSOLL-RAND COM 95392803-71 PANY 12/00 GITEM CPN. QTY _ DESCRIPTION 96844900 1 RH FRONT INTAKE BAFFLE 92368687 38 SCREW 36844884 RH INTAKE BAFFLE 36844876 LH INTAKE BAFFLE 36848315 LH FRONT INTAKE BAFFLE 36844892 BRACE BAFFLE 36847259 BRACE BAFFLE 36845345 OIL COOLER BAFFLE 36887743 COOLER TOP BAFFLE 36845352 OIL COOLER BAFFLE 36757652 SCREW 36757652 SCREW 36848794 BRACKET 36847317 MUFFLER BAFFLE 36851715 BAFFLE 36849644 STREET INLET DUCT 36849636 STREET INLET DUCT 36849628 CURB INLET DUCT 36851707 SUPPORT 36852580 ‘COOLER BAFFLE BRACKET 36852788 BRACKET A B c D E F G H J K L M N Pp a R s FF u v w x Y z TNGERSOLL-RAND COMPANY ENCLOSURE COMPLETE 35392893-63 |3/97_D Book 35392893 (4/01) 718= DRAWBAR END Book 35392893 (4/01) aeCPN. ary DESCRIPTION 36849123 3684913 36849149 ‘36849222 36849248 ‘36849230 36849362 36849396 96849156 36849164 36849255 96851863 36851855 Book 35392893 (4/01) ROOF ACST PANEL CENTER ROOF ACST PNL REAR ROOF ACST PNL FRONT END ACST PNL RT FRT END ACST PNL LF FRT END ACST PNL INST PNL ACST PNL MUFFLER ACST PNL UPPER DOOR ACST PNL. LOWER DOOR ACST PNL SIDE ACST PNL TOP REAR ACST PNL BOT REAR ACST PNL ~T0- TNGERSOLL-RAND COMPANY 35392893-65 FOAM LOCATION.= DRAWBAR END TNGERSOLL-RAND COMPANY ease Book 35392893 (4/01) ooCPN. QTY DESCRIPTION 36849362 INST PNL ACST PNL 96519289 BAFFLE ACST PNL. 36849271 BAFFLE ACST PNL 36849297 BAFFLE ACST PNL. 36849347 BAFFLE ACST PNL 36849339 BAFFLE ACST PNL 36849313 BAFFLE ACST PNL 36849921 BAFFLE ACST PNL. 36851749 BOX SIDE ACST PNL 36851756 BOX REAR ACST PNL 96851731 BOX TOP ACST PNL 36849750 WHEEL WELL ACST FNL 36849842 OUTSIDE CURB ACST PNL 36849867 BAFFLE CURB ACST PNL ‘36849800 BAFFLE TOP ACST PNL 96851764 REAR BAFFLE ACST PNL 36849768 BAFFLE ACST PNL. 36849818 BOT BAFFLE ACST PNL 36849784 FR ACST PNL 36849834 FAN SHROUD ACST PNL 36849859 CROSSMEMBER ACST PNL 36849743 OUTSINF ACST PNI 36849776 FR ACST PNL 36849792 RAD SUPPORT ACST PNL 36849826 FRAME ACST PNL A B c D E F 6 H J K L M N Pp Q R s T u v w x Y Zz AL A2 43 TNGERSOLL-RAND COMPANY ‘FOAM LOCATION 36392893-67 |3/97_B Book 35392893 (4/01) Taz4\ WARNING 4, DANGER 4 WARNING 4 WARNING re & tare ry Book 35392893 (4/01) 4 WARNING A\WARNINGCPN. DESCRIPTION 96518744 96519924 54568779 84568761 84568803 64629902 54625207 36522290 36847861 54568787 GENERAL DATA DECAL OPERATING INSTRUCTIONS. WARNING ROTATING FAN WARNING HOT FLUID DECAL 2-PART 65MPH DANGERWARNING DECAL DIESEL FUEL DECAL SAFETY CARD CABLE TIE IMPROPER OPERATION Book 35392893 (4/01) iss TNGERSOLL-RAND COMPANY{\WARNING Book 35392893 (4/01) Iss Ls {\WARNINGITEM CPN. 54604962 154568779 936522118, 54568753 36530715 54604970 36502995 54568795 Book 35392893 (4/01) DESCRIPTION RADIATOR FILL DECAL WARNING ROTATING FAN WIRING DIAGRAM WARNING BATTERY ADJUSTING INSTRUCTIONS OIL FILL DECAL FOLDING STEP DECAL WARNING HIGH PRESSURE TT36- INGER: {SOLL-RAND COMPANYSECTION 11 - OPTIONS LIST CONTENTS Aftercooler Asserrbly Coalescing Filter Assembly Axle, Electric Brake Axle, Hydraulic Brake Brakes, Electric wi 2-Lights Brakes, Electric wi 4-Lights Brakes, Electric wi Park Brakes, Adj Height Drawbar Hydraulic Brakes, Hydraulic Brakes, Hydraulic w/ Park Shoe, Electric Brake Shoe, Hydraulic Brake Caster Whee! Cold Start Drawber, Adjustable Height Drawbar, Extended Gauge, Compressor Discharge Temp Gauge, Engine Oil Pressure Gauge, Engine Temperature Gauge, Tachometer Gauge, Voltmeter Heaters, 110v Batiery/lock Lights, 4 ‘Schematic, Option Wiring Parts, Miscellaneous Option Schematic, 110v Heater Wiring Book 35392898 (01) “ToORDO + EXISTING ITEMS TO BE RE-USED TNGERSOLL-RAND COMPANY ‘AFTERCOOLER ASSEMBLY Book 35392898 (2/01) "TaCPN. ary DESCRIPTION A B c D E F G H J K L M N P Q R s T u 36853273 36855401 35252741 35320944 35252618 36855393 36855955 95934642 195935003 136856250 36797652 36856946 35252758 35209048 195928966 36871010 196856003 36856011 96856912 Book 35392898 (01) DRAWBAR REAR BRACKET ‘SCREW, LOCK 1/2-13 X1.5, WASHER, BEVEL 1/2" NUT, LOCK WASHER 1/213, FRONT BRACKET AFTERCOOLER ‘SCREW, HEX 1/2-13 X1 WASHER, FLAT 1/2" RELAY SCREW BRACKET SCREW MUFFLER CLAMP WASHER, FLAT 5/16" HARNESS, FAN CORE AFTERCOOLER FAN AFTERCOOLER SHROUD AFTERCOOLER 35392803-08 35392901 -03 TNGERSOLL-RAND COMPANY ‘AFTERCOOLER ASSEMBLYBook 35392898 (2/01) "Ts:CPN. QTY _DESCRIPTION 95944526 COUPLING, 2" PIPE 95944591 NIPPLE 6” 95944682 TEE 95944609 NIPPLE 2" 35335124 CONNECTOR 36856920 HOSE 36786127 ELBOW, 90(] 2" NPT 95944641 ADAPTER 95944674 ELBOW, STREET 2" NPT 95946174 NIPPLE 4” 95944534 UNION 36850840 WATER SEPARATOR 36856938 NIPPLE 25" 35602473 BALL VALVE 195944633 BUSHING 95944617 BUSHING (ALTERNATE) 95944567 NIPPLE 1.5" 35324839 BALL VALVE 95944666 ELBOW, STREET 1/4 NPT 36840437 CHECK VALVE 35931842 HOSE 95283472 CONNECTOR 95944690 ‘TEE, STREET 1/4 NPT Ovz=rxcera@amo90a> R s T u v w x 35392893-05 INGERSOLL-RAND COMPANY 35992901-05 [eames IAFTERCOOLER ASSEMBLY Book 35392898 (01) "TasBook 35392898 (2/01) “TsCPN. QTY _DESCRIPTION 95944609 NIPPLE 2.5" 95944534 UNION 36856029 * FILTER, HEAD 35148014 CHECK VALVE 95911559 NIPPLE 8" 35602473 BALL VALVE 195944633 BUSHING 95944567 NIPPLE 1.5" 35324839 BALL VALVE 95944674 ELBOW, STREET 2" NPT Acer@mmI0m> * FILTER ELEMENT 36857381 35382805-07 TNGERSOLL-RAND COMPANY 35392901-07 — foareowner oescienen (COALESGING FILTER ASSY. OPTION Book 35392898 (01) "Tis= DRAWBAR END Book 35392898 (01) TTTCPN. QTY _DESCRIPTION 35316850 AXLE 95315126 SPRING 95136959 U-BoLT 36865962 GREASE SEAL 35816876 BEARING CONE 95316884 BEARING CUP 35388669 HUB. ‘95316900 BEARING CUP 35316918 BEARING CONE 95915209 ‘SPINDLE WASHER 95315217 ‘SPINDLE NUT 35393792 GREASE CAP 35316967 TIE PLATE 35315258 NUT 35361898 WHEEL STUD 95315274 WHEEL NUT 195926958 FRONT HANGER 35315340 ‘SHACKLE BOLT 35815357 ‘SHACKLE NUT 35326966 REAR HANGER, 95315365 KEEPER BOLT 95315373 KEEPER NUT 96855377 LH BRAKE ASSEMBLY 36855385 HH BHAKE ASSEMBLY 95315225 PIN, COTTER 95991135 PLUG, EZ LUBE A B c D E F G H J K L M N P Q R s T u v w x Y 35392893-09 TNGERSOLL-RAND COMPANY 39902801-09 frweom’e"™mscommenonowoon Book 35392898 (01) Ts= DRAWBAR END Book 35392898 (01) “TyCPN. QTY _DESCRIPTION 35316850 AXLE 95315126 SPRING 95136959 U-BoLT 36865962 GREASE SEAL 35816876 BEARING CONE 95316884 BEARING CUP 35388669 HUB. ‘95316900 BEARING CUP 35316918 BEARING CONE 95915209 ‘SPINDLE WASHER 95315217 ‘SPINDLE NUT 35393792 GREASE CAP 35316967 TIE PLATE 35315258 NUT 35361898 WHEEL STUD 95315274 WHEEL NUT 195926958 FRONT HANGER 35315340 ‘SHACKLE BOLT 35815357 ‘SHACKLE NUT 35326966 REAR HANGER, 95315365 KEEPER BOLT 95315373 KEEPER NUT ‘35393800 LH BRAKE ASSEMBLY 35393818 HH BHAKE ASSEMBLY 95315225 PIN, COTTER 95991135 PLUG, EZ LUBE A B c D E F G H J K L M N P Q R s T u v w x Y 35G92803-11 TNGERSOLL-RAND COMPANY 3590280111 feomie™™mecommenonowoon Book 35392898 (01) “T30-* USE (2) EXISTING GROMMETS 35392803-12 TNGERSOLL-RAND COMPANY 35392901-12 ELEC BRK w/ 2-UGHT ASSY Book 35392898 (01) “Tr3 a z CPN. QTY _DESCRIPTION 96788081 TAILLIGHT 36895282 HARNESS, ELECTRIC BRAKE 36787968 GROMMET 36896264 HARNESS, TAIL LIGHT 36375427 ‘TERMINAL, SNAP 96315944 ‘SWITCH, BREAKAWAY 36287572 ‘TERMINAL, SPLICE 36346337 ‘TERMINAL, LUG 35253038 CLAMP, 3/8 36799724 GEAR, ELEC BRAKE w/ RUNNING 92368687 ‘SCREW, TAPPING M06-100 X 14 36794774 GROMMET, SCREW 96789261 HARNESS, 6 CONDUCTOR CABLE (STD LENGTH DRAWBAR) 36787216 HARNESS, 6 CONDUCTOR CABLE (EXTENDED LENGTH DRAWBAR) 35225093 CLAMP, 1/2 35252451 SCREW, LOCK 1/4-20X 1 35144492 NUT, LOCK 1/4-20 35225077 CLAMP, 5/8 36895860 LIGHT, LICENSE 36782837 SCREW, HEX SHT METAL #10 X 1 zErxcrommooD> Pp Q R s T U 35392803-13 TNGERSOLL-RAND COMPANY Sesseo ira totus amounts Book 35392898 (01) TT35392901-14 Book 35392898 (01) “Ts3 a z CPN. QTY _DESCRIPTION 96788081 TAILLIGHT 36896264 HARNESS, 4-TAIL LIGHT 36787968 GROMMET 36895860 LIGHT, LICENSE PLATE 36782837 SCREW, SHEET METAL 35252451 SCREW, LOCK 1/4-20 X 1 96700851 NUT, LOCK WASHER 1/4-20 36895282 HARNESS, ELECTRIC BRAKE 35253038 CLAMP, 3/8 36799724 GEAR, ELEC BRAKE w/ RUNNING 35225077 CLAMP, RUBBER COATED 5/8 92368687 SCREW, TAPPING M06-100 X 14 96375427 TERMINAL, SNAP 36794774 GROMMET, SCREW 95315944 ‘SWITCH, BREAKAWAY 35287572 TERMINAL, SPLICE 35307651 TERMINAL, LUG 36789261 HARNESS, 6 CONDUCTOR CABLE (STD LENGTH DRAWBAR) 36787216 HARNESS, 6 CONDUCTOR CABLE (EXT LENGTH DRAWBAR) 35225093 CLAMP, 1/2 4oDOvzZEr xc rOnMoOoOa> c 35392803-15 TNGERSOLL-RAND COMPANY 35392901-15 Book 35392898 (01) “ar3 a z CPN. QTY _DESCRIPTION 36799724 RUNNING GEAR W/ BRAKES 35225093 CLAMP, RUBBER COATED 1/2" 95116433 BRACKET, BRAKE LEVER 35145259 SCREW, LOCK 3/8-16 X 1.25 35145077 NUT, LOCK 3/8-16 35370055 LEVER, PARKING BRAKE 195829006 SCREW, HEX 5/16-18 X1 35252600 NUT, LOCKING 5/16-18 96846780 PIN, CLEVIS 31 X.75 195934998 WASHER, FLAT 3/8 195928867 PIN, COTTER .09 95126325 CLAMP, CABLE 195943668 SCREW, HEX 5/16-18 X 1.3/4 95126358 SPACER 195589753 ASSEMBLY, BRAKE CABLE 90 96503134 ASSEMBLY, BRAKE CABLE 108 A B c D E F G H J K L M N Pp Q R 35080800-17 TNGERSOLL-RAND COMPANY 35992901-17 coieutcomremoncrewes PARKING BRAKE Book 35392898 (01) “TseBook 35392898 (2/01) “TTCPN. QTY _DESCRIPTION 38379908 GEAR, HYD BRAKE RUNNING 35356369, HOSE, BRAKE 9/8 X13 36356302 CLIP, HOSE 35316603, TEE, 1/4 INVERTED 35141365, ‘SCREW, TAPPING 5/16-18 X 1/2 36758647 ‘SUPPORT, HYDRAULIC ACTUATOR 35376094 ‘SCREW, HEX M16-2.0 X 120 96700885 NUT, HEX M16-2.0 35316611 ACTUATOR, HYDRAULIC BRAKE 38333673 ‘SPACER, HYDRAULC DRAWBAR, 95935169 SCREW, 1/2-13X 4 95923348 NUT, NYLOC 1/2-13 95564373 TUBING, 1/4 36853174 CLAMP, SUPPORT 1/4 35356310 BRACKET, HOSE MOUNTING 35279025 ‘SCREW, TAPPING M08-1.25 X 30 35282904 HOSE, BRAKE 36315779 BRACKET, BULKHEAD FITTING. 35315712 ELBOW, BULKHEAD UNION 95209060 NUT, TUBE 35136423 SCREW, TAPPING 1/4-20 X 1/2 35315738 ADAPTER 35315746 ADAPTER 35252279 ‘SCREW, TAPPING #10-32 X 1/2 36759207 BRACKET, ADJUSTABLE HEIGHT 35252758 SCREW, LOCKING 1/2-13 X 1 35252618 NUT, LOCK WASHER HD 1/2-13, A B c D E F G H J K L M N P Q R s T u v w x Y Zz a Ae 13 35392803-19 TNGERSOLL-RAND COMPANY Sesseo ra totus amounts Book 35392898 (01) TTSTNGERSOLL-RAND COMPANY ‘116/87 bq HYD BRAKE wiSTDOBAR OPTION ‘Book 35392895 101) TT3 a z CPN. QTY _DESCRIPTION 38379908 GEAR, HYD BRAKE RUNNING 35356369, HOSE, BRAKE 9/8 X13 36356302 CLIP, HOSE 35316603, TEE, 1/4 INVERTED 35141365, ‘SCREW, TAPPING 5/16-18 X 1/2 36758647 ‘SUPPORT, HYDRAULIC ACTUATOR 35376094 ‘SCREW, HEX M16-2.0 X 120 96700885 NUT, HEX M16-2.0 35316611 ACTUATOR, HYDRAULIC BRAKE 38333673 ‘SPACER, HYDRAULC DRAWBAR, 95935169 SCREW, 1/2-13X 4 95923348 NUT, NYLOC 1/2-13 95564373 TUBING, 1/4 36853174 CLAMP, SUPPORT 1/4 35356310 BRACKET, HOSE MOUNTING 35279025 ‘SCREW, TAPPING M08-1.25 X 30 35282904 HOSE, BRAKE 36315779 BRACKET, BULKHEAD FITTING. 35315712 ELBOW, BULKHEAD UNION 95209060 NUT, TUBE 35136423 SCREW, TAPPING 1/4-20 X 1/2 35315738 ADAPTER 35315746 ADAPTER 35252279 ‘SCREW, TAPPING #10-32 X 1/2 NY TNGERSOLL-RAND COMPANY Book 35392898 (01) TTa0-3 a z CPN. QTY _DESCRIPTION 35379908 RUNNING GEAR W/ BRAKES 35225093 CLAMP, RUBBER COATED 1/2" 95116433 BRACKET, BRAKE LEVER 35145259 SCREW, LOCK 3/8-16 X 1.25 35145077 NUT, LOCK 3/8-16 35370055 LEVER, PARKING BRAKE 195829006 SCREW, HEX 5/16-18 X1 35252600 NUT, LOCKING 5/16-18 96846780 PIN, CLEVIS 31 X.75 195934998 WASHER, FLAT 3/8 195928867 PIN, COTTER .09 ‘95256981 CLAMP, CABLE 195943668 SCREW, HEX 5/16-18 X 1.3/4 95126358 SPACER 95517168 ASSEMBLY, BRAKE CABLE 90 ‘95594076 ASSEMBLY, BRAKE CABLE 117 A B c D E F G H J K L M N Pp Q R 35392893-23 TNGERSOLL-RAND COMPANY sessao ito totus umount Book 35592805 C01) TaDCPN. QTY _DESCRIPTION 35393859 LH BACKING PLATE ASSEMBLY 95393867 RH BACKING PLATE ASSEMBLY 36895803, BRAKE SHOE KIT 96895811 MAGNET KIT 35390913 PARKING BRAKE LEVER 35393726 ADJUSTING SCREW KIT 35391069, ADJUSTING SLOT PLUS 36895829 LH PARK BRAKE LEVER KIT 36895837 RH PARK BRAKE LEVER KIT 35392893-25 TNGERSOLL-RAND COMPANY 3990280125 fweomie™™mecommenenowoon Book 35392898 (01) TTar-35392893-26 INGERSOLL-RAND COMPANY SECTION A-A pr I _ cena Book 35392898 (01) TasCPN. QTY _DESCRIPTION 35393634 LH BACKING PLATE ASSEMBLY 95393842 RH BACKING PLATE ASSEMBLY 95393776 BRAKE SHOE KIT 96867851 CYLINDER, LH BRAKE 36867885, CYLINDER, RH BRAKE 95290707 LH PARKING BRAKE LEVER, 35290715 RH PARKING BRAKE LEVER 35399785 ADJUSTING SCREW ASSEMBLY 35991069, ADJUSTING SLOT PLUG 136895795 BRAKE SPRING KIT 35G82805-27 TNGERSOLL-RAND COMPANY 35392901-27 fremansotmacormeeeonenet HYDRAULIC BRAKE SHOE Book 35592805 C01) TTa6-35392803-28 35392901-28 Book 35592805 C01) TTaT-3 a z CPN. QTY _DESCRIPTION 95966319 HANDLE, LOCK PLUNGER, 35366327 SPRING, LOCK PLUNGER 35366335 PIN, HINGE 38966343 PLUNGER, LOCK 36866994 TIRE & WHEEL, 35366368 BRACKET, FRAME 36366376 FORK 35366418 HEAD, SWIVEL 35366426 PIN, COLLAR 35966434 FORK, SHAFT 35366442 FITTING, LUBE 35366459 BOLT, AXLE 35966467 NUT, AXLE BOLT 38966475 COLLAR A B c D E F G H J K L M N Pp 35392893-29 TNGERSOLL-RAND COMPANY 3990200129 wea’ mecommenenowon Book 35592805 C01) Tas35392803-30 TNGERSOLL-RAND COMPANY 35392901-30 (COLD START OPTION Book 35392898 (01) Ta3 a z CPN. QTY _DESCRIPTION 36857878 VALVE, 24V COLD START 36796910 CYLINDER, ETHER, 92368687 SCREW, TAPPING MO6-1.0 X 14 39183769 ‘SCREW, HEX M12-1.75 X 16 36857852 ‘SWITCH, COLD START THERMO 36857845 TUBING, 1/8 X 48" 36857837 ELBOW, 90] 1/8 NPT 3509558 ATOMIZER 35103506 CLAMP, CYLINDER BRACKET 35255553 ‘SWITCH, SPST MOMENTARY PUSH-BUTTON 36848760 HARNESS, COLD START 35306141 CONNECTOR, 1/4 MALE ZrAcronmooa> * FURNISHED WITH COLD START KIT 36857811 TNGERSOLL-RAND COMPANY Book 35392898 (01) TT30-35G82805-O2 TNGERSOLL-RAND COMPANY 35392901-32 oareowner oescRenen EXT ADJ HT DRAWBAR Book 35392898 (01) “TI3 a z CPN. QTY _DESCRIPTION 36843803, DRAWBAR, 36763670 ‘SCREW, HEX M20-2.50 X 60 35356526 NUT, TORQ LOCK M20-2.50 36759207 LUNETTE, ADJ HEIGHT 35610377 CHAIN, SAFETY 35972432 LINK, COUPLING 36752228 JACK ASSEMBLY 35609544 PIN, QUICK RELEASE 35252758 ‘SCREW, LOCKING 1/2 -13 X1 35252618 NUT, LOCK WASHER HEAD 1/2 -13 AcrOnmooOa> 35392803-33 TNGERSOLL-RAND COMPANY Sessoeo ites! esTaacscoubeeson ovis Book 35392898 (01) TT35392803-34 TNGERSOLL-RAND COMPANY 39902001-34 fweomie™™mecommenenowon Book 35392898 (01) "Ts3 a z CPN. QTY _DESCRIPTION 36853273 DRAWBAR, EXTENDED 36763670 ‘SCREW, HEX M20-2.50 X 60 35356526 NUT, TORQ LOCK M20-2.50 36757284 CHANNEL, 3 POS 35610377 CHAIN, SAFETY 35972432 LINK, COUPLING 36752228 JACK ASSEMBLY 35609544 PIN, QUICK RELEASE 39179072 ‘SCREW, HEX M16 X50 36879211 NUT, HEX FLANGE M16 A B c D E F G H J K 35380805-05 TNGERSOLL-RAND COMPANY 35392901-35 a ESR EXTENDED DRAWBAR Book 35392898 (01) es~ DRAWBAR END "Book 35392893 (2101) ~155-ITEM CPN. QTY _DESCRIPTION A 96604115 1 GAGE, TEMPERATURE 300] F B 35367218 = 1_—s SENDER, TEMPERATURE 300[] F C 36851319 1_— ADAPTER, 3/8 NPTF. (VHP 400 ONLY) 35350800-87 TNGERSOLL-RAND COMPANY 35392901-37 — Poareowney yoesepren DISCHARGE TEMP OPTION Book 35392898 (01) “Tse= DRAWBAR END Book 35392898 (2/01) TTITEM CPN. QTY _DESCRIPTION A 36870590 1 ~~ GAGE, ENGINE OIL, B 36870608 ©«=«1_—Ss SENDER, PRESSURE 150 Ib C 95972085 1 ELBOW, 1/8 35392893-39 INGERSOLL-RAND COMPANY 35992901-39 | weomrtiesat ENGINE OL PRESS OPTION Book 35392898 (01) TTS~ DRAWBAR END INGERSOLLRAND Book 35392898 (2/01) ~i39-ITEM CPN. QTY _DESCRIPTION A 35604115 GAGE, TEMPERATURE 300] F B 35604180 SENDER, TEMPERATURE 9001] F TNGERSOLL-RAND COMPANY ENGINE TEMP OPTION Book 35392898 (01) Too~ DRAWBAR END INGERSOLLRAND Book 35392898 (2/01) “TorITEM CPN. QTY _DESCRIPTION A 96371566 = 1S TACHOMETER, 12 V TNGERSOLL-RAND COMPANY ‘TACHOMETER OPTION Book 35392898 (01) TTer-~ DRAWBAR END INGERSOLLRAND Book 35392898 (2/01) “TesITEM CPN. QTY _DESCRIPTION A 96841153 1: VOLTMETER, 24 VDC TNGERSOLL-RAND COMPANY \VOUTMETER OPTION Book 35392898 (01) “TorCPN. QTY _DESCRIPTION 36859494 HARNESS, PRESSURE SWITCH 36852812 BRACKET, PRESSURE SWITCH 95283464 ELBOW, 909) 95315407 HOSE 35806687 ELBOW, 900) 36852952 PAD, BATTERY HEATER 36898971 HEATER, BLOCK 96858751 PLUG, THERMOSTAT 195953949 BUSHING, REDUCING 96518561 DECAL, NOTICE 120V HEAT 92368687 ‘SCREW, TAPPING M06-100 X 14 36899086 ASSEMBLY, AC POWER, 36852960 PAD, 4D BATTERY HEATER, 19471921 NIPPLE 95930327 ‘TEE, 1/8 NPT 36898989 SHIELD, BLOCK HEATER DOVZEF Re TO nMIOoD * INCLUDED IN 36899086 AC POWER ASSEMBLY TNGERSOLL-RAND COMPANY ‘ov BTRY/BLK HEATER Book 35392898 (01) “Tes* USE 2 EXISTING GROMMETS Book 35392898 (01) TToT-3 a z CPN. QTY _DESCRIPTION 96788081 TAILLIGHT 36896264 HARNESS, 4 LIGHT 36787968 GROMMET 36895860 LIGHT, LICENSE PLATE 36782837 SCREW, SHEET METAL 35252451 SCREW, LOCK 1/4-20 X 1 35144492 NUT, LOCK WASHER 1/4-20 36794774 GROMMET, SCREW 35253038 CLAMP, 3/8 35225077 CLAMP, 5/8 RUBBER COATED 36789261 HARNESS, CABLE 6 CONDUCTOR (STD LENGTH DRAWBAR) 36787216 HARNESS, CABLE 6 CONDUCTOR (EXT LENGTH DRAWBAR) 92368687 ‘SCREW, TAPPING N06-1.0 X14 135225093 CLAMP, 1/2 rReroOnmooa> M N TNGERSOLL-RAND COMPANY Book 35392898 (01) TTos-TOSTANDARD WANG GRAM 35302803-50 TNGERSOLL-RAND COMPANY 36392901-50 TBook 35392893 (101) "169CPN. DESCRIPTION 36856011 FAN MOTOR 36856011 FAN MOTOR 96786259 SOAFUSE 96852960 HEATER 36853952 HEATER 96856250 RELAY 96856250 RELAY 36857878 SOLENOID VALVE 95373729 ENGINE OIL PRESSURE GAGE. 95604115 ENGINE TEMPERATURE GAGE 36371566 TACHOMETER 36841153 VOLTMETER 35604115 COMPRESSOR TEMPERATURE GAGE 36842136 —- RESISTOR 96842136 RESISTOR 36842136 RESISTOR 96842136 RESISTOR 95373737 ENGINE OIL PRESSURE SENDER, 35367218 COMPRESSOR TEMPERATURE SENDER 35604180 ENGINE TEMPERATURE SENDER, 35255553 ETHER SWITCH 36899086 AC POWER ASSEMBLY 95337435 LIGHT SWITCH 95397435 TOGGLE SWITCH 96857852 ENGINE THERMO SWITCH 36846632 8 GAGE HARNESS 36846640 LIGHT HARNESS. 36848760 ETHER HARNESS 36871010 AFTERCOOLER HARNESS. 35302800-51 TNGERSOLL-RAND COMPANY 36392901-51 TBook 35392893 (2/01) TT70-sé RFT CLEARANCE LIGHT JUNCTION s7 LFT CLEARANCE LIGHT NOTE: WHITE WIRE MAY BE FRAME GROUND. Book 35592805 C01) ps4 RR CLEARANCE LIGHT bss LR CLEARANCE LIGHT 35392893-52 35392901-52 "Ti so RIGHT TURN LIGHT HC) e— Dst RIGHT TAIL/STOP LI He) ~— Ds3 LICENSE PLATE LIGHT Ds2 LEFT TAIL/STOP LIGHT el et pss TURN LIGHT TNGERSOLL-RAND COMPANY 4 LIGHT WIRING DIAGRAM OPTIONDESCRIPTION LAMP ASSEMBLY LAMP ASSEMBLY LIGHT, LICENSE LAMP, RED CLEARANCE LAMP, YELLOW CLEARANCE LAMP, RED CLEARANCE LAMP, YELLOW CLEARANCE LAMP ASSEMBLY LAMP ASSEMBLY HARNESS, 4-LIGHT SYSTEM PLUG / SOCKET WIRING CONNECTIONS 1 WHITE - GROUND 2 YELLOW - LEFT TURN SIGNAL 3 RED - STOP LIGHT 4 GREEN - RIGHT TURN SIGNAL 5 BROWN - TAIL/ CLEARANCE LIGHTS 6 BLUE - ELECTRIC BRAKES 35392893-53 INGERSOLL-RAND COMPANY 35992901-53 [socom esa TTB” pf UAT WING OAGRAM OPTION _5/98_Al Book 35392898 (01) "ThCPN. DESCRIPTION 36780252 96794345 35612746 35370469 35376094 196700885, 36509073 35131499 * 35131481 * 35131457 * 35131465 * 35376094 196700885 KEY IGNITION SWITCH KEY LOCK CYLINDER KEY (REPLACEMENT) COUPLER, 2.31” BALL ‘SCREW, HEX M16-2.0 X 120 NUT, HEX M16 COUPLER, 2” BALL uP. SPRING NUT, LOOP HANDLE BOLT ‘SCREW, HEX M16-2.0 X 120 NUT, HEX M16 * FURNISHED WITH 2" COUPLER Book 35392898 (01) "Ts 35392893-54 35392901-54 TNGERSOLL-RAND COMPANY 'MISCELANEOUS OPTIONSst THERMOSTST os o Gi ox sexren BATTERY PAD BATTERY PAD (Comans one HEATER HEATER REFER TO MODEL FOR LIST OF OPTIONAL HEATERS AVAILABLE Jpeene CUMMINS KUBOTA ‘cummins. 250-P375 pro0-p160 | Ptoo-P160 | pizs-xpres | E2s-es0 Ls;1s18 | vHPao0-P600 - - 36920387 36920387 | 36920387 | 36920379 36843563 | 35379221 | 96874659 36898971 | ses98252 | 36898971 ~ ~ 36920387 36858751 36858751 36920361 36920361 cummins | JDEERE cat CUMMINS ‘CUMMINS: HP600-xP825 |HP600-xP825_| xHPso0-xHPe00 | vHPe2s-xP1050 | VHP7S0-xP1000 | HP100-P1600 36920411 | 36920411 | sesz0s38 | 36920411 36920411 | 36920338 36874642 | 36874659 | 36871325 | 36852614 | 36871283 | 36882520 36874675 - - 36869691 - 96882512 36920429 | 36920429 | se920346 | 36920020 | 36920429 | seo20346 36858751 | 36858751 | 36858751 | 36858751 | 36858751 | 36858751 36920437 | 36920403 | 36871317 | 36852508 | 36871275 | 36020320 ‘35992895-55 _] 35900277-44 | 3590182500 | J5300095-04 INGERSOLL RAND COMPANY 35992901-55 |} 3s90G996-44 | 35901713-99 | 35391099-84 fraeamrty” jes 35993065-40 | 35991721-95 | 3592877-84 “10 VAC HEATER WIRING 3539362840] 35991739-99 | s5g92885-84 54497173-93__] 35392084-99__] 35393172-84 Book 35590895 (101) = Tefe) e eR ee a Manual — B Series Engines U.S.A, Canade, Australia, ‘New Zealand, and Puerto Rico SECTION 12 - ENGINE INFORMATION This information complied from Cummins Bulletin 3810205-11. ‘Supplied by: Cummins Engine CompanyTable of Contents Maintenance Procedures - Daily. Maintenance Procedures at 10,000 Kilometers [6,000 Miles], 250 Hours or 3 Months.. Maintenance Procedures at 19,000 Kilometers [12,000 Miles], 500 Hours or 6 Months Maintenance Procedures at 38,000 Kilometers [24,000 Miles}, 1000 Hours or 12 Months. Maintenance Procedures at 77,000 Kilometers [48,000 Miles], 2000 Hours or 2 Years. ‘Adjustment, Repair and Replacement. Additional Service Literature ‘Specifications and Torque Values.To The Owner and Operator Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations outlined in Maintenance Guidelines (Section 2). Keep records of regularly scheduled maintenance. Use the correct fuel, oil and coolant in your engine as specified in Engine Specifications (Section V). ‘Cummins Engine Company, Inc. uses the latest technology and the highest quality components to produce its ‘engines. Cummins recommends using only genuine Cummins parts and ReGon exchange parts. Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support. Ifyou have a problem that cannot be resolved by a Cummins Authorized Repair Location, follow the steps outlined in the Service Assistance (Section S). About the Manual ‘This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins Engine Company, Inc. Additional service literature (Shop Manual, Troubleshooting and Repair Manual, etc.) can be orderad by filling out and mailing the Literature Order Form located in Service Literature, Section L This manual does not cover vehicle or equipment maintenance procedures. Consult the vehicle or equipment manufacturer for specific maintenance recommendations. Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets. Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to page i-5 for a complete listing of symbols and their definitions. Each section is preceded by a “Section Contents” to aid in locating information more quickly. How to Use the Manual ‘This manual is organized according to intervals at which maintenance on your engine is to be performed. A table which states the required intervals and the checks to be madi is located in Section 2. Locate the interval at which you are performing maintenance then follow the steps given in that section for all the procedures to be performed. In addition, all the procedures done under previous maintenance intervals must be performed also. Keep a record of all the checks and inspections made. A record form for recording date, mileage/kilometer or hours, and which maintenance checks were performed is located in Section 2. Refer to Section T for a guide to troubleshooting your engine. Follow the directions given on page T-2 to locate and correct engine problems. Refer to Section V for specifications recommended by Cummins Engine Company, Inc., for your engine. Speci- fications and torque values for each engine system are given in that section.Symbols The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: A A Re WARNING - Serious personal injury or extensive property damage can result if the waming instructions are not fo CAUTION - Minor personal injury can result or a part, an assembly, or the en- gine can be damaged if the Caution in- Structions are not followed. Indicates a REMOVAL or DISASSEM- BLY step. Indicates an INSTALLATION or AS- ‘SEMBLY step. INSPECTION is required. CLEAN the part or assembly. ® $ POKEI® PERFORM a mechanical or time MEA- ‘SUREMENT. LUBRICATE the part or assembly. Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque. PERFORM an electrical MEASURE- MENT. Refer to another location in this manual or another publication for additional in- formation. ‘The component weighs 23 kg [50 Ib] or more. To avoid personal injury, use a hoist or get assistance to lift the compo- rent.General Safety Instructions Important Safety Notice A warning A Improper practices or carelessness can cause bums, cuts, mutilation, asphyxiation or other bodily injury or death. Read and understand all of the safety precautions and warnings before performing any repait. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. ‘+ Make sure the work area surrounding the product is dry, well lit, ventilated; free from clutter, loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist. ‘+ Always wear protective glasses and protective shoes when working. * Rotating parts can cause cuts, mutilation or strangulation. * Do not wear loose-fitting or tom clothing. Remove all jewelry when working. * Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a ‘Do Not Operate” tag in the operator's compartment or on the controls. ‘+ Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. * fan engine has been operating and the coolant is hot, allow the engine to coo! before you siowly loosen the filler cap and relieve the pressure from the cooling system. * Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work. * Relieve all pressure in the air, oll, and the cooling systems before any lines, fitings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure laaks with your hand. High pressure oil or fuel can cause Personal injury. * Toprevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (fiuorocarbons) into the atmosphere. Federal law requires capture and recycling refrigerant. ‘+ To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 Ib] ‘or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctty. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded. * Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated Contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. ‘+ Naptha and Methy! Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN. ‘* To avoid bums, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes, and compartments. ‘+ Always use tools that are in good condition. Make sure you understand how to use them before performing any service work. Use ONLY genuine Cummins or Cummins Recon@ replacement parts. ‘+ Always use the same fastener part number (or equivalent) when replacing fasteners. Donot use afastener of lessor quality if replacements are necessary. * Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning. * Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.in of Terms Air Fuel Control ‘American Petroleum Institute Air Signal Attenuator rican Society of Testing and faeries seoricha Celsius California Air Resources Board Cubic Inch Displacement Centimeter Control Paris List Centistokes Diesel Coolant Additive Electronic Control Module Emission Control System Environmental Protection Agency Engine Position Sensor Fahrenheit Foot Pound Gross Vehicle Weight Meroury Horsepower aRgQiRe32° FEAF RPM SAE. Water Inch Pound Kilograms Kilometers Kilometers per Liter Kilopascal Liter Meter Millimeter Megapascal Miles Per Hour Miles Per Quart Newton-meter Original Equipment Manufacturer Parts Per Million Pounds Per Square inch Power Takeoff Revolutions Per Minute Society of Automotive Engineers Step Timing Control Variable Speed Vehicle Speed SensorEngine Identification Engine Dataplate ‘The engine dataplates show specific information about your engine. The engine serial number (1) and Control Parts List (CPL) (2) provide information for ordering parts and service needs. NOTE: The engine dataplate must not be changed unless approved by Cummins Engine Company, Inc. Industrial Engine Nomenclature The model name for Industrial engines provides the following engine data: 4BTA39 (ae Engine Series Number of Cylinders Automotive Engine Nomenclature The model name for Automotive engines provides the following engine data: B 59-190 LL Horsepower Rating Displacement in Liters Engine Series oy m= = Tr 7 Ege Soroan re |e — [EIB co mle sae ee [OO [me — Mose BUSA. seca | citeretb | Caxatyoour No. nox eae LE ae ar SS a = 1 | Bes. Ech | Ret No Dib comeart 3 pes cane oe ees = 7] Rast rate : apspigbGeneral Information Cummins 1@ Company, ine. recommends that the engine be maintained according to the Maintenance ‘Schedule in this section. Ifthe engine is operating in ambient temperatures consistently below -18°C [0°F] or above 38°C [100°F], perform maintenance at shorter intervals. Shorter maintenance intervals are also required if the engine is operated in a dusty environment or if frequent stops are made. See your Cummins Authorized Repair Location for recorn- mended intervals. Use the chart provided at the end of this section as a convenient way to keep a record of maintenance performed. Hfyour engine is equipped with a component or an accessory not manufactured by Cummins Engine Company, Ine., refer to the component manufacturer's maintenance recommendations. A listing of suppliers’ addresses and telephone numbers is provided in Component Manufacturers, Section C. Tool Requirements In the text, a symbol followed by the wrench size or tool description is used to identify the tooling required to Perform each step. A list of wrench sizes and descriptions indicate more than one tool is needed. Sockets Wrenches Other Tools 19mm 19mm Fuel fine nuts 17mm 17mm Filter Wrenches (75-80mm and 90-95mm) 15mm 15mm Ratchet (1/2 inch drive) 14mm Torque Wrench 13mm Flat Blade Screwdriver 10mm 5/16 Allen Wrench Feeler Gauges (0.25 mm and 0.51 mm) Engine Barring Gear Part No. 3377371.Maintenance Schedule mayor Ss Ta a — Sara Lene. Rae eoeaee eas = intestate Hea * Oil Level + Lube O17 * Lube Oil Lube Oil '* Lube Oil a a Coos Suan peo i aS Sree Soca oe, oan oe Sos ee i com =A Gos nh eC + Intake System * Intake System Intake System '* Charge Air Cooler® Lome Teageee Timmamee : Guat Frege een pou Pear co oe eee Es Poe foes © eter to the Oil Change interval chart given in Section 4 to find the specific ol change interval for your application. ® intial valve lash clearance adjustment, subsequent adjustments to be performed at 77,000 Km (48,000 mile intervals or every &th oil ‘change for automotive engines or, 2000 hours, 2 year intervals for industrial engines. Mustuse a heavy duty year around antifreeze that meets the chemical composition of GM6038M. The change intervals 2years or 320,000 Km [200,000 Mij, whichever occurs first. Antifreeze is essential for freeze, overheat and corresion protection. * Service interval is 2 years or 320,000 Km [200,000 Mi, whichever occurs first. * Service interval is every other oil change or 19,000 Km {12,000 miles}, 500 hours or 6 months, whichever comes first.General Information All checks or inspections listed under daily or previous maintenance intervals must also be performed at this time in addition to those listed under this maintenance interval. ‘The procedures given in this section for valve lash adjustment are to be performed at the initial 38,000 km [24,000 mi] adjustment. Subsequent adjustments are to be performed at 77,000 km [48,000 mi] intervals. Valves Adjustment 15mm Remove the valve cover. 1/2 Inch Drive, 3377371 Engine Barring Gear Locate Top Dead Center (TDC) for Cylinder Number 1 by barring engine slowly while pressing on the engine tim- ing pin.Feeler Gauge Intake Clearance: 0.254 mm [0.010 IN] Exhaust Clearance: 0.508 mm [0.020 IN] (Check/set valves with engine cold-below 60°C [140°F]. NOTE: The clearance is correct when some resistance is “felt” when the feeler gauge is slipped between the valve ‘stem and the rocker lever. Four Cylinder Engine Adjustment 14 mm, Flatblade Screwdriver Locate Top Dead Center (TDC) for Cylinder Number 1. Check/adjust the valves as indicated in the illustration (= Intake; E = . Tighten the locknut and measure the valve lash again. Torque Value: 24Nem [18 fb] ‘When the pin engages the hole in the camshaft gear, Cylinder Number 1 is at TDC on the compression stroke. Caution, To prevent damage to the engine or pin, be sure to disengage the pin after locating TD‘Stanadyne DB4 Dataplate Location Robert Bosch In-Line Dataplate Location Injection Pump Dataplate Tho injection pump dataplate is located on the side of the injection pump. The dataplate provides information for fuel pump calibration. Robert Bosch VE dataplate location. Lucas CAV DPA dataplate location.‘The Cummins part number for the fuel pump-governor combination is located on the governor dataplate. Nippondenso Fuel Injection Pump Dataplate Location The Nippondenso fuel injection pump dataplate con- tains the Nippondenso fuel injection pump part number (A), the Nippondenso serial number (B), the Cummins part number (C) and the fuel injection pump bar code ©).Six-Cylinder Engine Adjustment 14 mm, Flatblade Screwdriver Locate Top Dead Genter (TDC) for Cylinder Number 1 Check/adjust the valves as indicated in the illustration (= Intake, E = Exhaust. Tighten the lock nut and measure the valve lash again. Torque Value: 24Nem [18 ftib] Mark the pulley/vibration damper and rotate the crank- shaft 360 degrees. Caution: To prevent engine or pin damage, be sure timing pin is disengaged. ‘Mark the pulley and rotate the crankshaft 360 degrees. Caution: To provent engine or pin damage, be eure timing is disengaged. 14 mm, Flatblade Screwdriver ‘Adjust the valves as indicated in the illustration. Tighten the lock nut and measure the valve lash again. Torque Value: 24Nem [18 fib] R) ae@) ‘Adjust the valves as indicated in the illustration. Tighten the lock nut and measure the valve lash again. 8 Torque Value: 24 Nem [18 feb] 15mm Install the valve covers and tighten capscrews. =] ‘Torque Value: 24 Nem [18 feb)

Exhaust - mm fin 0.51 [0.020] ~ Compression Ratio 18.5:1 1784 1651 18.5: 1754 16.51 Rotation viewed from the Front of the Engine = ++ Clockwise -~ x x x x x x x Xx LUBRICATION SYSTEM KPa [psi] 453.9 4B73.8__4BTA3.S" 685.9 @BTS.9 _ GBTASS Minimum Allowable Oil Pressure @ Tale 6910) 69 [10] 69 [10] 68 [10] 69 [10] 69 [10] Minimum Alowable 1 Pressure @ Fated 207 (90] 207 (80) 20780) 207 (90) 2790) -207 (3 Regulated Pressure 449 [65] 44965] 449 [65] 44965] 449 [65] Differential Pressure to Open Filter Bypass ‘Seo 138 [20] 13820] 138 [20] 13820} 138 [20] il Capacity L [QT] ‘Standard Pan Only 95 [10] 95 [10] 95 [10] 14.2 [15] 14.2115] 14.2115] ‘Total System (Pan, Filter, Lines) 109 [11.5] [11.6] 11[11.6] 16.3[17.2] 16.4117.3] 16.4 [16] No. QTS From “L” to “H” on Dipstick mW fl tt io La 2 COOLING SYSTEM L [QT] Engine Coolant Capacity 7074] 70174] 79184 9.0195] 9.0195) 9.91105) ‘Thermostat Modulating Range °C [°F] 395 8395 e395 ages 895) 83.05 [181-230] [181-203] [181-209] [181-203] [181-203] [181-203] Pressure Cap kPa [psi] 104°C [220°F| 70315] 103 [15] 10815] 103/15] 103115] 103 [15] 99°C (210°F] 407 48(7] 8] a8] 487] 48) * Jacketwater aftercooledINTAKE AIR, EXHAUST AND FUEL SYSTEM 483.9 4573.9 45BTA3.9 —_—GBE.9 6BT5.9 _ GBTAS.9 Maximum Allowable Intake ‘Speed ‘and Load with Dirty Air Fit ter Element - mm H0 fin. HO] ne Maximum Allowable Ex- haust Restriction at Rated Speed and Load - mm Hg [in. Hg} Maximum Allowable Re- stiction to Transfer Pump - 508 [20} 635 [25] 635 [25] ‘508 [20] 635 [25] 635 [25] 76.2 mm {3 in.] ~ mm Hg fin. Ha} === 100 mm [4 in, == Maximum Allowable Retum Line Restriction - mm Hg [in. Hg] -- 518 mm [20.4 in,] Maximum Fuel Pressure Drop Across Filters kPa [psi] .. ~ S48} -- ELECTRICAL SYSTEM 453.9 4BT3.9ABTAS.S 665.9 GBTS.9 _6BTAS.S Minimum Recommended Battery Capacity - With Light Accesso- 625CCA G25CCA B00CCA BOUCCA— 800CCA. 400CCA 400CCA 400GCA 4006CA 4006CA, B00CCA — BOUCCA 950CCA 950CCA950CCA. A00CCA 400CCA 475CCA 475CCA475CCA o.0012 0.0020 "Win 12 V Staer - Ohms - With 24 V Starter - Ohms * Typical light accessories include alternator, small steering pump, and disengaged clutch. **"Typical heavy accessories include hydraulic pump and torque converter. Batteries (Specific Gravity) Rare eed State of Charge 7-260 - 1.280 700% 1.280 - 1.250 75% 1.200 - 1.220 50% 1.170 - 1.190 25% 1.110 - 1.130 DischargedGeneral Specifications (Automotive Engines) Lubricating SystemkPa [psi] | 63.9-110 | B3.9-130 | B5.9-160 | 85.9-176 | B5.9-190 | 85.9210 | B5.9-230 ‘Bore - mm fin. "102 (4.02) 102 [4.02] | 102 4.02) | 102 [4.02] | 102 [4.02] | 102 [4.02] | 102 [4.02} Stroke - mm [in. 420 [4.72] | 120 (4.72) | 120 [4.72] | 120 [4.72] | 120 [4.72] | 120 [4.72] | 120 [4.72] Displacement - liter fin] 3.9 [239] | 3.9 [239] | 5.9 [359] | 5.9 [959] | 5.9 [959] | 5.9 [359] | 5.9 [959] Engine Weight (Dry) Less Flywheel and Electrics - kg lbs} 308 [680] | 308 [680] | 428 (942] | 428 [942] | 428 [942] | 428 [942] | 428 [942] 153 | 153 | 153 | 153 | 153 Firing Order . 1342 | 1942 | 624 | 624 | 624 | 624 | 624 Valve Clearances: 0.25 0.25 0.25 0.25 0.25 0.25 0.25 + Intake - mm fin] [0.010] | {0.010} | 0.010) | fo.010) | [0.010] | [0.010] | (0.010) ost ost 0.51 0.51 O51 ost 0.51 Exhaust - mm fin {0.020} | {0.020} | [0.020] | {0.020} | [0.020] | [0.020] | 0.020] wer | 1761 | 1751 | 17s | aan | aan | tas Rotation, viewed from the Front of the Engine Clockwise | Clockwise | Clockwise | Clockwise | Clockwise | Clockwise | Clockwise Aspiration: - Naturally Aspirated - Turbocharged x x x x x x x - Afteroooled. - Charge Air Cooled. x x x x x x x General Specifications (Automotive Engines) Lubricating System kPa [psi] _| 65.9-110 | 63.9-190 | 85.9-160 | B5.9-175 | 85.9-190 | 85.9-210 | B5.9-230 Min. Allowable Press. @ Idle.... 69 [10] | 69[10) | 69[10) | 69[io] | 69[10] | 69[10) | 69 [10] Min, Allowable Press. @ Rated | 207 [30] | 207 [30] | 207 [30] | 207 [30] | 207 [30] | 207 [80] } 207 [30] Regulated Pressure 449 [65] | 449 [65] | 449 [65] | 449 [65] | 449 [65] | 449 [65] | 449 [65] Filter Bypass Dift. Pressure | 138 [20] | 198 [20] | 198 [20] | 138 [20] | 198 (20) | 138 [20] | 138 (20) il Capacity L [aT]: - Standard Pan Only. 95 [to | 9510) | 14.2 [15] | 14.2115) | 14.2 [15] | 14.2 115) | 142115] - Total System. 16.4 164 164 | 164 16.4 aig) | nine) | 73) | 73) | 973) | 173) | 1173) QTS From “L" to"! tt R fl 2 a fal ‘COOLING SYSTEM L [GT] 9-105 | B3.9-120 | B5.9-160 | B5.9-180 | B5.9-190 | B5.9-210 | 85.9-230 Engine Coolant Capacity 7.0 [7.4] | 7017-4] | 9.0 (9.5) | 9.0/9.5) | 9.0[9.5) | 9.0/9.5] | 9.0 [9.5] Thermostat Modulating c ases | s3e5 | e395 | e395 | a305 | 8395 | 8395 A 1181-203] | [181-203] | (181-203) | {181-203} | [181-209] | [181-203] | [181-203], Pressure Cap kPa [psi = 104C° [220° = 990° [210°F} 103 {15} | 103 [15] | 103 {15} | 103 [15] | 103[15] | 103 [15] | 103 [15] 48171 4817) 48 7) 48171 4871 48 (7) 48 171Intake Air, Exhaust, And Fuel System 83.9-110 | B3.9-130 | B5.9-160 | B5.9-175 | B5.9-190 | B5.9-210 | B5.9-230 ‘Maximum Allowable Intake Restriction at Rated Speed ‘and Load with Dirty Air Filter Element - mm H0 fin. #20) 635 [25] | 635 [25] | 635 [25] | 635 [25] | 635 [25] | 635 [25] | 635 [25] Maximum Allowable Exhaust Restriction at Rated Speed 152.4 and Load - mm Hg fin. Hg] ......| 152.4 (6]* | 152.4 (6}* | 152.4 [6]* | 152.4 [6]* | 152.4 [6]" | 152.4 [6]"| [6)* Maximum Allowable Restriction to fuel transfer Pump = With Dirty Filter mm Hg fin. Hg 100 [4] | 10014 | 10044) | 10074) | 100; | 10044) | 10014 ‘Maximum Allowable Return Line Restriction - mm Hg fin. Hl. 518 [20.4] | 518 [20.44] 518 [20.4] | 518 [20.4] 518 [20.4]| 518 [20.4]| 518 [20.4] Maximum Fuel Pressure Drop [Across Filters kPa [psi] 34 [5] S45} 34 (5) 34 [5] 34 [5] * with catalyst General Specifications (Automotive Engines) [Electrical System .9-110 | B3.9-130 | B5.9-160 | B5.9-175 | B5.9-190 | B5.9-210 | B5.9-230 goocca | 800cca | B00ccA 4oocca | soocca | 400cca gsocca | 9506CA | 950CCA 4750CA | 475CCA | 475CCA -With 12 Starter-Ohms | .oo12 | .oo12 | .oo12 | .oo12 | .oo2 | .oo12 | oo12 =With 24 Starter-Onms | .0020 | .oa20 | .oo20 | .oo20 | .oo20 | .oo20 | 0020 “Typical light accessories include alternator, small steering pump, and disengaged clutch. * “Typical heavy accessories include hydraulic pump and torque converter.Fuel Recommendations/Specifications A ‘Warning: Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion. A Caution: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and the injection nozzles. A Caution: Do NOT use diesel fuel blended with lube oil in engines equipped with a catalytic convertor (including all model year 1984 and beyond). Damage to legally required emission control may result. Use ASTM No. 2 D fuel with a minimum Cetane number of 40. No. 2 diesel fuel gives the best economy and performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke. ‘At operating temperatures below 0°C [32°F], use a blend of No. 1 D and No. 2 D fuels, also known as “winterized” No. 2D. NOTE: No. 1 D fuel can be used, however, fuel economy will suffer. Use low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel ‘temperature. Cloud point is the temperature at which was crystals begin to form in diesel fuel. ‘The viscosity of the fuel must be kept above 1.3 centistokes to provide adequate fuel system lubrication at 40°C [104°F}. For a more detailed description of fuel properties, rafer to Fuel For Cummins Engines, Bulletin No. 3378001. The following chart lists acceptable alternate fuels for MidRange engines. ‘Acceptable Alternate Fuels - Component Wear/Durability Fuel Bosch Nippondenso | Stanadyne ] Lucas CAV ‘Type A P7100 VE EPS pea | DPA DPS NO. 1D Diesel OK OK OK ‘OK OK [| OK OK NO. 2 Fue! it OK OK OK oK OK oK OK NO.1-K Kerosene | OK OK oK 5 5 NO.2K Kerosene | OK OK : oK . : . seta OK Ok oK a Jet At OK = OK S oK 9 5 wPS OK OK o oK o ° uP8 OK = OK ° oK : 5 Jet Not ok Not ok Not ok Not ok Notok | Notok — Not ok wP4 Notok Notok Not ok Not ok Notok | Notok Not ok Cite Not ok Not ok _Not ok Not ok Not ok | Not ok Not ok * OK ONLY if 5% new lube oil is blended with these fuels to increase the lubricity to acceptable level. Caution: Do NOT use diesel fuel blended with lube oil in engines equipped with a catalytic convertor (including all model year 1994 and beyond). Damage to legally required emission control may result. NOTE: Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not war- rantable. NOTE: Wear on any mid-range fuel pump component attributed to the lack of lubrication in the fuel is not a warrantable repair.Lubricating Oil Recommendations/Specifications Oil Performance Recommendations The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals are critical factors in maintaining engine performance and durability. ‘Cummins Engine Company, inc. recommends the use of a high quality SAE 15W-40 heavy duty engine oil (such as Cummins Premium Blue) which meets the American Petroleum Institute (API) performance classification CEISG. : NOTE: CC/CD or CD/SF engine oils can be used in areas where CE oil is not yet available, but the oil change interval must be reduced to one half the interval given in the maintenance schedule. sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control. The sulfated ash must not exceed 1.85 mass percent. Oil Viscosity Recommendations ‘The use of multi-viscosity lubricating oil has been found to improve oil consumption control and improve engine ranking in cold temperatures while maintaining lubrication at high operating temperatures. While 15W-40 oil is recommended for most climates, refer to the accompanying table for oil viscosity recom- mendations for extreme climates. NOTE: Limited use of low viscosity oils, such at 10W-30 may be used for easier starting and providing sufficient oil ‘flow at ambient temperatures below -5°C [23°F]. However, Continuous use of low viscosity oils can decrease engine life due to wear. Refer to the accompanying chart. Alt Seasons winter Condon Arce Conditions sce bee Tee ee we amtas New Engine Break-In Oils Donot use special “break-in” lubricating oils for new or rebuilt Cummins engines. Use the same type of oil during the “break-in” as that which is used in normal operation. Recommended Oil Change Intervals Refer to the following flowchart for the recommended oil change interval based on engine application.pal easTaTon Sey rg me rare ‘Homey application? Yes reese YES KM MILES HOURS MOS = Vehicle accum 8000 miles/mth. or more. 17900 mo DS NO Ta BEE TGS ra (0) Or whichever comes fist. your vevenue at tee ew ts application accumulates "high eco we A es fursandlowmieage, he charge NO MeeeDumper 2000 gon Zz I interval is determined by hours. Satyr: Gas i BS Example: Wansit buses and ara oe Be: fetuse tucks may average. 16 Rinica wise “BOS BG Kmin [10 MPH] when used in an all urban routes. Oil drain intervals Boo wie wed ne | YES [Use te fotowng of cin ntnal fr your appcation CF inthose applications are 4,800Km ? VeNCLEEQUP KM MILES. HAS. MOS. i . ‘ogoing Appa? HRS mgs 18,000 mi] or less. Boe Gao we Na Na Na Na Na Oil Consumption In addition to the information that follows, a service publication entitled Technical Overview of Oil Consumption is available, Bulletin 3379214-00. ‘Cummins defines “Acceptable Oil Usage” as outlined in the following tabi "ACCEPTABLE OIL USAGE ‘ANY TIME DURING COVERAGE PERIOD HOURS MILES KILOM HRS HRS PER | MILES MILES | PER | KLOM KILOM PER ENGINE|PER PER IMPERIAL | PER PER IMPERIAL | PER PER IMPERIAL FAMILY | QT UTER QUART | QUART LITER QUART | QUART LITER QUART. 48 100 106 120 | 400 42 475 650 «6751S 68 00 106 120 ~«| 400 «45ST 650 «67ST 6C yoo 106 120 =| 400 425 «475 650675: 75Arctic Operation Itan engine is operated in ambient temperatures consistently below -23°C [-10 °F] and there are no provisions to keep the engine warm when it is not in operation, use a synthetic CE/SG engine oil with adequate low temperature properties such as; SW-30. ‘The oil supplier must be responsible for meeting the performance service specifications. Caution: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can decrease engine life due to factors such as; corrosion, deposits and wear. Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines.” The data book may be ordered from the engine Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601. ‘The telephone number is: (312) 644-6810. Coolant Recommendations/Specifications Heavy duty diesel engines require a balanced coolant mixture of water and antifreeze. Drain and replace the mixture every 2 years, 320,000 KM [200,000 miles] or 6,000 hours of operation (whichever occurs first) to eliminate buildup of harmful chemicals. ‘+ Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreaze in the mixture unless additional freeze protection is required. Never use more than 68 percent antifreeze under any condition. ‘© Use soft water in the coolant mixture. Contaminants in hard weter neutralize the corrosion inhibitor components. Water must not exceed 300 ppm hardness, or contain more than 100 ppm of either chloride or sulfate. '* Specifications - Use low silicate antifreeze which meets ASTM4985 test (GM6038M spec.) critera. Concentration - Antifreeze must be used in any climate for both freeze and boiling point protection. Cummins recommends a 50 percent concentration level (40 percent to 60 percent range) of ethylene glycol or propylene glycol in most climates. Antifreeze at 68 percent concentration provides the maximum freeze protection and must never be exceeded under any condition. Antifreeze protection decreases above 68 percent. Ethylene Glycol Propylene Glycol 40% = -23°C [-10°F] 40% = -21°C [-6°F] 50% = -37°C [:34°F] 50% = -33°C [27°F] 60% = -54°C [-65°F] 60% = -49°C [-56°F] 68% = -71°C [90°F] 68% = -63°C [-82°F] Concentration Testing - Antifreeze concentration must be checked using a refractometer (such as Fleetguard Part No. CC2800). Floating ball” type density tasters or hydrometers are not accurate enough for use with heavy duty diesel cooling systems.‘Socket or Wrench Size MM (inch) 10 13 134) 15 18 10 Allen 5 mm 18 15 (516) " 15 16 ane 10 10 13 19 7 Engine Component Torque Value ‘Aftercooler Mounting = ‘Aitercooler Water Hose Ciamp Alternator Link (Delco 10-15 SI) Alternator Link (Delco 20-27 Si!) Aiternator Mig. Bott 10-15 SI Altermator Mig. Bott 27 SI .. Alternator Support (Upper) Belt Tensioner Fiat Bracket .. Belt Tensioner Mounting Crankshaft Damper & Pulley Crossover Clamp ‘Tee Bolt Type Clamp .. Exhaust Manifold Exhaust Outlet Pipe Mig Bracket Exhaust Outlet Pipe, V Band Clamp Fan Bracket Mounting ... Fan Pulley Fan Pulley Flywheel Front Cover Ciamp Access Cap... Fuel Drain Line Banjo Screw (Rotary Pump) Te GaeRraavo wks RossonEngine Component Torque Value (Continued) ‘Socket or Wrench Size Tor MM (Inch) Nem: (Ft) 17 Fuel Banjo Screw (in Filter Head) 24 118) 10 Fuel Vent Screw (in Banjo) .. 9 a 10 Fuel Banjo Screw (Injector) 9 al 75-85 Fuel Filter 3/4 Tum After Contact 24 Fuel Filter Adapter Nut 32 [24] 17 or 19 Fuel Line Fitting (High Pressure) 24 (18) 2 Fuel Pump Drive Gear (with Pump Unlocked) Rotary 65 148} 22 Fuel Pump Drive Gear (Pump Unlocked) Nippondenso .. 123 [82] 30 Fuel Pump Drive Gear (Pump Unlocked) Bosch inline. 165 [122] 10 Fuel Pump Lock (Bosch) Rotary 30 (22) Fuel Pump Unlock (Bosch) Rotary 3 [10] 14 Fuel Pump Lock (CAV) 7 (8) Fuel Pump Unlock (CAV) .. 20 115] 13 Fuel Pump Mounting Nuts (Bosch Rotary) 24 [18] 15 Fuel Pump Mounting Nuts (Bosch In-Line, Nippondenso) .. 423 [32] 13 Fuel Pump Mounting Nuts (CAV) 30 [22] 13 Fuel Pump Support Bracket 24 (18) 24 Injector Retaining Nut .. 60 (44) 18 Intake Manifold Cover 24 [13] 10 Litt Pump/Cover Plate .. 24 113} 18 Lifting Bracket (Rear) 7 157] ‘Socket or Wrench Size Torque ‘MM (inch) Nem (Ft) 7585 3/4 Turn Afler Contact 10 24 118) 7 Oil Pan Drain Plug 80 [60] 27 Oil Pan Heater Plug 80 {0} 19 Oil Pressure Regulator Plug 80 [60] 10 Rear Seal Housing 9 il 14 Rocker Lever Nut .. 24 [13] 10 Starter Mounting 43 {32} 10 Tappet Cover/Fuel Drain Line Supports, 24 18} 10 ‘Thermostat Housing 24 {18} 13 ‘Turbine Housing 20 [15] 10 ‘Turbo Compressor Housing Clamp 85 (6) 16 Turbo Mounting Nuts 43 [32] 13 Turbo Drain Tube 24 [18] 16 ‘Turbo Oil Supply (Both Ends) 35 [8] 5 Water Inlet Connection 43 [32] B Water Pump Mounting 24 118) 15 Valve Cover 24 (18) Valve Cover Oil Fill . Hand Tighten