Ingersoll Rand P100WD P125WD 1

INGERSOLL-RAND®
AIR COMPRESSORS
Portable Compressor Division
P.O. Box 868
Mocksville, N.C. 27028
COMPRESSOR MODEL
P100WD
P125WD
Book P/N 35389816 (April, 1995)
.257386.-257425
Code:E
© !-Rand Co. 1
Book 35389816 (4/95) ( 1)

QUALITY POLICY
We will supply products and services that consistently meet the requirements
of our customers and each other.
Book 35389816 (4/95) (2)

TABLE OF CONTENTS
SECTION SAFETY
SECTION WARRANTY
SECTION WARRANTY REGISTRATION
SECTION OPERATION
SECTION GENERAL DATA
SECTION MAINTENANCE/LUBRICATION
SECTION PARTS ORDERING
SECTION ENGINE INFORMATION
SECTION PARTS LIST
SECTION PARTS REFERENCE
Book 35389816 (4/95) (3)

SECTION 1 - SAFETY
I'
I
Look for these signs which point out potential hazards to the safety of you and others.
Read and understand thoroughly. Heed warnings and follow instructions. If you do not
understand, inform your supervisor.
Indicates the presence of a hazard which WILL cause

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

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

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

information.
(Blue Background)
Book 35389816 (4/95) (4)

Never operate unit without first observing all safety warnings and carefully reading the operation
and maintenance manual shipped from the factory with this machine.
Air discharged from this machine may contain carbon

monoxide or other contaminants which will cause severe
Injury or death. Do not breathe this air.
DANGER I I CAUTION~
Never operate the engine of this machine Inside
a building without adequate ventilation. Avoid Exercise extreme caution when using booster
breathing exhaust fumes when working on or battery. To jump battery, connect ends of one
near the machine. booster cable to the positive (+) terminal of
each battery. Connect one end of other cable to
!wARNING I the negative (-) terminal of the booster battery

and other end to a ground connection away
from dead battery (to avoid a spark occurring
A battery contains sulfuric acid and can give off near any explosive gases that may be present).
gases which are corrosive and potentially ex- After starting unit, always disconnect cables In
plosive. Avoid contact with skin, eyes and reverse order.
clothing. In case of contact, flush area Immedi-
ately with water.
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 35389816 (4/95) (5)

IWARNING I IWARNING I
This machine produces loud noise with the
doors open or service valve vented. Extended Never Inspect or service unit without first
exposure to loud noise can cause hearing loss. disconnecting battery cable(s) to prevent
Always wear hearing protection when doors are accidental starting.
open or service valve Is vented.
I
I
Disconnected Air Hoses Whip.
Can cause severe Injury or death.
High pressure air.
Can cause severe Injury or death. Always attach a safetyflowrestrlctor
Relieve pressure before removing filler to each hose "at the source of supply
plugs/caps, fittings or covers. or branch line" In accordance with
OSHA Regulation 29CFR Section
1826.302(b).
!wARNING I
Never run unit with guards, covers or screens
removed. Keep hands, -hair, clothing, tools,
blow gun tips, etc. well away from moving
parts.
jwARNINGI
Do not use petroleum products (solvents or
Air pressure can remain trapped In air fuels) under high pressure as this can penetrate
supply line which can result In
serious Injury or death. the skin and result In serious Illness. Wear eye
protection while cleaning unit with
Always carefully vent air supply line
at tool or vent valve before compressed air to prevent debris from Injuring
performing any service. eye(s).
Book 35389816 (4/95) (6)

Collapsing jack stand.
Will cause severe
Insert locking
pin completely.
Hot pressurized fluid.

Can cause severe burns.
Do not open radiator while hot.
Rotating fan blade.
Can cause severe Injury.
Do not operate without guard In
I CAUTION~ IWARNING I
Use extreme care to avoid contacting hot
surtaces (engine exhaust manifold and piping, Always make sure wheels, tires and tow bar
air receiver and air discharge piping, etc.). connectors are In safe operating condition and
tow bar Is properly connected before towing.
Ether Is an extremely volatile, highly flammable I CAUTION~

gas. USE SPARINGLYIIf too much Is Injected,
It may result In costly damage to the engine. Do not connect the air discharge on this unit
onto a common header with any other unit of
Never allow the unit to sit stopped with any description, or any other source of
pressure In the receiver-separator system. As compressed air, without first making sure a
a precaution, open the service valve. check-valve Is used between the header and
the unit. If this unit Is connected with another
unit, a safety hazard could occur.
Book 35389816 (4/95) (7)

WARNING
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof:
(1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or
replacement, of any device or element of design incorporated into any new compressor for the purpose of
noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the
compressor after such device or element of design has been removed or rendered inoperative by any person.
Among those acts included in the prohibition against tampering are these:
1. Removal or rendering inoperative any of the following:

a. the engine exhaust system or parts thereof
b. the air intake system or parts thereof
c. enclosure or parts thereof
2. Removal of any of the following:

a. fan shroud
b. vibration mounts
c. sound absorption material
3. Operation of the compressor with any of the enclosure doors open.
Book 35389816 (4/95) (8)

& Hazardous Substance Precaution
The following substances are used in the manufacture of this machine and
may be hazardous to health if used incorrectly.
SUBSTANCE PRECAUTION
Compressor Oil A void ingestion, skin contact and breathing fumes.

Engine Lubricating Oil A void ingestion, skin contact and breathing fumes.
Preservative Grease A void ingestion, skin contact and breathing fumes.
Rust Preventative A void ingestion, skin contact and breathing fumes.
Diesel Fuel A void ingestion, skin contact and breathing fumes.
Battery Electrolyte A void ingestion, skin contact and breathing fumes.
The following substances may be produced during the operation of this machine
and may be hazardous to health.
SUBSTANCE PRECAUTION
Engine Exhaust Fumes Avoid breathing.
Engine Exhaust Fumes Avoid build-up of fumes in confined spaces.
Brake Lining Dust A void breathing during maintenance.
Book 35389816 (4/95) (9)

OJ
g
INGERSOll-RAND® PORTABLE COMPRESSOR
"'""'
Ol
AIR COMPRESSORS SAFETY CARD
"'
"'
~ DANGER IS USED TO INDICATE THE
&. WARNING
~ PRESENCE OF A HA2ARO WHICH WILL
L1ii. DANGER
"' CAUSE SEVERE INJURY OR DEATH IFrne
WARNING IS IGNORED.
j WARNING IS USED TO INDICATE THE
PRESENCE OF A HAZARD WHICH CAN
Improper operation of this
equipment
Can cause severe InJury or
Modification or alteration of
this machine.
Can result in severe InJury or
&WARNING CAUSE SEVERE INJURY OR DEATH IF THE death. death.
WARNING IS IGNORED.
Discharge Air can contain carbon monoxide or
Read Operator's Manual Do not alter or modify this
contaminants.
CAUTION IS USED TO INDICATE THE supplied with this machine machine without the express
Will cause severe Injury or death.
~
PRESENCE OF A HAZARD WHICH WILL OR before operation or service. written consent of the
&CAUTION CAN CAUSE MINOR INJURY OR PROPERTY Do not breathe this air. manufacturer.
DAMAGE IF THE WARNING IS IGNORED. This docal near seNic.o This decal rlNtr control pancf.
.. ~
&. WARNING &. WARNING &. WARNING &. WARNING &. WARNING
,~;''·
-
~
-8- f ~2.w.~' ~.:-~,~="

~
Disconnected air hoses whip.
Can cause severe InJury or death. ~
~
Combustible gas.
Trapped air pressure. Attach safety flow restrictor to each
Ct~n cause severe burns,
High pressure air. can cause severe injury or death. hose ..at the source of supply or blindness or death. Rotating fan blade.
Can cause severe Injury or death. branch line" in accordance with Can cause severe InJury.
Close service valve and operate OSHA Regulation 29CFR Section
Keep sparks and open flame
Relieve pressure before tool to vent trapped air before 1926.302(b). Do not operate without
away from batteries.
removing filler plugs/caps, performing any service. guard in place.
This decaf near receiver tank. rn1s dflCdl no:Jr sofllicc valve. This decaf near SoflliCC outlet. Tflfs doctJI near battery. This decal near Jan.
&. WARNING
/ ...
&. WARNING
'
:•..
.
~
Excessive towing speed. ('</]~
~~ 1
Hot pressurized fluid.
~, ;'·,7
Collapsing Jackstand.
Can cause severe Injury or
death. /
Can cause severe bums.
,,\
' Do not open radiator while
Can cause severe Injury.
Do NOT exceed 50 mph hot. ([c l!!g'];A
(80 km/ph.) ( ~
Insert locking pin completely.
!\'-.. This decal on drawbar. This dacal naar radiator cap.
SECTION 2- WARRANTY
Ingersoll-Rand, through its distributor, warrants that each item of equipment manufactured
by it and delivered hereunder to the initial user to 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 to the initial user, whichever first occurs.
With respect to the following types of equipment, the warranty period enumerated will apply
in lieu of the foregoing warranty period.
Aftercoolers, Drill Mountings and Klemm Rotary Heads- The earlier of six (6) months from initial operation
or nine (9) months from date of shipment to the initial user.
Portable Compressors, Portable Generator Sets (GENSET), Portable Light Towers and Abrasive Blasting
Equipment- The earlier of twelve {12) months from shipment to, or the accumulation of 2,000 hours of service
by, the initial user.
All Compressor Air Ends, GENSET Generators and Paving Breakers- The earlier of twenty-four (24) months
from shipment to, or the accumulation of 4000 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
unopened.
Pavers, Milling Machines, Pedestrian Compactors (Including baseplates, upright and walk behinds) and
Rotary Drills- The earlier of (6) months from shipment to, or the accumulation of 1000 hours of service by, the
initial user.
Jackhammers, Forklifts and Self-Propelled Compactors- The earlier of twelve (12) months from shipment
to, or accumulation of 1000 hours of service by, the initial user.
Downhole Drills - In lieu of the repair or replacement of defective parts, Ingersoll-Rand may elect to Issue full
or partial credit toward the purchase of a new part. The extent of credit issued will be determined by pro rating
against the normal service life of the part in question.
Spare Parts (excluding downhill drills)- Three (3) months from date of shipment.
Book 35389816 (4/95) (11)

arising out of this sale or any breach thereof, or any
defects in, or failure of, or malfunction of the
Warrantv equipment under this sale whether based upon loss
Ingersoll-Rand will provide a new part or repaired of use, lost profits or revenue, interest, lost goodwill,
part, at its election, in place of any part which is work stoppage, impairment of other goods, loss by
found upon its inspection to be defective in material reason of shutdown or non-operation, increased
and workmanship during the period prescribed expenses of operation of the equipment, cost of
above. Such part will be repaired or replaced with- purchase of replacement power or claims of users
out charge to the initial user during normal working or customers of the user for service interruption
hours at the place of business of an lngersolf-Rand whether or not such loss or damage is based on
distributor authorized to sell the type of equipment contract, warranty, negligence, indemnity, strict
involved or other establishment authorized by ln- liability or otherwise.
gersolf-Rand. User must present proof of purchase AIREND EXCHANGE PROGRAM
and date at the time of exercising warranty.
This warranty does not apply to failures occurring Your Ingersoll-Rand Company Construction
as a result of abuse, misuse, negligent repairs, cor- Equipment Group Sales Offices and authorized
rosion, erosion and normal wear and tear, alter- distributors as well as lngersolf-Rand International
autonomous companies and authorized distributors
ations or modification made to the product without now have an airend exchange program to benefit
express written consent of Ingersoll-Rand; or fail- portable compressor users.
ure to follow the recommended operating practices
On the airend exchange program the exchange
and maintenance publications.
price is determined by the age and condition of the
Accessories or equipment furnished by lngersolf- airend and may be classified by one of the following
Rand, but manufactured by others, including, but categories.
not limited to, engines, tires, batteries, engine elec- Category "A": The airend must not be over two
trical equipment, hydraulic transmissions, carriers, years old and must have reusable rotor housing{s)
shall carry whatever warranty the manufacturers and rotor{s).
have conveyed to Ingersoll-Rand and which can be
passed on to the initial user.
Category "B": The airend must be between two
This warranty Is In lieu of all other warranties and five years old and returned with two or more
(except of title), expressed or implied, and there reusable major castings.
are no warranties of merchantablllty or of
fitness for a particular purpose.
Category "C": The airend must be over five years
Limitation of Liabilitv old.
The remedies of the user set forth under the Your nearest sales office, autonomous company or
provisions of warranty outlined above are exclusive authorized distributor must first contact the Parts
and the total liability of lngersolf-Rand or its Service Department at the factory at which your
distributors with respect to this sale, delivery, portable air compressor was manufactured for an
installation, repair or technical direction covered by airend exchange number. The airend must be
tagged with this preassigned number and returned
or furnished under this sale whether based on
to the factory prepaid. The airend must be intact,
contract, warranty, negligence, indemnity, strict with no excluded parts, otherwise the exchange
liability or otherwise shall not exceed the purchase agreement may be cancelled. The warranty on an
price of the unit of equipment upon which such exchange or factory rebuilt airend is 365 days.
liability is based.
Ingersoll-Rand, its suppliers{s) and its distributors Note: Airends being returned to the factory in
shall in no event be liable to the user, any connection with a WARRANTY CLAIM must be
processed through the Customer Service
successors in interest or any beneficiary or Department. If returned without a Warranty MRR
assignee relating to this sale for any consequential, {Material Return Request) Number, no warranty
incidental, indirect, special or punitive damages claim will be considered.
Book 35389816 {4/95) (12)

General Warranty Information
(20--50 KW) 2 hrs.

(2.5-6 KW) 1 yr/2000 hrs (parts & PRODUCT
hrs WARRANTY
ENGINE
WARRANTY
Kubota 24 2000 major components

25-36 mo/3000 hrs
PARTS WARRANTY
A/REND EXCHANGE
WARRANTY
Book 35389816 (4/95) (13)

SECTION 3 - WARRANTY REGISTRATION
Complete Machine Registration
Machines shipped outside the United States require notification be made to initiate the
machine warranty.
Machines shipped to locations within the United States do not require a warranty
registration unless the machine status changes (i.e. change of ownership).
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.
Engine Registration:
No engine registration required. Must present Proof of Purchase whenever engine warranty
service is required.
Book 35389816 (4/95) (14)

INGERSOLL-RAND®
AIR COMPRESSORS Warranty Registration Form
SELliNG O!SIB!B\JTOB SERVICING Q!SJB!Bl!TOB WARRANTY REGISTRA110N

Name ______________________
Name --------------------- Owner/User Name -------------
Address ------------------- Address------------------- Address-------------------

Chy _ _ _ _ _ _ _ _ _ __ Chy ___________________
City ----------------------
County ____________________ County ___________________
County --------------------
Slate _____________________
Stale ------------------- State - - - - - - - - - - - - - - - - - -
Zip Code ------------------ Zip Code ------------------ Zip Code -----------------
Telephone ------------------- Telephone------------------- Telephone-------------------
COMPLETE THE APPLICABLE BLOCKS

Owner/User Type of Business
(check only one)
:·;
CJ Construction-Heavy ~
~ Asphalt Contractor 0 Coal Mining Other Mining
(Highway, excavation, etc.)
CJ Construction-Light CJ Government 0 Quarry :1 Shallow Oil & Gas

(carpentry, plumbing, pools, (municipal, state,
mason, etc.) county, etc.)
0 Rental o Building Contractor 0 Waterwell 0 Utility Company

(rental center, (gas, electric, water, etc.)
rentallleet, etc.)
0 Industrial C Other 0 Exploration 0 Utility Contractor

(plant use) specily - - - - - - - - -
Model Unrr SIN Engine SiN Date Delv'd
Unit-Hours Air End SIN Truck SIN Truck Engine SIN
SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT

1. The Purchaser has been instructed and/or has read the manual and understands proper preventative maintenance, general
operation and safety precautions
2. The warranty and limitation olliability (see reverse side) has been reviewed and understood by the owner/user.
3. In the event that this unh is to be used wrrhin a nuclear faciley, the owner/user shall notify fngersoii·Rand of such use so that
Ingersoll-Rand may arrange for appropriate nuclear Iiabilhy protection from the owner-licensee of the facilny.
4. lngersoii·Rand reserves the right to make design changes or modifications to Ingersoll-Rand products at anytime wnhout
incurring any obligation to make similar changes or modifications on previously sold unhs.
I hereby acknowledge acceptance of above and the conditions on reverse side.
Owner/User --------------------------------------- Date----------~----------------

I hereby certify that the above is accurate and complete
Distributor/1-R Rep. ---------------------------------- Date-------------------------
COMPLETION OF THIS FORM VALIDATES THE WARRANTY X-4051-C

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SECTION 4 - OPERATION
BEFORE TOWING
IwARNING I - Ensure that tires are inflated to 32 psi (220kPa).

- Do not tow this unit in excess of 50 mph (80
Failure to follow these Instructions could result km/hr).
In very serious personal Injury or death.
- Use a tow vehicle whose towing capacity is
greater than the gross weight of this unit.
I CAUTION~ DISCONNECT
- Position the tow vehicle to align its hitch with the -Set the vehicle parl<ing brake. Chock wheels of
pintle eye or coupler of the compressor. unit.
- Engage the parl<ing brake and chock the wheels -Standing to the side, remove pin from tube of jack.
of the tow vehicle. As jack tube swings down, FULLY insert pin in the
tube.
-Stand to the side and ensure pin is FULLY inserted
(secure) in tube of jack. Crank jack to seat pintle eye -Disconnect safety chains. Crank jack to raise eye
or coupler onto hitch. Latch and lock hitch. Cross or coupler from hitch. Tow vehicle can be moved.
safety chain(s) under drawbar. Attach to vehicle.
-Crank jack to raise pad off the ground, etc. Pull pin
from tube of jack. Fold jack handle down and
UTILITY PACKAGE SET-UP
forward. Swing up jack tube and FULLY insert pin (no running gear)
in tube. The unit must be located on vehicle bed to allow
SETTING - UP (ALL UNITS) access for normal servicing and maintenance.
The air going into the inlet grille must be relatively
• Place the unit in an open, well-ventilated area.
free of oil, dirt, soot and other debris. It must be no
Position as level as possible. The design of these
more than 10 degrees F. (5 degrees C) over the
units permits a 15 degree sidewise limit on
ambient temperature.
out--<>f-level operation.
•When the unit is to be operated out--<>f-level, it is
important: (1) to keep the engine crankcase oil level OIL COOLED ENGINE
near the high level mark (with the unit level), and (2)
to have the compressor oil level gauge show no
more than mid-scale (with the unit running at full
I CAUTION~
load). Do not overtill either the engine crankcase or
the compressor lubricating oil system. Do not remove oil coolant hose or connections
while engine Is running.
TOWING
IwARNING I IwARNING I
Failure to follow these Instructions could result NO SMOKING, SPARKS or OPEN FLAME near
In very serious personal Injury or death. fuel.
-Ensure that tires, wheels and running gear are in
good condition and secure.
Book 35389816 (4/95) (15)
Control Panel
D~al00§@:111~G:J@.
® 0 0-- 0
0 -~ 0
Pr6Stige SeriBS. <ll=-,%]
0 .l. C! '"(!)- ~AM
~~-
~=~~
~ = 8
®0 -0- ~"" ~~0..
~=
~ ~
"i\0 ~·-~~
~ = 'f(
CD ~-~
® ®0 0 0
s~ ~-~ r::!l \'C(.'NI!I'e'i <:> ~~
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36525830
Operating Controls/Instruments (Standard) Diagnostics/Auto Shutdown Lamps (Optional)
1. Master Switch (start)- 6. High Compressor Temperature-

Rotate to "ON"; observe any lit Diagnostic Lamps. Glows when compressor discharge air temperature
See Lamp Test Instructions. Rotate to"START' to exceeds 248°F (120°C)±.
crank engine; release when engine sustains firing.
7. Low Engine 011 Pressure -
Glows when engine oil pressure drops below 2.5 psi

2. Service Air Button- Push After Warm-up (17 kPa)±.
(Optional)
8. High Engine Temperature -
A wo-way valve that provides full air pressure at
the service outlet. Glows when engine coolant temperature is exces-
sive. Oil cooled Engine: 266° F (130° C).
9. Low Fuel Level (Optional)-

3. Light Switch (Option, for Gauges)-
Glows when less than 1 gallon in tank.
Otherwise, lights in gauges are controlled by the-
Master Switch (1). 10. Alternator Not Charging -
Indicates alternator or drive belt failure.

4. Air Discharge Pressure Gauge - 11. Air Filters Restricted (Optional)-
Indicates pressure in receiver tank, normally from 0 Indicates the air filters need servicing.
psi (kPa) to the rated pressure of the machine.
12. Any Special Option
5. Hourmeter-
OPTIONAL GAUGES Not Shown
Records running time for maintenance.
Engine Oil Pressure Tachometer
Engine Temperature Voltmeter
Compressor Temp. Fuel Level
Book 35389816 (4/95) (16)

BEFORE STARTING
WARNING
I CAUTION~
This machine produces loud noise with doors
Do not connect the air discharge on this unit open. Extended exposure to loud noise can
cause hearing loss. Wear hearing protection
Into a common header with any other unit of
when doors or valve (s) are open.
any description, or any other source of
compressed air, without first making sure a • Close the side doors to maintain a cooling air
check valve Is used between the header and the path and to avoid recirculation of hot air. This
will maximize the life of the engine and
unit. If this unit Is connected with another unit,
compressor and protect the hearing of
a safety hazard could occur. surrounding personnel.
• Be sure no one Is IN or ON the compressor

IWARNING I unit.
Unrestricted air flow from a hose will result In

a whipping motion of the hose which can cause
I CAUTION~
severe injury or death. A safety device must be
attached to the hose at the source of supply to Exercise extreme caution when using a booster
reduce pressure In case of hose failure or other battery to start. To jump start: Connect the ends
sudden pressure release. Reference: OSHA of one booster cable to the positive (+)
regulation 29 CFR Section 1926.302 (b). terminals of each battery. Then coonect one
end of the other cable to the negative (-)
Before Starting: terminal of the booster battery and the other
end to the engine block. NOT TO THE
• Open service valve {s) to ensure pressure is NEGATIVE (-) TERMINAL OF THE WEAK
relieved in receiver-separator system. Close valve BATTERY.
{s) in order to build up full air pressure and ensure
After Starting:
proper oil circulation.
a. Reduce engine speed to IDLE.
• Check battery for proper connections and condi- b. Disconnect the negative (-) cable from the
tion. engine block first, then from the booster
• Check the engine oil level. Maintain per marks on battery.
c. Disconnect positive {+) cable from both
dipstick. batteries.
• Check the fuel level. Add only CLEAN DIESEL

fuel for maximum service from the engine. OIL-COOLED DiESEL ENGINE
• Check the compressor lubricating oil level. The I CAUTION~

proper oil level is mid-way on the sight gauge. Add
oil if the level falls to the bottom of the sight gauge. Do not remove oil coolant hoses or con-
Do not overfill. nections while engine Is running.
Book 35389816 {4/95) (17)

STARTING UNITS WITH OPTIONAL DIAGNOSTICS LAMPS
NOTICE
1. Turn the POWER switch to "ON".
None of the panel lamps should be glowing when
2. Turn power switch to "START' position to machine is operating. If they are, shut unit down
crank engine. and refer to Trouble Shooting Section.
NOTICE
Do not operate the starter motor for more than

STOPPING
10 seconds without allowing at least 30 sec·
onds cooling time between start attempts. Close air service valve.
Allow the unit to run at idle for 3 to 5 minutes to re-
duce the engine temperatures.
Cold Weather Starting: Turn Power Switch to "OFF" position.
Open manual blowdown valve, if so equipped, and When the engine stops, automatic blowdown valve
press ether inject button. Use ether sparingly. Close should relieve system air pressure. If automatic
manual blowdown valve after engine is running. blowdown valve malfunction is suspected, open
manual blowdown valve if so equipped.
Never allow unit to sit under pressure when engine
is not running.
I CAUTION~
NOTICE I
Ether Is an extremely volatile, highly flammable
gas. Use sparingly! If too much Is Injected, the Do NOT wire around or bypass a shutdown
uncontrolled explosion may result In costly sensor or switch.
damage to the engine. All units in this family of machines are protected by
sensors or switches at the following locations:
3. Release POWER SWITCH when the engine
(1) Low engine oil pressure, in the engine.
starts and sustains running.
High Discharge AIR Temperature
4. Allow engine to warm up 5 to 10 minutes
(2} At the airend outlet.
(3) In separator tank.
5. If so equipped, press Service Air Button. Open
air service valve(s).
Note: If equipped with the optional cold starting aid Units with Diagnostic Lamps:
(ether), operate the valve once or twice ONLY while
the engine is cranking. In a shutdown situation, the function of the panel
lamps is to indicate what specific failure caused the
• Rotate the Master Switch to "ON". unit to shut down.These lamps will remain illumi·
nated until the Power Switch is turned "OFF".
Book 35389816 (4/95) (18)

Speed and Pressure Regulation
The engine idle and full speed settings are DISCHARGE
PRESSURE
set and sealed at the factory, and should not GAGE
be adjusted. Removal of the seals without
authorization could affect the warranty. If
PRESSURE REGULATOR
speed settings are lost due to engine fuel A
pump service or other repairs, the speed B TO SEPARATOR TANK
settings can be reset as follows:
Before Starting [)==t:(~=ro UNLOADER
CHECKVALVE ORIFICE
1. At the Pressure Regulator (on
service pipe near receiver tank),
remove the cover to expose the
adjusting screw. Loosen the jam nut
(A). Turn screw (B) counterclockwise AIRCVUNDER
until tension is no longer felt at the 36611896

"
screw. Then, tum screw clockwise
one full turn.
2. On Air Cylinder rod (C), loosen lock
nut (D). Remove bolt (E) and 6. Open the service valve and adjust the
disconnect rod end bearing (F). Pull discharge pressure to 100 psi (689 kPa). If
engine speed lever (G) toward air necessary, at full engine speed, adjust pressure
cylinder (Full Load Position). Adjust regulator screw (B) clockwise to increase
rod end bearing to line up with hole in pressure.
lever. Replace bolt (E) and tighten.
7. With the discharge pressure at 100 psi, adjust
3. Close service valve(s). the engine speed to the FULL load RPM by
loosening lock nut (D) against rod end bearing
After Starting Unit (F).
4. Allow unit to warm up at an engine
8. While still maintaining 100 psi, turn the pressure
speed greater than IDLE speed for at
regulator screw (B) until speed lever (G) just
least five minutes. The engine should
begins to move. Tighten jam nut (D).
speed up and then slow down.
9. Close the service valve and recheck IDLE
5. If equipped, push the SERVICE AIR speed. The engine will slow down. To set the
button on the control panel, making idle or NO LOAD speed, loosen jam nut (H) on
certain the button does not pop back the side of engine. Turn adjusting screw (J) to
out. The unit should speed up and then the specified speed. Tighten jam nut (H).
unload (and drop back to IDLE). With
the unit unloaded, turn the adjusting 10. To obtain maximum ctm at any pressure
screw on the pressure regulator between 80 psi (552 kPa) and maximum
clockwise until the discharge pressure pressure rating (*}, make adjustment at the
gauge indicates 120--122 psi pressure regulator to obtain desired discharge
(827-841 kPa). Tighten the pressure pressure at FULL engine speed. Lock adjusting
regulator jam nut. Replace cover. screw and replace cover.
Book 35389816 (4/95) (19)

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

order to follow in trouble shooting.
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
ACTION PLAN failure will not be repeated. A complaint of "premature
breakdown" may be corrected by repairing any improper
A. Think Before Acting wiring connections, but something caused the defective
wiring. The cause may be excessive vibration.
Study the problem thoroughly and ask yourself
these questions:
(1) What were the warning signals that preceded

the trouble?
(2) Has a similar trouble occurred before?
(3) What previous maintenance work has been
done?
(4) If the compressor will still operate, is it safe to
continue operating it to make further checks?
Book 35389816 (4/95) (20)

TROUBLE SHOOTING CHART
Bold Headings depict the COMPLAINT- Subheadings depict the CAUSE
Note: Subheadings suggest order to follow in cause of troubleshooting.
Excessive Compressor Oil Temperature:

Short Air Cleaner Life: Ambient Temperature Too High
Dirty Operating Conditions Out of Level > 15 degrees
Low Oil Level
Inadequate Element Cleaning
Dirty Cooler
Defective Service Indicator
Dirty Operating Conditions
Incorrect Stopping Procedure
Loose or Broken Belts
Wrong Air Filter Element Operating Pressure Too High
Malfunctioning Thermostat
Defective Minimum Pressure Valve
Blocked or Restricted Oil Lines
Excessive Ollln Air:
Airend Malfunctioning
High Oil Level
Out of Level > 15 degrees
Clogged Scavenge Orifice
Scavenge Tube Blocked
Defective Scavenge Check Valve Engine RPM Low:
Sep. Tank Blown Down Too Quickly
Clogged Fuel Filter
Defective Minimum Pressure Valve
Operating Pressure Too High
Incorrect Pressure Regulator Adjustment
Dirty Air Filter
Malfunctioning Speed Control Cylinder
Defective Separator Element
Wlll Not Unload: Ice In Regulation Lines/Orifice
Leaks in Regulator Piping Engine Malfunctioning
Incorrect Pressure Regulator Adjustment Airend Malfunctioning
Malfunctioning Pressure Regulator
Malfunctioning Inlet Unloader/Butterfly Valve
Ice in Regulation Lines/Orifice
Excessive VIbration:
Low Engine RPM
Rubber Mounts Damaged
Ollln Air Cleaner: Out of Balance Fan
Engine Malfunctioning
Incorrect Stopping Procedure Airend Malfunctioning
LowCFM:
Low Engine RPM
Safety Valve Relieves: Dirty Air Filter
Leaks In Regulator Piping Incorrect Linkage Adjustment
Incorrect Pressure Regulator Adjustment Incorrect Pressure Regulator Adjustment
Malfunctioning Pressure Regulator Malfunctioning Inlet Unloader/Butterfly Valve
Malfunctioning Inlet Unloader/Butterfly Valve Malfunctioning Speed Control Cylinder
Defective Separator Element Defective Minimum Pressure Valve
Ice in Regulation Lines/Orifice Defective Separator Element
Defective Safety Valve
Book 35389816 (4/95) (21)

Unit Shutdown: Won't Start/Run:
Out of Fuel Low Battery Voltage
Compressor Oil Temp. Too High Blown Fuse
Engine Oil Pressure Too Low Malfunctioning Start Switch
Broken Engine Fan Belt Clogged Fuel Filters
Loose Wire Connection Out of Fuel
Defective Switches Compressor Oil Temp. Too High
Defective Shutdown Solenoid Engine Water Temp. Too High
Malfunctioning Relay Engine Oil Pressure Too Low
Blown Fuse Loose Wire Connection
Engine Malfunctioning Defective Switches
Airend Malfunctioning Malfunctioning Relay
Airend Malfunctioning
Unit Falls To Shutdown: Engine Temperature Lamps Stays On:

Defective Switches Broken Engine Fan Belt
Defective Shutdown Solenoid Malfunctioning Circuit Board
Malfunctioning Relay Defective Engine Belt Break Switch
Defective Start Switch Ambient Temperature Too High
Dirty Operating Conditions
Dirty Cooler
Out of Level > 15 degrees
Operating Pressure Too High
Alternator Lamp Stays On:

Loose or Broken Belts
Loose Wire Connection
Defective Battery
Malfunctioning Alternator Engine 011 Pressure Lamp Stays On:
Malfunctioning Circuit Board Low Oil Level
Out of Level >15 degrees
Wrong Lube Oil
Alternator Lamp Stays Off:
Malfunctioning Circuit Board
Engine Temperature Lamps Stays Off:

Bulb Burned Out
Defective Engine Belt Break Switch
Engine 011 Pressure Lamp Stays Off:

Bulb Burned Out
Defective Engine Oil Pressure Switch
Book 35389816 (4/95) (22)

SECTION 5- GENERAL DATA
Unit Model: .......................................... P100WD ................... P125WD
Air Delivery- elm (litres/sec) ............................ 100 (47) . . . . . . . . . . . . . . . . . . . 125 (59)
Engine Speed- RPM (Full Load} ........................ 2300 2800
- RPM (No Load} ........................ 2000 2000
COMPRESSOR
Rated Operating Pressure- psi (kpa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 {689)
Safety Valve Setting- psi (kPa) ..................................................... 150 (1034)
ENGINE (Diesel)
Manufacturer ......................................... , . . . . . . . . . . . . . . . . . . . . . . . . . . . KHD/Deu1z
Model ........................................................................... F3M1011F
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
FLUID CAPACITIES
Compressor Lubricant ................................................... 10 quarts (9.51itres)
Engine Lube (including cooler) ............................................ 10 quarts (9.5 litres)
Fuel Tank .............................................................. 16.6 u.s. gal. (63 litres)
UNITS MEASUREMENTS/WEIGHTS
Overall Length .......................................................... 11.8 feet (3.60 meters)
Overall Height .......................................................... 4.7 feet (1.44 meters)
Overall Width ........................................................... 5.2 feet (1.60 meters)
Net Weight (less fuel} pounds (kg) ......................................... 1830 pounds (830 kg)
RUNNING GEAR
1ire Size ............................................................... P185/80R x 13
Inflation Pressure (Cold) ................................................. 32 psi {220 kPa)
Towing Speed (Maximum) ................................................ 50 mph (80 km/hr)
CAUTION: Any departure from the specifications may make this equipment unsafe.
EXPENDABLE SERVICE PARTS
Compressor Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35296920

Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36845303
Air Cleaner Element (compressor) ................................................... 35291970
Air Cleaner Element (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35291970
Book 35389816 (4/95) (23)

SECTION 6 - MAINTENANCE
COMPRESSOR OIL LEVEL
I CAUTION~ 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
Any unauthorized modification or failure to maintain
this equipment may make it unsafe and out of the decal beside the sight tube. If the oil level is not
factory warranty. in the "OK" range, make appropriate corrections
(Add or Drain). A totally filled sight tube in which the
If performing more than visual inspections, level is not visible indicates an over-full condition
disconnect battery cables and open manual
blowdown valve. and requires that oil be drained.
AIR CLEANER
Use extreme care to avoid contacting hot surfaces
(engine exhaust manifold and piping, air receiver If this unit is equipped with the Optional Diagnostic
and air discharge piping, etc.).
Panel, it has an AIR FILTERS RESTRICTED lamp
Never operate this machine with any guards on the instrument panel, covering both the engine
removed. and the compressor.
Inch and metric hardware was used in the design This should be checked daily during operation. If
and assembly of this unit. Consult the parts manual the lamp glows (red) with the unit operating at full
for clarification of usage. speed, servicing of the cleaner element is
necessary.
Notice: Disregard any maintenance pertaining to
components not provided on your machine. Also weekly squeeze the rubber valve (precleaner
dirt dump) on each air cleaner housing to ensure
GENERAL
that they are not clogged.
In addition to periodic inspections, many of the The air filters restricted sensor will automatically re-
components in these units require periodic set after the main power switch is turned to "OFF."
servicing to provide maximum output and
performance. Servicing may consist of To service the air cleaners on all units proceed as
pre-operation and post--{)peration procedures to be follows:
performed by the operating or maintenance
personnel. The primary function of preventive 1. Loosen outer wing nut and remove with
cover. Remove Element.
maintenance is to prevent failure, and
consequently, the need for repair. Preventive 2. Inspect air cleaner housing for any condition
maintenance is the easiest and the least expensive that might cause a leak and correct as
type of maintenance. Maintaining your unit and necessary.
keeping it clean at all times will facilitate servicing.
3. Wipe inside of air cleaner housing with a
SCHEDULED MAINTENANCE clean, damp cloth to remove any dirt
accumulation, especially in the area where
The maintenance schedule is based on normal the element seals against the housing.
operation of the unit. This page can be reproduced
4. Inspect element by placing a bright light
and used as a checklist by the service personnel. In
inside and rotating slowly. If any holes or
the event unusual environmental operating tears are found in the paper, discard this
conditions exist, the schedule should be adjusted element. If no ruptures are found, the
accordingly. element can be cleaned.
Book 35389816 (4/95) (24)
5. If a new air filter element is to be used check GAUGES
it closely for shipping damage.
The instruments or gauges are essential for safety,
6. Install cleaned or new elements in the maximum productivity and long service life of the
reverse order to the above. Tighten wing nut
machine. Inspect the gauges and test any
firmly.
diagnostic lamps prior to start-up. During operation
7. Inspect to ensure that the end cap seals observe the gauges and any lamps for proper
tightly 360 degrees around the air cleaner functioning. Refer to Operating Controls, for the
body.
normal readings.
In the event that the filter element must be reused
immediately, compressed air cleaning (as follows)
is recommended since the element must be FUEL TANK
thoroughly dry. Direct compressed air through the
CLEAN fuel in the fuel tanks is vitally important and
element in the direction opposite to the normal air
every precaution should be taken to ensure that
flow through the element. only clean fuel is poured or pumped into the tank.
Move the nozzle up and down while rotating the When filling the fuel tank on this unit, by methods
element. Be sure to keep the nozzle at least one other than a pump and hose, use a CLEAN
inch (25.4 mm) from the pleated paper.
non-metallic funnel.
NOTE: To prevent damage to the element, never

exceed a maximum air pressure of 100 psi (700
kPa). BATIERY
Keep the battery posts-to-cable connections
In the event the element is contaminated with dry clean, tight and lightly coated with a grease. Also
dirt, oil or greasy dirt deposits, and a new element is the electroly1e level in each cell should cover the top
not available, cleaning can be accomplished by of the plates. If necessary, top-up with clean
washing, using the air cleaner element manufactur- distilled water.
er's recommendations.
TIRES
NOTE: It Is recommended that replacement efe·
A weekly inspection is recommended. Tires that
ments be Installed In the unit. The elements just
have cuts or cracks or little tread should be repaired
removed for cleaning can be washed and
or replaced. Monthly check the wheel lug nuts for
stored as future replacement elements.
tightness.
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 that all clamps and flange joints are tight.
Book 35389816 (4/95) (25)

COMPRESSOR OIL COOLER
Premature wear of both the engine and compressor
The compressor lubricating and cooling oil is cooled
is ASSURED whenever dust-laden air is permitted
by means of the fin and tube-type oil cooler, located
to enter the engine's combustion chamber or the
below the radiator. The lubricating and cooling oil, compressor intake.
flowing internally through the core section, is cooled
by the air stream from the cooling fan flowing past The flexible hoses used in the fuel, oil and air lines
on these units are primarily used for their ability to
the core section. When grease, oil and dirt
accommodate relative movement between
accumulate on the exterior suriaces of the oil cooler, components. It is important they be periodically
its efficiency is impaired. inspected for wear and deterioration. It is also
Each month it is recommended that the oil cooler be important the operator does not use the hoses as
cleaned by directing compressed air which contains convenient hand hold or steps. Such use can cause
early cover wear and hose failure.
a nonflammable, non-<:austic safety solvent
through the core of the oil cooler. This should NOTICE
remove the accumulation of grease, oil and dirt from
the exterior suriaces of the oil cooler core so that the Piping systems operating at less than 150 psi
entire cooling area can transmit the heat of the (1 050 kPa) may use a special nylon tubing. The
associated fittings are also of a special
lubricating and cooling oil to the air stream.
"push-In" design. If so, features are as follows:
In the event foreign deposits, such as sludge and Pulling on the tubing will cause the inner sleeve to
lacquer, accumulate in the oil cooler to the extent withdraw and compress, thus tightening the
connection. The tubing can be withdrawn only while
that its cooling efficiency is impaired, a resulting
holding the sleeve against the fitting. The tubing
high discharge air temperature is likely to occur, can be removed and replaced numerous times
causing shut down of the unit. To correct this without losing its sealing ability.
situation it will be necessary to clean it using a
•
To install the nylon tubing, make a mark (with tape or
cleaning compound in accordance with the
grease pencil) approximately 7/8 inch from the end
manufacturer's recommendations. 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 inchD.D. tubing; 1/8 inch for
the 0.25 inch O.D. tubing. This will ensure that the
ENGINE OIL COOLER
tubing is fully engaged in the sealing mechanism.
The engine in this machine is oil cooled. The engine
oil cooler is located above the compressor oil cooler NOTICE
and functions the same as the compressor oil
cooler. The oil filter must be replaced every 500 hours
of operation or six (6) months, whichever
HOSES comes first. On new or overhauled units, re-
Each month it is recommended that all of the intake place the element after the first 50 and 150
lines to and from the air cleaners, the engine cooling hours of operation; thereafter, service the oil fll·
system hoses and all of the flexible hoses used for
ter every 500 hours.
air, oil, and fuel be inspected.
To service the oil filters it will first be necessary to
To ensure freedom from air leaks, all rubber hose shutthe unit down. Wipe off any external dirt and oil
joints and the screw-type hose clamps must be from the exterior of the filter to minimize any
absolutely tight. Regular inspection of these contamination from entering the lubrication system.
connections for wear or deterioration is necessary. Proceed as follows:
Book 35389816 (4/95) (26)
I wARNING I NOTICE
Installing a new oil filter element when the old
gasket remains on the filter head, will cause an
High pressure air can cause severe Injury or oil leak and can cause property damage.
death from hot oil and flying parts. Always
4. Lubricate the new filter gasket with the same oil
relieve pressure before removing caps, plugs, being used in the machine.
covers or other parts from pressurized air 5. Install new filler by turning element clockwise
system. until gasket makes initial contact. llghten an
1. Open the service air valve(s) to ensure that additional! /2 to 3/4 turn.
system is relieved of all pressure. Close the 6. Start unit and allow to build up to rated pressure.
valve(s). Check for leaks before placing unit back into
service.
2. Turn the spi~n filter element counterclockwise
to remove it from the filter housing. Inspect the
filter. FASTENERS
NOTICE Visually check entire unit in regard to bolts, nuts and
If there Is any Indication of formation of var· screws being properly secured. Spot check several
nlshes, shellacs or lacquers on the oil filter ele· capscrews and nuts for proper torque. If any are
ment, It Is a warning the compressor lubricating found loose, a more thorough inspection must be
oil has Improper characteristics and should be made. Take corrective action.
Immediately changed.
3. Inspect the oil filter head to be sure the gasket COMPRESSOR OIL
was removed with the oil filler element. Clean the
gasket seal area on the oil filter head. The lubricating and cooling oil must be replaced
every 500 hours of operation or six (6) months,
whichever comes first.
RUNNING GEAR
Every month or 500 miles, tighten the wheel lug nuts
to 85 - 95 lbs.-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.
Book 35389816 (4/95) (27)

Place a spoonful of grease in the palm of one hand RECEIVER-sEPARATOR SYSTEMS
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
!wARNING I
into the edge of the grease pile until grease oozes
out both from the top and from between the rollers. High pressure air can cause severe Injury or
Then rotate the bearing to repeat this operation on death from hot off and flying parts. Always
the next segment. Keep doing this until you have relieve pressure before removing caps, plugs,
the entire bearing completely filled with grease. covers or other parts from pressurized air
system.
NOTICE • Open service valve at end of machine.

Excessive grease In the hub or grease cap
serves no purpose due to the fact that there Is
• Ensure pressure Is relieved, with BOTH:
no way to force the grease Into the bearing. The
manufacturer's standard procedure Is to -Discharge air pressure gauge reads zero (0).
thoroughly pack the Inner and outer bearing - No air discharging from service valve.
with grease and then to apply only a very small
amount of grease Into the grease cap. When draining oil, remove plug from bottom of
separator tank.
When adding oil, remove and replace (make tight)

If bearing adjustment is required or the hub has
plug on side of separator tank.
been removed for any reason, the following
procedure must be followed to ensure a correct
bearing adjustment of 0.001 to .012 free play. In the compressor lubricating and cooling system,
separation of the oil from the compressed air takes
1. While rotating hub slowly to seat the place in the receiver~eparator tank. As the
bearings, tighten spindle nut to compressed air enters the tank, the change in
velocity and direction drop out most of the oil from
approximately 15 lbs.-ft. Grasp the tire at
the air.
the top and bottom and rock, in and out.
There should be no evidence of looseness Additional separation takes place in the oil
(free play) at the bearing. separator element which is located in the top of the
tank.
2. Loosen nut to remove preload torque. Do Any oil accumulation in this separator element is
not rotate hub. continuously drained off by means of a scavenge
tube which returns the accumulated oil to the
3. Finger tighten nut until just snug. Loosen nut system.
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. Nut should be free to move with only restraint

being the cotter pin.
Book 35389816 (4/95) (28)

The life of the oil separator element is dependent • Place a straightedge across top of element and
upon the operating environment (soot, dust, etc.) measure from bot1om of straightedge to bot1om of
and should be replaced every twelve months or element (See Fig. 4.1 ).
2000 hours. To replace the element proceed as
follows: • Replace scavenge tube in cover (cover is still off
of tank).
• Ensure the tank pressure is zero.
• Measure from bot1om of cover to end of
scavenge tube. Measurement should be from 1/8"
• Disconnect the hose from the scavenge tube. to 1/4" less than the element measurement. If
not, cut to size.
• Remove scavenge tube from tank cover. • Remove scavenge tube.
• Disconnect service line from cover. • Reposition cover (use care not to damage
gaskets).
• Remove cover mounting screws.
• Replace cover mounting screws: tighten in a

• Remove cover and element.
crisscross pat1ern.
• Remove any gasket material left on cover or tank. • Reconnect service line. Replace scavenge tube.
Reconnect hose.
• Install new element.
• Close service valve. Start unit and look for leaks.
NOTICE
When replacing the element, the scavenge lines,
Do not remove staples from the element/gasket orifice, filter, and check valve should be thoroughly
connection. cleaned and the oil changed.
TANK TOP--
'i c;l
I ' l J I
...,._SCAVENGE TUBE
SHOULD BE 1/B" TO 1/4"--1!,_

SHORTERTHAN
ELEMENT MEASUREMENT
u
**
- - - - - cut line
L _____j--01---- SEPARATOR TANK If necessary
Book 35389816 (4/95) (29)

SCAVENGE LINE EXTERIOR FINISH CARE
jwARNINGI This unit was painted and heat cured at the factory
with a high quality, thermoset polyester powder
High pressure air can cause severe injury or coating. The following care will ensure the longest
death from hot oil and flying parts. Always possible life from this finish.
relieve pressure before removing caps, plugs,
1. If necessary to remove dust, pollen,
covers or other parts from pressurized air
etc. from housing, wash with water
system.
and soap or dish washing liquid
detergent. Do not scrub with a rough
The scavenge line originates at the
cloth, pad, etc.
receiver-separator tank cover and terminates at
the compressor airend near the oil filter element. An
orifice check valve is located on the scavenge tube. 2. If grease removal Is needed, a fast
evaporating alcohol or chlorinated
Once a year or every 1000 hours of operation, solvent can be used. Note: This may
whichever comes first, replace the separator cause some dulling of the paint
element and clean the scavenge orifice/check
valve. finish.
3. If the paint has faded or chalked, the

NOTICE use of a commercial grade, non-
abrasive car wax may partially re·
Excessive oil carry-over may be caused by an store the color and gloss.
oil-logged separator element. Do not replace
element without first performing the following To touch-up or paint over and retain the superior fin·
maintenance procedure:
ish requires the following:
1. Check oil level. Maintain as Indicated
earlier In this section. 1. The area to be painted should be
finish sanded with 320 grit paper.
2. Thoroughly clean scavenge line, any
orifice and check valve.
2. Remove all sanding dust with alco·
hoi using clean, lint free rag(s}.
3. Assure minimum pressure valve/or!·
Change rag when soiled. Remove
flee Is operational.
any lint and other loose contamlna·
4. Run unit at rated operating pressure tion with atitomobll9-iJrade tack
for 30 to 40 minutes to permit element rag(s}.
to clear Itself.
3. Before applying paint: Inspect to
Insure that area Is free of all dirt,
fibers, lint, grease, moisture or any
other form of surface contamination.
coat area with a solvent based,
automotive-type, high quality liquid
paint that will adhere to powder
coatings. DO NOT USE WATER
BORNE OR LATEX PRODUCTS.
4. If possible, allow 30 days before

washing with anything but clean
water.
Book 35389816 (4/95) (30)

PREVENTIVE MAINTENANCE SCHEDULE
If operating In extreme environments (very hot, cold, dusty or wet), these
time periods should be reduced.
3MO. 6MO. 12MO.

Dally Wkly MO. 500 HRS 1000 HRS 2000 HRS
COMPRESSOR OIL LEVEL c

ENGINE OIL LEVEL c
'RADIATOR COOLANT LEVEL c
GAUGES/LAMPS c
'AIR CLEANER SERVICE INDICATORS c
FUEL TANK (FILL AT END OF DAY) c DRAIN
'FUEL/WATER SEPARATOR DRAIN c
AIR CLEANER PRECLEANER DUMPS c
FAN ALTERNATOR BELTS c
BATTERYCON SIELECTROLVTE c
TIRE PRESSURE AND SURFACE c
'WHEEL LUG NUTS c
HOSES (OIL,AIR,INTAKE,ETC.) c
AUTOMATIC SHUTDOWN SYSTEM TEST c
AIR CLEANER SYSTEM VISUAL c
COMPRESSOR OIL COOLER EXTERIOR c CLEAN
ENGINE RADIATOR/OIL COOLER EXTERIOR c CLEAN
FASTENERS c
AIR CLEANER ELEMENTS WI
'FUEL/WATER SEPARATOR ELEMENT R
COMPRESSOR OIL FILTER ELEMENT R
COMPRESSOR OIL R
'WHEELS (BEARINGS, SEALS, ETC.) c
'ENGINE COOLANT TEST c R
SHUTDOWN SWITCH SETTINGS TEST c
SCAVENGER ORIFICE & RELATED PARTS CLEAN
OIL SEPARATOR ELEMENT R
ENGINE (OIL CHANGES, FILTERS, ETC.) REFER TO ENGINE OPERATOR•s MANUAL
*Disregard If not appropriate for this particular machine. R=Replace Ingersoll-Rand
C=Check (and adjust or replace If necessary). WI=OR when Indicated. 36509966
Unit _ _ _ _ __ Date: _ _ _ __
Hours _ _ _ _ __ Serviceman _ _ _ __
Book 35389816 (4/95) (31)

LUBRICATION
FLUIDS AND LUBRICANTS TABLE

ITEM FLUID AMBIENT TEMP. SPECIFICATION
Compressor Lubrlcan • Dexron ® or
-10°F to 125°F
Models: Dexron ® II ATF
(-23°C to 52°C)
VHP-(200+ • MIL-L-46152
psi) SAE 10W, API CC
HP-(150 psi) -40°F to 125 ° F 0 1-R PIN 35382472
XP-(125 psi)
P-(100 pslj (-40°C to 52°C) Synthetic Fluid
XHP (300 psi) -10°F to 125°F • Dexron® II ATF

• 1-R XHP 505 Synthetic
(-23°C to 52°C)
or Equivalent
-10°Fto 100°F • 1-RXHP 505
XHP (350 psi) (-23°C to 38°C) Synthetic
or Equivalent
70°F to 125°F
•1-R XHP 1001 Synthetic
(21 °C to 52°C) or Equivalent
Engine: • 011
•Coolan
• Fuel
Running Gear
•wheel Bearings Grease All MIL-G-10924
• Other Grease All Multi-Purpose
• Hydraulic Brakes Fluid All Dot 3 or4
DEXRON®- Reg. T.M. of General Motors Corp.
Book 35389816 (4/95) (32)

NOISE EMISSION CONTROL
MAINTENANCE LOG
COMPRESSOR MODEL _ _ _ _ _ __
SERIAL NO. _ _ _ _ _ _ _ _ _ __
USER UNIT NO. _ _ _ _ _ _ _ _ __
UNIT IDENTIFICATION DEALER OR DISTRIBUTOR

FROM WHOM PURCHASED:
ENGINE MAKE & M O D E L : - - - - - - - - - - - -
SERIAL N O . : - - - - - - - - - - - - - - - -
PURCHASER OR O W N E R : - - - - - - - - - - -
ADDRESS: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
DATE P U R C H A S E D : - - - - - - - - - - - - - -
The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor
manufactured and sold under the above regulations, specifically the following acts or the causing thereof:
(1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or
replacement, of any device or element of design incorporated into any new compressor for the purpose of noise
control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the compressor after
such device or element of design has been removed or rendered inoperative by any person.
NOISE EMISSION WARRANTY

The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was
designed. built and equipped to conform at the time of sale to the first retail purchaser. with all applicable U.S. EPA
Noise Control Regulations.
This warranty is not limited to any particular part, component. or system of the air compressor. Defects in the design,
assembly, or in any part, component, or system of the compressor which. at the time of sale to the first retail purchaser,
caused noise emissions to exceed Federal Standards are covered by this warranty for the life of the air compressor.
(40CFR204.58-1 ).
Book 35389816 (4/95) (33)

INTRODUCTION
The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations
for Noise Emissions, applicable to Portable Air Compressors.
The purpose of this book is to provide (1) the Maintenance Performance Schedule below
for all required noise emission controls and (2) space so that the purchaser or owner can
record what maintenance was done, by whom, where and when. Detailed instructions on the
maintenance items below are given on the following page.
MAINTENANCE SCHEDULE
ITEM AREA PERIOD
A. COMPRESSED AIR LEAKS AS DETECTED
B. SAFETY AND CONTROL SYSTEMS AS DETECTED
c. ACOUSTIC MATERIALS DAILY
D. FASTENERS 100 HOURS

E. ENCLOSURE PANELS 100 HOURS
F. AIR INTAKE & ENGINE EXHAUST 100 HOURS
G. COOLING SYSTEMS 250 HOURS
H. ISOLATION MOUNTS 250 HOURS
I. ENGINE OPERATION SEE OPERATOR'S MANUAL
J. FUELS & LUBRICANTS SEE OPERATOR'S MANUAL
Book 35389816 {4/95) (34)

A. COMPRESSED AIR LEAKS F. AIR INTAKE AND ENGINE EXHAUST
Correct all compressed air leaks during the first Engine and compressor air intake and engine exhaust
shutdown period after discovery. If severe enough to systems should be inspected after each 100 hours of
cause serious noise problems and efficiency loss, shut operation for loose, damaged. or deteriorated
down immediately and correct the leak(s). components. Repairs or replacements should be made
before the next period of use.
B. SAFETY AND CONTROL SYSTEMS G. COOLING SYSTEMS

Repair or replace all safety and control systems or All components of the cooling systems for engine
circuits as malfunction occurs. No compressor should water and compressor oil should be inspected every
be operated with either system bypassed, disabled, or 250. hours of use. Any discrepancies found should be
nonfunctional. corrected before placing the unit back in operation.
Unrestricted airflow over the radiator and oil cooler must
be maintained at all times during operation.
C. ACOUSTIC MATERIALS H. ISOLATION MOUNTS

In daily inspections observe these materials. Maintain Engine/airend isolation mounts should be inspected
all acoustic material as nearly as possible in its original after each 250 hours of operation. Those mounts with
condition. Repair or replace all sections that have: 1) cracks or splits in the molded rubber, or with bent or
sustained damage, 2) have partially separated from broken bolts due to operation or storage in severe
panels to which they were attached, 3) are missing, or environments. all should be replaced with equivalent
have otherwise deteriorated due to severe operating or parts.
storage conditions.
D. FASTENERS I. ENGINE OPERATION

All fasteners such as hinges. nuts. bolts, clamps, Inspect and maintain engine condition and operation
screws, rivets, and latches should be inspected for as recommended in the manuals supplied by the engine
loosenes& after each 100 hours of operation. They manufacturer.
should be retightened. repaired, or- if missing-
replaced immediately to prevent subsequent damage
and noise emission increase.
E. ENCLOSURE PANELS J, FUELS AND LUBRICANTS
Enclosure panels should also be inspected at 100- Use only the types and grades of fuels and lubricants
hour operational intervals. All panels that are warped, recommended in the Ingersoll-Rand Company and
punctured, torn, or otherwise deformed, such that their Engine Manufacturer's Operator and Maintenance
noise containment function is reduced, should be Manuals.
repaired or replaced before the next operation interval.
Doors, access panels, and hatch closures especially,
should be checked and adjusted at this time to insure
continuous sealing between gasket or acoustic material
and the mating frame.
Book 35389816 (4/95) (35)

MAINTENANCE RECORD FOR NOISE EMISSION CONTROL
HOURMETER MAINTANSPECT LOCATION WORK DONE
ITEM NO. DESCRIPTION OF WORK OR COMMENTS
READING DATE CITY/STATE BY(NAME)
- -
Book 35389816 (4/95) (36)

SECTION 7 PARTS ORDERING
GENERAL of parts used in the machine. Where no quantity is
specified the quantity is assumed to be one.
This publication, which contains an illustrated parts Each description of a part is based upon the "noun
breakdown, has been prepared as an aid in locating first" method, i.e., the identifying noun or item name
those parts which may be required In the is always the first part of the description. The noun
maintenance of the unit. All of the compressor name is generally followed by a single descriptive
parts, listed in the parts breakdown, are modifier. The descriptive modifier may be followed
manufactured with the same precision as the by words or abbreviations such as upper, lower,
original equipment. For the greatest protection inner, outer, front, rear, RH, LH, etc. when they are
always insist on genuine Ingersoll-Rand Company essential.
parts for your compressor.
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
NOTICE facing the drawbar (front) will determine the right
Ingersoll-Rand Company can bear no and left sides.
responsibility for Injury or damages resulting
directly from the use of non-approved repair
FASTENERS
parts.
Both SAE!inch and ISO/metric hardware have been

Ingersoll-Rand Company service facilities and used in the design and assembly of these units. In
parts are available worldwide. There are Ingersoll- the disassembly and reassembly of parts, extreme
Rand Company Construction Equipment Group care must be taken to avoid damaging threads by
Sales Offices and authorized distributors located in the use of wrong fasteners. In order to clarify the
the principal cities of the United States. In Canada proper usage and for exact replacement parts, all
our customers are serviced by the Canadian standard fasteners have been identified by part
number, size and description. This will enable a
Ingersoll-Rand Company, Limited. There are also
Ingersoll-Rand International autonomous customer to obtain fasteners locally rather than
companies and authorized distributors located in ordering from the factory. These parts are identified
the principal cities throughout the free world. 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 is a specially
engineered part that must be ordered by part
Special order parts may not be included in this number to obtain the exact replacement part.
manual. Contact the Mocksville Parts Department
with the unit serial number for assistance with these
special parts.
MARKINGS AND DECALS
DESCRIPTION NOTICE
Do not paint over safety warnings or In-
The illustrated parts breakdown illustrates and lists
structional decals. If safety warning decals
the various assemblies, subassemblies and become Illegible, immediately order re-
detailed parts which make up this particular placements from the factory.
machine. This covers the standard models and the
more popular options that are available.
A series of illustrations show each part distinctly and Part numbers for original individual decals and their
in location relative to the other parts in the mounting locations are shown within Parts List
assembly. The part number, the description of the Section. These are available as long as a particular
part and the quantity of parts required are shown on model is in production.
each illustration or on adjacent page. The quantities
specified are the number of parts used per one
assembly and are not necessarily the total number
Book 35389816 (4/95) (37)
TERMS AND CONDITIONS ON PARTS ORDERS
Afterwards, service sets of exterior decals and
current production safety warning decals are Acceptance: Acceptance of an offer is expressly
available. Contact the Product Support Group at limited to the exact terms contained herein. If
Mocksville for your particular needs and availability. purchaser's order form is used for acceptance of an
offer, it is expressly understood and agreed that the
HOW TO USE PARTS LIST
terms and conditions of such order form shall not
a. Turn to Parts List Section. apply unless expressly agreed to by Ingersoll-Rand
Company ("Company'') in writing. No additional or
b. locate the area or system of the compressor in contrary terms will be binding upon the Company
which the desired part is used and find illustration unless expressly agreed to in writing.
page number.
Taxes: Any tax or other governmental charge now
c. Locate the desired part on the illustration by visual or hereafter levied upon the production, sale, use or
identification and make note of part number and shipment of material and equipment ordered or sold
description. is not included in the Company's price and will be
charged to and paid for by the Purchaser.
HOW TO ORDER
Shipping dates shall be extended for delays due to
The satisfactory ordering of parts by a purchaser is acts of God, acts of Purchaser, acts of Government,
greatly dependent upon the proper use of all fires, floods, strikes, riot, war, embargo,
available information. By supplying your nearest transportation shortages, delay or default on the
sales office, autonomous company or authorized part of the Company's vendors, or any other cause
distributor, with complete information, you will beyond the Company's reasonable control.
enable them to fill your order correctly and to avoid Should Purchaser request special shipping
any unnecessary delays. instruction, such as exclusive use of shipping
In order that all avoidable errors may be eliminated, facilities, including air freight when common carrier
the following instructions are offered as a guide to has been quoted and before change order to
purchase order can be received by the Company,
the purchaser when ordering replacement parts:
the additional charges will be honored by the
a. Always specify the model number of the unit as Purchaser.
shown on the general data decal attached to the Warranty: The Company warrants that parts
unit. manufactured by it will be as specified and will be
b. Always specify the serial number of the unit. free from defects in materials and workmanship.
THIS IS IMPORTANT. The serial number of the unit The Company's liability under this warranty shall be
limited to the repair or replacement of any part
will be found stamped on a plate attached to the
which was defective at the time of shipment
unit. (The serial number on the unit is also
provided Purchaser notifies the Company of any
permanently stamped in the metal of the frame side
rail.) such defect promptly upon discovery, but in no
event later than three (3) months from the date of
c. Always specify the number of the parts list shipment of such part by the Company. The only
publication. exception to the previous statement is the extended
warranty as it applies to the special airend
d. Always specify the quantity of parts required. exchange program.
e. Always specify the part number, as well as the Repairs and replacements shall be made by the
description of the part, or parts, exactly as it is given Company F.O.B. point of shipment. The Company
on the parts list illustration. shall not be responsible for costs of transportation,
removal or installation.
In the event parts are being returned to your nearest
Warranties applicable to material and equipment
sales office, autonomous company or authorized
supplied by the Company but wholly manufactured
distributor, for inspection or repair, it is important to
by others shall be limited to the warranties extended
include the serial number of the unit from which the
to the Company by the manufacturer which are able
parts were removed.
to be conveyed to the Purchaser.
Delivery: Shipping dates are approximate. The
Company will use best efforts to ship by the dates
specified; however, the Company shall not be liable
for any delay or failure in the estimated delivery or
shipment of material and equipment or for any
damages suffered by reason thereof. ·
Book 35389816 (4/95) (38)
35389816
Operation Manual
FM 1011F DEUTZ SERVICE
A
KHD
DEU"'"Z
e Please read and observe the information given
in this Operation Manual. This will enable you
to avoid accidents, preserve the manufacturer's
warranty and maintain the engine in peak
operating condition.
0 This engine has been built exclusively for the
application specified in the scope of supply-
as described by the equipment manufacturer-
and is to be used only for the intended purpose.
Any use exceeding that scope is considered to
be contrary to the intended purpose. The
manufacturer will not assume responsibility for
any damage resulting therefrom. The risks
involved are to be borne solely by the user.
o Use in accordance with the intended purpose
also implies compliance with the conditions
laid down by the manufacturer for operation,
maintenance and servicing. The engine should
only be operated by personnel trained in its use
and the hazards involved.
e The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be
observed.
o Unauthorized engine modifications will ·
invalidate any liability claims against the manu- ·
facturer for resultant damage.
Manipulations of the injection and regulating
system may also influence the pertormance of
the engine, and its emissions. Adherence to
legislation on pollution cannot be guaranteed
under such conditions.
Operation Manual
FM 1011 F
Engine
Serial Number IIIIIIII
Please enter the engine serial number here. This number
should be quoted when inquiring about Customer
Service, Repairs or Spare Parts (see Section 2.1)
All rights reserved. Technical modifications required to

improve our engines are reserved with regard to
specification data and other technical information
contained in this Oper-ation Manual. No part of this
Manual may be reproduced in any form or by any means
without our written approval.
Foreword
Dear Customer,
Liquid-cooled DEUTZ engines are designed

for a large number of applications. Conse-
quently, a wide range of variants are offered
to meet the requirements of specific cases.
Your engine is appropriately equipped for the
installation concerned, which means that not
all of the components described in this Oper-
ation Manual are necessarily mounted to your
engine.
We have endeavored to highlight any differ-
ences so that you will be able to locate the
operating and maintenance instructions rele-
vant to your engine quickly and easily.
Please read this Manual before starting your
engine, and always observe the operating and
maintenance instructions.
We are available to help with any additional
inquiries.
Sincerely,
DEUTZ SERVICE INTERNATIONAL GmbH
•
Index
1 General 3.5.1 Winter Operation 6.5.3 Changing Alternator Belts
2
2.1
2.1.1
Engine Description
Model
Rating Plate
3.5 Operating Conditions
3.5.2
4
High Ambient Temperature,
Operating Media
6.5.4
6.6.1
6.6.1.1
Checking Toothed Belts
6.6 Adjustments
Checking I Adjusting Valve Clearances
Valve Clearance
D
2.1.2 Rating Plate Location 4.1 Lube Oil 6.7 Accessories
2.1.3 Engine Serial Number 4.1.1 Quality Grade 6.7.1 Battery
2.1.4 Cylinder Numbering 4.1.2 Viscosity 6.7.1.1 Checking Battery and Cable Connectors
2.1.5
2.2
2.2.1
2.2.2
Fuel Delivery Lock
Engine Illustrations
Service side
Service side
4.2
4.2.1
4.2.2
Fuel Operating Media
Quality Grade
Winter-Grade Fuel
6.7.1.2
6.7.1.3
6.7.2
6.7.3
Checking Electrolyle Level
Checking Specific Gravity of Electrolyle
Three-Phase Alternator
Lifting Tackle
D
2.3 Lube Oil Circuit 5 Routine Maintenance 6.7.4 Ether Starting System
2.3.1 Lube Oil Circuit Schematic 5.1 Maintenance Schedule 6.7.4.1 Changing the Fluid Container
2.4 Fuel System 5.2 Maintenance Chart
2.4.1 Fuel System Schematic 7 Troubleshooting
3
3.1
3.1.1
Engine Operation
Commissioning
Adding Engine Oil
6
6.1
6.1.1
6.1.2
Service and Maintenance
Lubrication System
Oil Change Intervals
Changing Engine Oil
7.1
8
8.1
Diagnosis Chart
Engine Preservation
Preservation
D
3.1.2 Initial Engine Oil Fill-Up for 6.1.3 Changing Oil filter 8.1.1 Preserving Engine
BF4M 1011 Series 6.2 Fuel System 8.1.2 Removing Engine Preservations
3.1.3 Filling Oil Bath Air Cleaner 6.2.1 Changing Fuel Filter
3.1.4
3.1.5
3.1.6
3.2
Adding Fuel
Other Preparations
Additional Maintenance Work
Starting
6.2.2
6.3
6.3.1
6.4
Fuel Pump
Cooling System
Cleaning Intervals
Combustion Air Cleaner
9
9.1
9.2
9.3
Technical Specifications
Engine Specifications and Settings
Torque Wrench Settings
Tools
D
3.2.1 Electric Starting 6.4.1 Cleaning Intervals
3.3 Monitoring Systems 6.4.2 Emptying Cyclone Type Precleaner 10 Deutz
3.3.1 Engine Oil Pressure 6.4.3 Cleaning Oil Bath Air Cleaner
3.3.2 Coolant Temperature 6.4.4 Dry Type Air Cleaner
3.4 Stopping 6.5 Belt Drives
3.4.1 Mechanical Shutdown 6.5.1 Checking V-Belts
3.4.2 Electrical Shutdown (Ignition Key) 6.5.2 Tensioning Alternator Belts
n
D
General
DEUTZ Diesel Engines Service and Maintenance DEUTZ SERVICE INTERNATIONAL GmbH
are the product of many years of research and

development. The resulting know-how, coupled with
stringent quality standards, guarantee their long
Sound service and maintenance practices will ensure
thattheengine continues to meet your requirements.
Recommended service intervals must be observed
Please contact one of our authorized service
representatives in the event of breakdowns or for
spare parts inquiries. Our trained specialists will
D
service life, high reliability and lowfuelconsumption. and service and maintenance work carried out carry out repairs quickly and professionally, using
It goes without saying that the highest standards for conscientiously. only genuine spare parts. Genuine spare parts from
environmental protection are met. Special care should be taken under abnormally DEUTZ SERVICE INTERNATIONAL GmbH are always
demanding operating conditions. manufactured to the highest technical standards.
A table of DEUTZ SERVICE INTERNATIONAL GmbH
contact numbers is given at the end of this Operation
Manual.
Beware of Running Engine Safety Asbestos
Shut the engine down before carrying out maintenance All safety instructions in this Manual The seals and gaskets used in this engine
or repair work. Ensure that the engine cannot be
accidentally started ·accidents may otherwise occur -.
When the work is complete, be sure to refit any
panels and guards that may have been removed.
Never fHI the fuel tank while the engine is running.
Observe industrial safety regulations when running
&
instructions.
are designated by the accompanying
symbol. Please follow them carefully.
The attention of operating personnel
should be drawn to these safety
General safety and accident prevention regulations
are asbestos~free. When carrying out
maintenance and repair work, please
[ ) use appropriate spare parts.
the engine in an enclosed space or underground. laid down by Jaw must also be observed.
Engine Description
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit Schematic
2.4 Fuel System Schematic
Engine Description 2.1 Model
2.1.1 Rating Plate 2.1.2 Rating Plate Location 2.1.3 Engine Serial Number
f)
26 332 0
The model A, the engine serial number B and the The rating plate C is attached to the ventilation The engine serial number D is stamped on the
performance data are stamped on the rating plate. hood. crankcase as well as the rating plate.
The model and engine serial number must be given
when ordering spare parts.
2.1.4 Cylinder Numbering 2.1.5 Fuel Delivery Lock
Cylinders are numbered consecutively, beginning The manufacturer shall not be held liable for
at the flywheel end. damages resulting from adjustments made to the
regulator by the operator.
The lock screws are protected ln order to prevent
this:
1. with locking paint on model:
torque balancer.
2. with plastic protective cap on model:
without torque balancer
Adjustments to the regulator are to

be carried out only by authorized
DEUTZ SERVICE specialists.
2.2 Engine Illustrations Engine Description
2.2.1 Service side
13
6
Engine Description 2.3 Lube Oil Circuit
2.3.1 Lube Oil Circuit Schematic
1 Oil sump
2 Intake manifold
9 15 8 11 3 Oil pump
4 Main oil duct
5 Oil-cooled cylinder
6 Cylinder head cooling neck
7 Oil duct for rocker arm lubrication
D 8
9
10
11
Rocker arm
Oil manifold for the thermostat
Intake to external engine oil cooler
Return from external engine oil cooler
12 Thermostat housing with slide thermostat
13 Oil duct to oil filter
14 Oilfilter
15 Oil ductto the cam, con-rod and crank shaft
bearing
16 Injection jet for cooling the pistons
17 Oil return via crankcase to the oil sump
14 17 18 16 2 3 4 26 430 0
2.4.1 Fuel System Schematic 2.4 Fuel System
4 3 2 5 26 437 0
Engine Operation
3.1 Commissioning
3.2 Starting
3.3 Monitoring Systems
3.4 Stopping
Engine Operation 3.1 Commissioning
3.1.1 Adding Engine Oil 3.1.2 Initial Engine Oil Fiii·Up
Fill in the engine oil in two phases as follows:

Phase 1
o Fill the oil sump with initial quantity of oil.
o Start the engine and le4ve it to run for approx.
one minute.
e Switch off the engine and wait for approx. two
minutes.
Phase 2
0 Fill in oil up to the ,max" marking on the engine
dipstick.
As a rule, engines are delivered empty of oil.

Pour lube oil into the oil filler neck (arrow).
For oil quantities, see 9.1
For oil grade and viscosity, see 4.1
3.1.3 Filling Oil Bath Air Cleaner 3.1.4 Adding Fuel
II I
~ ~
I 24 980 2
Fill oil cup 1 ofthe oil bath air cleaner with oil up to
FUEL
80 543 0
Use only commercial-grade diesel fuel. For fuel

the arrow. grade, see 4.2. Use summer or winter~grade fuel,
For oil grade and viscosity, see 4.1. depending on the ambient temperature.
A
~collector
Do not fill the precleaner dust
(if fitted) with oil.
Never fill the fuel tank while the
engine is running. Keep the filler cap
area clean and do not spill fuel.
3.1 Commissioning Engine Operation
3.1.5 Other Preparations 3.1.6 Additional Maintenance Work
Gl Check battery and cableconnections, see 6. 7.1 The following maintenance should be carried out
after 50 operating hours:
Gl Transport hooks
Remove if fitted (see 6.7.3). e Check the V-belts and retension as necessary
e Trial run Gl Change lube oil,

After the engine has been prepared, let it run see 6.1.2
for about 10 minutes without load.
e Check valve clearance and adjust as necessary,
During and after trial run see 6.6.1
- Check the engine for leaks e Check theengine for leaks
After the engine has been turned off
- Check the oil level, Gl Check the engine mount and adjust as
see 6.1.2 necessary,
If necessary, top up oil,
see 3.1.1/2 see 9.2
e
Retension V-belts,
see 6.5
Breaking in
D
During the break-in phase ·about 200 operating
hours • check the oil level twice a day.
After the engine is broken in, checking once a
day will be sufficient.
Engine Operation 3.2 Starting
3.2.1 Electric Starting

Starting without Cold-Start Aid
Before starting, make sure that
A nobody is standing in the immediate

vicinity of the engine or driven
machine.
After repair work:
Check that all guards have been
replaced and that all tools have been removed from
theengine.
When starting with glow plugs, do not use any other
starter substance (e.g. injection with start pilot).
Doing so could result in an accident.
D 25 746 2
0 Where possible, disengage the clutch to • Insert key.

separate the engine from any driven parts. - Position 0 = no operating voltage.
8 Move speed control lever 1 into idle position. e Turn key clockwise.
e Move cut·out handle 2 into operating position. - Position 1 =operating voltage.
- Pilot lights come on.
e Push the key in and turn it further clockwise
against spring pressure.
- Position 2 =no function
- Position 3 = start
e Release key as soon as engine fires.
Do not actuate the starter for more than 20 seconds. - Pilot lights go out.
If the engine does not catch, wait a minute then try
again.
If the engine does not catch after two attempts,
refer to the Diagnosis Chart (see 7.1).
with Cold·Start Aid with Cold·Start Aid

- Glow Plugs - Ether Starting System
25 746 2 25 746 2 25 963 0
e Insert key. 411 Insert key. o Starting fluid is injected automatically in switch
- Position 0 = no operating voltage. - Position 0 = no operating voltage. position A, as tong as the starter is operated.
e Turn key clockwise. • Turn key clockwise.
- Position 1 =operating voltage. - Position 1 =operating voltage. e To assist acceleration at lowertemperatures and
- Pilot lights come on. - Pilot lights come on. to avoid white fumes, briefly hold the arctic
e Push key in and turn further clockwise against e Push key in and turn further clockwise against switch in switch position H.
spring pressure. spring pressure.
- Position 2 = Preheat, hold for approx. - Position 2 = no function.
1 minute. - Position 3 = start.
Preheat lamp comes on. e Release key as soon as engine fires.
- Position 3 = start. Pilot lights go out.
0 Release key as soon as engine fires.
- Pilot lights go out. The switch must not be moved to
position H when the engine is
switched off and the ignition is
switched on.
3.3 Monitoring Systems Engine Operation
3.3.1 Engine Oil Pressure

Oil Pressure Pilot Light Oil Pressure Indicator Oil Pressure Gauge
25 i52 1 25 754 0 D
0 The oil pressure pilot light comes on with e The pointer must remain in the green sector over e The pointer must indicate the minimum oil
operating voltage on and engine off. the entire operating range. pressure (see 9.1).
e The oil pressure pilot light should go out when
the engine is running.
3.3.2 Coolant Temperature

Gauge Pointer
24 985 0
e The coolant temperature gauge pointer should

remain in the green sector most of the time. It
should rarely enter the yellow-green sector. If
the pointer enters the orange sector, the engine
is overheating. Turn it off and establish the cause
from the Diagnosis Chart (see 7.1 ).
Engine Operation 3.4 Stopping
3.4.1 Mechanical Shutdown 3.4.2 Electrical Shutdown

(Ignition Key)
D 25 746 2
e Move speed control lever 1 to low idle. e Turn key counterclockwise (to Position 0) and
remove. The pilot lights will go out.
e Operate shutdown lever 2 untilthe engine comes
to a stop. The charge pilot light and the oil
pressure pilot light will come on when the engine
stops.
41 Turn key counterclockwise (to Position 0) and
remove. The pilot lights will go out.
3.5.1 Winter Operation
e Lube Oil Viscosity e Battery

- Selectthe oil viscosity (SAE grade) according - Efficient cold starting requires a healthy
to the ambient temperature when the engine battery, see 6.7.1.
is started, see 4.1.2. - The starting limittemperaturecan be lowered
*
- Increase oil changetrequencywhen operating by 4-5 •c by heating the battery up to about
below -10 •c, see 6.1.1. +20 •c. (To do so, remove the battery and
store in awarm place).
e 0/esel Fuel
- Use winter-grade diesel fuel for operation
l
below 0 •c, see 4.2.2
0 Additional Maintenance Work
- Orain the sludge from the fuel tank once a
week.
- Adjustthe oil level in the oit bath airc/eaner(if
fitted) to suit the ambient temperature.
CD Cold-Start Aids
- At temperatures near or below freezing point,
use glow plugs it necessary, see 3.2. t.
This not only lowers the starting limit
temperature, but provides easier starting at
tern peratures normally not requiring astarting
aid.
3.5 Operating Conditions Engine Operation
3.5.2 High Ambient Temperature,

High Altitude
Ill As the altitude and ambienttemperature rise, the

density of the airtends to decrease, which affects
the maximum power output of the engine, the
exhaust gas quality and, in extreme cases, the
starting behavior. Under transient conditions,
the engine can be used at altitudes up to 1000
meters and temperatures up to 30'C. If the
engine is to operate under more severe conditions
(at higher altitudes or temperatures), it will be
necessary to reduce the injected fuel quantity
and thus, engine power.
Ill If you have any doubts about engine operation
underthese or similar conditions, askyou rengine
or equipment supplier whether the engine has
been derated in the interests of reliability, service
life and exhaust gas quality (smoke). Otherwise
contact DEUTZ SERVICE.
D
Operating Media
4.1 Lube Oil

4.2 Fuel
0
Operating Media 4.1 Lube Oil
4.1.1 Quality Grade 4.1.2 Viscosity
lube oils are differentiated according to their As the viscosity of the lube oil is dependent on
performance and quality class. In common use are temperature, the choice of SAE grade should be •F ·c
specifications named after the API (American
Petroleum Institute) and CCMC (Committee of
governed by the ambient temperature prevailing at
the engine operating site. Optimum operating
86 •30
~
•
Common Market Automobile Constructors). behavior will be attained if you take the 77
accompanying oil viscosity diagram as a guide.
Aooroved API Oils: Should the temperature fall temporarily below the 68 -t20 -1--
limits of the SAE grade selected, cold starting may
be affected but the engine will not be damaged. ~
59
Naturally aspirated engines: CCISE CCISF In order to keep wear to a minimum, do not exceed ~
application limits for extended periods of time. 50 .to
Oil changes dictated by the seasons can be avoided
Aonroved CCMC Oils:
by using multi-grade lube oils. Multi-grade oils-
particularly light-flowing oils - also reduce fuel 4 I _t
~
Naturally aspirated engines: 04
consumption.
32 .o Ii
~ ~
I ~~
I
23
~ ~
14 ·10
~
D Oil change intervals, see 6.1.1
Oil capacities. see 9.1
5
-4 -20
~
,.•
~
0
0
·1~
~
'5
-22 -30 .,•
.0
0
•
~~"'.
-31
40- -40 .t 0
0
4.2 Fuel
4.2.1 Quality Grade 4.2.2 Winter-Grade Fuel
Use commercially available diesel fuel with less Waxing may occur at low temperatures, clogging
•32 0
than 0.5% sulfur content. If the sulfur content is the fuel system and reducing engine efficiency. If SUm~er diesel fuel
higher than 0.5%, oil change intervals should be the ambient temperature is less than 0 °C, winter·
•23 - 5
r-....
reduced, see 6.1.1. grade fuel (suitable down to -15 'C) should be used. .........
The following fuel specifications I standards are
(This fuel is usually available from filling stations
well in advance of the cold months). Diesel fuel •14 -10 I
""'- ........
approved: containing additives (Super diesel) is often on sale • 5 -15
.........
as well, for use down to ·20 oc.
41 DIN 51 601 (Feb. 1986) - 4
-20,_
"'"r-.... 'k Winter diesel fuel
I
8 Attemperatures below -15 'C to -20 'G, kerosene
-
41 BS 2869: A1 and A2 should be added to the diesel fuel. The relevant - 13 -25 i'-
(With A2, take note of the sulfur content)
41 ASTM 0 975·88; 1-0 and 2-D
percentages are given in the adjacent diagram.
-22 -301
M Suoer diesel fuel .. ~ r-..,.
"'"
If summer-grade diesel fuel must be used at
temperatures below 0 °C, up to 60% kerosene can .,t to
•c
10 20 30 40
-·'"90 ol k.,_,.
50
-----+-
60%
It CEN EN 590 or DIN EN 590 be added (see diagram).

L_____,j__ ....,.~~
~
C1 NATO Code F-54 and F-75 In most cases, adequate resistance to cold can be
obtained by adding a flow improver (additive).
Inquire at the nearest service representative.
A
Mix in tank only. Fill with the
appropriate amount of kerosene
first, then add the diesel fuel
Routine Maintenance
5.1 Maintenance Schedule

5.2 Maintenance Chart
5.3 Maintenance Record
Routine Maintenance 5.1 Maintenance Schedule
Operating Hours (OH') chack

once every
clean see
after
"'~ change Section
100H 50 21 250
I
125 500 750 11000 2000 3000
or daily Operation
• •• Oil level in engine/separate container 6.1.2
• •
Engine leaks
• Oil bath- and dry type air cleaners 314151 6.4
• • Battery and cable connectors 6.7.1
• • est
• • • • Cooling system (depending on engine use) 31 61 6.3.1
• • Engine oil (depending on engine use) 4161 6.1.1
•••
• 6)
• Oil filter cartridge (depending on oil change interval) 61 6.1.3
• • Fuel filler cartridge 6.2.1
• • •
•
Valve clearance (adjust if necessary)
Engine mounts (retighten if necessary)
6.6.1
9.2
• • •
•
•
V-belts (retension if necessary)
Toothed belts 71
6.5
6.5.4
• •• Injection valves
• Fuel pump I strainer 5J 6.2.2
1) recommended maximum 5) change if required

2) commissioning new or reconditioned engine 6) for oil change intervals. see 6.1.1
3) clean if needed 7) change every 5 years or 4500 OH with sprocket
4) Oil quality API·CO or CCMC~D4 + 05
5.2 Maintenance Chart
The maintenance chart shown here is supplied as a

self-adhesive label with each engine. ft should be
affixed where it can be seen clearly on the engine or
driven equipment.
Check that this is the case.
If necessary, ask your engine or equipment supp lie r
for a fresh supply of labels.
Routine work should be carried out according to the
schedule in 5.1.
1011
0297 49n IQJ
Stop the engine before carrying

out any maintenance work.
5.3 Maintenance Record Routine Maintenance
OH Datum Signature I Stamp OH Date Sionature 1Stamo
so· -
125 250
375 500
625 750
875 1000
1125 1250
1375 1500
1625 1750
1875 2000
2115 2250
2375 2500
2625 2750
*after commissioning of new and reconditioned engines
Duly completed maintenance jobs can be recorded and signed off in the above chart.
OH Date Signature I Stamp DH Date Signature I Stamp
2875 3000
3125 3250
3375 3500
3625 3750
3875 4000
4125 4250
4375 4500
4625 4750
4875 5000
5125 5250
5375 5500
5625 5750
Routine Maintenance 5.3 Maintenance Record
OH Datum Signature I Stamp OH Date Signature I Stamp
5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7825 8000
8125 8250
8375 8500
8625 8750
Service and Maintenance
6.1 Lubrication System

6.2 Fuel System
6.3 Cooling System
6.4 Combustion Air Cleaner
6.5 Belt Drives
6.6 Adjustments
6. 7 Accessories
Service and Maintenance 6.1 Lubrication System
6.1.1 Oil Change Intervals

lube oil intervals in OH
Installed Engines
Pressure charged engines
411 The oil change intervals are dependent on the API classification cc 1) CD/CE!CF-4 1)
engine application and the quality of the lube oil. Lube oil quality
CCMC classific'ation 04 D5(SH PO) 2)
• If the engine runs fewer hours during the year
than stated in the table, the oil should be changed Normal oil usage, e.g.:
at least once a year.
Road vehicles, tractors, industrial trucks, cranes,
construction machinery, ships, electrical units, 500 750
II The table refers to the following conditions:
- For diesel fuel: sulfur content max. 0.5% by pumps, rail-run vehicles
weight.
- Continuous ambient temperatures down to
-10 'C (+14 'F). Heavy-duty oil usage, e.g.:
II If the sulfur content is > 0.5 to 1% or the Combine harvesters, emergency pumps, undergro
continuous ambient temperature below -10 oc Wintequipment, sweeping machines, winter 250 375
(+14 'F), the intervals between oil changes should operation equipment, emergency power generating
be halved.
units.
•·In the case of fuels containing more than 1%
sulfur, contact your service representative. 11 Lube oils having bolh aC- and an Sclassification (e.g. CD/SE) can be used. Oils with only a Cclassification
(e.g. CE) generally perform very well in diesel engines and are to be preferred.
21 05 grade oil with sulfate ash content> 1.8% by mass.
3J SHPD lube oils can be used.

These are the equivalent of 05 grade.
Change the oil with the engine off but still warm
(lube oil temperature approx. 80'C).
6.1.2 Changing Engine Oil,

Checking Oil Level
OIL ~
?•
II
II
I[
~~MAX
~<}-MIN
26022 0 25729
e Ensure that the engine or vehicle is on a level e Place oil tray under the engine. • Turn the engine off.
surface. e Unscrew drain plug. 411 Check oil level.
e Drain oil. - If necessary, top up with oil as far as the
CD Allow the engine to warm up 411 Fit oil drain plug with new gasket and tighten upper bar.
- Lube oil temperature approx. 80 °G. firmly (for torque, see 9.2).
411 Fill with lube oil
411 Turn the engine off. - For grade/viscosity, see 4.1
- For quantity, see 9.1.
0 Start engine and run at low idle for about 2
minutes.
Be careful when draining hot oil •
danger of scalds! Do notlet used oil
run into the soil but catch it in a
container ready for proper disposal.
6.1 Lubrication System Service and Maintenance
6.1.3 Changing Oil filter
258-80 0
e Undo the filter cartridge using acommercial tool e Clean any dirt from the filter carrier rim. e Tighten the oil filter cartridge with another half·
and spin off. turn.
0 Lightly oil the rubber gasket of the new oil filter
0 Catch any dripping oil. cartridge. 0 Check oil level, see 6.1.2.
8 Screw in the nei'J cartridge finger tight against o Check oil pressure, see 3.3.1.
the gasket.
e Check cartridge seal for leaks.
..&.. Beware of burns from hot oil.
6.2 Fuel System

6.2.1 Changing Fuel Filler
25882 0
o Close fuel stopcock. e Clean any dirt from the filter carrier rim. 0 Tighten the oil filter cartridge with a final half-
turn.
0 Undo fuel filter cartridge with commercial tool o Apply light film of oil or diesel fuel to the rubber
and spin off. gasket of the new fuel filter cartridge. e Open fuel stopcock.
o Catch any fuel. 8 Screw in the new cartridge finger tight against 0 Check for leaks.
the gasket.
Keep naked flames away when The fuel system does not need to be bled.
working on the fuel system. Do
not smoke!
Service and Maintenance 6.2 Fuel System
6.2.2 Fuel Pump

Cleaning the Strainer
e Close the fuel shut·off valve. • Mount the tuel strainer cover 2.
e Loosen and unscrew the hexagonal nut 1. e Tighten the hexagonal screw t.
e Remove the fuel strainer cover 2. e Check for leaks.
e Clean the fuel strainer with diesel fuel. Replace
if necessary.
e Place seals 3 in position.
Keep naked flames away when
&. working on the fuel system. Do not

smoke!
6.3 Cooling System

6.3.1 Cleaning Intervals
e The amount of contamination in the cooling I

system depends on the engine application. Checking or Cleaning !
Intervals
e Spilled oil or fuel on the engine increases the risk Engine Aplication
Guide Values
· of contamination. Be especially careful if the (running hours)
engine is used in dusty environments.
2000 Ships, Generating sets in closed rooms, Pumps
e Serious contamination can occur, for example;
- on construction sites where there is a high 1000 Vehicles on paved roads
level of air·borne dust.
- in harvesting application where there are 500 Tractors. Fork·lift trucks, Mobile gensets
high concentrations of chaff and chopped 250 Vehicles on construction sites and unpaved roads,
straw in the vicinity of the machine. Construction machineriy, Compressors, Underground mine units
e Because applications vary, cleaning intervals 125 Farm equipment, Tractors doing harvesting work
have to be determined from case to case. The
cleaning intervals given in the table on the right
can be used as a guide.
6.4 Combustion Air Cleaner Service and Maintenance
6.4.1 Cleaning Intervals
e The amount of dirt in the air cleaner depends on

the amount of dust in the air and the size of the
air cleaner used. If a high level of dust is
anticipated, a cyclone-type prec/eaner can be
fitted to the air cleaner.
Ill Cleaning inteNals will have to be determined

from case to case.
• If a dry type air cleaner is used, clean when
indicated by the service indicator or switch.
ct Air cleaner servicing is needed when:

- Service Indicator
the red signal 1 is fully visible when the
engine is off.
- Service Switch
the yellow pilot light comes on when the
engine is running.
• After carrying out service work, reset the signal
by pressing the button on the service indicator.
6.4.2 Emptying Cyclone Type 6.4.3 Cleaning Oil Bath Air Cleaner
Precleaner
I~
1
!II_& (5)
~
~870
e Undo wing nut 1 and remove cover 2. e Turn engine offandwaitabout 10minutesforthe e Clean filter housing 1 if very dirty.
• Remove collector bow/3 from lower section 4 oil to drain from filter housing 1. Ill Inspect and replace rubber gaskets 5 and 6 if
and empty. Clean leaves, strawandotherforeign e Release snap clips 2 and remove oil cup 3 necessary.
matter from lower section of prec!eaner. together with filter element 4. If necessary prize Ill Fill oil cup with engine oil up to the mark (arrow)
Ill Repositioncollectorbowl3 onto lower section 4, element out with ascrewdriver, taking care not to (for viscosity, see 4.1.2).
fasten cover 2 in place by tightening wing nut 1. damage the rubber gasket 5. Ill Refit oil cup and element to filter housing and
o Remove dirty oil and sludge. Clean oil cup. secure with snap clips.
e Clean filter element 4 in diesel fuel and allow to
drip-dry.
Never clean airc!eanerwith gasoline.

Dispose of old oil in accordance with
Neverfi!l collector bowl with oil. Replace collector environmental regulations.
bowl if damaged.
Service and Maintenance 6.4 Combustion Air Cleaner
6.4.4 Dry Type Air Cleaner

Dust Discharge Valve Filter Cartridge
e Empty dust discharge valve 1 by pressing apart e Undo clip fasteners 1. 8 After five cleaner services or after two years at
lips of discharge slot as indicated by arrows. e Take off hood 2 and remove cartridge 3. the latest, replace safety cartridge4 (neverclean).
e Clean discharge slot from time to time. e Clean cartridge (replace at least once a year). To do so:
e Remove any caked dirt by pressing together the e Clean cartridge 3: - Undo hex. nut 5 and remove cartridge 4.
upper section of the valve. Blow out from inside out with dry compressed - Install new cartridge, insert and tighten hex.
air (max. 5 bar), (or in difficult cases, tap out, nut.
taking care notto damage the cartridge, or wash e Install cartridge 3, replace hood 2 and do up clip
according to manufacturer's instructions). fasteners 1.
e Through regular removal and replacement, the
gaskets on the filter cartridge can become dam-
aged. Check paper filter (light showing through)
and gaskets for damage. Replace if necessary.
Never clean filler cartridge with

gasoline or hot fluids.
6.5.1 Checking V·Belts 6.5 Belt Drives
etnspect entire V-belt for damage. - Carefully remove the gauge without altering
e Replace damaged V-bells. the position of the indicator arm 1.
e After installing new belts, run engine for 15 - Read off the value: Turn the gauge sideways
minutes, then check belt tension. to see the exact spot where the top of the
e To checkthetension of the V-belt, use atension black indicator arm '1 intersects scale 5
gauge. (arrow). For settings, see 9.1
- Place indicator arm 1 into gauge. - If necessary, retension belt and measure again.
- Position gauge on V-belt 2, midway between
the pulleys, with flange 3on bottom of gauge
against the edge of belt.
- Push slowly on the black pad 4 at right angles
to belt 2 until the spring is heard or felt to
trigger. Check tension and change belts only
with the engine off. Refit belt guard,
if provided. When newV-belts are fined, check the belt tension
after approx. 15 minutes running time.
6.5 Belt Drives Service Maintenance
6.5.2 Tensioning Alternator Belts 6.5.3 Changing Alternator Belts
e Slacken off bolts 1,2 an 3. e Slacken off bolts 1,2 and 3.

• Adjust alternator 4 in direction of arrow by e Adjust alternator 4 in direction of arrow by
turning boJt3 until correct belt tension is achieved. turning bolt 3
e Retighten bolts 1, 2 and 3 e Remove and replace belt.
e Adjust alternator 4 against the direction of the
arrowbyturning bolt 3, until correct belt tension
is achieved.
e Retighten bolts 1,2 and 3.
Check, tension and change belts

only with the engine off. Refit belt
guard, if provided.
6.5.4 Checking Toothed Belts

Timing Belts
e Unscrew hex. bolts 2. Remove the cover. Ill Check the face and back of the teeth along the
complete length of the toothed belt (see arrows).
Ill To facilitate this, rotate the engine through nvo
turns.
Ill If damaged, replace the toothed beiVsprocket
(see workshop manual).
e Replace the cover 1 with hex. bolts 2.
Service and Maintenance 6.6 Adjustments
6.6.1 Checking/Adjusting Valve

Clearances
e Remove the cylinder head cover. e Adjust valve clearance il necessary:

8 Position crankshaft as per schematic 6.6.1.1. - Release locknut 4.
e Before adjusting valve clearance, allow engine to - Use screwdriver 7 to turn setscrew 5 so that
cool down lor at least 30 minutes. The oil the correct clearance is attained after locknut
temperature should be below 80 'C. 4 has been tightened.
e Check valve clearance 1 between rocker arm I • Check and adjust valve clearance on aU remaining
tappet contact face 2and valve stem 3with feeler cylinders.
gauge 6 (there should be only slight resistance e Replace cylinder head cover (use new gasket il
when feeler blade is inserted). needed).
For permissible valve clearance, see 9.1
6.6.1.1 Valve Clearance

Adjustment Schematic
e Crankshaft Posilion 1:
Turn crankshaft until both valves in cylinder 1
overlap (exhaust valve about to close, inlet valve
about to open). Adjust clearance ol valves
marked in black on schematic. Mark respective
rocker arm with chalk to show that adjustment
has been done.
e Crankshaft Position 2:
Turn crankshaft one lull revolution (360').
Adjust clearance ol valves marked in black on
schematic.
- 1 2 3 4
r-
[]l[[]l[i]l[[]]
'-
6.7 Accessories Service and Maintenance
6.7.1 Battery
6.7.1.1 Checking Battery and 6.7.1.2 Checking Electrolyte Level 6. 7.1.3 Checking Specific Gravity
Cable Connectors of Electrolyte
25 895 0
o Keep battery clean and dry. 0 Remove caps 1. e Measure the specific gravity of individual cells
0 Undo dirty clamps. e If testers 2are used, the electrolyte should come with a commercial hydrometer.
0 Clean terminal posts (+and-) and clamps of the up to their base.
battery, and grease with acid-free and acid- 0 lftestersare not used, theelectrolytelevel should The hydrometer reading (see table on following
resistant grease. be 10-15 mm above the top of the plates. page) indicates the state of charge.
e When reassembling, ensure that clamps make o If necessary, top up with distilled water. During measurement, the temperature of the
good contact. Do up clamp bolts finger tight. o Replace caps. electrolyte should preferably be 20 'C.
Specific Gravity
in kg/1 in' Be (Baumegrad)"
State of Charge
normal tropics normal tropics
1,28 1,23 32 27 Fully'charged
1,20 1'12 24 16 Half charged, recharge
1,12 1,08 16 11 Discharged, recharge immediately
* Measurement of specific gravity in o Be is out of

date and rarely used today.
The gases emitted by the battery

are explosive. Keep sparks and
naked flames away from the
battery. Do not allow battery acid to come into
contact with skin or clothing. Wear protective
goggles. Do not rest tools on the battery.
Service and Maintenance 6. 7 Accessories
6.7.2 Three·Phase Alternator 6.7.3 Lifting Tackle
Notes on the three-phase system:

e Never disconnect the cables between battery,
alternator and regulator while the engine is
running.
e If, however, it is necessary to start and operate
the engine wrrhout the battery, disconnect the
regulator from the alternator before starting.
e Be sure not to confuse the battery terminals.
II Replace defective bulb of the charge pilot lamp
immediately.
e When washing the engine, cover up the alternator
and regulator.
II The habit of touching a lead against the frame to
check whether it is live must under no
circumstances be used with three-phase electrical
systems.
• In case of electric welding, connect the ground
terminal on the welder directly to the piece being
welded. o Always use properliftingtac~ewhen transporting
the engine.
e After transportation and before commissioning
of the engine:
Remove the attachment eyes 2.
Use only the correct lifting tackle.
6. 7.4 Ether Starting System

6. 7.4.1 Changing the Fluid Container
• Before removing the container, clean the container • Place the container 1 on th8 solenoid valve 2 and
support and the top of the solenoid valve. tighten by hand.
e Loosen the bracket 1. o When mounting, ensure that gasket 3 is seated Before commissioning, leave the
• Unscrew the fluid container. correctly. fluid container of the ether starting
e Empty or replace the depressurized fluid o Pull in the bracket. system in position for 15 minutes.
container. II Check for leaks. Check for leaks. The starting fluid is
inflammable. Ensure that the container is not
damaged. Prevent foreign substances from entering
the container. The fluid container must not be
stored at temperatures above 50 °C.
Troubleshooting
7.1 Diagnosis Chart
D
Troubleshooting 7.1 Diagnosis Chart
Faull Remedy
Engine fails or is difficult to start Check p
Engine starts but runs unevenly or stalls Adjust E
Engine overheats. Temperature monitor gives warning Replace w
Engine gives poor performance Glean R
Engine not firing on all cylinders Top up A
Engine has little or no oil pressure lower level s
I Engine oil consumption excessive
I
Engine smokes -blue
I -white
'
I I
-black
I
I
i I
I I Cause Section !
••
I I Not declutched (where possible) Operation I p
· ..
!• Below starting limit temperature I p
..
• • • . ·.
Oil level too low ! A
•i•
'.
• '•• • r=+=
Oil level too high
I . Excessive inclination of engine
•• • •
I ' Incorrect lube oil SAE class or quality Operating I w
•
,.
;e .
Fuel quality not as per operating manual media I w
i
•• •
I.
• Air cleaner clogged I turbocharger defective
e 1 Air cleaner service switch I indicator defective
Combustion air PI W
PIW
le •
LOA' defective
J• Charge air line leaking
Oil cooler panels clogged
r+
Cooling system: PI R
I•
.
Cooling fan defective, split or loose V-belt
I Cooling air temperature rise I heating short circuit
I P~W
I•
I• I Resistance in cooling system too great I through-flow quantity too small ~
•
• LOA= Manifold-pressure compensator
! Battery defective or discharged Electrics ! PI A
Fault i Remedy
Engine fails or is difficult to start : Check p
I Engine starts but runs unevenly or stalls ' Adjust E
Engine overheats. Temperature monitor gives warning Replace w
Engine gives poor performance Glean R
Engine not firing on all cylinders Top up A
D Engine has little or no oil pressure

Engine oil consumption excessive
Engine smokes -blue
! lower level
I
s
-white i
-black I
I
.,.
Cause Section
•• \ Electric cable connections to starter electrical system loose or oxidised
• J Starter defect or pinion does not engage
I Electrics
! ;
p
p
• • •• Incorrect varve clearance ; Engine E
• ••• • • •• ..
I Leaking injection line p
•r• Injection valve defective

I
!
PIW
I
'
! I
'
Engine Preservation
8.1 Preservation
Engine Preservation 8.1 Preservation
8.1.1 Preserving Engine 8.1.2 Removing Engine

Preservatives
If the engine is to remain idle for an extended period e Clean engine (with cold cleansing agent if e Removeanti-corrosionagentfrom grooves in V-
of time, it is necessary to take protective measures preferred) using high pressure equipment. belt pulleys.
to prevent rust formation. The preservative 8 Run engine until warm, then turn off. e Install V-belts. Retension after brief operation if
measures described here will protect the engine for e Drain engine oil, see 6.1.2, and fill with anti- necessary, see 6.5.
up to 6 months. The procedure will have to be corrosion oil. • Remove covers from intake port and exhaust
reversed before the engine is recommissioned. e If necessary, clean oil bath cleaner, see 6.4.3, port.
e Anti·corrosion oils to specification: and fill with anti-corrosion oil. • Set the engine in operation, see also section 5.1,
MIL-L-212608 e Drain fuel tank. annotation 2.
TL 9150-037/2 • Make up a mixture of 90% diesel fuel and 10%
Nato code C640/642 anti-corrosion oil, and refill fuel tank.
e Anti-corrosion media for exterior protection only • Run engine for about 10 minutes.
to specification: e Turn engine off.
Nato Code c 632 • Turn engine over manually several times to
e Recommended cleansing agent to remove preserve the cylinders and combustion chamber.
preservatives when recommissioning engine: • Remove V-belts and store in wrapped condition.
Petroleum benzine (hazardous materials • Spray grooves of V-belt pulleys with anti-
class A3) corrosion spray.
Gl Close off intake ports and exhaust ports.
Technical Specifications
9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings
9.3 Tools
Technical Specifications 9.1 Engine Specifications and Settings
Model FM 1011F
Number of cylinders 3 4
Cylinder arrangement vertic! e. in line vertic! e. in line
Bore (mm] 91 91
Stroke (mm) 112 112
Total displacement (cm'' 2184 291 2
Compression ratio (e) 18.5 18. 5
Working cycle I Combustion system - 4-Siroke diese ld irect injection- - 4-Siroke diese ld irecl injection-
Direction of rotation counter cl ockwise counter cl ockwise
Weight incl. cooling system (kg approx. I Reier to head-office Reier lo hea d-office
Weight without cooling system
as per DIN 70020-A (kg approx.) 200 243
1) 1)
Engine power (kW)
1) 1)
Speed (1/min]
Valve clearance (cold engine) (mm) 1-- inlet 0,3 •o.1 I exhaust0,5' 0·1
,, bar - r--- inlet 0,3 • 1,,exhaust 0,5 '
0·1 0·1 -
Injector opening pressure (bar) 210 210 bar
Start of delivery ("crank angle bTDC] 1) 1)
Firing order 1-2-3 1-3-4-2
Lubrication pressure tubrica.tion pressure lu bricalion

SAE oil 20 w
20 20 w 20
Oil temperature in the oil sump ("C) 130 130
Min. oil pressure in warm condition (130°C)
and low idling speed (bar] 1,1 1,1
Oil change quantity with filter (ltr. approx.)
Oil content of external cooling system
8
" 10,5" (see3.1)
(Cooler and pipes) (ltr. approx.) 2.6 4.2
1
' Engine power, speed, start of delivery are stamped on engine rating plate (see also 2.1 ).
<J Approx. value can vary depending on oil sump or radiator design (external cooling system}.
The upper oil dipstick marking should always be taken as authoritative.
3l Only required for winter operation, see 3.5.1.
9.2 Torque Wrench Settings
Preload (Nml Torquing load INmJ

location Totai(Nm! Remarks
1st Stage 2nd Stage 3rd Stage lsi Stage 2nd Stage 3rd Stage 4th Stage
Rocker cover 8,5
Rocker arm setscrew 21
Air intake manrrold 8,5
Exhaust manrrold 22
Oil drain plug 55
Injector mounting 21 Torx
Injection Uoo mounting 30
Oil pan (cast iron) 31
Oil pan (sheet metal) 21

9.3 Tools Technical Specifications
TORX V·bell Tension Gauge
1f=
26002 0
ATORXwrenchsetis used with engines in the 1011 The V·belt tension gauge can be obtained under
series. This system was chosen because of the order number 91107 from:
many advantages it offers:
FA.WJLBAR
e Outstanding accessibility to bolts. PosHach 14 05 80
e High load transfer when loosening and tightening. 0·42826 Remscheid
0 Almost impossible for socket to slide off or
break.
TORX tools can be ordered from:
FA.WILBAR
PosHach 14 05 80
0·42826 Remscheid
Notes
Service
DEUTZ SERVICE INTERNATIONAL GmbH

Deutz·Miilheimer str.1 07
Postfach 80 05 09
0·51057 Kiiln
Germany North-,West-,Southeurope South America
Region Austria North America Algeria
Switzerland Asia Africa
East Europe Australia Greece, Turkey
Telephone (0221) 822 5247/5281 (0221) 822 5224 (0221) 822 5245
Sales service products Telefax (0221) 822 3674/822 5462 (0221) 822 2909
Telex 8812 253 KHD D

Telephone (0221) 822 5580/5556 (0221) 822 5557/2737 (0221) 822 5559
Order processing Telefax (0221) 822 2700/ 822 5304/ 822 2665
Telex 8812 251 KHD D
Telephone (0221) 822 3209
Service Engineering Telefax (0221) 822 3204
DEUTZ
Telex 8812 241 KHD 0
Give us a ring and we furnish you with the address of the DEUTZ SERVICE INTERNATIONAL GmbH outpost nearest to your facility.
A "SERVICE REGISTER WORLD" can be ordered under No. 0297 4709
A "list of Service Documentation WORLD" can be ordered under No. 0297 5198
SERVICE Phone for technical questions: (0221)822 5454

Direct dial from 8.00 a.m. to 5.00 p.m.
At night, on weekends and holidays automatic phone answerer.
(We shall responds the next working day.)
r
i
All rights rese!Ved. Printed in U.SA.

PARTS LIST 9-0
PARTS LIST
CONTENTS ILLUSTRATION PAGE

Frame & Running Gear, Sht 1 36525814 9-2
Frame & Running Gear, Sht 2 36525814 9-3
< Running Gear Complete, Sht 1 36511368 9-4
Running Gear Complete, Sht 2 36511368 9-5
Tire & Wheel Assembly, Sht 1 36522597 9-6
Tire & Wheel Assembly, Sht 2 36522597 9-7
Jack Assembly, Sht 1 36522605 9-8
Jack Assembly, Sht 2 36522605 9-9
Engine Complete, Sht 1 36512473 9-10
Engine Complete, Sht 2 36512473 9-11
Liquid Cooling Complete, Sht 1 36512515 9-12
Liquid Cooling Complete, Sht 2 36512515 9-13
Airend Complete, Sht 1 36512499 9-14
Airend Complete, Sht 2 36512499 9-15
Airend Assembly, Sht 1 36514545 9-16
Airend Assembly, Sht 2 36514545 9-17
Air Intake Complete, Sht 2 36512507 9-18
Air Intake Complete, Sht 1 36512507 9-19
Air Service Complete, Sht 1 36522613 9-20
Air Service Complete, Sht2 36522613 9-21
Seperator Tank Complete, Sht 1 36511426 9-22
Separator Tank Complete, Sht 2 36511426 9-23
Air Cleaner Assembly, Sht 1 36511418 9-24
Air Cleaner Assembly, Sht 2 36511418 9-25
Fuel Tank Complete, Sht 1 36512523 9-26
Fuel Tank Complete, Sht 2 36512523 9-27
Battery and Mounting, Sht 1 36512531 9-28
Battery and Mounting, Sht 2 36512531 9-29
Air and Oil Piping, Sht 1 36522621 9-30
Wiring Diagram, Sht 1 36521045 9-34
Wiring Diagram, Sht 2 36521045 9-35
lnst/Control Panel, Sht 1 36520716 9-36
lnst/Control Panel, Sht 2 36520716 9-37
Enclosure Complete, Sht 1 36512549 9-38
Acoustic Panels, Sht 1 36522639 9-42
Acoustic Panels, Sht 2 36522639 9-43
BOOK 35389816 (5/95)

PARTS LIST 9-1
PARTS LIST
CONTENTS ILLUSTRATION PAGE

Decal Location, Sht 1 36513729 9-44
"' Decal Location, Sht 3 36513729 9-46
Option Wiring Diagram, Sht 1 36521052 9-48
Option Wiring Diagram, Sht 2 36521052 9-49
Keyed Ignition Option, Sht 1 36512929 9-50
Keyed Ignition Option, Sht 2 36512929 9·51
Diagnostic Module Option, Sht 1 36512812 9-52
Diagnostic Module Option, Sht 2 36512812 9-53
Gauge Option, Sht 1 36512879 9·54
Gauge Option, Sht 2 36512879 9-55
Hose Reel Assembly, Sht 1 36522647 9·56
Hose Reel Assembly, Sht 2 36522647 9-57
Single Hose Reel Option, Sht 1 36512895 9·58
Single Hose Reel Option, Sht 2 36512895 9·59
Double Hose Reel Option, Sht 1 36522654 9·60
Double Hose Reel Option, Sht 2 36522654 9-61
Extended Drawbar Option, Sht 1 36512853 9-62
Extended Drawbar Option, Sht 2 36512853 9-63
Adjustable Drawbar Option,Sht 1 36512846 9-64
Adjustable Drawbar Option,Sht 2 36512846 9-65
Extd/Adj Drawbar Option, Sht 1 36512838 9·66
Extd/Adj Drawbar Option, Sht 2 36512838 9·67
BOOK 35389816 (5/95)

PARTS LIST 9-2
(
D
c G
INGERSOLL-RAND COMPANY
PORTABLI! OO~PRI!SSOR DIVISION
DI!SCRIPTIOH
FRAME COMPLETE
BOOK 35389816 (5/95)

PARTS LIST 9-3
ITEM C.P.N. QTY DESCRIPTION
A 36874352 1 FRAME
B 36773042 1 BUMPER
c 36765139 1 DRAWBAR
D 36767812 1 RUNNING GEAR
E 36763688 8 SCREW
F 35068345 2 TIRE & WHEEL ASSEMBLY
G 36780013 1 JACK ASSEMBLY
H 35605187 1 PINTLE EYE
J 35376094 2 SCREW
K 36795532 1 U-BOLT
L 36769057 4 SCREW
M 36780039 1 SNAP RING
N 35148030 4 SCREW
p 11A5D5Z1 8 WASHER
a 12A5D8Z1 2 WASHER
R 35374453 2 NUT
s 16M4JC26M3 4 NUT
T 35610377 2 CHAIN ASSEMBLY
u 35372432 2 COUPLING LINK
v 36770386 4 NUT
PORTABLe. COJdPRe.SSOR DIVISION
DESCRIPTION
FRAME COMPLETE
DATEIDWN
216195
BY:I
ti
MODEL HTIILLUSTRATIOH HO., SHEeT
~:J~g 36525814
H,
R~V; I~"!EI¢HKD ~!.ATI!!/APVO BY
A "-" '\-::._' 5 £?,C
2 of 2
f!./0
28136
BOOK 35389816 (5/95)

PARTS LIST 9·4
RUNNING GEAR COMPLETE

PART NO. 36767812
DEXTER 5-LUG
PORTABLI!' COUPRI!:880R DIVISION
BOOK 35389816 (5/95)

PARTS LIST 9·5
A 36768752 1 AXLE
B 36768778 2 SPRING
c 36768760 4 U-BOLT
D 35315142 2 GREASE SEAL
E
* 35361864 2 BEARING CONE
F
* 35361872 2 BEARING CUP
* HUB
**
G 35361880 2
H 35315183 2 BEARING CUP
J * 35315191 2 BEARING CONE
K 35315209 2 SPINDLE WASHER
L 35315217 2 SPINDLE NUT
M 35315225 2 COTTER PIN
N
p
* 35315233
35315241
2 GREASE CAP
TIE PLATE
2
Q 35315258 8 NUT
R 35361898 10 WHEEL STUD
s ** 35315274 10 WHEEL NUT
T 35326958 2 FRONT HANGER
u 35315340 2 SHACKLE BOLT
v 35315357 2 SHACKLE NUT
w 35326966 2 REAR HANGER
X 35315365 2 KEEPER BOLT
y 35315373 2 KEEPER NUT
35085398 HUB KIT

*
RUNNING GEAR COMPLETE

PART NO. 36767812
DEXTER 5-LUG
PORTABL! COMPRESSOR DIVISION
OI!SCRIPTION
RUNNING GEAR COMPLETE (DEXTER\
PATE/OWN BY:I R!:V: I?ATI!/CHKD "1ATI!IAPVO BY
9/28189 ~ B ~;, '\ .;;v · 5 §;C
MODI!L NO./
P·100E'NO
ILLUSTRATION HO.,SHI!:U NO.,: E/c
P·"""" 36511368 2 of 2 23955
BOOK 35389816 (5/95)

PARTS LIST 9-6
TIRE AND WHEEL ASSEMBLY 35068345
PORTABLI! COMPRI!SSOR DIVISION
BOOK 35389816 (5/95)

PARTS LIST 9-7
A 35292986 1 WHEEL
B 35282565 1 VALVE STEM
c 36773265 1 TIRE
TIRE AND WHEEL ASSEMBLY 35068345
PORTABLE COMPRI!880R DIVISION
OI!SCRIPTION
TIRE AND WHEEL ASSY.
DATIYDWN
4121/94
8r1
tl
RI!.V: rATI!!/CHKD fi(~~:ATI!IAPVD eY
A ~., '-\-:J.!. s L7;C
MODI!!L N~., ILLUSTRATION
P·100EWO
NO.I SHEET N~'J: E/C
P·12SEWO 36522597 2 of 2 24193
BOOK 35389816 (5/95)

PARTS LIST 9·8
JACK ASSEMBLY36780013
PORTAIIU! COMPRI!880R DIVISION
BOOK 35389816 (5/95)

PARTS LIST 9-9
A 36792489 1 HANDLE KIT

B 36792513 1 WHEEL KIT
c 36792505 1 PLUNGER PIN KIT
D 36792497 1 BEVEL GEAR KIT
JACK ASSEMBLY 36780013
INGERSOLL·RAND COMPANY
PORTABLE! COMPRO'!SSOR DIVISION
DI!.SCRIPTIOH
JACK ASSEMBLY
OATI!JDWN tiY:I RI!V: I~ATI!/CHKD &~jf~TI!fAPVJ;C-Y
4121/94 tl A .,_"- '-\ • .:>< 5 ..0,
MDDI!L H1'[1LLUBTRATIOH
P-100EWD
Ho.l SHI!I!T H0.1' 1!/C
P-12SEWD 36522605 2 ol2 24940
BOOK 35389816 (5/95)

PARTS LIST 9-10
PORTA.&ll!" COMPR~880R DIVISION
Ot!SCRIPTIOH
27276
BOOK 35389816 (5/95)

PARTS LIST 9-11
A 36871705 1 ENGINE
B 36774487 1 VALVE, DRAIN
c 35285600 8.5" HOSE
D 36775575 2 MOUNT, RUBBER
E 36775518 1 MOUNT, LH REAR
F 36772606 4 SCREW
G 12A5D7Z1 4 WASHER
H 36775542 1 MOUNT, RH REAR
J 36776136 2 SCREW
K 36793032 4 NUT
L 36858660 2 MOUNT, RUBBER
M 36871630 1 MOUNT, LH FRONT
N 36871648 1 MOUNT, RH FRONT
p 35290113 2 SCREW
Q 35609874 2 WASHER
R 36794485 1 PIPE, EXHAUST
s 35302223 1 CLAMP
T 36296342 1 CLAMP
u 36764587 1 FAN
v 12M5L29M3 4 WASHER
w 35374842 4 SCREW
X 36780633 1 BAIL, LIFTING
y 12A5D4Z1 9 WASHER
z 36769297 4 SCREW
ENGINE FUEL FILTER 92100981

ENGINE OIL FILTER 92793223
PORTABLE COMPRI!SSOR DIVISION
OI!SCRIPTION
ENGINE ASSEMBLY
OAT~OWH BY:' REV: ~~:Te'/CHKO I!Jb!'~I!!/~VDJH
1218189 tl G '-~ ~ ..::2< - ._u/-
MOO.!l H:·j ILLUSTRATION HO., SHI!!I!!T
P·100EWD
NO,,: E/C
P·125EWD 36512473 2of2 28107
BOOK 35389816 (5/95)

PARTS LIST 9·12
•
/
PORTASLI! COMPRI!$80R DIVISION
BOOK 35389816 {5/95}

PARTS LIST 9-13
A 36760726 2 OIL COOLER

B 36850436 1 FAN SHROUD
c 36852218 2 FAN GUARD
D 36843928 2 FAN SHROUD SUPPORT
E 35300771 6 SCREW
F 92368687 6 SCREW
G 36769024 2 SCREW
H 12A5D2Z1 4 WASHER
J 36769032 2 NUT
K 35144336 2 SCREW
L 35252600 2 NUT
PORTABLE COMPRESSOR DIVISIOH
OI!SCRIPTIOH
LIQUID COOLING COMPLETE
DATE/OWN BY:I RI!V: t~IHCHKD B~t;.ATfiAPVD BY
12/21/89 ti c c;-~' .<;- L-7/
ldOOI!L Nr·J tlU8TRATIOH NO., SHU:T H0.
P-100EWO
:; I!IC
P-125EWD 36512515 2 of 2 126782
BOOK 35389816 (5/95)
PARTS LIST 9-14
,/
PORTABLI! CONPRI!880R D!Vl810H
BOOK 35389816 (5/95)

PARTS LIST 9-15
A 35353978 6 SCREW
B 35332295 6 DRIVER
c 36851939 1 COUPLING
D 35582295 1 BUSHING
E 35A2D67Z1 3 SCREW
F 36769289 1 KEY
G 119M2A244M3 10 SCREW
H 12A5D4Z1 9 WASHER
J 109A2A5 1 SETSCREW
PORTASU! COMPRI!SSOR DIVISION
DI!SCRIPTIOH AIREND COMPLETE

DAT!.IDWN IIY:J RI!:V: ~~ATI!tCHKD e:tA'TI!IAPVD ay
1/24190 ~ D '"'' ~--;,.i- 5 .L}~
MOD!L N0. ILLUSTRATION HO.rH!!T N0. : 1!/C
~:~= 1 36512499 2 of 2 127793
BOOK 35389816 (5/95)

PARTS LIST 9-16
I
3.69:1, 85mm AIR END ASSEMBLY 36007839

PORTABL~ CO.CPRESSOR DIVISION
BOOK 35389816 (5/95)

PARTS LIST 9-17
A 36506772 1 SEAL COVER

B 35375369 1 SEAL
c 35611961 4 SCREW
D 95022331 1 0-RING
E 119M2AB221 32 SCREW
F 36791689 2 SCREW
G 95094306 2 WASHER
H 35286004 1 BEARING
J 39101449 1 PLUG
K 95641734 1 0-RING
L 36512134 1 SCREW
M 36506442 1 BEARING COVER
N 35611953 7 SCREW
p 95023115 1 0-RING
Q 35289057 1 PLUG
R 35287556 2 PLUG
s 35287655 4 SCREW
T 36508471 1 INLET COVER
u 36511623 1 UNLOADER VALVE
v 90523107 1 0-RING
w 35379817 1 SPRING CAP
X 35376342 1 SPRING
y 35611557 1 STEM
z 35376334 1 SPRING
A1 36511615 1 PISTON
A2 35376359 1 SEAL
A3 35376326 1 SPRING
A4 35612175 1 CONNECTOR
A5 95257333 1 CAP
A6 35376318 1 BALL
A7 36764553 1 TUBEASSY
AS 35286491 2 ELBOW
AS 35296920 1 FILTER ELEMENT
B1 35372986 1 NIPPLE
3.69:1, 85mm AIR END ASSEMBLY 36007839

PORTA&ll!! COMPRI!880R DIVISION
OJ!! SCRIPTION
AI REND ASSEMBLY
OATE/DWN
1/31/95
sr:l
~
RJ!!V: IOATJ!!fCHKD ~~~ATI!/APVD BY
A •._~ '-\ -¥- s ._!},C
MODI!.l No. ILLUSTRATION HO.rHI!U NOl f.IC
~~= 1 36525715 2of2 28107
BOOK 35389816 (5/95}

PARTS LIST 9·18
'
PORTABLI! COUPAI!880R DIVISION
DI!8CRIPTION
AIR INTAKE COMPLETE
PIOOEW
Pt2SEWD 27511
BOOK 35389816 {5/95)

PARTS LIST 9·19
A 36862829 2 AIR CLEANER ASSEMBLY

B 36773950 1 HOSE ELBOW
c 36773448 1 HOSE ELBOW
D 35374073 3 CLAMP
E 35585009 4 MOUNTING BAND
F 35M2AB360M3 8 SCREW
G 12A5D3Z1 4 WASHER
H 35278530 8 NUT
J 35295781 1 CLAMP
K 35300615 1 RESTRICTION INDICATOR
PORTA!ILI! COMPRI!$80R DIVISION
DESCRIPTION
AIR INTAKE COMPLETE
RI!:V: ~ATI!:ICHKD B~~~TI!aY
1 \i>
DATE/OWN IIY:
12/14189 tl 1 D '-l-::H S 1C.
MODI!L No. ILLUSTRATION NO,ri>HI!I!T No. EIC
~~= 1 36512507 2of2 127511

BOOK 35389816 (5/95)
PARTS LIST 9·20
\---(A
B
POFITA!ILe: COMPRI!!8SOR DIVISION
DI!SCRIPTION
AIR SERVICE COMPLETE
26062
BOOK 35389816 {5/95)

PARTS LIST 9-21
A 36768828 1 SERVICE PIPE

B 35592377 1 SONIC ORIFICE
c 35287747 1 BULKHEAD FITTING
D 19A7J53Z1 1 NIPPLE
E 35576115 1 BALL VALVE
PORTABLI! COMPRUSOR DIVISION
DI!SCRIPTIOH
AIR SERVICE COMPLETE
DATf/DWH er:l RI!V: IDATI!"ICHKO e;~A~VD BY
4125194 tl A I~i> t.j-::11 A /-
M.ODI!.L NO., ILLUSTRATION HO.,SHI!ET NO., :!IC
m~~ 36522613 2 of 2 26062
BOOK 35389816 (5/95)

PARTS LIST 9·22
0~---G,
@r----$
PORTAI!ILI! CONPRI!:880R OIVISIOH
BOOK 35389816 (5/95)

PARTS LIST 9-23
A 36846574 1 SEPARATOR TANK

B 36845303 1 ELEMENT
c 36766947 1 COVER
D 36763662 8 SCREW
E 12A5D6Z1 8 WASHER
F 174A10C6 1 PLUG
G 35579630 1 PLUG
H 36860468 1 FITTING
J 35324849 2 GASKET
K 92121532 1 TUBE
L 92368687 6 SCREW
M 67A7M4Z1 1 ELBOW
N 35325166 1 SAFETY VALVE
PORTABLe COI.IPRI!SSOR DIVISION
DUCRIPTIO~EPARATOR TANK ASSEMBLY

OATI!/DWN
9/19/89 tl
BY:I RI!.V: ~~ATEICHKD l*ATI!!~J? BY
D ~~ ~~~ic . :C
MODI!:L NO.I lLLUSTRATlON NO.I SHI!IH NO, "c
~:= 36511426 2of2 I 27366
BOOK 35389816 (5/95)
PARTS LIST 9·24
AIR CLEANER ASSEMBLY 36862829
PORTAISLI! COMPRI!SSOR DIVISION
DI!SCRIPTIOH
AIR CLEANER ASSEMBLY
PIOOEWD
P12SEWD 27511
BOOK 35389816 (5/95)

PARTS LIST 9·25
A 35388883 1 BODY
B 35291970 1 ELEMENT
c 35388891 1 VACUATOR VALVE
D 35291475 1 WING NUT
E 35326032 1 COVER
F 35321637 OPTIONAL SAFETY ELEMENT
G 35291475 OPTIONAL WING NUT
AIR CLEANER ASSEMBLY 368$2829
PORTA !ILl! COJiiPRI!SSOR DIVISION
DI!SCRIPTION
AIR CLEANER ASSEMBLY
PATL'DWN DY:I RI!V: I~ATI!/CHKD !IJ-OATI!/~VP !IY
11/8189 tl D '<.~ Li.,;>\<\.1 ~ 1/-.
MODI!l HO.,lLLUSTRA.TIOH NO.,SHI!I!T HO., : f!.IC
~:= 36511418 2of2 27511
BOOK 35389816 (5/95)

PARTS LIST 9·26
TO FUEL RETURN
liNE ON ENGINE
TO FUEL PUMP
ON ENGINE
~
I
PORTAISLI! COMPRI!SSOR DIVISION
DI!SCRIPTIOH
FUEL TANK COMPLETE
PIOOEWD
P12$EWO
BOOK 35389816 {5/95)

PARTS LIST 9·27
A 36770212 1 TANK, FUEL
B 36859049 1 CAP
c 35363498 37.5' HOSE
D 35296342 6 CLAMP
E 36764272 2 STRAP, TANK
F 35300771 1 SCREW
G 36767051 2 FOAM
H 36774388 1 HEATSHIELD n
J 35307818 4 SCREW
K 12A5D2Z1 4 WASHER
L 35363498 2.5' HOSE
M 35316587 1 ADAPTER
N 11A7S1Z1 1 COUPLING
p 36772747 1 CONNECTOR
Q 35363498 42' HOSE
R 36845501 1 FILTER
PORTABLE COMPRESSOR DIVISION
PE$CRIPTIOH
FUEL TANK COMPLETE
OAT~DWH BY;I REV: IDATI!ICHKP 8\Y.l:."TI!/~ !_Y
12113189 tl G I~:, '-\·"-' s :.bi..L
I
MOPI!:L HO., ILLUSTRATION HO. SHEET HO., 1!/C
~:= 36512523 2of2 27278
BOOK 35389816 (5/95)

PARTS LIST 9-28
ENGINE FRAME
,-
1
PORTABLI!: COMPRI!&&OR DIVISION
DI!:BCRIPTION
BATIERY MOUNTING
BOOK 35389816 {5/95)

PARTS LIST 9-29
A 36844264 1 BATIERY
B 36766822 1 BATIERYTRAY
c 35591783 1 HOLDDOWN FRAME
D 35579143 1 NEGATIVE BATIERY CABLE
E 36779973 1 POSITIVE BATIERY CABLE
F 36764595 2 STUD
G 35278530 4 NUT
H 12A5D3Z1 2 WASHER
J 92368687 5 SCREW
K 35130293 1 SCREW
L 35578194 1 GROUND STRAP
PORTAfiLII!: COMPRI!SSOR DIVISION
DI!:SCRIPTION
BATTERY MOUNTING
DATE/OWN IIY:I RI!V: ~~~1!/CHKP ~~~~~AU:/APYD 8
1/24/90 tl C \(. -,_L~ s .£)/
WODI!L No., ILLUSTRATION NO.,SHI!I!.T NO.J E/C
P·100EWD
P·125EWO 36512531 2 of2 27630
BOOK 35389816 (5/95)

PARTS LIST 9-30
NOTE:
SEE SHEET 3 FOR MATCH POINTS
[A][ID[Q][QJ[[)
42
t----{59
3l---~,.j
1-----< 15
34
-@
L ___ l
J ~,-46-----.,
""'
59 I
0
I 4
L
c
0
0
L
E
R
5 I I 17
dJdJ
PORTABLI!" COl>IPRI!SSOR DIVISION
o!SORIPTION
AIR AND OIL PIPING
28107
BOOK 35389816 (5/95)

PARTS LIST 9-31
ITEM C.P.N. DESCRIPTION ITEM C.P.N. DESCRIPTION
1 35356484 TUBING 33 35A7SZ4 PLUG

2 35329861 UNION-12JIC 34
3 36746308 HOSE ASSEMBLY 35 36757573 PRESSURE SWITCH
4 36793248 TUBE ASSEMBLY 36
6 36768828 SERVICE PIPE 38 35287747 BULKHEAD FITTING
7 39 35323955 SIGHT TUBE FITTING
8 35370386 ELBOW 40 35324649 GASKET
9 35369354 ELBOW 41 92121532 SIGHT TUBE
10 42 36781227 SCAVENGE TUBE
11 43 35329309 LENZ FITTING
12 44 36770188 MANIFOLD
13 35283191 ELBOW 45 35579630 VENTED PLUG W/ 0-RING
14 35294750 ELBOW 46 174A10C6 PLUG W/ 0-RING
15 35358662 HOSE ASSEMBLY 47
16 72A7M4Z1 TEE 48
17 35369503 TEE 49
18 50 35295880 STRAIGHT CONNECTOR
19 51
20 52 36840411 INLINE ORIFICE/CHECK VLV
21 19A7JZ53 NIPPLE 53
22 19A7JZ2 NIPPLE 54 36766798 CHECK VALVE
23 11A7SZ1 COUPLING 55 35322379 SLOWDOWN VALVE
24 56 35301506 TEE W/ 0-RING
25 35592377 SONIC ORIFICE (P100 ONLY) 57
26 36846673 HOSE ASSEMBLY 58 36779999 TEE W/ 0-RING
27 36766772 ORIFICE, .062 59 36874097 HOSE ASSEMBLY
28 35603067 SONIC ORIFICE (P125 ONLY) 60 36792786 HOSE ASSEMBLY
29
30 35576115 SERVICE BALL VALVE
31 35325166 SAFETY VALVE
32 35369347 CONNECTOR
PORTASL~ COiiiPRI!SSOR DIVISION
OI!SCR1PTION
AIR AND OIL PIPING
PATE/OWN ev:j RI!V: ~~AT!!tOHKD a,~cl:ATI!IAPVD e
5120194
UODI!L
~ c I\~ '-''""- .s ...[);::.
NO.l ;LLUSTRATION NO.ISHI!!ET NO.II!/0
~:= 36522621 2ol4 28107
BOOK 35389816 (5/95)

PARTS LIST 9-32
NOTE:
SEE SHEET 1 FOR MATCH POINTS
[AJ[[J[QJ[Q][§J
10
~ ~ 9 ~~
~\1 I~ I I I
~ l r ;-®1 l
~ i iJt -
Jl I
1,- l-~
i
I
--,-1-,
~ ~~r? L+-
L
1--------{7 ~
19 II 1 I~_ -~-a---+-1----....-__./
2
1 (15" lg)
PORTABl.l!! COt.iPRI!SSOR DIVISIOH
DI!SCRIPTIOH
AIR AND OIL PIPING
BOOK 35389816 (5/95)

PARTS LIST 9·33
ITEM C.P.N. DESCRIPTION ITEM C.P.N. DESCRIPTION
1 35356484 TUBING 33
2 36765105 HOSE ASSEMBLY 34
3 35
4 36 35596436 SHUTDOWN SWITCH
5 37 39404165 0-RING
6 38
8 35370386 ELBOW 40
9 35369354 ELBOW 41
10 35612175 CONNECTOR 42
11 35286491 ELBOW 43
12 35374867 ELBOW 44
13 45
14 46
15 47 35287556 PLUG W/ 0-RING
16 48 35289057 PLUG W/ 0-RING
17 49 35279959 0-RING
18 50
19 35302314 ADAPTOR 51 36781540 PRESSURE REGULATOR
20 35295880 CONNECTOR WI 0-RING 52
21 53 36840395 CHECK VALVE
22 54
23 55
24 56
25 57
26 58
27 59
28 60
29 36766756 ORIFICE MUFFLER, .140 61
30
31
32 35369347 CONNECTOR
PORTABLe CONPRI!SSOR DIVISION
D!:SCRIPTION
AIR AND OIL PIPING
&20/Q:t ~t/ REr ~~~e~~~:~:rs-n~:C

.,.
WODI!:L NO., ILLUSTRATION NO.JSHI!ET NO,
~:= 36522621 4 of 4 28107
BOOK 35389816 {5/95)

PARTS LIST 9·34
REO· UNS'h1TCHEO 1z..rt:¢ POSffi~
Pti<f REO:ORN· SfflTCt£0 12\'0CPOSilTVE

) THERMAL FUSE
SENSOR SA
1 K ffiKMO T$1 F2
2
CONTACT ~.. COMPRESSOR ~ ~ SPARE
3 No ~ lr TEMP S'NITCH r - "l
· ' S4 N.C. LT Bt.U f'2-Q P2-2 B-i---+-----J---""""--
I ~~ 5-
ffi!WLV ENGINE OIL
c PRESS SINITCH
A
.t'"'l SS N.O. .
P2-1~
n-n It"
r
0
J'-----""-""""'""'"'-loI P2-10 _ _I
PN!OORN ENGINE r ** P2~ 11--+---i----''"-'!!!"'-"""-!!!!>>.
•"
~lr$6
TEMP SWITCH
N.C.
I
DIAGNOSTIC
MODULE Ut
I RESISTOR
LT et.UQRJ ~FJIONAL)
820HM
AI I
~
lOW FUel
~Wl,';F'
I f>2-3. J\'JOI'r1!:L
'~
L~:::::::::::JJJ.I f'2:·11
LTBLUWHT
Pl·1 TO OPTION
WIRING
DIAGRAM
MY
*
STARTER !, ~'lr----,
Bl CXJ' ''"""' 4
START
PROTECT ).. FUEL
* DIODE
-4 SHUT
";.DOWN
AUXSTART RElAYK32: ~ 0l 2
~~lf'Y Kt /
5
~ COIL g; 1 gj
D3
!
6 RELAY K2
COIL
r
8RN·12.VDCiiEG.I.TIVE
.
PORTA&LI! COMPRI!SSOR DIVISION
DeSCRIPTION
STD WIRING DIAGRAM
OAUlOWH &YIJ RI!V; JpA;rl!tCHKD BYjDATI!/APVO ~y
11/9/92 tll C 1~1. \\.-:..1!1\S ,0,-c
MOOI!L HO.IILLUSTRATIOH H0.,8HI!I!T HO., Ef¢
~l: I 36511954 I 1 ot 2 127757

BOOK 35389816 (5/95)
PARTS LIST 9-35
ITEM C.P.N. DESCRIPTION
B1 STARTER
BT1 *
36844264 BATTERY
D2 35376169 DIODE
D3 35376169 DIODE
F1 36782456 FUSE15A
F2 36782654 FUSE5A
G1 ALTERNATOR
K1 *
35364611 RELAY AUX START
K2 35583442 RELAY SHUTDOWN
K3 35583442 RELAY START PROTECT
L1 FUEL SOLENOID
M5 *
35605229 HOURMETER
R1 36774198 RESISTOR 82 OHM
S1 36509396 START SWITCH
S3 36757573 START PROTECT SWITCH N.C.
S4 35596436 COMPRESSOR TEMP SWITCH N.C.
~
S5 36757581 ENGINE OIL PRESSURE SWITCH N.O.

S6 36788503 ENGINE TEMP SWITCH N.C.
TS1 36865756 THERMAL SENSOR
U1 DIAGNOSTIC MODULE
**
HARNESS ENGINE 36859908

HARNESS GAGE 36853422
* FURNISHED BY ENGINE MANUFACTURER

**OPTIONAL EQIUPMENT
PORTABLe COMPRESSOR DIVISION
DESCRIPTION
STD WIRING DIAGRAM
DATr:toWN ev:J RI!V: ~~ATI!ICHKD e~ATI!!fAPVD ey
11/9/92 ~ D ~ \l,-oJ5\ 2J,C
MODI!L HO.,ILLUSTRATIOH NO.I SHI!tT NO.I: E/C
~)= 36511954 2of2 27923
BOOK 35389816 (5/95)

PARTS LIST 9·36
>----fE
I
I
I
~ INGERSOLL-RAND COMPANY
PORTABL~ COMPRI!SSOR DJVISION
26872
BOOK 35389816 {5/95)

PARTS LIST 9-37
A 36850030 1 INSTRUMENT PANEL

B 36850048 1 INSRTUMENT PANEL DECAL
c 36768851 1 SHUTDOWN DECAL
D 36850022 1 HINGE
E 36850089 1 DOOR
F 36850378 1 OPERATING INSTRUCTIONS DECAL
G 36513695 1 PRESTIGE DECAL
H 36785921 16 RIVET
J 36781540 1 2-WAYVALVE
K 36509396 1 IGNITION SWITCH
L 36853414 1 PRESSURE GAUGE
M 35605229 1 HOURMETER
N 36767440 6 HOLE PLUG
p 35607829 1 EYEBOLT
Q 36772028 1 NYLON WASHER
R 35607837 1 SPRING
s 12A5D2Z1 1 WASHER
T 67A4C1Z1 1 NUT
PORTABLI! COMPJU!8SOR DIVISION
DI!SCRIPTION
INSTRUMENT/CONTROL PANEL ASSY
DATE/OWN IIY:I RI!Vi-tATI!fCHKO ~~ATEIA.~D BY
2122/93 tl B ';..~ '\ _;;,,. ...£)/-'
MODI!L HO,IILLUSTRATION NO., SHI!I!~T HO.,~ 1!/C
~:= 36520716 2 ol2 26872
BOOK 35389816 (5/95)
PARTS LIST 9-38
./
PORTAeL~ COUPRI!SSOR DIVISION
D!SCRIPTION
PIOOEWD
P12:SEWO
BOOK 35389816 (5/95)

PARTS LIST 9-39
A 92368687 60 SCREW
B 36774529 1 TOP BAFFLE
c 12A5D2Z1 2 WASHER
D 36769032 2 NUT
E 36783520 8 STUD
F 36769024 2 SCREW
G 36797652 48 SCREW
H 36794816 8 RIVET
J 36796266 1 RH COOLER BAFFLE
K 36783496 8 RETAINER
L 36783504 8 RECEIPTACLE
M 16M4JC22M3 4 NUT
N 12A5D3Z1 4 WASHER
p 35337328 4 BALL STUD
Q 35600287 2 GAS SPRING
R 36764678 1 REAR ENDCAP
s 36852945 1 FRONT ENDCAP
T 36797124 2 DOOR
u 36793602 2 LATCH
v 36770956 1 ROOF
w 36764710 1 LH SIDE SUPPORT
X 36764728 1 RH SIDE SUPPORT
y 36766780 2 HINGE
z 36770980 1 AIR FOIL BAFFLE
A1 36768166 1 TOP EXHAUST BAFFLE
A2 36768174 1 BOTIOM EXHAUST BAFFLE
A3 36768182 4 BRACKET
A4 36768190 1 LH BRACKET
A5 36768208 1 RH BRACKET
A6 36796274 1 LH COOLER BAFFLE
PORTAI!Ill!: COMPRI!:SSOR DIVISION
••• CRIPTIOH ENCLOSURE COMPLETE

DATE/OWN BY:I REV: I;ATIE/CHKD ~~~~4~ATE/APVO BY
716190 tl F ~-\, '-\ ,;,L s <£);:
JdOPEL NO., ILLUSTRATION NO.ISHI!I!T HOT l!!fC
~:= 36512549 2of4 26872
BOOK 35389816 (5/95)

PARTS LIST 9·40
PORTA8LI! COMPRI!SSOR DIVISION
DI!SCRIPTIOH ENCLOSURE COMPLETE
26215
BOOK 35389816 (5/95)

PARTS LIST 9-41
A 92368687 40 SCREW
B 36769024 5 SCREW
c 36769032 6 NUT
D 12A5D2Z1 2 WASHER
E 36783512 2 STUD
F 36797652 23 SCREW
G 36783496 2 RETAINER
H 36783504 2 RECEIPTACLE
J 36799922 1 LOWER RH ENCLOSURE
K 36799930 1 LOWER LH ENCLOSURE
L 36765568 2 FENDER
M 36768398 1 INTAKE BAFFLE
N 36772044 1 RH FRONT BELLY PAN
p 36772036 1 LH FRONT BELLY PAN
Q 36769552 1 RH REAR BELLY PAN
R 36767663 1 LH REAR BELLY PAN
s 36768372 1 SEPARATOR TANK GUARD
T 36764634 1 TOOLBOX GUARD
u 36764744 1 COOLER COVER
PORTABLe COWI'RII!880R OIVISIOH
O.I!!SCRIPTION ENCLOSURE COMPLETE

OATEIOWH 8r1 R.I!!Vz,7ATI!/CHKD B~tATI!i?~O ~y
7/6/90 tl E "~ "~!\ I 1-
MODEL HO,,ILLUSTRATIOH HO., SHI!I!T HO.,: 1!!/C
m~~~ 36512549 4 of 4 26215
BOOK 35389816 (5/95)

PARTS LIST 9·42
B
L
E
J (BOTH P100 & P125)
PORTAI'Jll!: COMPRI!S80R DIVISION
OI!:SCRIPTION ACOUSTICAL PANELS
BOOK 35389816 (5/95)

PARTS LIST 9·43
A 36866630 2 TOP END CAP ACST PNL

B 36866648 2 BOTTOM END CAP ACST PNL
c 36772853 1 REAR ROOF ACST PNL
D 36772861 1 FRONT ROOF ACST PNL
E 36768216 1 TOP EXHAUST BAF ACST PNL
F 36768224 1 BOTTOM EXHAUST BAF ACST PNL
G 36647911 1 BOTTOM STSD DOOR ACST PNL
H 36847929 1 TOP STSD DOOR ACST PNL
J 36768380 1 INTAKE BAF ACST PNL
K 36647903 1 BOTTOM CRBSD DOOR ACST PNL
L 36773182 2 TOP CRBSD DOOR ACST PNL
NOTE:
ACOUSTICAL PANELS FOR P-125 ONLY, EXCEPT ITEM J
GOES ON BOTH P-1 00 AND P-125.
PORTABLI! ¢0WPRI!880FI PIVISIOH
PI!:SCRIPTIOH ACOUSTICAL PANELS

PAT~DWH Br:l RI!V: rATI!/CHKD ~~~ATI!/~ ~0 BY
5/24194 tl A ·~"- 4 .;,.1: 5 5
, , ;::
MODEL HO.j ILLUSTRATION HO.,SHI!U NO.,: 1!/C
~Jm::g 36522639 2 of 2 27793
BOOK 35389816 (5/95)

PARTS LIST 9-44
Lt WARNING
Collapsing Jackstand. &WARNING
Can cause severe~~
Injury. Q
Insert locking pin Do NOT exceed 50 mptl
completely. f\"( {SO km/hr.)
Rotal!ng fan blade.

can caun taVer•lnJury.
Do not operata without {IUard
In plac•.
&WARNING
~
Combustlblo gas.
Cencauu
sovoraburn-.
bllndnu.s or doath,
Keep sparke and

open fiamn away
from batterie1,
&WARNING
High prouuro etr.

C.n etun aaverelnjury
or death.
l>tfore
& DANGER &WARNING &WARNING
Discharged air can contain carbon monoxld&

or other contamlmmts.
Will cauu uverelnjury or death,
~--
TI"'Ippo<lalr p ... 11ura.
Can cauM Mv-lnjuryor
doath,
Close teMe9 vMre and
op&rate tool b vent tapped
DlaconnKted air hosot whip.
Cfln cau.. MveralnJury
«•!h.
Alt6e:h ufaty tcwrestrletof to
each hose •at lhe &OUree of
supply or branch line· In
~~v.ilhOSHA
Reou!ation 29CFR S&e:tion
alr OO!ae perlonning Nrf 1m.302(b).
Do not breathe this air. seMee.
BOOK 35389816 (5/95)

PARTS LIST 9-45
A 36523223 WIRING DIAGRAM

B 36523306 SERIAL NUMBER PLATE
c 36522050 WARNING ROTATING FAN
D 36794816 RIVET
E 36519445 WARNING BATTERY
F 36518108 OIL FILL
G 36522027 WARNING HIGH PRESSURE
H 36512325 DANGER/WARNING 3-PART
J 36850378 OPERATING INSTRUCTIONS
K 36520161 WARNING 2-PART DRAWBAR
L 36512416 SPEED/PRESSURE REGULATION
M 36768851 SHUTDOWN DECAL
PORTABLI! COMPRI!&SOR DIVISION
••scRIPTION DECAL LOCATION CHART

OAT~OWH 8Y:I RI!V: I;ATI!/CHI<.D ti~~ATI!/~0 BY
716190 ~ G ;,:-. ~.:;,,Q- j:
MODI!L HO.,ILLUSTRATIOH No., SHI!!T No.I: !IC
;:: 36513729 2 of 4 27923
BOOK 35389816 {5/95)

PARTS LIST 9-46
BOOK 35389816 (5/95)

PARTS LIST 9-47
A 36525681 GENERAL DATA

B 36522050 WARNING ROTATING FAN
c 36516474 DIESEL FUEL
PORTA8LI! COMPRI!BSOR DIVISION
OI!SCfUPTIOH DECAL LOCATION CHART

DATI!/OWH 11'1: FII!V: r;ATI!/CHKD ~~~ATEUD BY
716190 tl 1 G ~~ 1\-~t: s F
MODI!L HO.,IL.LUSTRATION HO., SHI!I!T HO'j:l!/0
i:: 36513729 4 ol4 28107
BOOK 35389816 (5/95)

PARTS LIST 9-48
/TnoNAt PANEL LIGHT

SWfTCH$2
~~·
,.., v-o PW LOCATION
,.,.
""'
"""
{, '""""
~" """
,.,. """''
lTIIW'm.
to-
"""',.,.,.,
""""-' Ul ~~E
m FlLTER
RESTRICT
-
SWITCHSS
"'
,..,
~"
n<
CPJR
AJR
ALTER
! 0
• ! 0
• ! ! 0
• • ! !
TOM~~ARD .0: ~w~w~
DIAGRAM
""""' LOW
1K4 LCWFLU
FUEL
SWITCH
~DRY
CPRSR
TEMP
eiGJNE
TEMP
FUEl.
LEVa
if
;@~~G:o ~e~G~ ~G ~
OP110N
:@(• ::@(• GAGE
'"'''""
CONTACT
N.O.
~:-~
TACH
;@Q
Q
m~
'~
~:Y
I H d G;""
I " VOLT
AJR ENG!NEOI!..
GAGE
PRESS
~rtr
H H METER DISCHARGE
..,,.,. M7 PRESSURE
I
0 GAG EMf M2
..;!""' FUEL
FUEl
~GINE
LEVEL LEVEl.
RElAY C;RsR SENDER
"'
g COlt. K4 i i ~ i!
• ~b~
Rn • m:beRi
RT2
i
• R2
i 'H i
•
PORTABLI! C05oiPRt:SSOR DIVISION
.....,,,o• OPTION WIRING DIAGRAM

OATeJOWN BY: fli!V; Ort:ICHKO llr~~TI!/~ J!!.Y
412193 ~ B ~ '\ ~"-t s II-
NO.I SHI!I!T NO.I: 1!/¢
MODI!L NOTI1.LUSTRATION
::: 36521052 1 of 2 27310
BOOK 35389816 (5/95)

PARTS LIST 9·49
ITEM C.P.N.
K4 35583442 RELAY FUEL LEVEL

M1 36853414 AIR DISCHG PRESS GAGE
M2 36853406 ENG OIL PRESS GAGE
M3 35604099 FUEL LEVEL GAGE
M4 35604115 ENGINE TEMP GAGE
M6 35371566 TACHOMETER
M7 36769230 VOLTMETER
M8 35604115 CPRSR TEMP GAGE
R2 35604206 FUEL SOLENOID
RT1 35372457 CPRSR TEMP SENDER
RT2 35367218 ENGINE TEMP SENDER
S2 35337435 LIGHT SWITCH
S7 36508950 LOW FUEL SWITCH
S8 36778488 ENG AIR FLTR SWITCH
89 36778488 CPRSR AIR FLTR SWITCH
U1 36771426 DIAGNOSTIC MODULE
HARNESS ENGINE 36859908

HARNESS GAGE 36853422
PORTABlt! COMPRI!SSOR DIVISION
. . . CRIPTION OPTION WIRING DIAGRAM

DATEJOWH BY:I RI!V; I~TI!/CHICD ~~DATE:OO ~y
4/2/93 ti 8 -..\ '-\ -;}l- 5 - /
MODELHO.! ILLUSTRATION NO.t SHI!I!T HOl EtC
: \ : 36521052 2of2 27310
BOOK 35389816 {5/95)
PARTS LIST 9-50
PORTABLE COMPRESSOR DIVISION
BOOK 35389816 (5/95)

PARTS LIST 9·51
A 36780252 1 KEYED IGNITION SWITCH
PORTABLt: COWPRI!SSOR OIVIB!OH
D!!SCRIPTION KEYED IGNITION OPTION

DATt/DWN a;:l Rt:V: IDATt:fcHKD a\.1\:Ali!IAP.vo e~v
4112190 ~ B '1,<; "~' s .0,t:.
MODI!l HO.IILLUBTRATIOH HO.,SHI!ET HO.,~ 1!/C
36512929 2 of 2 24508
BOOK 35389816 (5/95)

PARTS LIST 9-52
c B
PORTADLI! CONPRIP:880R DIVISION
BOOK 35389816 (5/95)

PARTS LIST 9-53
A 36771426 1 DIAGNOSTIC MODULE

B 36768844 1 DIAGNOSTIC DECAL
c 36775484 4 RIVET
PORTAliU: CONPRt!SSOR DIVl8lOH
••scRIPTo'fliAGNOSTIC MODULE OPTION

DATI!IDWH Bn RI!V: ;ATI!/OHKD ~~~AT~YD.,
3/21/90 ~ B "'"'
1 ~~o-";l_\ _s -' F
MODEL HO.j IlLUSTRATION HO., SHI!t.T HO.J~ E/C
36512812 2of2 24420
BOOK 35389816 (5/95)

PARTS LIST 9-54
PORTA&Lt: COMPRI!SSOR DIVISION
- BOOK 35389816 (5/95)

PARTS LIST 9-55
A 35337435 1 TOGGLE SWITCH

B 35135037 1 ON-OFF PLATE
c 35143320 2 TERMINAL LUG
D 36853406 1 PRESSURE GAGE
E 36777589 1 CONNECTOR
F 35374008 1 FELT PLUG
G 35333715 60" TUBING
H 35374701 1 STREET TEE
J 35604099 1 FUEL GAGE
K 35604206 1 FUEL SENDER
L 36769230 1 VOLTMETER
M 35371566 1 TACHOMETER
N 35604115 2 TEMPERATURE GAGE
p 35372457 1 TEMPERATURE SENDER
Q 35278571 1 0-RING
R 35367218 1 TEE
s 36796571 1 TEMPERATURE SENDER
oescooPTo~'AGE & GAGE LIGHT OPTIONS

DAT.~DWN 8Y:
4/11/90 ~ 1 B 1 ~~
RI!V: ~ ... TI!(CHKD
"_;;J~
rm. .,.o.vo'F BY
ld.OD!L NO.I lLLUSTRATlON NO., SH!.U HO.,::! 1!/C

36512879 2 of 2 27001
BOOK 35389816 (5/95)

PARTS LIST 9-56
PORTABLI! COMPRI!880R DIVISION
BOOK 35389816 (5/95)

PARTS LIST 9-57
A 36778710 1 HOSE REEL

B 36765188 2 BEARING COVER
c 36765196 1 BEARING SHAFT
D 20A 11 C2M326 2 0-RING
E 36762706 1 HOSE REEL BEARING
F 34A7S4Z1 1 PLUG
G X1091T331 1 SPRING
H W86708 1 DETENT BALL
J 19A7S5Z1 1 NIPPLE
K 84A17B5 1 GLOBE VALVE
L W86707 1 GREASE FITTING
M 14A5C76Z1 4 WASHER
N 35A2D115Z1 4 SCREW
DI!SCRIPTIOH
HOSE REEL ASSEMBLY
DAUJOWH BY:/ AI!V: /'?A'TI!tCHKD ~*n/~o _BY
3/28190 tl B "-~ '\~i- J/..
MOD!L H~.~ILLUSTRATIOH HO.,SHI!I!T NO.,~ E/C
3652264 7 2 of 2 26287
BOOK 35389816 (5/95)

PARTS LIST 9-58
PORTAtiLI! COMPRI!!880R DIVISION
BOOK 35389816 {5/95)

PARTS LIST 9-59
A 36002756 1 HOSE REEL ASSEMBLY

B 68A7M5Z1 1 ELBOW
c 67A7M5Z1 1 ELBOW
D 35364371 1 CHECK VALVE
E 36778736 1 HOSE BRACKET
F 35316355 1 DISCHARGE HOSE
G 104A23S11 1 ELBOW
H 34A7S6Z1 1 PLUG
J 35296748 1 BRACKET
K 92368687 2 SCREW
L W86709 1 HOSE LOCK
M W20664 1 HOSE LOCK CAP
N 12A5C10Z1 2 WASHER
p 36779726 2 U-BOLT
Q 67A4C3Z1 4 NUT
R 34A7S8Z1 1 PLUG
PORTA!Il~ COMPRI!!SSOR OIVISIOH
OESCRIPTIOMSINGLE HOSE REEL OPTION

DATE/OWN fJY:I RI!!V: IOATI!ICHKO B\Y~1TI!!/2J DY
419190 ~ B \,_i> ".:;,' 5 , j:'
MOOI!L HO,IILLUSTRATIOH Ho.lsHI!!I!T H0., 1!/C
36512895 2 of 2 26062
2
BOOK 35389816 (5/95)

PARTS LIST 9-60
PORTAISL!! COMPRI!SSOR DIVISION
BOOK 35389816 (5/95)

PARTS LIST 9-61
A 36002756 2 HOSE REEL ASSEMBLY

B 68A7M5Z1 2 ELBOW
c 67A7M5Z1 2 ELBOW
D 35364371 2 CHECK VALVE
E 36778736 1 HOSE BRACKET
F 35316355 1 DISCHARGE HOSE
G 104A23S11 1 ELBOW
H 34A7S6Z1 1 PLUG
J 35296748 2 BRACKET
K 92368687 4 SCREW
L W86709 2 HOSE LOCK
M W20664 2 HOSE LOCK CAP
N 12A5C10Z1 4 WASHER
p 36779726 2 U-BOLT
Q 67A4C3Z1 4 NUT
PORTAIILI! COMPRI!SSOR DIVISION
o•scRIPTIDHDOUBLE HOSE REEL OPTION

PATI!IPWN D~:, RI!V: ~~ATI!/CHKD ~Y.!\ATEIA~D flY
419190 tl B ~~ '1: ~ S ,f)_;;·
MODEL HO., ILLUSTRATION HO.' SHI!ET HO,~~ E/0
36522654 2 of 2 26062
BOOK 35389816 (5/95)

PARTS LIST 9-62
PORTABLI! COMPRI!SSOR DNISION
BOOK 35389816 {5/95}

PARTS LIST 9-63
A 36778363 1 EXTENDED DRAWBAR
NOTE:
USE EXISTING HARDWEAR TO INSTALL OPTION
PORTAliLI!: COMPRI!SSOR DIVISION
o•scRoPT~JITENDED DRAWBAR OPTION

DATI!JOWN BY;I RI!V: I~ATI!:/CHI<D 8~~ATI!I-Y;VD BY
3/26/90 tl B 11-.i,. ~ - S ..L.J,C.
MOPI!L NO.! ILLUSTRATION HO.,SHI!I!T HOli!/C
36512853 2 of 2 24420
BOOK 35389816 {5/95)

PARTS LIST 9·64
I
I
I
I
I I
I
PORTABLe: COioiPRI!880R DIVISION
BOOK 35389816 (5/95)

PARTS LIST 9-65
A 36778322 1 ADJUSTABLE DRAWBAR
NOTE:
PORTA!IU: COMPRtSSOR DIVISION
o.sc•"fiB~USTABLE DRAWBAR OPTION

OAT~DWN
3/26/90 ~
en RI!V: ~0~~1!/CHKD ~~ATI!IAJ'VO flY
B ._ ";;:;,'. s .:J;::
MODEL No.II~~;;R~;~Ho.,s;E:fT;o-~
2~;20
BOOK 35389816 (5/95)
PARTS LIST 9·66
PORTA!ILI! COMPRI!SSOR DIVIS!OH
BOOK 35389816 (5/95)

PARTS LIST 9-67
A 36778413 1 EXTND & ADJ DRAWBAR
NOTE:
PORTAtiU: COMPR2880R DIVISION
•••c•"E\:I¥ND & ADJ DRAWBAR OPTION

PATEIDWN BY:I RI!V: IDA~I!/CHKD e~~AT:rJ'Vo e
3/26/90 ~ B ~.. >\-"'- s I ;:-
MOO!L N0. IlLUSTRATION HO.rHe!T N0. : 1!/¢
1 36512838 2 of 2 124420
BOOK 35389816 {5/95)

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Ingersoll Rand P100WD P125WD 1

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INGERSOLL-RAND®

Book 35389816 (4/95) ( 1)

Book 35389816 (4/95) (2)

SECTION WARRANTY REGISTRATION

SECTION GENERAL DATA

SECTION PARTS ORDERING

SECTION ENGINE INFORMATION

SECTION PARTS LIST

SECTION PARTS REFERENCE

Book 35389816 (4/95) (3)

Indicates the presence of a hazard which WILL cause

Indicates the presence of a hazard which CAN

Indicates the presence of a hazard which WILL or

Indicates important set-up, operating_ or maintenance

Book 35389816 (4/95) (4)

Air discharged from this machine may contain carbon

!wARNING I the negative (-) terminal of the booster battery

FREE SAFETY DECALS!

Book 35389816 (4/95) (5)

Book 35389816 (4/95) (6)

Hot pressurized fluid.

Ether Is an extremely volatile, highly flammable I CAUTION~

Book 35389816 (4/95) (7)

1. Removal or rendering inoperative any of the following:

2. Removal of any of the following:

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

Book 35389816 (4/95) (8)

Compressor Oil A void ingestion, skin contact and breathing fumes.

Book 35389816 (4/95) (9)

-8- f ~2.w.~' ~.:-~,~="

Book 35389816 (4/95) (11)

Book 35389816 {4/95) (12)

(20--50 KW) 2 hrs.

Kubota 24 2000 major components

Book 35389816 (4/95) (13)

Complete Machine Registration

Note: Completion of this form validates the warranty.

Book 35389816 (4/95) (14)

SELliNG O!SIB!B\JTOB SERVICING Q!SJB!Bl!TOB WARRANTY REGISTRA110N

Address ------------------- Address------------------- Address-------------------

COMPLETE THE APPLICABLE BLOCKS

CJ Construction-Light CJ Government 0 Quarry :1 Shallow Oil & Gas

0 Rental o Building Contractor 0 Waterwell 0 Utility Company

0 Industrial C Other 0 Exploration 0 Utility Contractor

Model Unrr SIN Engine SiN Date Delv'd

Unit-Hours Air End SIN Truck SIN Truck Engine SIN

SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT

I hereby acknowledge acceptance of above and the conditions on reverse side.

Owner/User --------------------------------------- Date----------~----------------

Distributor/1-R Rep. ---------------------------------- Date-------------------------

COMPLETION OF THIS FORM VALIDATES THE WARRANTY X-4051-C

BZOLZ I!!U!JOJI!!:J 1./IJON '81/fiiSJf:JOfN

IwARNING I - Ensure that tires are inflated to 32 psi (220kPa).

Operating Controls/Instruments (Standard) Diagnostics/Auto Shutdown Lamps (Optional)

1. Master Switch (start)- 6. High Compressor Temperature-