Operation & Maintenance Manual: Compressor Model Xp185Wir P260Wir

OPERATION & MAINTENANCE MANUAL
XP185WIR P260WIR
COMPRESSOR MODEL
Code: D14 Code: D13
Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
Doosan Infracore Portable Power

1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 23294655 (7-09) Rev A

Revised (09-12)
2
TABLE OF CONTENTS
Manual-Name
TITLE PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
DRAWBAR NOTICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Drawbar Notice - This machine may have been shipped from the factory with the drawbar
positioned upright. To convert from Shipping Position to Towing Position. . . . . . . . . . 2-2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
NOISE EMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

This section pertains only to machines distributed within the United States. . . . . . . . . . . . . . . . . . . 3-30
Noise Emission Control Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Noise Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
General Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
ENGINE (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
UNITS MEASUREMENTS WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
EXPENDABLE SERVICE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
BEFORE TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
1-1
TABLE OF CONTENTS
Manual-Name
TITLE PAGE
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Compressor Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Receiver-Separator Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Exterior Finish Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Action Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
4IRI8NE-2/4IRI8TE Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66
1-2
Foreword
Book: 23294655 (8-08) 3

Operating & Maintenance Manual Foreword
Foreword
The contents of this manual are considered to be proprietary and confidential to Doosan
Infracore Portable Power (herein referred to as “Portable Power”), and should not be
reproduced without the prior written permission of Portable Power.
Nothing contained in this document is intended to extend any promise, warranty or
representation, expressed or implied, regarding the products described herein. Any such
warranties or other terms and conditions of sale of products shall be in accordance with the
standard terms and conditions of sale for such products, which are available upon request.
This manual contains instructions and technical data to cover all routine operation and
scheduled maintenance tasks by operation and maintenance staff. Major overhauls are
outside the scope of this manual and should be referred to authorized Portable Power Service
Department.
All components, accessories, pipes and connectors added to the compressed air system
should be:
• of good quality, procured from a reputable manufacturer and, wherever possible, be

of a type approved by Portable Power.
• clearly rated for a pressure at least equal to the machine maximum allowable working
pressure.
• compatible with the compressor lubricant/coolant.
• accompanied with instructions for safe installation, operation and maintenance.
Details of approved equipment are available from the Portable Power Service Departments.
The use of repair parts/lubricants/fluids other than those included within the Portable Power
approved parts list may create hazardous conditions over which Portable Power has no
control. Therefore Portable Power cannot be held responsible for equipment in which non–
approved repair parts are installed.
Portable Power reserves the right to make changes and improvements to products without
notice and without incurring any obligation to make such changes or add such improvements
to products sold previously.
The intended uses of this machine are outlined below and examples of unapproved usage are
also given, however Portable Power cannot anticipate every application or work situation that
may arise.
IF IN DOUBT CONSULT SUPERVISION.
4 Book: 23294655 (8-08)

Foreword Operating & Maintenance Manual
This machine has been designed and supplied for use only in the following specified
conditions and applications:
• Compression of normal ambient air containing no known or detectable additional

gases, vapors or particles.
• Operation within the ambient temperature range specified in the GENERAL
INFORMATION section of this manual.
UNITS MANUFACTURED IN NORTH AMERICA: Generation of electricity at 120V (1ph) at 60
Hertz.
The use of the machine in any of the situation types listed in table 1:–
a) Is not approved by Portable Power,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Portable Power.
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity checks.
Use of the machine outside the ambient temperature range specified in the GENERAL
INFORMATION SECTION of this manual.
This machine is not intended and must not be used in potentially explosive atmospheres,
including situations where flammable gases or vapors may be present.
Use of the machine fitted with non Portable Power approved components/lubricants/ fluids.
Use of the machine with safety or control components missing or disabled.
Use of the machine for storage or transportation of materials inside or on the enclosure
except when contained within the toolbox.
GENERATOR
Use of the generator to supply load(s) greater than those specified.
Use of unsafe or unserviceable electrical equipment connected to the generator.
Use of electrical equipment:
(a) Having incorrect voltage and/or frequency ratings.
(b) Containing computer equipment and/or similar electronics.
The company accepts no responsibility for errors in translation of this manual from the original
English version.
Book: 23294655 (8-08) 5

6 Book: 23294655 (8-08)
DRAWBAR NOTICE
7
Operating & Maintenance Manual DRAWBAR NOTICE
8
DRAWBAR NOTICE Operating & Maintenance Manual
DRAWBAR NOTICE (Important)

This machine may have been shipped from
the factory with the drawbar positioned
upright.
To Convert From Shipping Position to
Towing Position
The following tools are required:
Ratchet
13mm socket to fit ratchet
Torque wrench set to 68 foot pounds (9.4 kg-
meters)
16mm socket to fit torque wrench
5 inch extension for torque wrench
Hardware Included:
(4) 12mm bolts with pre-applied thread lock
(2) 8mm Taptite Bolts
(2) Washers
(2) Safety Chains
1. Remove hardware box from compressor
toolbox.
2. Open box and remove the bag containing
hardware, safety chains and assembly
instructions.
3.Using the jack, raise the front of the unit so
that the legs are approximately 1” above the
ground.
4.Remove the temporary retaining bolts from
both sides of the frame at the drawbar
connection (See Figure 1).
5.Carefully lower drawbar to the Level
Position.
6.Install the four bolts (with pre-applied
thread lock) to the four points inside the
enclosure and torque to 68 ft. lbs.(9.4kg-m)
(See Figure 2).
7.Install safety chains by sliding the second
link of one chain into the slot in drawbar
plate. Fasten chain to plate using taptite and
washer. Repeat for the other chain (See
Sketch).
9
Operating & Maintenance Manual DRAWBAR NOTICE
10
Safety
11
Operating & Maintenance Manual Safety
Safety Precautions
General check valves and isolation valves must be
fitted and controlled by work procedures, so
Ensure that the operator reads and
that one machine cannot accidentally be
understands the decals and consults the
pressurized or over pressurized by another.
manuals before maintenance or operation.
Compressed air must not be used for a feed
Ensure that the Operation and Maintenance
to any form of breathing apparatus or mask.
manual, and manual holder if equipped, are
not removed permanently from the machine. The discharged air contains a very small
percentage of compressor lubricating oil and
Ensure that maintenance personnel are
care should be taken to ensure that
adequately trained, competent and have
downstream equipment is compatible.
read the manuals.
If the discharged air is to be ultimately
Make sure that all protective covers are in
released into a confined space, adequate
place and that the canopy/doors are closed
ventilation must be provided.
during operation.
When using compressed air, always use
The specification of this machine is such that
appropriate personal protective equipment.
the machine is not suitable for use in
flammable gas risk areas. If such an All pressure containing parts, especially
application is required then all local flexible hoses and their couplings, must be
regulations, codes of practice and site rules regularly inspected, be free from defects and
must be observed. To ensure that machine be replaced according to the Manual
can operate in a safe and reliable manner, instructions.
additional equipment such as gas detection,
Avoid bodily contact with compressed air.
exhaust spark arrestors, and intake (shut-off)
valves may be required, dependent on local The safety valve located in the separator
regulations or the degree of risk involved. tank must be checked periodically for correct
operation.
Air discharged from this machine may
contain carbon monoxide or other Never operate unit without first observing all
contaminants which will cause serious injury safety warnings and carefully reading the
or death. Do not breathe this air. operation and maintenance manual shipped
from the factory with this machine.
Compressed air can be dangerous if
incorrectly handled. Before doing any work Never operate the engine of this machine
on the unit, ensure that all pressure is vented inside a building without adequate
from the system and that the machine cannot ventilation. Avoid breathing exhaust fumes
be started accidentally. when working on or near the machine. Do not
alter or modify this machine.
Ensure that the machine is operating at the
rated pressure and that the rated pressure is A battery contains sulfuric acid and can give
known to all relevant personnel. off gases which are corrosive and potentially
explosive. Avoid contact with skin, eyes and
All air pressure equipment installed in or
clothing. In case of contact, flush area
connected to the machine must have safe
immediately with water.
working pressure ratings of at least the
machine safety valve rating. Exercise extreme caution when using
booster battery. To jump battery, connect
If more than one compressor is connected to
ends of one booster cable to the positive (+)
one common downstream plant, effective
terminal of each battery. Connect one end of
12
Safety Operating & Maintenance Manual
other cable to the negative (-) terminal of the flammable gas. USE SPARINGLY! DO NOT
booster battery and other end to a ground use ETHER if unit has GLOW Plug starting
connection away from dead battery (to avoid aid. Engine damage will result.
a spark occurring near any explosive gases
Never allow the unit to sit stopped with the
that may be present). After starting unit,
pressure in receiver-separator system. As a
always disconnect cables in reverse order.
precaution, open manual blowdown valve.
High Pressure Air can cause serious injury or
Never operate unit with guards, covers or
death. Relieve pressure before removing
screens removed. Keep hands, hair,
filler plugs/caps, fittings or covers.
clothing, tools, blow gun tips, etc. well away
Air pressure can remain trapped in air supply from moving parts.
line which can result in serious injury or
Make sure wheels, tires and tow bar
death. Always carefully vent air supply line at
connectors are in safe operating condition
tool or vent valve before performing any
and tow bar is properly connected before
service.
towing.
This machine produces loud noise with doors
Steps for determining correct load limit -
open or service valve vented. Extended
exposure to loud noise can cause hearing
1. Locate the statement “The
loss. Always wear hearing protection when
weight of cargo should never
doors are open or service valve is vented. exceed xxx kg or xxx lbs” on
Never inspect or service unit without first your vehicle’s placard.
disconnecting battery cable(s) to prevent
2. This figure equals the
accidental starting.
available amount of cargo
Do not remove the pressure cap from a HOT and luggage load capacity.
radiator. Allow radiator to cool down before
removing pressure cap. 1. Determine the combined
weight of luggage and cargo
Do not use petroleum products (solvents or being loaded on the vehicle.
fuels) under high pressure as this can That weight may not safely
penetrate the skin and result in serious exceed the available cargo.
illness.
Whenever the machine is stopped, air will
Wear eye protection while cleaning unit with flow back into the compressor system from
compressed air to prevent debris from devices or systems downstream of the
injuring eye(s). machine unless the service valve is closed.
Disconnected air hoses whip and can cause Install a check valve at the machine service
serious injury or death. Always attach a valve to prevent reverse flow in the event of
safety flow restrictor to each hose at the an unexpected shutdown when the service
source of supply or branch line in accordance valve is open. Stop machine to add fuel.
with OSHA Regulation 29CFR Section Hazardous Substance Precaution
1926.302(b).
The following substances are used in the
Rotating fan blade can cause serious injury. manufacture of this machine and may be
Do not operate without guard in place. hazardous to health if used incorrectly.Avoid
Use care to avoid contacting hot surfaces ingestion, skin contact and breathing fumes
(engine exhaust manifold and piping, air for the following substances:Antifreeze,
receiver and air discharge piping, etc.). Compressor Oil, Engine Lubricating Oil,
Preservative Grease, Rust Preventative,
Ether is an extremely volatile, highly Diesel Fuel and Battery Electrolyte.
13
14
Look for these signs on machines shipped to markets in North America, which point out
potential hazards to the safety of you and others. Read and understand thoroughly. Heed
warnings and follow instructions. If you do not understand, inform your supervisor.
15
! DANGER
DANGER (Red Background) indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
! WARNING
WARNING (Orange Background) indicates a potentially hazardous
situation which, if not avoided, could result in death or serious injury.
! CAUTION
CAUTION (Yellow Background) indicates a potentially hazardous
situation which, if not avoided, may result in minor or moderate injury.
NOTICE
NOTICE (Blue Background) indicates important set-up, operating or
maintenance information.
16
17
18
19
Free Safety Decals

Safety Decals are available free of charge. Safety Decals are identified by the decal
heading: DANGER, WARNING, or CAUTION.
Decal part numbers are on the bottom of each decal and are also listed in the
compressor’s parts manual. Submit orders for Safety Decals to the Statesville Parts
Service Department. The no charge order should contain only Safety Decals. Help
promote safety! Assure that decals are present on the machines. Replace decals that
are not readable.
20
NOISE EMISSION
29
Operating & Maintenance Manual NOISE EMISSION
Noise Emission
This section pertains only to machines distributed within the United

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

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

A. The removal or rendering inoperative, other than for the purpose of
maintenance, repair, or replacement of any noise control device or element of
design incorporated into this compressor in compliance with noise control act;
B. The use of this compressor after such device or element of design has been
removed or rendered inoperative.
NOTE: The above information applies only to units that are built in
compliance with the U.S. Environmental Protection Agency.
Doosan Portable Power reserves the right to make changes or add improvements without
notice and without incurring any obligation to make such changes or add such improvements
to products sold previously.
The Purchaser is urged to include the above provisions in any agreement for any resale of this
compressor.
30
NOISE EMISSION Operating & Maintenance Manual
Noise Emission Control Maintenance Log
COMPRESSOR MODEL __________________________

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

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

The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this
air compressor was designed, built and equipped to conform at the time of sale to the first retail
purchaser, with all applicable U.S. EPA Noise Control Regulations.
This warranty is not limited to any particular part, component, or system of the air compressor.
Defects in the design, assembly or in any part, component, or system of the compressor
which, at the time of sale to the first retail purchaser, caused noise emissions to exceed
Federal Standards are covered by this warranty for the life of the air compressor.
Introduction
The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for
Noise Emissions, applicable to Portable Air Compressors.
The purpose of this book is to provide (1) the Maintenance Performance Schedule for all
required noise emission controls and (2) space so that the purchaser or owner can record what
maintenance was done, by whom, where and when. The Maintenance Schedule and detailed
instructions on the maintenance items are given on following page.
31
Maintenance Schedule
Item Area Period
A. Compressed Air Leaks As Detected
B. Safety and Control Systems As Detected
C. Acoustic Materials Daily
D. Fasteners 100 hours
E. Enclosure Panels 100 hours
F. Air Intake & Engine Exhaust 100 hours
G. Cooling Systems 250 hours
H. Isolation Mounts 250 hours
I. Engine Operation See Operator’s Manual
J. Fuels & Lubricants See Operator’s Manual
A. Compressed Air Leaks

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

Repair or replace all safety and control systems or circuits as malfunction occurs. No
compressor should be operated with either system bypassed, disabled, or nonfunctional.
C. Acoustic Materials
In daily inspections, observe these materials. Maintain all acoustic material as nearly as
possible in its original condition. Repair or replace all sections that have: 1) sustained damage,
2) have partially separated from panels to which they were attached, 3) are missing, or have
otherwise deteriorated due to severe operating or storage conditions.
D. Fasteners
All fasteners such as hinges, nuts, bolts, clamps, screws, rivets, and latches should be
inspected for looseness after each 100 hours of operation. They should be retightened,
repaired, or if missing, replaced immediately to prevent subsequent damage and noise
emission increase.
E. Enclosure Panels
Enclosure panels should also be inspected at 100 hour operational intervals. All panels that
are warped, punctured, torn, or otherwise deformed, such that their noise containment
function is reduced, should be repaired or replaced before the next operation interval. Doors,
access panels, and hatch closures especially, should be checked and adjusted at this time to
insure continuous seating between gasket or acoustic material and the mating frame.
F. Air Intake and Engine Exhaust

Engine and compressor air intake and engine exhaust systems should be inspected after each
100 hours of operation for loose, damaged, or deteriorated components. Repairs or
replacements should be made before the next period of use.
G. Cooling Systems
All components of the cooling system for engine water and compressor oil should be inspected
32
NOISE EMISSION Operating & Maintenance Manual
every 250 hours of use. Any discrepancies found should be corrected before placing the unit
back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at
all times during operation.
H. Isolation Mounts
Engine/airend isolation mounts should be inspected after each 250 hours of operation. Those
mounts with cracks or splits in the molded rubber, or with bent or broken bolts due to operation
or storage in severe environments, all should be replaced with equivalent parts.
I. Engine Operation
Inspect and maintain engine condition and operation as recommended in the manuals
supplied by the engine manufacturer.
J. Fuels and Lubricants

Use only the types and grades of fuels and lubricants recommended in the Portable Power
and Engine Manufacturer’s Operator and Maintenance Manuals.
33
Maintenance Record For Noise Emission Control And Extended Warranty

Item Hourmeter Maint/inspect Location Work Done
Description Of Work
No. Reading Date City/state By (Name)
34
GENERAL DATA
35
Operating & Maintenance Manual GENERAL DATA
General Data
Unit Model:
UNIT MODEL P260WIR XP185WIR
CFM (litres/sec) 260(123) 185 (87)

Engine Speed - RPM (Full Load) 2300 2500
Engine Speed - RPM (No Load) 1700 1700
COMPRESSOR
Rated Operating Pressure - psi (kPa) 100 (689) 125 (861)
Safety Valve Setting - psi (kPa) 150 (1034) 200 (1379)
Net Weight (less fuel) pounds 2510 2130
ENGINE (Diesel)
Model 4IRI8TE 4IRI8TE
Electrical System 12VDC 12VDC
FLUID CAPACITIES
Compressor Lubricant...............................................12 quarts (11.4 litres)
Engine Crankcase Lubricant ....................................10.8 quarts (10.2 litres)
Fuel Tank .................................................................27 U.S gal. (103 litres)
RUNNING GEAR
Tire Size....................................................................ST205/75D15
Inflation Pressure (Cold) ...........................................50 psi
Towing Speed (Maximum) ........................................65 mph (105 km/hr)
UNITS MEASUREMENTS WEIGHTS

Overall Length...........................................................11.5 (3.5 meters)
Overall Height ...........................................................5.2 feet (1.46 meters)
Overall Width ...........................................................5.7 feet (1.74 meters)
Track Width...............................................................4.9 feet (1.49 meters)
36
GENERAL DATA Operating & Maintenance Manual
EXPENDABLE SERVICE PARTS
Description XP185WIR P260WIR

Part No. Part No.
Compressor Oil Filter Element 22436323 36897353
Compressor Oil Separator Element 54625942 92754688
Air Cleaner Element (Compressor) 35393685 54415377
Air Cleaner Element (Engine) 35393685 35393685
Engine Oil Filter Element 22226351 22226351
Engine Fuel Filter Element 16539462 16539462
Fuel Water Separator Element 22926737 22926737
! WARNING
Modification or alteration of this machine. Can result in severe injury or
death. Do not modify or alter without the express written consent of
Doosan Infracore Portable Power.
37
Operating & Maintenance Manual GENERAL DATA
38
OPERATION
39
Operating & Maintenance Manual OPERATION
BEFORE TOWING
! WARNING
! WARNING Always raise (or remove) jack for
maximum ground clearance before
towing.
Failure to follow these instructions
CAN cause severe injury or death.
SETTING UP (ALL UNITS)
• Assure tow vehicle has towing
• Position as level as possible. The
capacity for weight of this unit as
design of these units permits a 15
stated on general data decal.
degree sidewise limit on out-of-level
• Position the tow vehicle to align its operation.
hitch with the pintle eye or coupler of
the compressor. • When the unit is to be operated out-
of-level, it is important:
• Engage the parking brake and chock
the tires of the tow vehicle. 1. To keep the engine crankcase oil level
near the high level mark (with the unit
• Stand to the side and ensure pin is level).
FULLY inserted (secure) in tube of 2. To have the compressor oil level gauge
jack. . show no more than mid-scale. Do not
overfill either the engine crankcase or
• Crank jack to seat pintle eye or the compressor lubricating oil system.
coupler onto hitch. Latch and lock
hitch. Cross safety chain(s) under 3. The side doors must be closed to
drawbar. Attach to vehicle maintain a cooling air path and to avoid
recirculation hot air.
• Crank jack to raise pad off the
ground. Pull pin from tube of jack. TOWING
• Fold jack handle down and forward.
Swing up jack tube and FULLY insert
pin in tube. ! WARNING
• Remove tire chocks.
Failure to follow these instructions
• Test brakes, if so equipped. CAN cause severe injury or death.
• Test lights (running, stop, and turn

signals).
40
OPERATION Operating & Maintenance Manual
DISCONNECT
• Engage tow vehicle parking brake.
• Chock tires of compressor.
• Set the vehicle parking brake. Chock

wheels of unit.
• Standing to the side, remove pin from

tube of jack.
• Disconnect safety chains. Crank jack

to raise eye or coupler from hitch.
Tow vehicle can be moved.
UTILITY PACKAGE SET-UP (no running
gear)
This unit must be located on vehicle bed to
allow access for normal servicing and
maintenance.
The air going into the inlet must be relatively
free of oil, dirt, soot and other debris. It must
be no more than 10 degrees F. (5 degrees C)
over the ambient temperature.
41
10. Spare
CONTROL PANEL 11. Spare
12. Fuel Level Gauge (Optional) -
Indicates amount of fuel in tank.
13. Tachometer (Optional) - Indicates
engine speed
Before Starting
• Open service valve(s) to ensure pressure

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

condition.
• Check battery for proper connections and

1. Compressor Discharge Pressure condition.
Gauge - Indicates pressure in
receiver tank, psi (kPa). • Check engine coolant level.
2. Hourmeter - Records running time
for maintenance.
3. Power Switch - Flip “ON” to activate ! WARNING
system prior to Starting. Flip “OFF” to
stop engine. Do not remove pressure cap from
a HOT radiator. Allow radiator to
4. Discharge Air Temperature cool down before removing
(Optional) - Indicates in °F (82°C) to pressure cap. Use extreme care
210°F (99°C). when removing a pressure cap
5. Engine Oil Pressure Gauge from a liquid cooling system for
(Optional) - Indicates engine oil the engine. The sudden release of
pressure. pressure from a heated cooling
system can result in a loss of
6. Engine Water Temp Gauge coolant and possible severe
(Optional) - Indicates coolant personal injury.
temperature, with normal operating
range from 180°F (82°C) to 210°F • Check the engine oil level. Maintain per
(99°C) marks on dipstick.
7. Voltmeter (Optional) - Indicates • Check the fuel level. Add only CLEAN
battery condition. DIESEL fuel for maximum service from
8. Spare the engine.
9. Service Air Button - After warm-up, • Check the compressor lubricating fluid
PUSH. Provides full air pressure at level between bottom and midway of the
the service outlet. sight glass on the separator tank.
42
! WARNING NOTICE
This machine produces loud noise Do not operate the starter motor for more
with doors open. Extended exposure than 10 seconds without allowing at least
to loud noise can cause hearing loss. 30 seconds cooling time between start
Wear hearing protection when doors attempts.
or valve (s) are open.
Release Power Switch (it will automatically
• Close all doors to maintain a cooling air move to the “ON” position) when the engine
path and to avoid recirculation of hot air. starts and sustains running.
This will maximize the life of the engine
and compressor and protect the hearing • Allow engine to warm up 5 to 10
of surrounding personnel. minutes.
• Be sure no one is IN or ON the • If so equipped, press the “Service Air

compressor unit. Button”. Open air service valve(s)
Cold Weather Starting

! WARNING • Turn power switch to the glow plug
position and hold 10 seconds. Then
Unrestricted air flow from a hose will turn to start.
result in a whipping motion of the
hose which can cause severe injury or
death. A safety device must be
attached to the hose at the source of NOTICE
supply to reduce pressure in case of
hose failure or other sudden pressure Exercise extreme caution when using a
release. Reference: OSHA regulation booster battery to start. To jump start:
29 CFR Section 1926.302 (b). Connect the ends of one booster cable to
the positive (+) terminals of each battery.
Then connect one end of the other cable
Starting
to the negative (-) terminal of the booster
• Turn the POWER switch to “ON”.
battery and the other end to the engine
• Turn Power switch to “START” block. Not to the negative (-) terminal of
position to crank engine. Hold switch the weak battery.
in “START” position for
approximately 5 seconds after engine
starts.
43
Stopping
NOTICE
NOTICE Do NOT wire around or bypass a
shutdown sensor or switch.
Whenever the machine is stopped, air will
flow back into the compressor system
from devices or systems downstream of Machine has shutdown and sensors
the machine unless the service valve is as follows:
closed. Install a check valve at the
machine service valve to prevent reverse • Low Engine oil pressure, in the
flow in the event of an unexpected engine.
shutdown when the service valve is open.
• High engine coolant temperature, in
the engine.
Close air service valves.
• Allow the unit to run at idle for 3 to 5
minutes to reduce the engine Compressor Air/Oil Temperature:
temperatures.
• Turn Power Switch to “OFF” position. • At the airend outlet.
• When the engine stops, automatic • Discharge tube.

blowdown valve should relieve
system air pressure. If automatic
blow-down valve malfunction is
suspected, open manual blowdown
valve.
• Never allow unit to sit under pressure
when engine is not running.
! WARNING
Since the service valve is closed, air
downstream of the valve may be trapped.
A vent hole in the service valve will slowly
bleed air from the hose. Do not
disconnect hoses until all pressure has
been vented.
44
Pressure Regulator Adjusting Instructions
Before Starting
1. At the Pressure Regulator (on service

pipe near receiver tank), remove the
cover to expose the adjusting screw.
Loosen the jam nut and turn screw
counterclockwise until tension is no
longer felt at the screw. Then, turn screw
clockwise one full turn.
2. Close service valve(s).
After Starting Unit
3. If equipped, push the SERVICE AIR

button on the control panel, making
certain the button does not pop back out.
The unit should speed up and then
unload (and drop back to IDLE). With the
unit unloaded, turn the adjusting screw
on the pressure regulator clockwise until
the discharge pressure gauge indicates
125-130 psi (P260) or 150-155 psi
(XP185).Tighten the pressure regulator
jam nut. Replace cover.
4. To obtain maximum CFM at any pressure
between 80 psi (550kPa) and maximum
pressure rating (*), make adjustment at
the pressure regulator to obtain desired
discharge pressure at FULL engine
speed. Lock adjusting screw and replace
cover.
* See General Data Specifications.
45
5. Low Engine Oil Pressure:

Indicates shutdown due to
Small Electronic Control Unit
low engine oil pressure.
(SECU)
6. Compressor Sensor Failure:
Display Panel
Indicates pressure sensor
The SECU display panel is arranged as malfunction. Compressor will not
shown below. A description of each start.
diagnostic indicator is as follows:
7. Low Engine Speed:
low engine speed.
8. Low Fuel Level: Indicates

shutdown due to low fuel
level. (Optional)
9. Restricted Air Filter: Alarm

indicator. Indicates engine/
compressor air inlet filters
need service. (Optional).
A. Engine Communication Error: Engine
Model was not recognized. Compressor will
start and operate with a 1700-2300 rpm
range.
C. CAN Communication Error: CAN
communication failure.
Normal Conditions
Center Bar Blinking: Compressor is ready
to start (no faults).
H. Crank Signal Detected: Displayed while
1. High A/E Temp: Indicates shutdown start switch is in the pre-heat or crank
due to high compressor temperature. position.
During SECU/power up, the 8 digit lights to
2. High Separator Temp:
check the display. Next the display will step
through the 3 digit software revision number.
high temperature at separator
tank discharge.
3. Low Battery Voltage: Alarm

indicator. Indicates battery or
charging system requires
service.
4. High Engine Coolant Temp:

Indicates shutdown due to high
engine water temperature.
46
MAINTENANCE
47
Operating & Maintenance Manual MAINTENANCE
Maintenance
easiest and the least expensive type of
maintenance. Maintaining your unit and
! CAUTION keeping it clean at all times will facilitate
servicing.
Any unauthorized modification or
failure to maintain this equipment may
make it unsafe and out of factory Scheduled Maintenance
warranty. The maintenance schedule is based on
normal operation of the unit. This page can
If performing more than visual be reproduced and used as a checklist by the
inspections, disconnect battery service personnel. In the event unusual
cables and open manual blowdown environmental operating conditions exist, the
valve. schedule should be adjusted accordingly.
Use extreme care to avoid contacting Compressor Oil Level

hot surfaces (engine exhaust manifold
Check the compressor fluid level when the
and piping, air receiver and air
machine is not operating. Always check the
discharge piping, etc.).
oil level while the unit is level, the engine off,
and there is zero pressure in the separator
Never operate this machine with any
tank. Maintain the fluid level between bottom
guards removed.
and midway of the sight glass on the
separator tank.
Inch and metric hardware was used in
the design and assembly of this unit. P260WIR: The optimum oil level is with the
Consult the parts manual for pointer at the top of the green section on the
clarification of usage. level gauge. Add oil if the pointer reaches the
bottom of the green section.
NOTICE Air Cleaner

If this unit is equipped with the Optional Air
Disregard any maintenance pertaining Filter Restriction Indicators, it has a
to components not provided on your Restricted Air Filter Alarm (9) on the SECU
machine. Display Panel.
This should be checked daily during
General operation. If the indicator displays the
digit:T9 with the unit operating at full speed,
In addition to periodic inspections, many of
servicing of the cleaner element is
the components in these units require
necessary.
periodic servicing to provide maximum
output and performance. Servicing may Also weekly squeeze the rubber valve
consist of pre-operation and post-operation (precleaner dirt dump) on each air cleaner
procedures to be performed by the operating housing to ensure that they are not clogged.
or maintenance personnel. The primary The air filters restricted sensor will
function of preventive maintenance is to automatically reset after the main power
prevent failure, and consequently, the need switch is turned to “OFF.”
for repair. Preventive maintenance is the
48
MAINTENANCE Operating & Maintenance Manual
To service the air cleaners on all units When filling the fuel tank on this unit, by
proceed as follows: methods other than a pump and hose, use a
CLEAN non-metallic funnel.
1. Loosen outer wing nut and remove with
cover. Remove Element.
2. Inspect air cleaner housing for any Battery
condition that might cause a leak and
Keep the battery posts-to-cable connections
correct as necessary.
clean, tight and lightly coated with a grease.
3. Wipe inside of air cleaner housing with a Also the electrolyte level in each cell should
clean, damp cloth to remove any dirt cover the top of the plates. If necessary, top-
accumulation, especially in the area up with clean distilled water.
where the element seals against the
housing.
Tires
A weekly inspection is recommended. Tires
4. Install new elements in the reverse order that have cuts or cracks or little tread should
to the above. Tighten wing nut firmly. be repaired or replaced. Monthly check the
5. Inspect to ensure that end cap seals wheel lug nuts for tightness.
tightly 360° around air cleaner body.
In addition, the air cleaner system (housing Fasteners
and piping) should be inspected every month
for any leakage paths or inlet obstructions. Visually check entire unit in regard to bolts,
Make sure the air cleaner mounting bolts and nuts and screws being properly secured.
clamps are tight. Check the air cleaner Spot check several capscrews and nuts for
housing for dents or damage which could proper torque. If any are found loose, a more
lead to a leak. Inspect the air transfer tubing thorough inspection must be made. Take
from the air cleaner to the compressor and corrective action.
the engine for leaks.
Make sure that all clamps and flange joints
are tight.
Radiator
Gauges
The instruments or gauges are essential for
NOTICE
safety, maximum productivity and long
service life of the machine. Inspect the The use of water alone in this engine
gauges and test any diagnostic lamps prior to can result in major engine failure.
start-up. During operation observe the Refer to engine section for coolant
gauges and any lamps for proper functioning. recommendation.
Refer to Operating Controls, for the normal
readings.
Hoses
Fuel Tank Each month it is recommended that all of the

intake lines to and from the air cleaners, the
CLEAN fuel in the fuel tanks is vitally engine cooling system hoses and all of the
important and every precaution should be flexible hoses used for air, oil, and fuel be
taken to ensure that only clean fuel is poured inspected.
or pumped into the tank.
49
To ensure freedom from air leaks, all rubber Compressor Oil Filters
hose joints and the screw-type hose clamps
must be absolutely tight. Regular inspection The oil filter must be replaced every 500
of these connections for wear or deterioration hours of operation or six (6) months,
is necessary. whichever comes first.
Premature wear of both the engine and To service oil filters it will first be necessary
compressor is ASSURED whenever dust- to shut the unit down. Wipe off any external
laden air is permitted to enter the engine’s dirt and oil from the exterior of the filter to
combustion chamber or compressor intake. minimize any contamination from entering
the lubrication system. Proceed as follows:
The flexible hoses used in the fuel, oil and air
lines on these units are primarily used for
their ability to accommodate relative
movement between components. It is ! WARNING
important they be periodically inspected for
wear and deterioration. It is also important High pressure air can cause severe
the operator does not use the hoses as injury or death from hot oil and flying
convenient hand hold or steps. Such use can parts. Always relieve pressure before
cause early cover wear and hose failure. removing caps, plugs, covers or other
parts from pressurized air system.
1. Open the service air valve(s) to ensure

that system is relieved of all pressure.
NOTICE Close the valve(s).
2. Turn the spin-on filter element
Some of the airlines are nylon tubing. counterclockwise to remove it from the
The associated fittings are “push-in” filter housing. Inspect the filter.
design. Features are as follows:
3. Inspect the oil filter head to be sure the
Pulling on the tubing will cause the inner gasket was removed with the oil filter
sleeve to withdraw and compress, thus element. Clean the gasket seal area on
tightening the connection. The tubing can be the oil filter head.
withdrawn only while holding the sleeve
against the fitting. The tubing can be
removed and replaced numerous times
without losing its sealing ability. NOTICE
To install the nylon tubing, make a mark (with
tape or grease pencil) approximately 7/8 inch Installing a new oil filter
from the end of the tubing. Insert the tubing element when the old
into the sleeve and “push-in” past the first gasket remains on the filter
resistance to the bottom. The mark should be head, will cause an oil leak
approximately 1/16 inch from the sleeve, for and can cause property
the 3/8 inch O.D. tubing; 1/8 inch for the 0.25 damage.
inch O.D. tubing. This will ensure that tubing
is fully engaged in the sealing mechanism. 4. Lubricate the new filter gasket with the
same oil being used in the machine.
50
Receiver-Separator Systems
5. Install new filter by turning the element
clockwise until gasket makes initial
contact. Tighten an additional 1/2 to 3/4
turn. ! WARNING
6. Start unit and allow to build up to rated
pressure. Check for leaks before placing High pressure air can cause severe
unit back into service. injury or death from hot oil and flying
parts. Always relieve pressure before
removing caps, plugs, covers or other
Compressor Oil Cooler parts from pressurized air system.
The compressor lubricating and cooling oil is • Open service valve at end of machine.
cooled by means of the fin and tube-type oil
• Ensure pressure is relieved, with BOTH:
cooler, located beside the radiator. The
lubricating and cooling oil, flowing internally — Discharge air pressure gauge reads
through the core section, is cooled by the air zero (0).
stream from the cooling fan flowing past the
— No air discharging from service valve.
core section. When grease, oil and dirt
accumulate on the exterior surfaces of the oil Remove plug in bottom of separator tank to
cooler, its efficiency is impaired. drain compressor oil.
Each month it is recommended that the oil When adding oil, remove and replace (make
cooler be cleaned by directing compressed tight) plug on side of separator tank.
air which contains a nonflammable, non- In the compressor lubricating and cooling
caustic safety solvent through the core of the system, separation of the oil from the
oil cooler. This should remove the compressed air takes place in the receiver-
accumulation of grease, oil and dirt from the separator tank. As the compressed air enters
exterior surfaces of the oil cooler core so that the tank, the change in velocity and direction
the entire cooling area can transmit the heat drop out most of the oil from the air.
of the lubricating and cooling oil to air stream.
Additional separation takes place in the oil
In the event foreign deposits, such as sludge separator element which is located in the top
and lacquer, accumulate in the oil cooler to of the tank.
the extent that its cooling efficiency is
impaired, a resulting high discharge air Any oil accumulation in this separator
temperature is likely to occur, causing shut element is continuously drained off by means
down of the unit. To correct this situation it of a scavenge tube which returns the
will be necessary to clean it using a cleaning accumulated oil to the system.
compound in accordance with the The life of the oil separator element is
manufacturer’s recommendations. dependent upon the operating environment
(soot, dust, etc.) and should be replaced
every twelve months or 1000 hours. To
Compressor Oil replace the element proceed as follows:
The lubricating and cooling oil must be • Ensure the tank pressure is zero.
replaced every 500 hours of operation or six
• Disconnect the hose from scavenge tube.
(6) months, whichever comes first. Refer to
warranty section about extended warranty. • Remove scavenge tube from tank cover.
• Disconnect service line from cover.
51
MAINTENANCE Operating & Maintenance Manual
• Remove cover mounting screws. Exterior Finish Care

• Remove cover and element.
This unit was painted and heat cured at the
• Remove any gasket material left on cover factory with a high quality, thermoset
or tank. polyester powder coating. The following care
will ensure the longest possible life from this
• Install new element.
finish.
1. If necessary to remove dust, pollen, etc.

from housing, wash with water and soap
Scavenge Line or dish washing liquid detergent. Do not
scrub with a rough cloth, pad, etc.
2. If grease removal is needed, a fast
! WARNING evaporating alcohol or chlorinated
solvent can be used. Note: This may
cause some dulling of the paint finish.
High pressure air can cause severe
injury or death from hot oil and flying 3. If the paint has faded or chalked, the use
parts. Always relieve pressure before of a commercial grade, non-abrasive car
removing caps, plugs, covers or other wax may partially restore the color and
parts from pressurized air system. gloss.
The scavenge line originates at the receiver-

separator tank cover and terminates at the
compressor air-end near the oil filter Field Repair of Texture Paint
element. An orifice check valve is located on
the scavenge tube. 1. The sheet metal should be washed and
clean of foreign material and then
Once a year or every 1000 hours of thoroughly dried.
operation, whichever comes first, replace the
separator element and clean the scavenge 2. Clean and remove all grease and wax
orifice/check valve. from the area to be painted using
Duponts 3900S Cleaner prior to sanding.
NOTE: Excessive oil carry-over may be
caused by an oil-logged separator element. 3. Use 320 grit sanding paper to repair any
Do not replace element without first scratches or defects necessary.
performing the following maintenance
4. Scuff sand the entire area to be painted
procedure:
with a red scotch brite pad.
1. Check oil level. Maintain as indicated 5. Wipe the area clean using Duponts
earlier in this section. 3900S.
2. Thoroughly clean scavenge line, any 6. Blow and tack the area to be painted.
orifice and check valve.
7. Apply a smooth coat of Duponts 1854S
3. Assure minimum pressure valve/orifice is Tuffcoat Primer to all bare metal areas
operational. and allow to dry.
4. Run unit at rated operating pressure for 8. Apply 2 medium - wet coats of Duponts
30 to 40 minutes to permit element to 222S Adhesion Promoter over the entire
clear itself. area to be painted, with a 5 minute flash
in between coats.
52
9. To apply the texture coat, use Duponts minutes or until dry to touch.
1854S Tuffcoat Primer. The proper
10. Apply any of Duponts Topcoat Finishes
technique to do this is to spray the
such as Imron™ or Centari™ according
Tuffcoat Primer using a pressure pot and
to the label instructions.
use about 2-5 pounds of air pressure.
This will allow the primer to splatter NOTE: To re-topcoat the textured surfaces
causing the textured look. when sheet metal repairs are not necessary,
follow steps 1, 2, 4, 5, 6, 8 and 10.
NOTE: You must be careful not to put too

much primer on at one time, this will effect
the amount of texture that you are trying to
achieve. Allow the texture coat to flash for 20
53
MAINTENANCE SCHEDULE
Daily Weekly Monthly 3 MOS. 6 MOS. 12 MOS.

250 hours 500 hours 1000 hours
Compressor Oil Level C
Engine Oil Level C
Radiator Coolant Level C
Gauges/Lamps C
Air Cleaner Service Indicators C
Fuel Tank (fill at end of day) C DRAIN
Fuel Water Separator (Drain) C
Oil Leaks C
Fuel Leaks C
Drain Water From Fuel Filters DRAIN
Coolant Leaks C
Radiator Filler Cap C
Air Cleaner PreCleaner Dumps C
Fan/Alternator Belts C
Battery Connections/Electrolyte C
Tire Pressure and Surface C
Wheel Lug Nuts C
Hoses (oil, air, intake, etc) C
Automatic Shutdown System Test C
Air Cleaner System Visual C
Compressor Oil Cooler Exterior C CLEAN
Engine Radiator Exterior C CLEAN
Fasteners, Guards C
Air Cleaner Elements R
Fuel/Water Separator Element R
Compressor Oil Filter Element R
Compressor Oil R
Engine Oil Change (initial change @ 50 hrs) R -non IR R*
fluids
Engine Oil Filter (initial change @ 50 hrs) R - non IR R*
fluids
Wheels (bearings, seals, etc) C
Engine Coolant Test C R
Fuel Filter Element R
Injection Valve Pressure C
Shutdown Switch Settings Test C
Scavenge Orifice & related parts CLEAN
Oil Separator Element R
Injection Pump (check & adjust) C@2000hrs
Valve Clearance Check C
Adjust Intake and Exhaust Valves C@ 2000 hrs
Lights (running, brake, & turn) CBT
Pintle Eye Bolts CBT
R=replace, C=check (adjust if necessary) CBT = check before

towing.
* Applies only when using IR Protec™ Engine Fluid
54
LUBRICATION
55
Operating & Maintenance Manual LUBRICATION
Lubrication
Portable Compressor Fluid
Chart
Refer to these charts for correct compressor
fluid required. Note that the selection of fluid
is dependent on the design operating
pressure of the machine and the ambient
temperature expected to be encountered
before the next oil change.
NOTE: Fluids listed as “preferred” are

required for extended warranty.
Compressor oil carryover (oil

consumption) may be greater with the use
of alternative fluids.
Design
Ambient
Operating Specification
Temperature
Pressure
100 psi to -100F to 1250F Preferred:
300 psi IR Pro•Tec™
(-230C to 520C)
Alternate:
ISO Viscosity Grade 46 with rust
and oxidation inhibitors, designed Preferred Ingersoll-Rand Fluids - Use of
for air compressor service. these fluids with original I-R filters can extend
350 psi (-230C to 520C) Preferred: airend warranty. Refer to operator’s manual
IR XHP 605
-100F to 1250F warranty section for details or contact your IR
Alternate: representative.
IR XHP405
ISO Viscosity Grade 68 Group 3
or 5 with rust and oxidation
inhibitors designed for air
compressor service.
650F to 1250F Preferred:
(-18°C to 52°C) XHP605
IR XHP1001
Ingersoll-Rand
1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Litre)
Preferred Fluids
Preferred:
IR Pro-Tec™ 36899698 36899706 36899714 36899722
IR XHP605 - 22252076 22252050 22252068
IR XHP1001 - 35612738 35300516 -
XHP405 - 22252126 22252100 22252118
Engine Oil 54480918 36875938 36866903
56
LUBRICATION Operating & Maintenance Manual
57
Operating & Maintenance Manual LUBRICATION
58
Trouble Shooting
57
Operating & Maintenance Manual Trouble Shooting
Trouble Shooting B. Do The Simplest Things First

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

corrected, be sure to locate and correct the
cause of the trouble so the same failure will
A. Think Before Acting not be repeated. A complaint of “premature
breakdown” may be corrected by repairing
Study the problem thoroughly and ask
any improper wiring connections, but
yourself these questions: something caused the defective wiring. The
cause may be excessive vibration.
1. What were the warning signals that
preceded the trouble?
2. Has a similar trouble occurred before?
3. What previous maintenance work has
been done?
4. If the compressor will still operate, is it
safe to continue operating it to make
further checks?
58
Trouble Shooting Operating & Maintenance Manual
Trouble Shooting Chart

Bold Headings depict the COMPLAINT - Subheadings indicate CAUSES
NOTE: Subheadings suggest sequence to follow troubleshooting.
Table 1: Unit Shutdown

Cause Corrective Action
Out of Fuel Add CLEAN diesel Fuel
Compressor Oil Level Too Low Add correct oil
Compressor Oil Temp. Too High See Table 7
Engine Water Temp. Too High Check coolant level. If necessary, Add.
Loose Wire Connection Wiggle wires at switches & connector blocks. Make repairs.
Low Fuel Level Shutdown Switch Replace switch.
Defective Discharge Air Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Replace switch.
Broken Engine Fan Belt Replace fan belt.
Engine Oil Pressure Too Low See Table 4.
Malfunctioning Relay Replace relay.
Blown Fuse Replace fuse/Check for Short.
Engine Malfunctioning See Trouble Shooting in Engine Section.
Airend Malfunctioning See Table 7 & 10.
Table 2: Won’t Start/Run:

Out of Fuel Add CLEAN diesel Fuel
Clogged Fuel Filters Service filters.
Compressor Oil Level Too Low Add corrected oil
Loose Wire Connection Repair or replace connection.
Low Battery Voltage Check electrolyte level. Check connections.
Defective Alternator Replace/Repair Alternator
Out of Fuel Add CLEAN fuel.
Engine Water Temp. Too High Check fluid level. If necessary, Add.
Malfunctioning Start Switch Replace switch.
Defective D2 Diode Replace D2 Diode.
Blown Fuse Replace fuse/Check for Short.
Engine Oil Pressure Too Low See Table 3 and Table 4.
Compressor Oil Temp. Too High See Table 10.
Defective Discharge Air Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Replace switch.
Defective Engine Temp. Switch Replace Switch
Defective Separator Tank Temp Switch Replace Switch
Defective Low Fuel Shutdown Switch Replace Switch
Airend Malfunctioning See Table 7 & 10.
59
Table 3: High Engine Temperature Indicator (4) Stays On:

Complaint Corrective Action
Dirty Cooler Clean exterior of cooler.
Operating Pressure Too High Reduce pressure to spec.
Recirculation of Cooling Air Close side doors.
Dirty Operating Conditions Move unit to cleaner environment.
* Out of Level >15 degrees Relocate or reposition unit.
* Ambient Temp. >125×F (52×C) Above spec limit.
Loose Wire Connection Repair or replace.
Broken Engine Fan Belt Replace fan belt set.
Table 4: Low Engine Oil Pressure Indicator (5) Stays On:

Low Oil Level Add oil.
Clogged Oil Filter Element(s) Replace element(s).
Out of Level >15 degrees Relocate or reposition.
Loose Wire Connection. Repair or replace.
Wrong Lube Oil See Engine Oil Spec. Change oil.
Table 5: Low Battery Voltage Indicator (3) Stays On:

Low Battery Voltage Check electrolyte level. Add if necessary.
Loose or Broken Belts Tighten or replace belt set.
Check connectors. Clean & tighten.
Recharge battery.
Malfunctioning Alternator Repair or replace alternator.
Shorted wire (ground) Repair short.
Table 6: Unit Fails To Shutdown:

Defective Low Fuel Shutdown Switch Pull wire off shutdown solenoid. Replace switch.
Defective Discharge Air Temperature Switch Pull wire off. Replace switch.
Defective Sep. Temp. Switch Replace switch.
Defective Engine Temp. Switch Replace switch.
Defective Engine Oil Pressure Switch Pull wire off. Replace switch.

Defective Start Switch Replace defective item.
Wire Shorted Hot Repair short.
60
Table 7: Excessive Compressor Oil Temperature:

Dirty Cooler Clean exterior surfaces.
Low Oil Level Add oil. Look for any leaks.
Clogged Oil Filter Elements Replace elements. Change oil.
Operating Pressure Too High Reduce pressure to spec.
Ambient Temp. > 125°F (52°C) Above spec limit.
Out of Level > 15 degrees Relocate or reposition unit.
Wrong Lube Oil Check spec in this manual.
Recirculation Of Cooling Air Close side doors. Replace belly pan.
Malfunctioning Thermostat Replace thermostat in bypass valve.
Loose or Broken Belts Tighten or replace belt set.
Defective Oil Cooler Relief Valve Replace valve.
Defective Minimum Pressure Valve Repair or replace valve.
Malfunctioning Fan Check fan belt tension. Tighten or replace belt set.
Blocked or Restricted Oil Lines Clean by flushing or replace.
Airend Malfunctioning See Tables 11, 12, 13, 15, 16 or 18.
Table 8: Engine RPM Down

Clogged Fuel Filter Clean primary filter. Replace final filter. Drain tanks.
Add CLEAN fuel.
Dirty Air Filter Clean or replace elements.
Operating Pressure Too High Reduce pressure to spec limit.
Incorrect Pressure Regulator Adjustment Adjust regulator.
Wrong Air Filter Element Install correct element.

Malfunctioning Pressure Regulator Replace regulator.
Defective Separator Element Install new element.

Airend Malfunctioning Consult Dealer.
Table 9: Excessive Vibration

Dirty Fuel/Filters Replace filters/fuel.
Engine idle speed too low. Raise “No Load” speed.
Rubber Mounts, Loose or Damaged Tighten or replace.
Anti-rumble valve not working. Repair or Replace.
Drive Coupling Defective Replace coupling.
Defective Fan Replace fan.
Airend Malfunctioning Consult Dealer
61
Table 10: Low CFM

Engine RPM too Low Adjust RPM
Malfunctioning Inlet Unloader Inspect valve.
Dirty Air Filter Clean or replace elements.
Incorrect Pressure Regulator Adjustment Adjust linkage.
Wrong Air Filter Element Install correct element.
Defective Separator Element Install new element.
Defective Minimum Pressure Valve Repair or replace valve.
Table 11: Short Air Cleaner Life

Inadequate Element Cleaning Install new element.
Incorrect Stopping Procedure Read procedure in this manual.
Wrong Air Filter Element Install proper element.
Table 12: Excessive Oil In Air

High Oil Level Read procedure in this manual.
Clogged Scavenge Orifice Remove scavenge orifice. Clean and Replace.
Incorrect Oil Replace by spec. in this manual.
Defective Scavenge Check Valve Remove check valve. Replace with new valve.
Out of Level > 15 degrees Relocate or reposition unit.
Defective Separator Element Remove element. Install new.
Scavenge Tube Blocked Remove scavenge tube. Clean and Replace.
Sep. Tank Blow Down Too Quickly Allow unit to blow down automatically.
Defective Minimum Pressure Valve Remove valve. Repair valve and replace.
Table 13: Oil Seal Leak

Contaminated Lube Oil Drain and flush system. Add new CLEAN oil.
Replace seal.
Blocked or Restricted Oil Line(s) Remove, clean and replace line(s). Replace seal.
Malfunctioning Seal Consult dealer. Replace seal.
Scored Shaft See instructions in new seal kit.
62
Table 14: Will Not Unload

Incorrect Pressure Regulator Adjustment Adjust regulator.
Leak in Regulator Piping Find and repair leak(s).
Malfunctioning Inlet Valve Unloader Inspect valve. Repair/Replace.
Ice in Regulation Lines/Orifice Apply heat to line(s) and or orifice.
Table 15: Oil In Air Cleaner

Incorrect Stopping Procedure Read Procedure in this manual.
Malfunctioning Unloader Repair/Replace.
Table 16: Safety Valve Relieves

Operating Pressure Too High Reduce pressure to spec limit.
Incorrect Pressure Regulator Adjustment Refer to Section 6 in this manual.
Leak In Regulator Piping Repair leak(s).
Malfunctioning Inlet Unloader Inspect valve. Repair/Replace.
Defective Safety Valve Replace safety valve.
Ice in Regulation Lines/Orifice Remove ice.
63
Engine Diagnostic Codes:
- Failure Flashes can be read on the Engine Failure Lamp when the on/off power switch is
“ON” or when the unit is running.
- The Engine Failure Lamp is located behind the front end panel (see figure).
- The Failure Lamp is luminated for 2 seconds when the ECU is powered on.
- A lamp flash duration of 0.5 second is a “Short” flash.
- A lamp flash duration of 1.5 seconds is a “Long” flash.
- A failure flash sequence of “1 Long and 3 Short” would be displayed by flashing the lamp one
time with a duration of 1.5 seconds and three times with a duration of .5 seconds.
- When two or more failures have occurred simultaneously, the failure lamp will pause for 3
seconds between flash sequences.
- Failure flash sequences continuously repeat with 3 second pauses between flash sequences
until the failure is corrected.
Failure Failure Flashes Remark

Coolant temperature sensor failure 4 Short
Speed sensor failure 6 Short
Rack position sensor failure 7 Short
Rack actuator failure 8 Short
EGR valve failure 1 Long and 3 Short
CSD solenoid valve failure 1 Long and 4 Short
Main relay failure 1 Long and 6 Short
Rack actuator relay failure 1 Long and 7 Short
ECU temperature alarm 2 Long and 5 Short ECU temp >221°F
Coolant temperature alarm 3 Long and 6 Short Coolant temp >230°F
ECU failure 4 Long and 1 Short
64
4IRI8NE-2 / 4IRI8TE ENGINE
Book: 23294655 (8-08) 65

Operating & Maintenance Manual 4IRI8NE-2 / 4IRI8TE ENGINE
ENGINE - General Information

The Portable Power industrial diesel engines are a product of long years of experience,
advanced technology, and up-to-date production facilities. Portable Power takes great pride in
the superior durability and operating economy of these engines.
In order to get the fullest use and benefit from your engine, it is important that you operate and
maintain it correctly. This section is designed to help you do this. Please read this section
carefully and follow the operating and maintenance recommendations. This will ensure many
years of trouble-free and economical engine operation.
Should your engine require servicing, please contact your nearest Portable Power branch or
distributor.
All information, illustrations, and specifications contained in this manual are based on the
latest product information available at the time of publication.
Portable Power reserves the right to make changes in this manual at any time without prior
notice.
66 Book: 23294655 (8-08)

4IRI8NE-2 / 4IRI8TE ENGINE Operating & Maintenance Manual
Table 1:
Item Description Item Description
1 Lifting Eye (Flywheel 15 Intake Manifold

End)
2 Turbocharger* 16 Fuel Filter
3 Lifting Eye (Engine 17 Fuel Inlet

Cooling Fan End)
4 Engine Coolant Pump 18 Fuel Return to Fuel Tank
5 Engine Cooling Fan 19 Top Filler Port (Engine Oil)
6 Crankshaft V-Pulley 20 Rocker Arm Cover
7 V Belt 21 Air Intake Port (From Air Cleaner)
8 Side Filler Port (Engine 22 Flywheel

Oil)
9 Drain Plug (Engine 23 Starter Motor

Oil)**
10 Fuel Injection Pump 24 Exhaust Manifold
11 Engine Oil Cooler*** 25 Alternator
12 Engine Oil Filter 26 EGR Valve
13 Dipstick (Engine Oil) 27 EGR Cooler****
14 Eco-governor 28 EGR Pipe
Book: 23294655 (8-08) 67

Table 2:
Engine model name 4IRI8NE-2 / 4IRI8TE

Engine type Vertical inline water cooled diesel engine
Combustion type Direct injection
Aspiration Natural/Turbocharged
No. of cylinders - bore x stroke 4-98x110
Engine displacement L 3.319
Compression ratio 18.5:1 / 18.1:1
Firing order 1 -3 - 4 - 2
Exhaust emission control system Fuel injection nozzles, fuel injector pump
Governor Electronic
Specified fuel Diesel fuel (ISO 8217 DMX, BS2869 A1/

A2) No. 2-3, No. 1-D, ASTM D975-94
Starter (V-kW) 12-2.3
Alternator 12-40
Specified engine oil (API grade) CI-4+ (15W40)
(SAE grade)
Coolant volume (Engine only) L 4.2
Engine dry weight kg 235/245
Overall length mm 719
Overall width mm 508
Overall height mm 717
Nozzle injection pressure MPa 21.6
Engine Identification
Serial Number Location
The engine serial number is stamped on engine name plate on top of rocker cover. See
illustration on Table 1.
Confirmation of Engine Number
It is advisable to quote the engine serial number together with the machine serial number, as
it is required when you contact the Portable Power branch or distributor for repair, service or
parts ordering.
68 Book: 23294655 (8-08)

ENGINE AFTER SERVICE

Contact your Portable Power dealer for periodical inspection and maintenance.
Portable Power parts are identical with those used in the engine production, and accordingly,
they are warranted by Portable Power.
Genuine Ingersoll Rand parts are supplied by your Portable Power branch or distributor.
Please ensure that only genuine Ingersoll Rand parts, lubricants and fluids are used for
service and/or repair.
! WARNING
Conduct confirmation of engine serial number with the engine stopped.
To avoid being injured, do not check it while the engine is still hot.
Book: 23294655 (8-08) 69

Engine Label (for EPA) Emission Control Label

Emission control label is attached on the “top of rocker arm cover.”
The location of emission control label attached on the engine may vary depending on the
engine specification.
The following is the sample of a label required for engine emission control information, along
with location.
70 Book: 23294655 (8-08)

Fluid, Lubricants, and Coolant

Fuel Selection
The following properties are required of the diesel fuel.
• The fuel cetane number should be equal to 45 or higher.

• The sulfur content must not exceed 0.5% by volume. A higher sulfur content fuel may
cause sulfuric acid corrosion in the cylinders of the engines.
• NEVER mix kerosene, used engine oil, or residual fuels with the diesel fuel.
• Water and sediment in the fuel should not exceed o.05% by volume.
• Keep the fuel tank and fuel-handling equipment clean at all times.
• Poor quality fuel can reduce engine performance and/or cause engine damage.
• Fuel additives are not recommended. Some fuel additives may cause poor engine
performance. Consult your Portable Power representative for more information.
• Ash content not to exceed 0.01% by volume.
• Carbon residue content not to exceed 0.35% by volume. Less than 0.1% is preferred.
• Total aromatics content should not exceed 35% by volume. less than 30% is
preferred.
• PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume.
• Metal content of Na, Mg, Si, and AI should be equal to or lower than 1 mass ppm.
(Test analysis method JPI-5S-44-95).
• Lubricity: Wear mark of WS1.4 should be Max. 0l018 in (460 um) at HFRR test.
Diesel fuel should comply with the specifications listed in Table 3 below. The table lists several
worldwide specifications for diesel fuels.
Table 3: Diesel Fuel Specifications
Diesel Fuel Specification Location

No. 2-D, No. 1-D, ASTM D975-94 USA
EN590:96 European Union
ISO 8217 DMX International
BS (BRITISH STANDARD) BS2869-A1 or A2 United Kingdom
JIS K2204 Grade No. 2 Japan
KSM-2610 Korea
GB252 China
Book: 23294655 (8-08) 71

Fuel Requirements
The fuel injection pump, injector or other parts of the fuel system and engine can be damaged
if you use an fuel or fuel additive other than those specifically recommended by Portable
Power.
If any fuel other than the one specified is used, engine operation will be impaired. Engine
failure or malfunction resulting from use of such improper fuel will not be warranted by Portable
Power.
To help avoid fuel system or engine damage, please read the following:
Do not use diesel fuel which has been contaminated with engine oil. Besides causing engine
damage, such fuel can also affect emission control. Before using any diesel fuel, check with
the fuel supplier to see if the fuel has been mixed with engine oil.
Your engine is designed to use either Number 1-D or Number 2-D diesel fuel. However, for
better fuel economy, use Number 2-D diesel fuel whenever possible. At temperatures less
than -7°C, (20°F), Number 2-D fuel may pose operating problems (see “Cold Weather
Operation” which follows).
At colder temperatures, use Number 1-D fuel (if available) or use a “winterized” Number 2-D
(a blend of Number 1-D and Number 2-D). THis blended fuel is usually called Number 2-D
also, but can be used in colder temperatures than Number 2-D fuel which has not been
“winterized.”
Check with the fuel supplier to be sure you get the properly blended fuel.
NOTICE
Do not use home heating oil or gasoline in your diesel engine. Either may
cause engine damage.
Handling of Fuel
Any fuel containing dust particles or water might cause engine failure. Therefore, the following
must be observed:
• Take care to protect the fuel from entry of dust particles or water when filling the tank.
• If refueling is done from an oil drum directly, ensure that is has been kept stationary
to allow any dust, sediment or water to settle at the bottom. Do not draw fuel direct
from the bottom of the drum to prevent pickup of any settled foreign material.
• Always fully fill the fuel tank. Drain the sedimentary particles in the fuel tank
frequently.
72 Book: 23294655 (8-08)

problems, you should have your authorized

Water In Fuel dealer correct these problems. Then, use a
During refueling, it is possible for water (and diesel fuel biocide to sterilize the fuel system
other contaminants) to be pumped into your (follow the biocide manufacturer’s
fuel tank along with the diesel fuel. This can instructions),
happen if a fuel provider does not regularly
inspect and clean its fuel tanks, or receives Biocides are available from your dealer,
contaminated fuel from its supplier(s). To service stations, parts stores and other
protect your engine from contaminated fuel, automotive places. See your authorized
there is a fuel filter system on the engine dealer for advise on using biocides in your
which allows you to drain excess water. area and for recommendations on which
biocides you should use.
! CAUTION Smoke Suppressants

The use of a smoke suppressant additive is
not allowed because of the greater possibility
The water/diesel fuel of stuck rings and valve failure, resulting from
mixture is flammable, and excessive ash deposits.
could be hot. To avoid
personal injury and/or
property damage, do not Lubricant
touch the fuel coming from The quality of engine oil can affect engine
the drain valve, and do not performance, start ability and engine life.
expose the fuel to open Use of unsuitable engine oil will result in
flames or sparks. piston ring, piston and cylinder seizure and
accelerate surface wear causing increased
Be sure you do not overfill the fuel tank. Heat oil consumption, lowered output and, finally
(such as from the engine) can cause the fuel engine failure.
to expand. If the tank is too full, fuel could be
forced out. This could lead to a fire and the To avoid this, use the specified engine oil.
risk of personal injury and/or equipment. 1) Engine Oil Selection ProTec™
2) Oil Viscosity
Biocides Engine oil viscosity affects engine start
In warm or humid weather, fungus and/or ability, performance, oil consumption, wear
bacteria may form in diesel fuel if there is and the potential for seizure, etc.
water in the fuel.
Always ensure that lubricants with the correct
viscosity for the operating temperature are
used. Refer to SAE Chart below.
NOTICE
Fungus or bacterial can
cause fuel system damage
by plugging the fuel lines,
fuel filters or injector. They
can also cause fuel system
corrosion.
If fungus or bacteria has caused fuel system
Book: 23294655 (8-08) 73

NOTICE ! CAUTION
Using a mixture of different When handling Long Life
brands or quality of oils will Coolant Antifreeze, wear
adversely affect the original protective rubber gloves. If
oil quality; therefore, never contact with the eyes or
mix different brand or skin should occur, wash
different type oils. with clean water.
Do not use API, CA, CB

Engine Operation
grade and reconstituted
Engine damage due to Engine Exhaust Gas (Carbon Monoxide)
improper maintenance, or
using oil of the improper
quality and/or viscosity, is
not covered by
warranty.engine oil.
the ! WARNING
Do not breathe exhaust gas
Coolant because it contains carbon
monoxide, which by itself
All Portable Power compressor engines are has no color or odor.
factory filled with a 50/50 Ethylene glycol Carbon monoxide is a
base antifreeze/water mix. which provides dangerous gas. It can
protection to -33°C (-27°F). cause unconsciousness
and can be lethal.
• Be sure to add Long Life Coolant
Antifreeze (LLC) to soft water. In
Check Before Operation
cold season, the LLC is especially
important. Without LLC, cooling
performance will decrease due to
scale and rust in the cooling water
line. Without LLC, cooling water will
! CAUTION
freeze and expand to break the
cooling line. Conduct the inspection
with the engine stopped.
• Be sure to use the mixing ratios
specified by the LLDC
manufacturer for your temperature
range.
• Do not mix different types (brand) of
LLC. Chemical reactions may make
the LLC useless and engine trouble
could result.
• Replace the cooling water once a
year.
74 Book: 23294655 (8-08)

Note: Take care to avoid engine oil being

Engine Oil Level splashed on the fan drive belt because it
causes belt slippage or slackness.
• Place the engine or the machine on
a level surface.
• Remove the dipstick, wipe with a
cloth. Insert it fully and take it out ! CAUTION
again.
• Check the oil level against the When adding oil, take care
marks on the dipstick. not to spill it. If you spill oil
on the engine or
The oil level must be between the upper level equipment, wipe it off, to
mark and the lower level mark as illustrated. prevent the risk of fire,
personal injury, and/or
equipment damage.
Fan Belt Check

Check the fan belt for tension and
abnormalities.
When the belt is depressed 7 - 10 mm with
the thumb (about 100 N [10 kg] pressure)
midway between the fan pulley and
alternator pulley, the belt tension is correct.
If the belt tension is too high, it will result in
alternator failure.
A. Filler Cap
A loose belt will cause belt slippage which
B. Filler Port (Engine Oil) may result in a damaged belt, abnormal
C. Dipstick noise, poor battery charging and engine
overheating.
D. Upper Limit
E. Lower Limit
F. Dipstick
Remove filler cap “yellow colored) on the
rocker arm cover side of engine.
Fill with engine oil up to the upper limit on the
dipstick.
Manually tighten the filler cap. Do not use a
tool such as pliers to tighten it.
Engine oil pan capacity (oil pan) (L) - 10.2
(10.8 quarts).
A certain period of time is required before the
engine oil completely flows down from the oil
filler to the crankcase. Wait at least ten
minutes before checking the oil level.
Book: 23294655 (8-08) 75

will damage the electrical parts.
Coolant Level Check

A. Battery Cable
The coolant level must be between MAX
“COLD" and MIN" marks on the reserve tank B. Connections
depending on the temperature of the engine. Battery Electrolyte Level
Check and ensure that the level is correct.
The amount of electrolyte in the batteries will
be reduced after repeated discharge and
recharge. Check the electrolyte level in the
! CAUTION batteries, replenish with a commercially
available electrolyte such as distilled water, if
When removing the radiator necessary. The battery electrolyte level
filler cap, while the engine checking procedure will vary with battery
is still hot, cover the cap type.
with cloth, then turn it NOTE: Do not replenish with dilute sulfuric
slowly to gradually release acid in the daily service.
the internal steam
pressure. This will prevent
anyone from being scalded
by hot steam spurting out
from the filler neck.
! CAUTION
When inspecting the
Add coolant mixed to the correct ratio: 50/50 batteries, be sure to stop
ethylene glycol/water. the engine first.
Radiator Cap Condition
As dilute sulfuric acid is
After the replenishment of the coolant, install used as electrolyte, be
the radiator filler cap. Make sure the cap is careful not to contaminate
securely installed. your eyes, hands, clothes,
Battery Cable Connection and metals with the
electrolyte. If it gets in your
Check the battery cable connections for eyes, flush with water
looseness or corrosion. A loosened cable immediately and seek
connection will result in hard engine starting medical attention.
or insufficient battery charge. The battery
cables must be tightened securely. Never
reverse +" and -" terminals when
reconnecting cables after disconnection.
Even a short period of reverse connection
76 Book: 23294655 (8-08)

Note: After start-up from cold, the engine

might be noisier and the exhaust smoke color
darker than when it has warmed up.
! CAUTION However, the condition will disappear after
warm-up.
As highly flammable Leakage in the System
hydrogen gas is released
from the batteries, do not Check the following items:
create a spark or allow any
naked flame near the • Lubrication oil leakage - Check the
batteries. engine for oil leaks, paying
particular attention to oil filter and
When handling such oil pipe joints.
metallic articles as tools • Fuel leakage - Check the fuel
near the batteries, be sure injection pump, fuel lines and fuel
not to contact the “+” filter for leakage.
terminal because the
compressor body is “-” and • Coolant leakage - Check the
a dangerous short circuit radiator and water pump hose
might result. connections and the water drain
cock on the cylinder block for
When disconnecting the leakage.
terminals, start with “-” • Check for exhaust smoke or gas
terminal. When connecting leakage.
them, connect the “-”
terminal last.
Fuel Level
Check the remaining fuel oil level in the fuel
tank and re-fuel if necessary.
CHECKS and OPERATION AFTER

START-UP
After engine start-up, check the following
items in the engine warming-up operation:
• Listen to the engine and, if any

abnormal noise is heard, check to
determine the cause.
• Check the fuel combustion
condition by observing the exhaust
smoke color. The exhaust smoke
color after engine warm-up and at
no-load condition should be
colorless or light blue. Black or
white smoke indicates incorrect
combustion.
Book: 23294655 (8-08) 77

Overheating
Checking Coolant Level
The coolant level could drop because any
mixed air is expelled in about 5 minutes after
the engine started. ! CAUTION
Stop the engine, remove radiator cap, and
add coolant. If you see or hear escaping
steam or suspect a serious
overheating condition, stop
the engine immediately.
! CAUTION If the Engine Coolant Temperature Gauge
(where fitted) shows an overheat condition,
HOT STEAM. Do NOT
or you have reason to suspect the engine
remove radiator cap when
may be overheating, take the following steps.
the engine is hot. Cover the
radiator cap with a thick
• Close the service valve to reduce
cloth and loosen the cap
the load.
slowly to reduce the
pressure, then remove the • Let the engine run at normal idle
cap. speed for two or three minutes. If
the engine coolant temperature
OPERATION AND CARE OF A NEW MACHINE does not start to drop, turn off the
engine and proceed as follows:
Your Portable Power engine is carefully
tested and adjusted in the factory, however, To avoid being burned -
further run-in is necessary. Avoid any harsh
engine operation within the initial 100
operating hours.
Do not operate the unit at full load until the
! CAUTION
engine is warmed-up.
Do not open the canopy or
Do not allow the engine to run unloaded for door if you see or hear
extended periods so as to minimize the risk steam or engine coolant
of cylinder bore glazing. escaping. Wait until no
During operation, pay attention to the steam or engine coolant
following points if the engine shows any sign can be seen or heard before
of abnormalities. opening the engine canopy
or door.
Engine Oil Pressure - The engine oil
pressure is monitored by a switch that will
stop the engine if the pressure falls below a
pre-set value.
Coolant Temperature - The engine
performance will be adversely affected if
engine coolant temperature is too hot or too
cold. The normal coolant temperature is 75 to
85°C (167°to 185°F).
78 Book: 23294655 (8-08)

conditions, the ethylene

glycol in engine coolant is
combustible.
! CAUTION
If the engine coolant level in the reserve tank
Do not remove the radiator is at the correct level but there is still an
filler cap if the engine indication of an overheat condition and no
coolant in the reserve tank cause was found, please consult your local
is boiling. Also do not branch or dealer.
remove the radiator filler Overcooling
cap while the engine and
radiator are still hot. Operating the engine at low coolant
Scalding fluid and steam temperature will not only increase the oil and
can be blown out under fuel consumption but also will lead to
pressure if either cap is premature parts wear which may result in
taken off too soon. engine failure. Ensure that the engine
reaches normal operating temperature 75 to
If no steam or engine coolant can be seen or 85°C (167 to 185°F) within ten minutes of
heard, open the canopy or door. If the engine starting.
coolant is boiling, wait until it stops before
Hourmeter
proceeding. The engine coolant level should
be between the MAX COLD" and MIN" marks This meter indicates the machine operation
on the reserve tank. hours. Make sure that the meter is always
working during engine operation. Periodical
Make sure the fan belt is not broken, or off
machine maintenance is scheduled on the
the pulley, and that the fan turns when the
operation hours indicated on the hourmeter.
engine is started. If the engine coolant level
in the reserve tank is low, look for leaks at the Liquid and Exhaust Smoke Leakage
radiator hoses and connections, radiator,
Make regular checks for lubricant, fuel,
and water pump. If you find major leaks, do
not run the engine until these problems have coolant and exhaust smoke leakage.
been corrected. If you do not find a leak or Abnormal Engine Noise
other problem, WAIT UNTIL THE ENGINE
HAS COOLED DOWN then carefully add In the event of any abnormal engine noise,
engine coolant to the reserve tank. please consult your local branch or dealer.
(Engine coolant is a mixture of ethylene Engine Stopping

glycol antifreeze and water. (See Engine Close the service valves.
Care in Cold Season for the proper
antifreeze and mixture). Before stopping the engine, cool down the
engine by operating it at reduced load about
three minutes. In this period, check the
engine noise for abnormalities.
! CAUTION Long Term Storage
To avoid being burned, do If the equipment is to be out of operation for

not spill antifreeze or an extended period, it should be started at
engine coolant on the least once per week and run on load for
exhaust system or hot about 15 minutes after it has reached normal
engine parts. Under some operating temperature.
Book: 23294655 (8-08) 79

If this is not possible: 5. Clean the engine oil filter

mounting face.
• Do not drain the cooling water.
6. Moisten the new engine oil
• Clean dust or oil from the engine filter gasket with the engine oil
extension. and install the new engine oil
filter manually turning it
• Either fill completely or drain the
clockwise until it comes into
fuel tank.
contact with the mounting
• Grease accelerator joints and surface, and tighten it further
electrical connections. to 3/4 of a turn with the filter
• Disconnect the negative battery wrench.
terminal. 7. Tightening torque:
19.6~23.5N•m
ENGINE MAINTENANCE
(2.0~2.4kgf•m)
Periodical Inspection and Maintenance
8. Applicable engine oil filter part
Inspection after initial 50 hours of operation no: 22226351
Replacing the engine oil and engine oil filter 9. Fill with the new engine oil
(1st time): until it reaches the specified
level as explained in
When the engine oil is still hot, be careful with
OPERATION section.
a splash of engine oil which may cause
burns. Cool the engine to replace engine oil 10. Warm up the engine by
until the engine oil becomes warm. It is most running for 5 minutes while
effective to drain the engine oil while the checking any oil leakage.
engine is still warm.
11. Stop the engine after warming
In early period of use, the engine oil gets dirty up and leave it stopped for
rapidly because of the initial wear of internal about 10 minutes to recheck
parts. Replace the engine oil earlier. the engine oil level with
dipstick and replenish the
Engine oil filter should also be replaced when
engine oil. If any oil is spilled,
the engine oil is replaced.
wipe it away with a clean
Engine oil and engine oil filter replacing cloth.
procedures are as follows:
12. Resume engine oil and filter
changes at 250 our intervals
1. Prepare a waste oil container
(with non IR fluids) or 500
collecting waste oil.
hour intervals with Ingersoll
2. Loosen the drain plug using a Rand Protec™ engine fluid
wrench (customer procured) and filters.
to drain the engine oil).
Note: The use of genuine Ingersoll Rand oil
3. Securely tighten the drain and filters will qualify for extended warranty
plug after draining the engine coverage. Refer to Warranty Section of the
oil. manual.
4. Turn the engine oil filter
counter-clockwise using a
Ingersoll Rand Protec™ Engine Fluid Part
filter wrench (customer
No. 54480918 (1 gallon).
procured) to remove it.
80 Book: 23294655 (8-08)

Important: Do not overfill the oil pan with When all the water has been evacuated,
engine oil. Be sure to keep the specified level tighten the drain valve “E” and follow the “fuel
between upper and lower limit on the system air bleeding” procedure below.
dipstick.
Fuel System Air Bleeding

The location depends on the engine installed
on the machine unit. The entry of air into the fuel system will cause
difficult engine starting or engine
(A) Dipstick (B) Oil Pan (C) Drain Plug malfunction.
When carrying out service procedures such
as emptying the fuel tank, draining the filter/
separator, and changing the fuel filter
element be sure to bleed air from the fuel
system.
To activate the “automatic air-bleeding
system”, turn the key switch to the “ON”
position and energize the electromagnetic
pump to bleed the air.
Air Bleeding Method:
(A) Engine Oil Filter (B) Loosen (C) Tighten When the “starter switch” is set to the “ON”
position to activate the electromagnetic
pump, fuel is forced to the fuel valve of each
Draining Water from Filter/Separator
injector nozzle, so that any air in the fuel
The fuel filter/separator is provided to allow system bleeds off automatically to the fuel
water to be drained from the fuel system. tank.
Water is heavier than fuel so any water
Note: Although the fuel system can bleed air
contained in the system will collect in the
automatically when the key switch is in the
bottom of the bowl.
“ON" position, air can also be manually bled
The clear bowl “D” should be checked on a by use of the primer pump facility in the filter/
daily basis and if water is present, it should separator assembly.
be drained from the separator.
By unscrewing the plastic primer pump head
Place a suitable container under the `A' and stroking it up and down, any air
separator to prevent any spillage inside the bubbles in the system will be purged back to
machine. the fuel tank.
Slacken the drain valve “E” until water drains
from the vent tube.
Book: 23294655 (8-08) 81

Change Procedure:
When this has been completed, the pump
head must be screwed back into the filter/ • Unscrew the element “C” from the
separator assembly.
head taking care not to spill fuel
Start the engine and visually check the fuel inside the machine. Drain any fuel
system for leaks. within into a suitable container, then
unscrew the clear bowl “D” from the
Replacing Fuel Filters element.
Replace the fuel filter at specified intervals
before it is clogged with dust to adversely • Discard the old element.
affect the fuel flow. Also, replace the fuel filter
after the engine has fully been cooled. • Remove the old “O” ring from the
bowl “D” and install the new one
1) Remove the fuel filter using a filter wrench supplied with the element. Apply a
(customer procured). When removing the light coat of clean engine oil to the
fuel filter, hold the bottom of the fuel filter with “O” ring and screw the bowl “D”
a piece of rag to prevent the fuel oil from onto the new element “C”.
dropping. Wipe up any fuel spillage.
2) Clean the filter mounting surface and • Using a clean cloth, wipe the
slightly apply fuel oil to the gasket of the new sealing face of the filter/separator
fuel filter. head to ensure correct seating of
the sealing ring.
3) Install the new filter, manually turning until
it comes into contact with the mounting • Fill the element/bowl assembly with
surface, and tighten it further to 1/2 at a turn, clean fuel oil then apply a light coat
using a filter wrench. of clean engine oil to the new
element seal ring.
Tightening torque:
11.8 ~15.6N•m (1.2~1.6kgf•m) • Screw the new element onto the
head firmly by hand.
Applicable Fuel Filter Part No. 16539462.
4) Bleed the fuel system. Refer to Inspection • Follow the “fuel system air
at 50 hours. bleeding” procedure.
IMPORTANT: Use genuine IR part (super
fine mesh filter). Otherwise, it will result in
engine damage, uneven engine performance
and shorter engine life.
Changing Oil/Water Separator

Element
Note: the cartridge and bowl contain fuel.
Take care not to spill it during disassembly
and reassembly.
The fuel filter/separator also provides
primary filtration and the element “C” should
be changed every 500 operating hours or 6
months, whichever comes first.
82 Book: 23294655 (8-08)

Inspect Turbocharger (Blower Wash as

Every 1000 Hours of Operation
Necessary) - Turbo charger service is
Replacing Cooling Water required by the EPA/ARB every 1500 hours.
Your authorized Portable Power dealer or
Cooling water contaminated with rust or
distributor will inspect and blower wash the
water scale reduces the cooling effect. Even
unit if necessary.
when antifreeze agent (LLC) is mixed, the
cooling water gets contaminated due to Inspect, Clean and Test EGR Valve - The
deteriorated ingredients. Replace the cooling EGR valve is a key component for cleaning
water at least once a year. Procedure: exhaust gas.
To prevent the valve from deteriorating in
• Remove the header tank cap.
exhaust gas recirculation performance due
• Remove the bottom radiator hose to carbon accumulation, inspect, clean and
of the radiator and drain the cooling test the valve at least every 1500 hours.
water. Consult your local Portable Power dealer for
this service.
• After draining the cooling water, Inspect and Clean EGR Lead Valve - The
reconnect the hose. EGR lead valve is located in the passage of
recirculated gas.
• Fill radiator and engine with cooling
water via the header tank. To prevent carbon accumulation in or
clogging of the lead valve, inspect and clean
the lead valve at regular intervals. Consult
your local Portable Power dealer for this
! CAUTION service.
Clean EGR Cooler - The EGR cooler is apt
Beware of scalding hot water. to be contaminated with rust and scale that
deteriorate the cooling performance. Carbon
Wait until the temperature goes down before accumulation in the exhaust gas passage of
draining the Cooling water. Otherwise, hot the cooler hinders circulation of exhaust gas,
water may splash to cause scalding. resulting in deterioration in exhaust gas
Adjusting Intake/Exhaust Valve cleanup performance.
Clearance- As this adjustment requires To prevent such a problem, clean the cooler
specialized knowledge and skill, consult your at least every 1500 hours. Consult your local
Portable Power dealer. The adjustment is Portable Power dealer for this service.
necessary to maintain the correct timing for
the opening and closing of valves. Neglecting
the adjustment will cause the engine to run
noisily and result in poor engine performance
and other damage.
Every 1500 Hours of Operation
Inspect, Clean and Test Fuel Injectors -
As the adjustment requires specialized
knowledge and skill, consult your Portable
Power dealer. This adjustment is needed to
obtain the optimum injection pattern for full
engine performance.
Book: 23294655 (8-08) 83

Inspect Crankcase Breather System - Diagnosis Tool

Proper operation of the crankcase breather
A connector is provided at an end of the
system is required to maintain the emission
harness of the driven machine so that the
requirements of the engine. The EPA/ARB
diagnosis tool can be loaded with data from
requires that you have the crankcase
the E-ECU.
breather system inspected every 1500
hours. See your authorized Portable Power When the fuel injection pump is replaced,
dealer or distributor for this service. data in the E-ECU must also be replaced for
accomodating the new pump. When the E-
ECU is replaced, the fuel injection data in the
Every 2000 Hours of Operation existing unit must be migrated to the new
unit. The diagnosis tool can be used for the
Flushing the cooling system and
checking the cooling system parts - data replacement or migration. Contact your
local Portable Power dealer for replacement
As this adjustment requires specialized of the fuel injection pump or E-ECU.
knowledge and skill, consult yourPortable
Power dealer. Rust and water scale will
accumulate in the cooling system through
many hours of operation. This lowers the
engine cooling effect.
Checking and replacing fuel hoses and
cooling water hoses - As this adjustment
requires specialized knowledge and skill,
consult your Portable Power dealer.
Regularly check the rubber hoses of the fuel
system and cooling water system. If cracked
or degraded, replace them with new one.
Replace the rubber hoses at least every 2
years.
Lapping the intake and exhaust valves -
As this maintenance requires specialized
knowledge and skill, consult your Portable
Power dealer. The adjustment is necessary
to maintain proper contact of the valves and
seats.
Checking and adjusting the fuel injection
timing - As this maintenance requires
specialized knowledge and skill, consult your
Portable Power dealer.
Checking and Adjusting the EPA emission
related parts.
The inspection and servicing require
specialized knowledge and techniques.
Consult your Portable Power dealer or
distributor.
Apply maintenance schedule for emission
related parts as follows:
84 Book: 23294655 (8-08)

SIMPLE ENGINE TROUBLESHOOTING

Table 4: Engine Does Not Start
Starter Does Not Turn Battery discharged. Bad cable connections. Starter or
starter switch failure.
Starter Turns but engine does not No fuel in fuel tank
fire (No Fuel Injection) Clogged fuel filter element
Air in fuel system
Control rack stuck at no fuel position
Starter Turns (Fuel Injected but Incorrect preheating operation
engine does not fire) Faulty air heater
Incorrect injection timing
Low cylinder compression pressure
Engine fires but stalls immediately Air in the fuel system
Table 5: Unstable Engine Running

Unstable Low Idling Crack in injection pipe
Injection nozzle failure
Uneven compression pressure between cylinders
Incorrect High Idle Speed Software/Electronic malfunction
Engine Hunting in Medium Speed Software/Electronic malfunction

Range
Insufficient Fuel Supply Air in the fuel system
Clogged fuel filter element
Piping failure (squeezed, restricted)
Engine Malfunction in High Speed Uneven fuel injection amount between cylinders
Range Incorrect valve clearance adjustment
Deteriorated valve spring
Engine Speed Stuck at High Idle Engine control restriction or seizure
Book: 23294655 (8-08) 85

Table 6: Engine Overheat

Cooling System Defect Insufficient coolant volume
Fan belt slippage
Thermostat malfunction
Radiator filler cap malfunction
Cooling system interior fouled
Radiator clogged
Improper Servicing Engine overload

Air cleaner element clogged
Insufficient airflow/restriction
Restricted coolant flow (high concentration of
antifreeze, etc).
Table 7: Low Oil Pressure
Lack of Oil Oil leakage
High oil consumption
Wrong Oil Wrong type and viscosity
High Coolant Temperature Overheat
Clogged Filter and Strainer Clean and/or replace
Worn Bearings and Oil Pump Replace
Faulty Relief Valve Replace
Table 8: Low Engine Output
Incorrect Injection Timing Too far advanced
Too far retarded
Injection Nozzle Malfunction Incorrect injection pressure
Incorrect spray condition
Incorrect Injection Pump Adjustment Lack of fuel in tank
Insufficient Fuel Supply to the Air in the injection pump
Injection Pump Fuel filter clogged
Overflow valve malfunction
Governor Malfunction Incorrect engine control adjustment
Deteriorated governor spring
Cylinder Compression Leakage Incorrect valve clearance adjustment
Injector nozzle misalignment
Low Cylinder Compressor Pressure Cylinder bore wear

Insufficient Air Intake Volume Air cleaner clogged
Restricted air flow
86 Book: 23294655 (8-08)

Table 9: Excessive Oil Consumption

Incorrect Oil Wrong selection of type and viscosity
Engine Burning Oil Faulty piston rings/damaged cylinder bores
Faulty valve stem seal
Oil Leakage Damaged seal/ Damaged turbocharger seal
Loose joints/gaskets
Improper installation of filter and piping
Table 10: Excessive Fuel Consumption

Excessive Injection Volume Injection pump defective
Table 11: Improper Exhaust
Excessive Black Smoke Clogged air cleaner
Damaged injector nozzle
Faulty EGR Valve
Injection timing incorrect
Excessive injection volume
Incorrect fuel
Excessive White Smoke Water mixing in fuel
Low compression pressure
Injection timing incorrect
Low coolant temperature
Faulty turbocharger
Table 12: Battery Over Discharge
Low Electrolyte Level Crack in battery body
Natural Consumption
Charging Failure Loose or damaged belt
Faulty alternator
Damaged wiring or contact failure
Excessive electrical loads Insufficient battery capacity for the application
Book: 23294655 (8-08) 87

88 Book: 23294655 (8-08)

Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
©2009 Doosan Infracore International, Inc. Printed in the USA

Operation & Maintenance Manual: Compressor Model Xp185Wir P260Wir

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OPERATION & MAINTENANCE MANUAL

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

This manual contains important safety information.

Do not destroy this manual.

Doosan Infracore Portable Power

Book: 23294655 (7-09) Rev A

DRAWBAR NOTICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

NOISE EMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

General Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

BEFORE TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

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

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

4IRI8NE-2/4IRI8TE Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66

Book: 23294655 (8-08) 3

• of good quality, procured from a reputable manufacturer and, wherever possible, be

4 Book: 23294655 (8-08)

• Compression of normal ambient air containing no known or detectable additional

Book: 23294655 (8-08) 5

DRAWBAR NOTICE (Important)

Free Safety Decals

This section pertains only to machines distributed within the United

Federal law prohibits the following acts or the causing thereof:

Compressor Noise Emission Control Information

Noise Emission Control Maintenance Log

COMPRESSOR MODEL __________________________

UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM

Noise Emission Warranty

A. Compressed Air Leaks

B. Safety and Control Systems

F. Air Intake and Engine Exhaust

J. Fuels and Lubricants

Maintenance Record For Noise Emission Control And Extended Warranty

UNIT MODEL P260WIR XP185WIR

CFM (litres/sec) 260(123) 185 (87)

UNITS MEASUREMENTS WEIGHTS

EXPENDABLE SERVICE PARTS

Description XP185WIR P260WIR

• Test lights (running, stop, and turn

• Engage tow vehicle parking brake.

• Chock tires of compressor.

• Set the vehicle parking brake. Chock

• Standing to the side, remove pin from

• Disconnect safety chains. Crank jack

• Open service valve(s) to ensure pressure

• Check battery for proper connections and

• Check battery for proper connections and

• Be sure no one is IN or ON the • If so equipped, press the “Service Air

Cold Weather Starting

• When the engine stops, automatic • Discharge tube.

Pressure Regulator Adjusting Instructions

1. At the Pressure Regulator (on service

After Starting Unit

3. If equipped, push the SERVICE AIR

5. Low Engine Oil Pressure: