COMPRESOR INGERSOLL-RAND XP750WCU.pdf

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I I I I I I I I I I I I

Ingersollland OPERATING, MAINTENANCE, PARTS MANUAL

MODELS: HP675WCU

XP825WCU HP750WCU XP750WCU

Code:

Code: D

1 1 ...

-I

- -

---

- -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.

11

1. ~~Inger.souftand ,I

Portable Power P.O. Box 868 - 501 Sanford Ave Mocksville, N.C. 27028 www.portablepower.irco.com

C.C.N. DATE

: 22330252 : October 2003

'-"

I I I I I I I I I I I I I I I I I I I

TABLE OF CONTENTS FOREWORD SAFETY

2

__.

.

SAFETY LABELS WARRANTY

.

NOISE EMISSION

..

. __.

..

.

.

.

. __.

6

.

. __.

14

.

.

. __. __.

.

.

GENERAL DATA __. __. _.. __.. __.

.

.

. .

. 3

. __.

.

.

.

.

19

. __. __. _ 23

Dimensions Data

OPERATING INSTRUCTIONS Commissioning

..

Compressor

. __...

Mounting

Prior to Starting

.

Starting Stopping

. _... __.. _. . __.. __.. .

. __. __.

Emergency Stopping __ Re-starting

_. __. __.

Decommissioning

.

. _. _

_

_

_.. _ __

__. __. _..

_.. _ _

___.. ..

ENGINE OPERATION and MAINTENANCE.

.. _ 24 .

_. _ . __.

.. _ 24

_. __.

25

. _. __..

. __.. _______________ _

Monitoring During Operation

. __.

. __. _____

.. __.

. __. _..

. __.

.. __. ____ ..

. __. __. _..

. __.

___. __. _.. _. _ .. _.. ..

.

28

.

28

_. _

_.. _. _. _. __

24

28

_. _. _.. 29 .

29

. __.

. __. _ 29

. __.. _. __. __. __.

. _ 30

MAINTENANCE Routine Maintenance Compressor

Lubrication

Speed and Pressure Regulation Torque Settings Table

FAULT FINDINGS PARTS ORDERING PARTS LISTS

XP825DWCU.

HP750DWCU,

XP750DWCU,

HP675WCU.

9/235,

9/215

FOREWORD

IF IN DOUBT CONSULT SUFIERVISION.

Nothing contained in this document is intended to extend any promise, warranty

regarding the Ingersoll-Rand such warranties

or implied,

ThiS machine has been designed and supplied for above ground

products described herein. Any

operation and only in the fOllowing specified conditions and

or representation,

expressed

or other terms and conditions

applications:

of sale of

compression

products shall be in accordance With the standard terms and

of normal ambient air containing no known or

detectable additional gases, vapours, or particles.

conditions of sale for such products, which are available upon

Operation within the ambient temperature range specified in

request.

the GENERAL DATA SECTION of this manual. This manual contains

instructions

The use of the machine in any of the situation

and technical data to

types

listed in table 1:-

cover all routine operation and scheduled maintenance tasks by

a) Is not approved

operation and maintenance staff. Major overhauls are outside

by lnqersotl-Hand,

b) May impair the safety of users and other persons,

the scope of this manual and should be referred to an authorised

and

c) May prejudice any claims made against Ingersoll-Rand.

Ingersoll- Rand service department.

All components, accessories, pipes and connectors added TABLE 1

to the compressed air system should be: of good quality, procured from a reputable manufacturer and,

Use of the machine to produce compressed air for:

wherever possible, be of a type approved by lnqersoll-Hanc

a) direct human consumption

clearly rated for a pressure at least equal to the machine

b) indirect human consumption, without suitable filtration and

maximum allowable working pressure.

puntv checks.

compatible with the compressor lubricant/coolant. accompanied

with

instructions

for

safe

Installation, Use of the machine outside the ambient temperature range

operation and maintenance.

specified in the GENERAL DATA SECTION of this manual. Details

of

Ingersoll-Rand

approved

equipment

are

available

from

Use of the machine where there is any actual or foreseeable

Service departments.

risk of hazardous levels of flammable gases or vapours. Use of the machine fitled with non Ingersoll- Rand approved

The use of repair parts / lubricants / fluids other than those included within the Ingersoll-Rand

approved

components / lubricants / fluids

parts list may

create hazardous conditions over which Ingersoll- Rand has no control. Therefore Ingersoll-Rand

Ingersoll-Rand

Use of the machine with safety or control components

cannot be held responsible

for equipment in which non-approved

missing or disabled.

repair parts are installed.

reserves the right to make changes and

Use of the machine for storage or transportation of materials

improvements to products without notice and without incurring

inside or on the enclosure except when contained within the

any obligation to make such changes or add such

toolbox.

improvements to products sold previously.

The intended uses of this machine are outlined below and examples

of unapproved

Ingersoll-Rand

Ingersoll- Rand accepts

usage are also given, however

no responsibility

for errors

translation of this manual from the original English version.

cannot anticipate every application or work

situanon that may arise.

2

in

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I I I I I I I I I I I I I I I I I I I

SAFETY

Ether is an extremely volatile, highly inflammable gas. When it is specified as a starting aid, use sparingly. DO NOT USE ETHER IF THE MACHINE HAS GLOW PLUGS OR INLET HEATER

STARTING

AIDS OR ENGINE

DAMAGE

WILL

RESULT

General Information Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual

Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, blow gun tips, etc. well away

shipped from the factory with this machine.

from moving parts. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation Compressed Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

air

Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started

Make sure that all protective covers are in place and that the

accidentally.

canopy/doors are closed during operation. Ensure that the machine is operating at the rated pressure The specification of this machine ISsuch that the machine is

and that the rated pressure is known to all relevant personnel.

not suitable for use in flammable gas risk areas. If such an application is required then all local regulations, codes of practice and Site rules must be observed

To ensure that the

machine can operate in a safe and reliable manner, additional

All air pressure equipment installed In or connected to the machine must have safe working pressure ratings of at least the machines safety valve setting.

equipment such as gas detection, exhaust spark arrestors, and intake (shut-off) valves may be required, dependant on local If more than one compressor is connected to one common

regulations or the degree of risk involved.

downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, so that one A weekly visual check must be made on all fasteners/fixing screws securing mechanical parts. In particular. safety-related parts

such

road-wheels,

as

coupling

hitch,

drawbar

machine cannot accidently be pressurised / over pressurised by another.

components,

and lifting bail should be checked for total Compressed air must not be used for a direct feed to any

security.

form of breathing apparatus or mask. All components which are loose, damaged or unserviceable, must be rectified Without delay. High Pressure Air can cause serious injury or death. Relieve Air discharged

from this machine may contaIn carbon

pressure before removing filler plugs/caps, fittings or covers.

monoxide or other contaminants which will cause serious injury or death. Do not breathe this air Air pressure can remain trapped In air supply line which can result in serious injury or death. Always carefully vent air supply This machine produces loud noise With the doors open or

line at tool or vent valve before performing any service.

service valve vented. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open or service valve is vented.

The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is comoanbie.

Never inspect or service unit without first disconnecting battery cable(s} to prevent accidental starting If the discharged Do not use petroleum products (solvents or fuels) under high

air Is to be ultimately released Into a

confined space, adequate ventilation must be provided

pressure as this can penetrate the skin and result in serious illness. wear eye protection while clearung unit with compressed air to prevent Uebrls from injuring eye(s}.

Rotating fan blade can cause serious inJUry.00 not operate without guard in place.

When

using

compressed

air always

use

appropriate

personal protective equipment.

All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual Instructions.

Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.).

Avoid bodily contact with compressed air. XP825DWCU,

HP750DWCU,

XP750DWCU,

HP675WCU.

9/235.

9/215

Never give fluids or induce vomiting if the patient is

The safety valve located in the separator tank must be checked periodically

unconscious or having convulsions.

for correct operation.

Safety data sheets for compressor and engine lubricants

Whenever the machine is stopped, air will flow back into the

should be Obtained from the lubricant supplier.

compressor system from devices or systems downstream of the machine unless the service valve is closed. Install a check valve at the machine service valve to prevent reverse flow in the

Do NOT start or operate this machine in a confined area.

event of an unexpected shutdown when the service valve is

Avoid breathing exhaust fumes when working on or near the

open.

machine.

Disconnected air hoses whip and can cause serious injury or death. Always attach

a safety

This machine may include such materials as oil, diesel fuel,

flow restrictor to each hose at

antifreeze, brake fluid, on/atr filters and batteries which may

the source of supply or branch line in accordance with OSHA

require proper disposal when performing maintenance and

Regulation 29CFR Section 1926.302(b).

service tasks. Contact local authorities for proper disposal of these materials.

Never allow the unit to sit stopped with pressure in the receiver-separator

system Battery A battery contains sulphuric acid and can give off gases which are corrosive and potentially explosive. Avoid contact with Skin, eyes and clothing. In case of contact, flush area

Materials

immediately with water

The following substances

may be produced during the

operation of this machine: DO NOT AnEMPTTOSLAVE

brake lining dust

START A FROZEN BATIERY

SINCE THIS MAY CAUSE IT TO EXPLODE.

angine exhaust fumes AVOID INHALATION

Exercise extreme caution when using booster battery To jump battery, connect ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to

Ensure that adequate ventilation of the cooling system and

the negative (-) terminal of the booster battery and other end to

exhaust gases is maintained at all times.

a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After The following substances are used in the manufacture of this

starting unit, always disconnect cables In reverse order

machine and may be hazardous to health if used incorrectly: anti-freeze

Radiator

compressor lubricant Hot engine coolant and steam can cause injury Ensure that

engine lubricant

the radiator filler cap is removed with due care and attention.

preservative grease rust preventative diesel fuel

Do not remove the pressure cap from a HOT radiator. Allow

battery electrolyte

radiator to Cool down before removing pressure cap.

AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES

Should compressor

Transport When loading or transporting machines ensure that the

lubricant come Into contact with the

specified lilting and tie down points are used.

eyes, then irrigate with water for at least 5 minutes.

Should compressor

When loading or transporting machines ensure that the

lubricant come into contact with the

towing vehicle, its size, weight, towing hitch and electrical

skin, then wash off immediately.

supply are all suitable to provide safe and stable

towing at

speeds either, up to the legal maximum for the country In which Consult a physician if large amounts of compressor lubricant are ingested.

it Is being towed or, as specified for the machine model If lower than the legal maximum.

Consult a physician if compressor lubricant is inhaled.

Do not exceed gross vehicle weight rating.

4

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I I I I I I I I I I I I I I I I I I I

Before towing the machine, ensure that:the tires and towing hitch are in a serviceable condition. the canopy is secure. all ancillary equipment is stored in a safe and secure manner. the brakes and lights are functioning correctly and meet necessary road traffic requirements. break-away cables/safety chains are connected to the towing vehicle.

The machine must be towed in a level attitude in order to maintain correct handling, braking and lighting functions. This can be achieved by correct selection and acjustrnent of the vehicle towing hitch and, on variable height running gear, adjustment of the drawbar. 1. Make sure wheels, tires and tow bar connectors are In safe operating condition and tow bar is properly connected before towing. 2. When parking always use the handbrake and, If necessary, suitable wheel chocks.

Safety chains/connections

and their adjustment where

fined: Ensure that the breakaway cable is securely coupled to the trailer and also to a substantial point on the towing vehicle. Ensure that the cable length IS as short as possible, while stili allowing enough slackness for the trailer to articulate without the handbrake being applied Loop the chains onto the towing vehicle using the towing vehicle hitch as an anchorage pomt, or any other point of similar strength. Ensure that the effective chain length is as short as possible while still allowing normal articulation of the trailer and effective operation of the breakaway cable.

XP82:,OWCU, HP7500WCU,

5

XP7500WCU,

HP675WCU,

9/235, 9/215

DECALS Look for these .Igns on machines manufactured In Europe. 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. infonn you supervisor. GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition I Mandatory

it

WARNING: Electrical shock risk.

&\ WARNING - Pressure control.

Information I Instructions

Warning

A

A;\

WARNING - PrBSSurlsed component or system.

~ WARNING - Corrosion risk.

vessel.

WARNING - Air/gaa flow or Air dlschargo.

it

A WARNING - Pressurl_d

WARNING - Hot surfaco.

IX,XBARI WARNING - Hot and harmful oxhauBt gas.

WARNING - Maintain correct tyre pressure. (Refer to the GENERAL INFORMATION ~on of this mWllolal).

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

WARNING - Flammable liquid.

WARNING - Befonl connecting the tow bar 01" commencing to tow consult the operation and maintenance manual.

WARNING - Do nat undertake any maintenance on this machine until the electrical supply III QillConnBCtod and the olr pressure I.totally relieved.

WARNING - eon.ulttfw operation lind maintenance manual before commencing any malntenllnce.

Do not removo the Operatlng and Maintenance manual and manual holder from this machine.

Do not stack.

XPS250WCU.

7

WARNING - For operating temperature below O"C, consult the opel'lltlon and maintenance manual.

Do not breathe tl'le compressed alr lrom

this machine.

•

Do not operate the machine without the guard being fitted.

HP750DWCU.

XP750DWCU.

HP67SWCU,

91235, 9/215

Do not stand on any 8&l'Vice valve or parts of the pressure system.

0

Do not operate with the ooors or endosu open.

Do not usa fork lift bUck from this side.

Do not exceed the trailer speed limit.

No naked lights.

Do not open the service valve before the

Use fork 11fttruck from this side only.

Emergency stop.

Tio down point

Lifting point.

On (power).

Off (power).

Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken.

When parking use prop stand, hand rake and wheel choCk&.

airhose is attached.

Compressor

a Diesel fuel No open flame.

011filling

1,5m. ~ lflP54

+- £

Rough Service Designation. Wet Loca1lon Operation.

Parlcing brake.

8

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I I I I I I I I I I I I I I I I I I I

Replace any cracked protective shield.

Fuel level!po int

011 draln.

Engine Oil

? •

.....

..... ....

Pressure control

Malfunction

_

_ ___ =I-:... __

---y---

Battery charging oondltlon

Low pressure

High pressure

Engine malfunction

High compressor temperature

Compressor malfunction

Low engine 011 pressure

Engine high temperature

XP8?5DWCU,

LJ

HP750DWCU,

XP750DWCU,

HP675WCLJ, 9/?35, 9/215

I I I I I I I I I I I I I I I I I I I

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

ADANGER

Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored.

(Red Background)

AWARNING

Indicates the presence of a hazard which CAN cause serious injury, death or property damage, if ignored.

(Orange Background)

ACAUTION

Indicates the presence of a hazard which WILL or can cause injury or property damage, if ignored.

(Yellow Background)

NOTICE

Indicates important set-up, operating or maintenance information.

(Blue Background)

&WARNING

DANGER

Trapped air pressure. Can cause serious injury or death. Close service valve and operate tool to vent trapped air before performing any service.

Discharged air can contain carbon monoxide or other contaminants. Will cause serious injury or death. Do not breathe this air.

& WARNING

~WARNING

High pressure air. Can cause serious injury or death.

Hot pressurized fluid. Can cause serious burns.

~

, ,

Relieve pressure before removing filler plugs/caps, fittings or covers.

Donotopen'Qrii~t·~~n while hot

XP825DWCU,

II

HP750DWCU,

XP750DWCU,

HP675WCU.

9/235, 9/21"

~

® 8 WARNING -

& WARNING Improper operation of this equipment. Can cause serious injury or death. Read Operator's Manual supplied with this machine before operation or servicing.

it

Falling off machine. can causa senous 'njury or death.

Modification or alteration of this machine. Can cause serious injury or death. Do not alter or modify this machine without the express written consent of the manufacturer.

J»'

Access lifting ball from inside machine.

& WARNING Rotating fan blade. Can cause serious injury.

~ Do not operate without guard in place.

~WARNING Disconnected air hoses whip. Can cause serious injury or death.

~ ;~'~" "04

When using air tools .'" attach safety device (OSHA Valve) at source of air supply for each tool.

& WARNING Door under pressure. Can cause serious injury. Use both hands to open door when machine is running.

~WARNING Combustible

g8S.

Can cause serious bu blindness or death.

DO NOT WELD. ELECTRONIC DAMAGE WILL OCCUR. This engine is equipped with an electronic engine controller and other electronic components.

Keep sparks and open flames away from batteries.

12

@

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I I I I I I I I I I I I I I I I I I I

USE DIESEL FUEL ONLY

FREE SAFETY DECALS! To promote communication of Safety Warnings on products manufactured by the Portable Compressor Division in Mocksville, N.C., Safety Decals are available free of charge. Safety decals are identified by the decal heading: DANGER, WARNING or CAUTION. Decal part numbers are on the bottom of each decal and are also listed in the compressor's parts manual. Submit orders for Safety Decals to the Mocksville Parts Service Department. The no charge order should contain only Safety Decals. Help promote product safety! Assure that decals are present on the machines. Replace decals that are not readable.

XP825DWCU.

13

HP150DWCU.

XP150DWCU,

HP615WCU.

9/235. S/215

WARRANTY Ingersoll-Rand, manufactured

through

its distributors,

warrants

to the initial user that each portable air compressor

by it, will be free of defects in material and workmanship

(12) months from shipment to or the accumulation Portable compressor

for a period of the earlier of twelve

of 2,000 hours of service by the initial user.

airends will be free of defects in material and workmanship

of twenty four months from shipment to or the accumulation

for a period of the earlier

of 4,000 hours of service by the initial user. The

warranty against defects will include replacement of the complete airend, provided the original airend is returned assembled and unopened. Portable Compressor or the accumulation

Airend Limited Optional Warranty - The earlier of sixty (60) months from shipment to

of , 0,000 hours of service. The optional warranty is limited to defects in rotors, housings,

bearings and gears and provided all the following conditions are met: 1.

The original air end is returned assembled and unopened.

2.

Continued use of genuine lnqersoil-Ranc

3.

Maintenance

Oil-Free

airends are fee-based

Ingersoll-Rand

parts, fluids, oil and filters.

is performed at prescribed intervals. and may require a maintenance agreement.

Formal enrollment is required.

will provide a new part or repaired part, at its election, in place of any part, which is found upon

its inspection to be defective in material and workmanship

during the period prescribed above. Such part will

be repaired or replaced without charge to the initial user during normal working hours at the place of business of an Ingersoll-Rand

distributor authorized to sell the type of equipment involved or other establishment au-

thorized by Ingersoll-Rand.

User must present proof of purchase at the time of exercising warranty.

The above warranty does not apply to failures occurring as a result of abuse; misuse, negligent repairs, corrosion, erosion and normal wear and tear, alterations or modifications made to the product without express written consent of Ingersoll-Rand;

or failure to follow the recommended

operating practices and maintenance

procedures as provided in the product's operating and maintenance publications. Accessories or equipment furnished by Ingersoll- Rand, but manufactured by others, including, but not limited to, engines, shall carry whatever warranty the manufacturers

have conveyed to Ingersoll-Rand

and which

can be passed on to the initial user. THIS WARRANTY

IS IN LIEU OF ALLOTHERWARRANTIES

OF TITLE), AND THERE ARE NO WARRANTIES TICULAR

EXPRESSED OR IMPLIED, (EXCEPTTHAT

OF MERCHANTABILITY

PURPOSE.

14

OR OF FITNESS FOR A PAR-

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

GENERAL WARRANTY INFORMATION GENERAL WARRANTY

Extended Coverage

Portable Compressor

Portable Genset BkW, 11KW, 20KVA thru 575KVA

Portable Genset 3.SKW thru 7.0KW and 10KW

Light Tower

Package

1 year/2000

hrs

Airend

2 yrs/4000 hrs

5 yrs/1 0,000 hrs Limited warranty, major components (refer to operator's manual).

Package

1 yr/2000

None

Generator

2 yrs/4000

Package

1 yr/2000

Generator

1 yrs/2000 hrs (parts only)

Package

1 yr/2000

hrs

Generator

1 yr/2000

hrs

hrs

hrs

None

hrs (parts only)

None None

hours, for Lightsource introduced 8/16/99.

2 years/4000

ENGINES CATERPILLAR

MonthlO

HourlO

Extended Coverage

12

unlimited

Available at dealer

CUMMINS

24

2000

Major components 3 yrs/l 0,000 hrs Available at dealer

JOHN DEERE (in compressors)

24

2000

5 yrs/SOOO hrs using OEM fluids and filters with $250 deductible

(in generators as of 1/1/01)

24

2000

2 yrs/4000 hrs USing IR fluids and filters

DEUTZ

24

2000

Available at dealer

INGERSOLL-RAND

24

4000

5 yrs/l 0,000 hrs when using genuine Ingersoll-Rand fluids and parts. Refer to operator's manual.

KUBOTA (North America only)

24

2000

Major components 36 mo/3000 hrs (parts only)

(Western Europe & Oceania)

24

2000

None

(Central & South America, Asia, Middle East & Africa)

12

1000

None

MITSUBISHI

24

2000

2 yrs/4000 hrs using IR fluids and filters

VOLVO

24

2000

2 yrs/4000 hrs using IR fluids and titters

HONDA

12

unlimited

None

VANGUARD

24

unlimited

None

PARTS Hours

Coverage

6

No LImit

Parts Only

Months

Hours

Extended Coverage

2000

5 yrs/1 0,000 hrs - available from IR.

Months Ingersoll-Rand

AIREND EXCHANGE

Airend

12

Note: Actual warranty times may change. Consult the manufacturer's warranty policy as shipped with each new product. XP825DWClJ,

IS

HP750DWClJ,

XP750DWCU,

HP675WCU,

9/230,

9/215

WARRANTY REGISTRATION

Complete Machine Registration Machines shipped to locations within the United States do not require a warranty registration unless the machine status changes (i.e. change of ownership). Machines shipped outside the United States require notification be made to initiate the machine warranty.

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

Note: Completion of this form validates the warranty.

16

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I I I I I I I I I I I I I I I I I I I

Selling

Servicing

Distributor

Distributor

WARRANTY REGISTRATION

Name

Name

Owner/User Name

Address

Address

Address

City

City

City

County

County

County

State

State

State

Zip code

Zip code

Zip code

Telephone

Telephone

Telephone

_

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

0

Construction-Heavy (highway, excavation, etc.)

D

Asphalt Contractor

D

Coal Mining

D

Other Mining

0

Construction-Light (carpentry, plumbing, pools, mason, etc.)

0

Government (municipal, state, county, etc.)

0

Quarry

0

Shallow Oil & Gas

D Rental

0

(rental center, rental fleet, etc.)

D Building Contractor

Industrial (plant use)

0

D Water well

D Utility Company (gas, electric, water, etc.)

0

Other specify

0 Utility

Exploration

Contractor

Model SIN

Unit SIN

Engine SIN

Date delivered

Unit-Hours

Airend SIN

Truck SIN

Truck Engine SIN

SERVICING DISTRIBUTOR I USER ACKNOWLEDGEMENT 1.

The Purchaser has been instructed and/or has read the manual and understands proper preventative maintenance, general operation and safety precautions.

2.

The warranty and limitation of liability has been reviewed and understood by the owner/user.

3.

In the event that this unit is to be used within a nuclear facility, the owner/user shall notify Ingersoll- Rand of such use so that Ingersoll-Rand may arrange for appropriate nuclear liability protection from the owner-licensee of the facility.

4.

Ingersoll- Rand reserves the right to make design changes or modifications of Ingersoll- Rand products at anytime without incurring any obligation to make similar changes or modifications on previously sold units.

XP825DWCU.

17

HP750DWCU.

XP750DWCU.

HP675WCU.

9/235.

9/215

I I I I I I I I I I I I I I I I I I I

NOISE EMISSION This section pertains only to machines distributed within the United States.

I

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, or element of design incorporated

into any new compressor

repair, or replacement, of any device

for the purpose of noise control prior to its sale or delivery to the ultimate

purchaser or while it is in use; or (2) the use of the compressor

after such device or element of design has been removed or rendered

inoperative by any person.

Among those acts included in the prohibition against tampering are these: 1.

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

2_

Removal of any of the following: a. fan shroud b vibration mounts

c. sound absorption material 3.

Operation of the compressor

with any of the enclosure doors open.

Compressor Noise Emission Control Information A. The removal or rendering inoperative, other than for the purpose of maintenance, or element of design Incorporated B_ The use of this compressor Note: the above information

into this compressor

repair, or replacement of any noise control device

in compliance with the noise Control act;

after such device or element of design has been removed or rendered inoperative. applies only to units that are built in compliance with the U.S. Environmental

Ingersoll- Rand Company reserves the right to make changes or add improvements to make such changes or add such improvements

Protection

Agency.

without notice and without incurring any obligation

to products sold previously.

The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor.

xP82,OWGU,

19

HP750DWGU.

XP7500WCU,

HPG7~WCU.

S/235, 91215

NOISE EMISSION CONTROL MAINTENANCE LOG COMPRESSOR

MODEL

_

SERIAL NO. USER UNIT

_ NO.

_

DEALER OR DISTRIBUTOR FROM WHOM PURCHASED:

UNIT IDENTIFICATION ENGINE MAKE & MODEL: SERIAL NO.: PURCHASER

_ _

OR OWNER

ADDRESS

_ _ DATEPURCHASED

_

The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations, specifically the following acts or the causing thereof:

(1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use 01the compressor after such a device or element 01de:oign 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 IIle of the air compressor. (40FR204.58-1).

20

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

INTRODUCTION The unit for which this Maintenance Log is provided conforms to U S. EPA. Regulations for Noise Emissions, applicable to Portable Air Compressors.

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

MAINTENANCE SCHEDULE ITEM

AREA

PERIOD

A

COMPRESSED AIR LEAKS

AS DETECTED

B.

SAFETY AND CONTROL SYSTEMS

AS DETECTED

C

ACOUSTIC MATERIALS

DAILY

D.

FASTENERS

100 HOURS

E.

ENCLOSURE PANELS

100 HOURS

F

AIR INTAKE & ENGINE EXHAUST

100 HOURS

G

COOLING SYSTEMS

250 HOURS

H.

ISOLATION MOUNTS

250 HOURS

I.

ENGINE OPERATION

SEE OPERATOR'S MANUAL

j

FUELS & LUBRICANTS

SEE OPERATOR'S MANUAL

XP825DWCU,

21

HP750DWCU,

XP150DWCLJ. HP675WCU.

9/235, 9/215

A. COMPRESSED

F. AIR INTAKE AND ENGINE EXHAUST

AIR LEAKS

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

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).

e. SAFETY

AND CONTROL

replacements should be made before the next period of use.

SYSTEMS

G. COOLING 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

All components of the cooling systems for engine water and compressor oil should be inspected every 250 hours of use. Any discrepancies found should be corrected before placing the unit back in operation. Unrestricted airflow over the radiator and oil cooler must be maintained at all times during operation.

MATERIALS

In dally 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

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

severe operating or storage conditions.

replaced with equivalent parts. D. FASTENERS I. ENGINE OPERATION 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

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

damage and noise emission increase. J. FUELS AND LUBRICATES E. ENCLOSURE

PANELS Use only the types and grades of fuels and lubricants recommended in the Ingersoll-Rand Company and Engine

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 sealing between gasket or acoustic

Manufacturers Operator and Maintenance Manuals>

material and the mating frame.

22

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

GENERAL DATA

ENGINE

Actual free air delivery

(9/235)

(9/235) (XP825DWCU)

23,4 m3/min (825 CFM)

(HP750DWCU)

21,2 (750 CFM)

(XP750DWCU)

21,2 (750 CFM)

(HP675WCU)

19,1 (675 CFM)

Normal operating

discharge

pressure

(9/235) (XP825DWCU)

8,6 bar (125 psi)

(HP750DWCU)

10,3 bar (150 psi)

(XP750DWCU)

8,6 bar (125 psi)

(HP675WCU)

10,3 bar (150 psi)

Maximum Allowable (9/235)

Pressure

Ingersoll- Rand/61RCBA

Number of Cylinders

6

Oil Capacity

31.7 litres (8.4 gal)

Speed at Full Load min Speed at Idle min

-1

1

(RPM)

(RPM)

2000 revs 1500 revs

Power Available at Full Load

10,3 bar (150 psi)

(XP825DWCU)

(HP750DWCU)

12,1 bar (175 psi)

(XP750DWCU)

10,3 bar (150 psi)

(HP675WCU)

12,1 bar (175 psi)

Safety Valve Setting (9/235)

Type/Model

(9/235)

205kW (275hp)

Electrical System

24 V neg. ground

Fuel Tank Capacity

462 litres (122 gal)

Oil Specification

Refer to engine manual

Coolant Capacity

34 litres (9 gal)

14 bar (200 psi)

(XP825DWCU)

(HP750DWCU)

14 bar (200 pSI)

(XP750DWCU)

14 bar (200 pSI)

(HP675 WCU)

14 bar (200 psi)

Maximum Pressure Ratio (absolute) (9/235)

9,6

(XP825DWCU)

1

SOUND LEVEL DATA

(HP750DWCU)

11,3: 1

(XP750DWCU)

9,6: 1

(HP675WCU)

11,3: 1

Operating ambient temperature Whisperized

A) "W' Model, EPA Noise

76 dB (A)

B) "HA" MOdel

NA

-12"C to +49°C (10UF to 120°F)

HA (High Ambient)

-12°C to +52"C (10"F to 125°F)

Cooling system

all Injection

Oil capacity

64 litres (17 gal)

Maximum oil system temperature

120°C (248"F)

WHEELS

and TIRES

(XP825DWCU), (HP750DWCU),

ENGINE (XP825DWCU), (HP750DWCU),

(XP750DWCU), (HP675WCU)

(XP750DWCU), (HP675WCU) Cummins/6CB.3TAA

Type/Model Number of Cylinders

6

Oil Capacity

31.7 litres (B.4 gal)

Speed at Full Load min Speed at Idle min -

1

-1

(RPM)

(RPM)

2000 revs

(XP750DWCU), (HP675WCU)

192kW (257hp) 24 V neg. ground

Fuel Tank Capacity

462 litres (122 gal)

Coolant Capacity

Tire Size

ST225!75R15 (D)

Tire Pressure

4.5 bar (65 psi)

Net Weight (less Fuel)

3600KG (7950 Ib)

205kW (275hp)

Electrical System

Oil Specification

4

1500 revs

Power Available at Full Load (XPB25DWCU), (HP750DWCU),

Number 01 Wheels

Refer to engine manual

(9/235)

Number of Wheels

4

Tire Size

7.50-16 LT

Tire Pressure

5.5 bar (80 psi)

Net Weight (Less Fuel)

3600KG (7950 Ib)

34 litres (9 gal)

XP825DWCU.

HP750DWCU,

XP750DWCU,

HP675WCU,

9/235,

9/215

OPERATING

Ensure that the machine is positioned securely and on a stable foundation. Any risk of movement should be removed by

INSTRUCTIONS

suitable means, especially to avoid strain on any rigid discharge piping.

COMMISSIONING Upon receipt of the unit, and prior to putting it into service, it

COMPRESSOR

is important to adhere strictly to the instructions given below in

MOUNTING

Portable compressors, which are modified to remove the

PRIOR TO STARTING.

running gear and mount the machine direct to trailers, truck beds or frame, etc. may experience failure of the enclosure, frame, and/or other components. It is necessary to Isolate the

Ensure that the operator reads and understands the decals

compressor package from the carrier base with a flexible

and consults the manuals before maintenance or operation.

mounting

system.

Such

a

system

must

also

prevent

detachmentofthe package from the carrier base in the event the Ensure that the position of the emergency stop device is known and recognized

by its markings.

isolators fall. Contact Ingersoll- Rand representative for flexible

Ensure that It IS

mounting kits.

functioning correctly and that the method of operation is known. Warranty does not cover failures attributable to mounting of the compressor

package to the carrier

base unless it is an

Ingersoll-Rand provided system. Attach the battery cables to the battery(s) ensuring that they

Before towing the unit, ensure that the tyre pressures are correct (refer to the GENERAL

DATA SECTION

are tightened securely.

of this

Attach the positive cable before

attaching the negative cable.

manual). Before towing the unit, ensure that the lights are functioning correctly (where fitted).

Ensure

that

all transport

and packing

materials are

WARNING:

All air pressure

equipment

connected

to

must

pressure

discarded.

setting, lubricant

the

ratings

machine

installed

have

safe

of at least the machine

and materials

compatible

in or

working

safety

valve

with the compressor

(refer to the GENERAL DATA SECTION).

Ensure that the correct fork lift truck slots or marked lifting / tie down points are used whenever the machine is lifted or transported.

WARNING: If more than one compressor

is connected to

one common downstream plant, effective check valves and isolation

When selecting the working position of the machine ensure

valves must be fitted

that there is sufficient clearance for ventilation and exhaust

procedures,

requirements.

pressurised lover pressurised

and controlled

so that one machine

cannot

by work

accidently

be

by another.

Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance

WARNING:When flexible discharqe hoses are used,

tasks.

rl'!comml'!ndl'!d that safety retaining

24

wires are fitted.

it is

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

2

~r~ ~ o.~

-- -

15

T2221 Revision 00 12/00

5.

PRIOR TO STARTING

1.

Drain the fuel filter water separator of water, ensuring that

any released fuel is safely contained.

Place the unit in a position that is as level as possible. The

design Of the unit permits a 15 degree lengthways and sideways

6.

limit on out of leval operation.

Open the service valve(s)

to ensure that all pressure is

relieved from the system. Close the service valve(s).

When the unit has to be operated out of level, it is important to keep tile engine oil level near the high level mark (with the unit level).

7.

CAUTION:

canopy/doors

2.

Check the engine lubrication

operating

instructions

011

in accordance

in the Engine Operator's

00 in

not

operate

the

the open position

machine

with

as this may

the

cause

overheating and operators to be exposed to high noise levels.

with the

Manual or

section.

8. 3.

Check the radiator coolant level (with the unit level).

Check the compressor oil level in the sight glass located on

the separator tank.

Check the air filter restriction indicator(s).

Refer to the

MAINTENANCE section of trus manual.

4.

Check the diesel fuel level. A good rule is to top up at the end

of each

working

occurring

in the

day. This tank

prevents

Refer

to the

condensation engine

from

When starting or operating the machine in temperatures

operator's

below or approaching DOC (32 F), ensure that the operation of D

manual/section for diesel fuel specification.

the regulation system, the unloader valve, the safety valve, and the engine are not impaired by ice or snow, and that all inlet and outlet pipes and ducts are clear of Ice and snow.

CAUTION: When refuelling:switch off the engine. do not smoke. extinguish

ai' naked

lights.

do not allow the fuel to come into contact with hot surfaces. wear personaf protective equipment.

XP8250WCU.

25

HP7f.10DWCU.

XP7~OOWCU.

MP675wCu.

91235. 9f21~

Control Panel r

-~~-----~---~~~-\

@r

,_/

r=r>:

-~~~~-~~~~--\

,

I

@ r---------~-~-~~,.

I

-

I

I I

I I

I

I

\

: I

I I I I I I I I I

I I I I I

.s

(@ , '1

E

El

8 1:

11

1. 2.

Hourmeter

12 "-----------______,. '_/@\ __-~~~- -- ~_~__~~_-_-- __ ~~~--~~_-~'j@\__'~ - ---~_~-

8.

- Records running time for maintenance.

Compressor

Discharge

Pressure

Gauge

- Indicates

9.

pressure in receiver tank _

3.

Fuel Level Gauge - Indicates amount of fuel in tank.

4.

Power

Switch

- After warm-up, PUSH. Provides full

air pressure at the service outlet. Allows unit to warm-up at

Engine Speed Gauge - Indicates engine speed (RPM).

7.

Discharge Air Temp. Gauge -

Gauge

-

Indicates engine oil

Engine

Water

Temp

Gauge

-

Indicales

coolant

1 O.

Voltmeter

11.

Spare- Used for optional accessories.

12.

Ether Injection - In cold weather, push once or twice

- Indicates charging system voltage.

during cranking. This injects a measured amount of Ether to the

reduced pressure.

6.

Pressure

210"F /99"C

-Acuvatas systems for STARTING and

Service Air Switch

Oil

temperature, with normal operating range from 180" F/82"C to

STOPPING.

5.

Engine

pressure.

engine.

Indicates airend discharge temperature.

26

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

DIAGNOSTICS AUTO SHUTDOWNS

0

1

(0\

ffi

I I

0 0 0 0 0

2 ~

3

(i)

4

ij

5

U

6

8

7

0 I I I I I I I I I I I I I I I I I I I I I I

~Q)

~

LAMP TeST .. WITH ENGINE OFF, TURN POWER SWITCH TO -OFF-, THEN TO -ON-. ALL LAMPS SHOULD LIGHT.

0 DIAGNOSTIC

PISPkAY

0

4.

PANE]"

Low Fuel Level; Fault indicator lamp. Indicates shutdown due to low fuel leveL Lamp blinks at low fuel warning.

The diagnostic display panel is arranged as shown above. A description of each diagnostic indicator is as follows.

5.

Low Battery

Voltage:

Alarm indicator lamp. Indicates

battery or charging system requires service. 1.

High Compressor

Temp:

Fault indicator lamp Indicates 6.

shutdown due to high compressor temperature.

Low

Engine

Coolant

Level:

Alarm indicator lamp.

Indicates coolant level in engine radiator is low. 2.

Low Engine Oil Pressure:

Fault indicator lamp. Indicates 7.

shutdown due to low engine oil pressure.

Restricted

Air Filter:

Alarm indicator lamp

Indicates

engine(compressor air inlet filters need service. 3.

High

Engine

Coolant

Temp:

Fault indicator lamp.

Indicates shutdown due to high engine water temperature.

XP825DWCU,

27

HP750DWCU,

XP750DWCU,

HP675WCU,

9/235,

9/215

STARTING

THE MACHINE

PUSH AFTER WARM UP NOTE: In order to allow the machine to start at a reduced load, a valve, which is operated by a button located on the instrument panel, is incorporated automatically

in the regulation

system.

(The valve

returns to the start position when the machine is

switched off and air pressure relieved from the system).

Allow the engine to reach its operating temperature

- then

press the button.

At this point in the operation of the machine it is safe to apply full load to the engine.

All normal starting

functions

are incorporated

in the key

operated switch.

DUAL PRESSURE Machines

REGULATION

WHEN FITTED

which operate in excess

of

7 bar (100 psi) can

optionally be fitted with a dual pressure switch inside the unit. Turn the key switch to position

I. The diagnostic lamps will

This switch selects between 7 bar (100 psi) and the machine rated pressure, ctm remains nominally constant.

flash. Turn the key switch

to crank

position

(3) (engine

start

Starting and stopping are unaffected by the selection and during normal running the selector

position)

Precaution NOTE: Position (2) not used on this model. Pre-heaters

or

glow plugs are not fitted on this rncoel. In cold weather, push Ether Injection Switch once or twice

must

be

switch may be safely operated

taken

to

ensure

that

downstream

equipment is rated to suit the available pressure. The pressure gauge indicates which setting has been selected.

during cranking. This injects a measured amount of ether to the engine .• STOPPING THE MACHINE CAUTION: gas.

ETHER is an extremely volatile, highly flammable

Use sparingly

explosion

Close the service valve.

If too much is injected, the uncontrolled

I

may result in costly damage to the engine. Allow the machine to run unloaded for

Release to position (1) when engine starts. The engine will

a short

period of time

to reduce the engine temperature.

now be running at a reduced speed. At temperatures

below 32"F (O°C) or if there is difficulty

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

starting first time:

Open the manual blowdown valve fully

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

Complete starting sequence above.

Close manual

blowdown

valve as soon as engine

runs If the automatic

freely.

pressure

biowdown

valve

fails to operate,

must be relieved from the system

then

by means of the

manual blowdown valve(s), Do not allow machine to run for long periods with manual blowdown

valve open.

CA UTlON: Never allow the machme to stand idle with pressure

Allow the engine to reach operating temperature

in the system. At this point in the operation of the machine it is safe to apply full load to the engine. EMERGENCY

STOPPING

In the event that the unit has to be stopped in an emergency, NOTE: Wear hearing protection at all times when the engine started with the manual blowdown from the valve.

IS

valve open and air is flowing

TURN THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO THE O(OFF) POSITION, EMERGENCY

Or puSh the

STOP SWITCH (when fined).

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

RE-STARTING AFTER AN EMERGENCY

DECOMMISSIONING

If the machine has been switched off because of a machine

When the machine is to be permanently decommissioned or

malfunction, then identify and correct the fault before attempting

dismantled, it is important to ensure that all hazard risks are

to re-start.

either eliminated or notified to the recipient of the machine. In particular:-

If the machine has been switched off for reasons of safety, Do not destroy batteries or components containing asbestos

then ensure that the machine can be operated safely before

without containing the materials safely.

re-starting.

Do not dispose of any pressure vessel that is not clearly

Refer to the PRIOR TO STARTING and STARTING THE MACHINE instructions earlier in this section before ra-startrnq

marked with its relevant data plate information or rendered

the machine.

unusable by drilling, cutting etc.

Do not allow lubricants or coolants to be released into land

MONITORING DURING OPERATION

surfaces or drains.

Should any of the safety shut-down conditions occur, the unit will stop.

Do

not

dispose

of

a

complete

machine

without

documentation relating to instructions for Its use. Refer to the diagnostic display page for a listing of shutdown conditions. CA UTiON: Toensure an adequate flow of oil to the compressor at low temperature, never allow the discharge pressure to fall below 3,5 bar (50 psi)

XP825DWCU.

29

HP750DWCU.

XP750DWCU.

HP675WCU.

9/235.

9/215

Operation and Maintenance Manual Industrial C8.3 Series Engine

c

ewIJOOgu

Portions of this manual reproduced by permission of Cummins Engine Company, Inc.

Copyrightltl 2002 Cummins Inc. All rights reserved

Bulletin 4021330 Printed 02102

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

Foreword This manual contains information for the correct operation and maintenance of your Cummins engine. It also includes important safety information, engine and systems specifications, troubleshooting guidelines, and listings of Cummins Authorized Repair Locations and component manufacturers. Read and follow all safety instructions. - Introduction. Keep this manual with the equipment.

Refer to the WARNING in the General Safety Instructions

If the equipment

in Section i

is traded or sold, give the manual to the new owner.

The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at the time of printing. Cummins Inc. reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada. The latest technology and the highest quality components were used to produce this engine. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts can be identified by the following trademarks:

NOTE: Note: Warranty information applicable to your engine.

(om-Irwd)

is located in Section W. Make sure you are familiar with the warranty or warranties

Table of Contents Section

Introduction

.

Engine Identification Operating

.'"

E

.

1

Instructions .

2

at Daily Interval

.

3

Procedures

at 10,000 Kilometers [6000 Miles], 250 Hours, or 3 Months

.

4

Maintenance

Procedures

at 19,000

Kilometers [12,000 Miles], 500 Hours, or 6 Months

.

5

Maintenance

Procedures

at 38,000

Kilometers [24,000 Miles], 1000 Hours, or 12 Months

.

6

Maintenance

Procedures

at 77,000

Kilometers [48,000 Miles], 2000 Hours, or 2 Years

.

7

Maintenance

Guidelines

Maintenance

Procedures

Maintenance

Adjustment,

A

Repair, and Replacement

System Diagrams

.

o

Service Literature

.

L

Component

.

M

.

S

Manufacturers

Service Assistance Troubleshooting Mai ntenance

Symptoms

TS V

Specifications

W

Warranty Index

.

x

I I I I I I I I I I I I I I I I I I I

I I I I

Important Reference Numbers Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service or maintenance is required. Part Name

Part Number

Part Number

Engine Model Engine Serial Number (ESN) Control Parts List (CPL)

I I I I I I I I I I I I I I I

Fuel Pump Part Number Electronic Control Module (ECM) Electronic Control Module Serial Numbers (ECM) '.

,

Filter Part Numbers:

.

,

'

'.

.

,

~

.'

':.'

'

. .

" '

"

• Air Cleaner Element • Lubricating Oil Filter • Fuel • Fuel-Water Separator • Coolant • Remote Gas Governor Control Module (GeM) (if applicable) Belt Part Numbers;

• •

• Clutch or Marine Gear (if applicable): • Model • Serial Number • Part Number • Oil Type • Sea Water Pump - Model - Part Number

,

'.

'.

..

'.~

•

>".

.

• •

• • •

....

>'1>..'

'.

.

.

C8.3 Industrial Section i-Introduction

Page i-a

Section i-Introduction Section Contents Page Maintenance Guidelines General Information

- Overview...

2-1 2-1

Tool Requirements.. General Information

2-1 2-1

Maintenance Schedule General Information Maximum Oil Drain Intervals

2-1 2-1 2-2

Maintenance Record Form. Maintenance Data

..

2-3 2-3

I I I I I I I I I I I I I I I I I I I

To the Owner and Operator Page i-1

CB.3 Industrial Section i-Introduction

To the Owner and Operator General Information Preventive maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations outlined in Maintenance Guidelines (Section 2). Keep records of regularly scheduled maintenance. Use the correct fuel, lubricating oil, and coolant in your engine as specified in Maintenance Specifications (Section V). Cummins Inc. uses the latest technology and the highest quality components to produce its engines. Cummins Inc. recommends using genuine Cummins new parts and ReCon® exchange parts. Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support. If you have a problem that can not be resolved by a Cummins Authorized Repair Location, follow the steps outlined in the Service Assistance (Section S). Product coverage, warranty limitations and owner responsibilities are available in Warranty (Section W).

A

CAUTION

A

Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect the ground cable of the welder to the ECMcooling plate or ECM. Welding on the engine or engine mounted components is not recommended.

About the Manual General Information This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins Inc. For additional service literature and ordering locations, refer to Service Literature (Section L). This manual does not cover vehicle, vessel, or equipment maintenance procedures. Consult the original vehicle, vessel, or equipment manufacturer for specific maintenance recommendations. Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets. Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to Symbols in this section for a complete listing of symbols and their definitions. Each section of the manual is preceded by a Section Contents to aid in locating information.

How to Use the Manual General Information This manual is organized according to intervals at which maintenance on your engine is to be performed. A maintenance schedule, that states the required intervals and maintenance checks, is located in Maintenance Guidelines (Section 2). Locate the interval at which you are performing maintenance; then follow the steps given in that section for all the procedures to be performed. Keep a record of all the checks and inspections made. A maintenance record form is located in Maintenance Guidelines (Section 2). Engine troubleshooting Specifications

procedures for your engine are located in Troubleshooting Symptoms (Section TS).

for your engine are located in Maintenance Specifications (Section V).

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Symbols Page i-2

C8.3 Industrial Section i-Introduction

Symbols General Information The following symbols have been used in this manual to help communicate of the symbols appears, it conveys the meaning defined below:

WARNING - Serious personal injury or extensive

the intent of the instructions.

When one

PERFORM a mechanical or time MEASUREMENT.

property damage can result if the warning instructions are not followed.

LUBRICATE the part or assembly

CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if the caution instructions are not followed.

Indicates that a WRENCH or TOOL SIZE will be given.

Indicates a REMOVAL or DISASSEMBLY step.

TIGHTEN to a specific torque. Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

&. ~ ~

PERFORM an electrical MEASUREMENT. Refer to another location in this manual or another publication for additional information The component weighs 23 kg [50 lbs] or more. To reduce the possibility of personal injury, use a hoist or get assistance to 11ft the component. 17800009

CB.3 Industrial Section i-Introduction

Illustrations Page i-3

Illustrations General Information Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition.

The illustrations are intended to show repair or replacement procedures. The procedure will be the same for all applications, although the illustration can differ.

ce Sve

C

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C8.3 Industrial Section i-Introduction

General Safety Instructions Page i-4

General Safety Instructions Important Safety Notice

A

WARNING

A

Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, other personal injury or death.

asphyxiation

or

Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. • Work in an area surrounding the product that is dry. wen ut, ventilated. free from clutter. loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist. • Always wear protective glasses and protective shoes when working. • Rotating parts can cause cuts, mutilation or strangulation. • Do not wear loose-fitting or torn clothing. Remove all jewelry when working. • Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in the operator's compartment or on the controls. • Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. • If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler cap to relieve the pressure from the cooling system. • Always use blocks or proper stands to support the product before performing any service work. Do not work on anything that is supported ONLY by lifting jacks or a hoist. • Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury. • To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law requires capturing and recycling refrigerant. • To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 Ib] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded. • Corrosion inhibitor, a component of SeA and lubricating oil, contains alkali. Do not get the substance in eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. • Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN. • Toreduce the possibility of burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes, and compartments. • Always use tools that are in good condition. Make sure you understand how to use the tools before performing any service work. Use ONLY genuine Cummins or Cummins ReCone") replacement parts. • Always use the same fastener part number (or equtvalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary. • Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning. • Some state and federal agencies in the United States of America have determined that used engine oil can be carcinoqenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. • Liquified petroleum gas is heavier than air and can accumulate near the floor, in sumps, and low-lying areas. • Natural gas is lighter than air and can accumulate under hood and awnings. • Toreduce the possibility of suffocation and frostbite, wear protective Clothing and ONLY disconnect natural gas and liquified petroleum gas tines in a well ventilated area. • Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.

General Repair Instructions

CB.3 Industrial Section i-Introduction

Page i-5

General Repair Instructions General Information This engine incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using normal repair practices performed to quality standards. • Cummins Inc. does not recommend or authorize any modifications or repairs to engines or components except for those detailed in Cummins Service Information. In particular, unauthorized repair to safetyrelated components can cause perscnal injury or death. Below is a partial listing of components classified as safety-related: Flywheel Mounting Capscrews Air Compressor Air Controls Fuel Shutoff Assemblies Fuel Supply Tubes Air Shutoff Assemblies lifting Brackets Balance Weights Throttle Controls Cooling Fan Turbocharger Compressor Casing Fan Hub Assembly Fan Mounting Bracket(s) Turbocharger Oil Drain Line(s) Turbocharger Oil Supply Line(s) Fan Mounting Capscrews Turbocharger Turbine Casing Fan Hub Spindle Vibration Damper Mounting Capscrews Flywheel Flywheel Crankshaft Adapter

• Follow all safety instructions

noted in the procedures

Follow the manufacturer's recommendations for cleaning solvents and other substances used during the repair of the engine. Some solvents and used engine oil have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety practices with tools and equipment. • Provide a clean environment -

and follow the cleaning instructions specified in the procedures

The engine and its components must be kept clean during any repair. Contamination of the engine or components wilt cause premature wear. .

• Perform the inspections specified in the procedures • Replace all components or assemblies which are damaged or worn beyond the specifications • Use genuine Cummins new or ReConCi Maintenance Check Performed E => Check Performed By F '" Comments C

(Continued)

D

E

F

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CB.3 Industrial Section 3 • Maintenance Procedures at Daily Interval

Section 3 - Maintenance

Page 3-a

Procedures at Daily Interval

Section Contents Page Air Intake Piping Maintenance

Check

.

Air Tanks and Reservoirs

3-7 3-7

Drain

Coolant Level. Maintenance

3-2 3-2

Check

Crankcase Breather Tube. Maintenance

Check

Daily Maintenance Procedures - Overview.... Engine Operation Report.... General Information.. Unusual Engine Noise

Drive Belts... Maintenance Check Cogged Belt Poly-Vee Belt

..

Fan, Cooling Inspect

Fuel-Water Separator

3-1 3-1 3-1 3-1 3-3 3-3 3-3 3-3

3-5 3-5 3-5 3-6

Drain Canister Type Spin-on Type ..

Lubricating Oil Level. Check

3-6 3-6

3-4 3-4

for Reuse

Maintenance

3-2 3-2

..

3-6 3-6

I I I I I I I I I I I I I I I I I I I

CB.3 Industrial Section 3 - Maintenance Procedures at Daily Interval

Daily Maintenance Procedures - Overview Page 3-1

Daily Maintenance Procedures - Overview General Information Preventative maintenance begins with day-to-day awareness of the engine and its system. Before starting the engine. check the oil and coolant levels. Look for: • Leaks • Loose or damaged parts • Worn or damaged belts • Any change in engine appearance. • Odor of fuel

Engine Operation Report The engine must be maintained in top mechanical condition if the operator is to get optimum satisfaction from its use. The maintenance department needs daily running reports from the operator to make necessary adjustments in the time allocated. The daily running report also helps to make provisions for more extensive maintenance work as the reports indicate the necessity. Comparison and intelligent interpretation of the daily report, along with a practical follow-up action, will eliminate most failures and emergency repairs. Report to the maintenance department any of the following conditions: • Low lubricating oil pressure • Low power • Power increases or engine surge • Erratic or no accelerator control or response • Any warning lights flashing or staying on • Abnormal water or oil temperature • Unusual engine noise • Excessive smoke • Excessive use of coolant, fuel, or lubricating oil • Any fuel, coolant, or lubricating oil leaks • Loose or damaged parts • Worn or damaged belts

Unusual Engine Noise During daily maintenance checks. listen for any unusual engine noise that can indicate that service is required.

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Air Intake Piping Page 3-2

Section 3 - Maintenance

Procedures

C8.3 Industrial at Daily Interval

Air Intake Piping Maintenance Check Visually inspect the intake piping daily for wear points and damage to piping, loose clamps, or punctures that can damage the engine. Replace damaged pipes, and tighten loose clamps, necessary, to prevent the air system from leaking. Torque Value:

8 N.m

as

[72 in-Ib)

Check for corrosion under the clamps and hoses of the intake system piping. Corrosion can allow corrosive products and dirt to enter the intake system. Disassemble and clean, as required.

Coolant Level Maintenance Check

.A

.~ ,

WATER

\

WARNING

£.

Do not remove a pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. TEMP

\) /)

152!lOO22

l:t..

CAUTION

J::".

Never use a sealing additive to stop leaks in the cooling system. This can result in cooling system plugging and inadequate coolant flow, causing the engine to overheat.

The coolant level must be checked daily. 50-PERCENT WATER

50·PERCENT WATER

50-PERCENT ANTIFREEZE

SO-PERCENT ANTIFREEZE

A

CAUTION

Do not add cold coolant

A.

to a hot engine.

Engine

cast-

ings can be damaged. Allow the engine to cool to below 50°C (120ClF] before adding coolant. Make up coolant added to the engine must be mixed with the correct proportions of antifreeze, supplemental coolant additive, and water to avoid engine damage. Coolant recommendations and specification details on correct mixing of coolant can be found in Maintenance fications (Section V).

Speci-

Drive Belts Page 3-3

CB.3 Industrial Section 3 • Maintenance Procedures at Daily Interval Fill the cooting system with coolant to the bottom of the fill neck in the radiator fill or expansion tank.

~.,

D

NOTE: Some radiators have two fill necks, both of which must be filled when the cooling system is drained.

Drive Belts Maintenance Check Poly-Vee Belt Inspect the belts daily. Check the belt for intersecting cracks. Traverse (across the belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces of material missing. Refer to Section A for belt adjustment and replacement procedures. Belt damage can be caused by:

d

@

(~.~.;!.~ '\

II

\'

II

\\

I

II'·

..' ,.,' "-1' rill' ,

I

hi,

\ _//!:J~l taqbts

a

• Incorrect tension • Incorrect size or length • Pulley misalignment • Incorrect installation • Severe operating environment • Oil or grease on the side of belts. Cogged Belt Inspect the belts daily. Replace the belts if they are cracked, frayed, or have chunks of material missing. Small cracks are acceptable. Adjust the belts that have a glazed or shiny surface, which indicates belt slippage. Correctly installed and tensioned belts will show even pulley and belt wear. Refer to Section A for belt adjustment and replacement procedures. Belt damage can be caused by: • Incorrect tension la8blsb

• Incorrect size or length • Pulley misalignment • Incorrect installation • Severe operating environment • Oil or grease on the belts

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Fan, Cooling Page 3-4

Section

3 - Maintenance

Procedures

CB.3 Industrial at Daily Interval

Measure the belt tension in the center span of the pulleys. Refer to the Belt Tension Chart in Section V tor the correct gauge and tension value for the belt width used. An alternate method (deflection method) can be used to check belt tension by applying 110 N [25 lbf] force between the pulleys on v-belts. If the deflection is more than one belt thickness per foot of pulley center distance, the belt tension must be adjusted. Refer to Section A for adjustment

procedures.

For cogged belts, make sure that the belt tension gauge is positioned so that the center tensioning leg is placed directly over the high point (hump) of a cog. Other positioning will result in incorrect measurement.

\J

Fan, Cooling Inspect for Reuse ...

WARNING

.A.

Do not rotate the engine by pulling or prying on the fan. The fan blade(s) can be damaged and cause the fan to fall and cause personal Injury Or property damage. Use the accessory drive shaft to rotate the crankshaft.

A visual inspection of the cooling fan is required daily. Check for cracks, loose rivets, and bent or loose blades. Check the fan to make sure it is securely mounted. Tighten the capscrews, if necessary.

CB.3 Industrial Section 3 - Maintenance

...

Fuel·Water Procedures

WARNING

at Daily Interval

Separator Page 3-5

...

Do not straighten a bent fan blade or continue to use a damaged fan. A bent or damaged fan blade can fail during operation and cause personal injury or property damage.

Replace original equipment fan that is damaged with a fan of the identical part number. Cummins Engine Company, Inc. must approve any other fan changes to be covered under warranty. Refer vehicle or equipment manufacturers specifications for capscrew torque.

fnBOO""

Fuel-Water

Separator

Drain ...

WARNING

A

Drain the water-fuel separator into a container and dispose of in accordance with local environmental regulations.

Cummins Inc. requires a fuel-water separator or fuel filter be installed in the fuel supply system. Drain the water and sediment from the separator daily.

Canister Type

Shut off the engine. Pull up on the drain valve lever until fluid drains out of the drain tube. Drain the filter sump until clear fuel is visible. Push up on the drain valve until fluid drains out of the drain tube.

I

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Lubricating Page 3-6

Oil Level Section Spin-on

3 - Maintenance

Procedures

CB.3 Industrial at Daily Interval

Type

Shut off the engine. Use your hand to open the drain valve. Turn the valve counterclockwise approximately 3'/2 turns until the valve drops down 25.4mm [1 in] and draining occurs. Drain the filter sump until clear fuel is visible.

~,l\

W 06800004

"W1I

A

CAUTION

A

When closing the drain valve, do not overtighten valve. Overtightening can damage the threads. To close the valve, lift the valve and turn clockwise is hand-tight.

Lubricating

Oil Level

Maintenance

Check

A

CAUTION

the until it

A

Never operate the engine with oil level below the L (low) mark or above the H (high) mark. Poor engine performance or engine damage can occur. The engine must be level when checking the oil level to make sure the measurement is correct.

L~

Shut off the engine for an accurate reading.

~III

I

/,

o,900sb

Wait at least 15 minutes after shutting off the engine to check the oil level. This allows time for the oil to drain into the oil pan. For additional lubricating oil recommendations and oil pan capacity information, refer to Maintenance Specifications (Section V).

Crankcase Breather Tube Maintenance

Check

Inspect the breather tube for sludge, debris, or ice in the tube. Inspect the tube more frequently

10?O0031

in icy conditions.

CB.3 Industrial Section 3 - Maintenance Procedures at Daily Interval

Air Tanks and Reservoirs Page 3-7

Air Tanks and Reservoirs Drain If automatic purging or spitter valves are used, confirm the valves are operating correctly. If a manual drain valve is used on the wet tank, open the draincock on the wet tank to drain any moisture accumulated in the air system. If oil is present, the air compressor system must be checked. Contact your Cummins Authorized Repair Location.

coarornn

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CB.3 Industrial Maintenance Procedures

at 10,000 km [6000 mi]

Page 4-8

Maintenance Procedures at 10,000 Kilometers [6000 Miles], 250 Hours, or 3 Months Section Contents Page Air Cleaner Restriction Maintenance Check

4-1 4-1

Air Compressor Maintenance Check

4-1 4-1

Charge-Air Cooler.... Maintenance Check

4-2 4-2

Charge-Air Piping........................................................................................................................ Maintenance Check

4-2 4-2

lubricating Drain Fill Install Remove

4-3 4-3 4-5 4-4 4-4

Oil and Filters..

Maintenance Procedures General Information

- Overview..

4-1 4-1

I I I I I I I I I I I I I I I I I I I

Maintenance Procedures·

CB.3 Industrial Maintenance Procedures at 10,000 km [6000 mil

Overview

Page

Maintenance Procedures - Overview General Information All maintena.nce checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval.

Air Compressor Maintenance Check NOTE: Depending on application, not be equipped

all engines will possibly with an air compressor.

Inspect compressor

housing

for cracks and damage.

Inspect hydraulic pump couplings age (if equipped). Inspect air plumbing

for cracks, wear, or dam-

for splits or cracks.

Inspect the air compressor mounting nuts, including port bracket, for loose or damaged hardware. Operate the engine and check for correct compressor eration and air, oil, and coolant leaks. Torque Value: Mounting mm

supop-

18

Torque Value: Bracket 10 mm

77 N·m

[57 ft-Ib]

45 N·m

[33 ft-Ib]

Air Cleaner Restriction Maintenance Check Mechanical

Indicator

NOTE: Do not remove the felt washer from the indicator. The felt washer absorbs moisture. A mechanical restriction indicator is available to indicate excessive air restriction through a dry-type air cleaner. This instrument can be mounted in the air cleaner outlet or on the instrument panel. The red flag (1) in the window gradually rises as the cartridge loads with dirt. After changing or replacing the cartridge, reset the indicator by pushing the reset button. Restriction or vacuum indicators need to be installed as close as possible to the turbocharger air inlet in order to obtain a true indication of restrictions.

8c4lagn.

4-1

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Charge~Air Cooler Page 4-2

Maintenance Vacuum

Procedures

CB.3 Industrial at 10,000 km [6000 mi]

Indicator

Vacuum switches actuate a warning light on the instrument panel when the air restriction becomes excessive.

Charge-Air

Cooler

Maintenance

Check

Inspect the charge-air cooler (CAG) for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, refer to the vehicle, vessel, or equipment manufacturer.

Charge-Air

Piping

Maintenance

Check

Inspect the charge-air piping and hoses for leaks, holes, cracks, or loose connections. Tighten the hose clamps if necessary. Refer to the vehicle or equipment rnanutacturer's specifications for the correct torque value.

Lubricating Oil and Filters Page 4-3

CB.3 Industrial Maintenance Procedures at 10,000 km [6000 mi]

Lubricating Oil and Filters Drain

.A

WARNING

A

Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations. PROTECT THE ENVIRONMENT: Handling and disposal of used lubricating engine oil is subject to federal, state, and local laws and regulations. Use authorized waste disposal facilities, including civic amenity sites and garages providing authorized facilities for receipt of used lubricating oil. If in doubt, contact your state and local environmental authorities or the Environmental Protection Agency for guidance as to proper handling and disposal of used lubricating engine oil.

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Lubricating Page 4-4

Oil and Filters Maintenance

Procedures

CB.3 Industrial at 10,000 km [6000 mil

NOTE: If the engine is in service, under no circumstances can the lubricating oil drain interval extend beyond the intervals given in the charts. Change the lubricating oil and filters to remove the contaminants suspended in the lubricating oil. NOTE: Drain the lubricating oil only when it is hot and the contaminants are in suspension.

ol8qwc

A. To avoid personal with your skin.

WARNING

A.

injury, avoid direct contact

of hot oil

NOTE: Use a container that can hold at least 25 liters [26 qt] of lubricating oil. Operate the engine until the water temperature reaches 60°C [140°F]. Shut the engine off. Remove the lubricating oil drain plug.

Remove Clean the area around the lubricating oil filter head. Remove the filter. Clean the gasket surface of the filter head. NOTE: The o-rinq can stick on the filter head. Make sure it is removed.

Install NOTE: Fill the filters with clean lubricating stallation. NOTE: The LF3000 lubricating Lubricate both gaskets.

oil before in-

oil filter has two gaskets.

Apply a light film of oil to the gasket sealing surface before installing the filters.

11900 wa

C8.3 Industrial Maintenance Procedures

a

Lubricating at 10,000 km [6000 mi]

a

CAUTION

Mechanical overtightening can distort the threads damage the lubricating oil filter element seal. I nstall the lubricating manufacturer.

oil tilter

Check and clean the lubricating sealing surface.

Oil and Filters Page 4-5

as specified

or

by the filter

oil drain plug threads and

Install the lubricating oil pan drain plug.

\

Torque Value: For steel stamp oil pans

80 N·m

[59 ft-lb]

Torque Value: For aluminum oil pans

60 N·m

[44 ft-Ib]

\

\

\ \

119pgsa

Fill NOTE: Use a high-quality 15W-40 multiviscosity lubricating oil, such as Cummins Premium Bluew, or equivalent, in Cummins engines. Choose the correct oil for your operating climate as outlined in Section V.

plSOOab

Fill the engine with clean lubricating

System Capacity: 23.8 liters [25.1 qt]

oil to the proper level.

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Lubricating Oil and Filters Page 4-6

Maintenance

Procedures

CB.3 Industrial at 10,000 km [6000 mil

Operate the engine at low idle to inspect for leaks at the lubricating oil filter and the drain plug.

Stop the engine. Wait approximately 15 minutes to let the lubricating oil drain from the upper parts of the engine. Check the level again. Add oil as necessary to bring the oil level to the H (high) mark on the dipstick.

olBdSYH

CB.3 Industrial Maintenance Procedures

at 19,000 km [12,000

Page 5-a

mil

Maintenance Procedures at 19,000 Kilometers [12,000 Miles], 500 Hours, or 6 Months Section Contents Page Coolant Filter Clean Install Remove

5-1 5-1 5-2 5-1

Fuel Filter (Spin-On Type)........... Clean Install Prime Remove

5-4 5-4 5-4 5-5 5-4

Maintenance Procedures General Information

5-1 5-1

- Overview..........

Supplemental Coolant Additive (SCA) and Antifreeze Maintenance Check Antifreeze Supplemental Coolant Additive (SCA) ..

Concentration

5-3 5-3 5-3 5-3

I I I I I I I I I I I I I I I I I I I

C8.3 Industrial Maintenance Procedures

Maintenance

at 19,000 km [12,000 ml]

Procedures

- Overview Page 5-1

Maintenance Procedures - Overview General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval.

Coolant Filter Remove ..

WARNING

..

Wait until the coolant temperature is below 50°C [122°F] before removing the pressure cap. Remove the coolant system pressure cap and close the shutoff valve before removing the coolant filter. Failure to do so can result in personal injury from heated coolant spray. Turn the shutoff valve to the OFF position by rotating the knob from vertical to horizontal in the direction shown. OBdOOO55

Remove and discard the coolant filter.

Clean Clean the gasket surface.

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Coolant Filter Page 5-2

Maintenance

Procedures

at 19,000

CB.3 Industrial km [12,000 mi]

Install

A.

CAUTION

A.

Do not allow oil to get into the filter. Oil will damage the DCA.

A.

CAUTION

Mechanical overtightening damage the filter head.

A.

can distort

the threads

or

Apply a thin film of lubricating oil to the gasket sealing surface before installing the new coolant filter. Install the coolant filter on the filter head. Tighten the filter until the gasket contacts the filter head surface.

wtasewa

Tighten the coolant filter an additional 1/2 to 3/4 of a turn, or as specified by the filter manufacturer.

A.

CAUTION

A.

The valve must be in the ON position to prevent engine damage. Turn the shutott to the ON position by rotating the knob from horizontal to vertical in the direction shown.

OBdOOOS6

~

~

9 I

OlldOOOO7

Install the coolant system pressure cap.

SCA and Antifreeze Concentration Page 5-3

CB.3 Industrial Maintenance Procedures at 19,000 km [12,000 mil Operate the engine and check for coolant leaks. After the air has been purged from the system, check the coolant level again.

Supplemental Coolant Additive (SeA) and Antifreeze Concentration Maintenance

~-==.fl

(S;~

r...

Check

--''''~'''

---

Supplemental Coolant Additive (SCA) Check the SeA concentration level: • At least twice a year • At every subsequent oil drain interval if the concentration is above 3 units • Whenever coolant is added to the cooling system between filter changes. Use Fleetguard®coolant test kit, Part No. CC2602, to check the SCA concentration level. Instructions are included with the test kit. Refer to Coolant Recommendations and Specifications in Maintenance Specifications (Section V) for the correct SCA and antifreeze level. Antifreeze

A

CAUTION

A

Overconcentration of antifreeze or use of high-silicate antifreeze can damage the engine. Check the antifreeze concentration. Use a mixture of 50percent water and 50-percent ethylene glycol or propylene glycol-based antifreeze to protect the engine to -32°C [-26°F] year-around. The Fleetguard® refractometer, Part Number C2BOO,provides a reliable, easy-to-read, and accurate measurement of freezing point protection and glycol (antifreeze) concentration. Antifreeze is essential in every climate. Antifreeze broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. The corrosion inhibitors also protect the cooling system components from corrosion and prolong component life.

-~-._-_.

"'==

Test Strip Bottle

(.

=-::

Syringe

~ Small Plastic Container

-:::-=. 08200002

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Fuel Filter (Spin-On Type) Page 5-4

Maintenance

Procedures

CB.3 Industrial at 19,000 km [12,000 mi]

Fuel Filter (Spin-On Type) Clean Clean the area around the fuel filter head.

Remove 75- to 80-mm and 90- to 95-mm Wrenches Remove the fuel filter. Clean the gasket surface of the fuel filter head.

Install Replace the a-ring. Fill the new fuel filter(s) with clean fuel, and lubricate the a-ring seal with clean lubricating engine oil.

ftaetwb

~ ~ ~

ll..

CAUTION

s:

To reduce the possibility of fuel leaks, make sure the fuel filter is installed tightly but not too tightly. Mechanical overtightening will damage the fuel filter. Install the fuel filter as specified by the filter manufacturer.

tfBett'1b

CB.3 Industrial Maintenance Procedures

Fuel Filter (Spin-On at 19,000

km [12,000

Prime Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the fuel filters or fuel injection pump supply line will be vented automatically if the fuel filter is changed in accordance with the instructions. NOTE: Manual bleeding

is required

• The fuel filter is not filled • Fuel injection

if:

prior to installation

pump is replaced

• High-pressure fuel line connections fuel lines replaced

are loosened or

• Initial engine start up or start up after an extended period of no engine operation occurs • Vehicle fuel tank has been run until empty. Open the bleed screw.

Operate the plunger on the fuel transfer pump until the fuel flowing from the fitting is free of air. Tighten

the bleed screw.

Torque Value:

9 N·m

[80 in-lb]

Type)

Page 5-5

mil

~ ~

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

Fuel Filter (Spin-On Page 5-6

Type) Maintenance

Procedures

..

CB.3 Industrial at 19,000 km [12,000 mil

WARNING

A

The pressure of the fuel in the line is sufficient to penetrate the skin and cause serious personal injury. Wear gloves and protective clothing. 17-mm (PES.A, PES.MW) and 19-mm (PES.P) Wrenches Loosen the fittings at the injectors, and crank the engine to allow entrapped air to vent from the lines. Tighten the fittings.

..

WARNING

A

It is necessary to put the engine in the run position. Because the engine could start, be sure to follow all the safety precautions. Use the normal engine starting procedure. Start the engine and vent one line at a time until the engine runs smoothly. NOTE: Do not engage the starter for more than 30 seconds each time when it is used to vent the system: Wait 2 minutes between engagements.

C8.3 Industrial Maintenance Procedures

at 38,000

km [24,000

Page 6-a

mil

Maintenance Procedures at 38,000 Kilometers [24,000 Miles], 1000 Hours, or 1 Year Section Contents Cooling

Page 6-1 ---- 6-1

Fan Belt Tensioner

Maintenance Check Maintenance

Procedures

General Information Overhead Adjust

Set

- Overview

-----__---

---------- 6-1 -------- 6-1 ---- 6-2 ------ 6-2

I I I I I I I I I I I I I I I I I I I

Maintenance Procedures - Overview Page 6-1

CS.3 Industrial Maintenance Procedures at 38,000 km [24,000 mil

Maintenance

Procedures

- Overview

General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval.

Cooling Fan Belt Tensioner Maintenance Check Every 48,000 km [30,000 mil. 1000 hours, or 1 year, whichever occurs first, inspect the automatic belt tensioner. With the engine turned off, check that neither the top nor bottom tensioner arm stop is touching the cast boss on the tensioner body. If either of the stops is touching a boss, the alternator belt must be replaced. Check to make sure the correct belt part number is being used if either condition exists.

Check the tensioner pulley and body for cracks. If any cracks are noticed, the tensioner must be replaced. Refer to a Cummins Authorized Repair Facility. Check the tensioner for dirt buildup. If this condition exists, the tensioner must be removed and steam-cleaned.

Check that the bottom tensioner arm stop is in contact with the bottom tensioner arm stop boss on the tensioner body. If these two are not touching, the tensioner must be replaced.

~@

(~ _

V

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

Overhead Page 6-2

Set Maintenance

Procedures

C8.3 Industrial at 38,000 km [24,000 mi]

Inspect the tensioner for evidence of the pivoting tensioner arm contacting the stationary circular base. If there is evidence of these two areas touching, the pivot tube bushing has failed and the tensioner must be replaced.

A worn tensioner that has play in it or a belt that "walks" off its pulley possibly indicates pulley misalignment. NOTE: Maximum pulley misalignment is 3 degrees. This measurement can be taken with a straightedge and an inclinometer. Install the belt.

Overhead

Set

Adjust Remove the air crossover tube from the engine if equipped.

Disconnect the support clamps, hose clamp, and wastegate sensing line. Remove the crankcase vent tube and any other parts that would prevent removal of the valve cover.

CB.3 Industrial Maintenance Procedures

at 38,000 km [24,000 mi]

Overhead Set Page 6-3

Remove valve cover.

Locate top dead center tor cylinder No. 1 by rotating the crankshaft slowly while pressing on the engine timing pin. The barring gear inserts into the flywheel housing and engages the flywheel ring gear. The engine can then be rotated by hand using a 1/2-inch ratchet or breaker bar.

When the engine timing pin engages the hole in the earnshaft gear, cylinder No. 1 is at top dead center on the compression stroke. Engine Timing Pin

eg9gllwa

A

CAUTION

A

Be sure to disengage the engine timing pin after locating top dead center to prevent damage to the engine timing pin.

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

Overhead Set Page 6-4

C8.3 Industrial Maintenance Procedures at 38,000 km [24,000 mil Intake clearance: 0.30 mm (0.012 in]. Exhaust clearance: 0.61 mm (0.024 in). Check1setvalves with engine cold· below 60QC [140°FI. NOTE: The clearance is correct when some resistance is Ufelt" when the feeler gauge is slipped between the valve stem and the rocker lever.

Locate top dead center for cylinder No.1. Check/adjust the valves indicated for STEP A (I E = exhaust).

=

intake;

After tightening the rocker lever locknut, check the valve clearance to make sure the valve clearance has not changed. Torque Value: 24 N.m

~

[212 in-Ib]

CAUTION

~

Be Sure the engine timing pin is disengaged to prevent damage to the engine timing pin. Mark vibration damper and rotate the crankshaft 360 degrees.

Set the valves indicated for STEP B. After tightening the rocker lever locknut, check the valve clearance to make sure the valve clearance has not changed. Torque Value: 24 N.m

(212 in-lb]

C8.3 Industrial Maintenance Procedures at 38,000 km [24,000 mil NOTE: If the seal is not damaged, it can be used again. If the seal is damaged, install a new seal. Install the rubber seal into the groove in the valve cover. Start the installation at the overlap area shown in the illustration. Do not stretch the rubber seal. If the seal has more overlap than shown in the illustration, trim the length to provide the correct overlap.

Install new sealing a-rings on the capscrews. Install the valve cover and wastegate

Torque Value: 24 N·m

sensing tube.

[212 in-lb]

Install the crankcase vent tube, and secure with the support clamps and hose clamp.

Torque Value: A

B =

24 N.m [212 in-Ib). 43 N·m [32 in-Ib}.

Install the air crossover tube and any other parts previously removed to gain access to the valve cover.

Overhead Set

Page 6-5

I I I I I I I I I I I I I I I I I I I

C8.3 Industrial Maintenance Procedures at 77,000 km [48,000 mil

Page 7-a

Maintenance Procedures at 77,000 Kilometers [48,000 Miles], 2000 Hours, or 2 Years Section Contents Page -------- 7-1

Air Compressor Discharge Lines .... General Information Maintenance Check

Cooling System Drain Fill Flush

------------------------------- 7-1 --------------------------------------- 7-1

--------------------------------------- 7-3 ------------------------------------------------ 7-3 7-5 ----------------------------------- 7-4

Maintenance Procedures - Overview General

---------- 7-1 ------------------------------------ 7-1

Information

Vibration Damper, Rubber Inspect

-

------------- ------------------ 7-6 ---------------------------------------- 7-6

I I I I I I I I I I I I I I I I I I I

C8.3 Industrial Maintenance Procedures at 77,000 km [48,000 mil

Maintenance

Maintenance Procedures - Overview Page 7-1

Procedures - Overview

General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval.

Air Compressor

Discharge Lines

General Information All air compressors have a small amount of lubricating oil carryover that lubricates the piston rings and moving parts. When this lubricating-oil is exposed to normal air compressor operating temperatures over time, the lubricating oil will form varnish or carbon deposits. If the following maintenance check are not performed, the air compressor piston rings will wear and not seal correctly.

Maintenance

Check

A-

WARNING

A-

Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Shut oft the engine. Open the drain valve on the wet tank to release the system air pressure. cpatbrah

Remove the air compressor discharge line from the air compressor. Location of the air compressor discharge line can be found in Flow Diagram, Compressed Air System in System Diagrams (Section D).

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

Air Compressor Page 7-2

ID of Discharge

Discharge

Lines Maintenance

Line

Procedures

at 77,000

CB.3 Industrial km [4B,000 mi]

Measure the total carbon deposit thickness inside the air discharge line as shown. If the total carbon deposit (X + X) exceeds 2 mm [1/16 in], clean and inspect the cylinder head, the valve assembly, and the discharge line. Replace if necessary. Contact the Cummins Authorized Repair Location for procedures.

ID of Carbon Build Up

If the total carbon deposit exceeds specifications, continue checking the air discharge line connections up to the first tank until total carbon deposit is less than 2 mm [1/16 in]. Clean or replace any lines or connections that exceed this specification.

[gl

k~~-=i

[

n

.

;

kj LiJ_j)

Inspect any air driers, splitter valves, pressure relief valves." and alcohol injectors for carbon deposits or malfunctioning parts. Inspect for air leaks. Maintain and repair the parts according to the manufacturer's specifications.

Cooling System Page 7-3

C8.3 Industrial Maintenance Procedures at 77,000 km [48,000 mil

Cooling System Drain

A

WARNING.

Do not removethe pressure cap from a hot engine. Walt until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury .

.A

WARNING

.A

Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

tl..

CAUTION

s:

Protect the environment: Handling and dlspo$ing of used antifreeze is subject to federal, state, and local regulations. Use authorized waste disposal facilities, including civic amenity sites and garages providing authorized facilities for the receipt of used antifreeze. If in doubt, contact local authorities of the Environmental Protection Agency (EPA) for guidance as to proper handling of used antifreeze. • Avoid excessive contact, and wash thoroughly contact. • Keep out of reach of children .

.A

WARNING

after

EtS~

.A

Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. Drain the cooling system by opening the drain valve on the radiator and removing the plug in the bottom of the water inlet hose. A drain pan with a capacity of 19 liters [5 gal) will be adequate for most applications.

Check for damaged hoses and loose or damaged clamps. Replace as required.

hose

Check the radiator for leaks, damage, and buildup of dirt. Clean and replace as required.

I I I I I I I I I I I I I I I I I I I

I I

Cooling System Page 7-4

C8.3 Industrial Maintenance Procedures at 77,000 km [48,000 mi]

Flush ~

I I I I I I I I I I I I I I I I

CAUTION

A

The system must be filled properly to prevent air locks. During filling, air must be purged from the engine coolant passages. Be sure to open the petcock on the aftercooler for aftercooled engines. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. NOTE: Adequate venting is provided for a fill rate of 19 liters [5 gal] per minute.

d

CAUTION

1l..

Do not install the radiator cap. The engine is to be operated without the cap for this process. Fill the system with a mixture of sodium carbonate water (or a commercially available equivalent).

NOTE: Use 0.5 kg [1 Ib] of sodium liters [6 gal] of water.

A

WARNING

carbonate

and

for every 23

A.

Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.

/--:.::~>

I·

Operate perature

~ '\

"~l"

t : " . ( \ ~.". )1 . .,-....,,'" '\.

'":

I,

,

,

than 152.4 mm Hg [6 in Hg] or excessive restriction exists bethe transfer pump, which must or tank module). Repeat test.

If bubbles are present, check for air leaks in the tuel supply circuit. Measure the amount ot tuel in the container. If more than 1.33liters [45 tl oz] are collected and the tuel is bubble-tree, then it is unlikely the low-pressure fuel system is the cause of engine operational problems.

\

_7J

, , , , ,' , '

, "

'

-~

Reconnect the lift pump that is retaining the fuel filter pressure connections. Running engine at high idle, the filter inlet pressure should be greater than 42.3 kPa [6 psi]; otherwise. there is a fuel lift pump malfunction.

CB.3 Industrial Section A - Adjustment, Repair, and Replacement If the fuel transfer pump does not run, check electrical circuits, and verify voltage is present at lift pump connector.

NOTE: When an engine is not running, with key on, the lift pump will run less than 2 seconds (varies with ECM calibration); with starter bump, about 25 to 30 seconds. If voltage is present, replace fuel transfer pump. Resistance measurement across the transfer pump terminals can be made for confirmation of pump malfunction. Resistance greater than 200 ohms or less than 0.2 ohm does confirm an electrical fault when voltage is present but the fuel pump is not running.

Air in Fuel Page A-23

I I I I I I I I I I I I I I I I I I I

CB.3 Industrial Section D - System Diagrams

Page O-a

Section D - System Diagrams Section Contents Page Flow Diagram, Air Intake System General

Information

0-11

Flow Diagram, Compressed Air System General Information General Information

..

Flow Diagram, Cooling System General Information General Information

Flow Diagram, Exhaust System General

Information

Flow Diagram, Fuel System .. General Information General Information

Flow Diagram, Lubricating Oil System General Information General Information

System Diagrams - Overview.. General

Information

0-11 0-13 0-13 0-13 0-7 0-7 0-7 0-12 0-12 0-2 0-2 0-2 0-3 0-3 0-3 0-1 0-1

I I I I I I I I I I I I I I I I I I I

System Diagrams - Overview Page D-1

CB.3 Industrial Section D - System Diagrams

System Diagrams - Overview General Information The following drawings show the flow through the engine systems. Although the parts can be different for various applications and installations, the flow remains the same. The systems shown are • Fuel system • Lubricating

oil system

• Coolant system • Intake air system • Exhaust system • Compressed Knowledge

air system.

of the engine systems can help in troubleshooting,

servicing, and general maintenance of the engine.

I I I I I I I I I

I I I I I I I I I I

I I I I

C8.3 Industrial Section 0 - System Diagrams

Flow Diagram, Fuel System Page 0-2

Flow Diagram, Fuel System General Information General Information

7

1 1 1 1

2

1

l-.·l: - 0 -

22330252

DRA.W'1NO

3A

NO

DATE

1 1

1 1 1 1

DESCRIPTION

ITEM

BASE ,JACK BOLT NUT. LOCK DROP LEG AND SLEEVE PIN, PULL CLIP TUBE, INNER BEARING, THRUST TUBE, OUTER WASHER NUT, LOCK CRANK ASSEMBLY BOLT DRAWBAR JACK ASSEMBLY

I

R[V

1 1/03 A

-

ePN

_._--

OTY

-.

__ __ .

..

_

...

DESCRIPTION

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

BRAKE ACTUATOR ASSEMBLY ~,?----

~.

I

)

.---------@ -~

@f----

- ---~-------------,

ITEM

CPN

------

--------------

A

35578194 35293075 96719869 22252811 35279025 36895746 36793545 22253892 22252829 22254981 36797652 36780609 35598986 35582410

B C D E F G H J K L M N

MANlJAl

N)

22330252

-

DRAWING t.I:l

3.1

OArE

-

1 11 7 2 1 1 6 1 1 1

_----------

----

DESCRIPTION

OTY ----

---

---_

----------

--------

ITEM ----------_.

CPN

QTY

--------~----

14" STARTER TO ENG. GROUND STRAP 10" STARTER TO FRAME GROUND STRAP SCREW ( TO ENGINE BLOCK) TRAY, BOTTOM BATTERY SCREW NUTSERT BATTERY SPACER, BATTERY TRAY ,TOP BRACE, TOP TRA Y SCREW CABLE, NEGATIVE CABLE, JUMPER CABLE, POSITIVE

I REV

11103

A

----.~---------------

DESCRIPTION

>--

@)

--(H) ---------

ITEM

---------------

OTY

CPN

- ------------------

----

1 2

A B

22201578 22211163

C

22208284

2

0

35130707 96702659 36769743 36793602 36794816 22197818 92912419 22202048 35310622 22202063 22207930 22197479 22300248 22208300 22237564 22199020

4 8 8 2 8 1 2 1 3 1 2 1

E F G

H J K L M N P Q

R

2 1 1

-

------------

ITEM

DESCRIPTION _---

----------

--

GRILL, LEFT FRONT DOOR, SIDE PANEL, HSRG ONLY HANDLE SCREW NUT LATCH ASSEMBLY RIVET PANEL, LEFT REAR HINGE, DOOR PANEL, PLUGS, GRILL, BRACE, PANEL, COVER, PANEL, PANEL, PANEL,

FRONT END HOLE FRONT END END PANEL REAR END END PANEL FRONT TOP TOP MIDDLE TOP REAR

-----------

--------

S T U V W X Y

Z A1 A2 A3 A4

A5 A6

A7 t.tANUA1

!'O

22330252

DRAWlNQ

34

f'J),

01 TL! !fUN

11103

A

CPN -

- -- ---- - ----

22243307 22243273

22208946 22197495 22203681 36755742 22198188 22198444 22244255 35337328 36881886 36844355 22068373 36895746 35279025 36797652 22312599 95934873 95935029 95931564 35278720

DESCRIPTION

OTY ----------

------

1 1 1 1 1 6 2 2 2 8 8 4 2

1

2 2 2

-----

FRAME, DOOR DOOR COVER, LIFT BAIL PANEL, RIGHT REAR GRILL, RIGHT FRONT FILLER, SIDE RAIL RAIL, TOP SIDE RAIL, TOP SIDE PANEL,STEER.ONLY STUD NUT SPRING, GAS SEAL,DOOR NUTSERT SCREW,8MM SCREW,6MM PLUG SCREW, SHOULDER WASHER NUT PIN

I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I

E_NCLOSURE(EXTE_RNAL GALVANEAL

------_-----

---0

0-

--------------------------

ITEM

CPN

A B C 0

OTY

22201578 22211171 22208292 35130707 96702659 36769743 36793602 36794816 22197826 92912419 22202055 35310622 22202063 22207930 22197487 22300644 22208318 22237557 22199038

E F G H

J K L M N P

0 R

2 2 4

8 8 2

8 1

2 1 3 1

2 1 2 1 1

DESCRIPTION

------_----

GRILL, LEFT FRONT DOOR, SIDE PANEL, HSRG ONLY HANDLE SCREW NUT LATCH ASSEMBLY RIVET PANEL, LEFT REAR HINGE, DOOR PANEL, PLUGS, GRILL, BRACE, PANEL, COVER, PANEL, PANEL, PANEL,

FRONT END HOLE FRONT END END PANEL REAR END END PANEL FRONT TOP TOP MIDDLE TOP REAR

-

--------_---ITEM

~

-

DRAWING

t.V

DATE

OTY

-

S T U V W X Y

Z A1 A2 A3 A4

A5 A6

A7 N»I.W_

22330252

CPN -

~.-----..-_

22243299 22243281 22208953 22197503 22203681 36755742 22198196 22198451 22244636 35337328 36881886 36844355 22068373 36895746 35279025 36797652 54413117 22312599 95934873 95935029 95931564 35278720

I REV

34A 11103 A -~---------

~~~------

DESCRIPTION

-- ---

1 1

1 1 6

2 2 2

8 8 4 2

2 1

2 2 2

FRAME, DOOR DOOR COVER, LIFT BAIL PANEL, RIGHT REAR GRILL, RIGHT FRONT FILLER, SIDE RAIL RAIL, TOP SIDE RAIL, TOP SIDE PANEL ,STEER. ONLY STUD NUT SPRING, GAS SEAL,DOOR NUTSERT SCREW,8MM SCREW,6MM DECAL, GALVANEAL PLUG SCREW, SHOULDER WASHER NUT PIN

ENCLOSURE BAFFLES

/-0

FRONT CPN

ITEM

A

22301089 22301097 54718184 54519202 22301048 22301105 22301717 22301113 36895746 35279025 36797652 22336184

B

C D E F G

H

t.IANUA.l

OTY

P«