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Ingersoll-Rand HP375AWIR, Operating, Maintenance & Parts Manual

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Ingersoll-Rand HP375AWIR Operating, Maintenance & Parts Manual Download Page 27

25

P425AWIR (7/120), XP375AWIR (9/110), 

HP375AWIR (10/105), VHP300AWIR (14/85)

General Arrangement 

MANUFACTURED IN NORTH AMERICA 

FRONT VIEW 

SIDE VIEW 

REAR VIEW 

TOP VIEW 

7/120  9/110  10/105  14/85
P425AWIR  XP375AWIR  HP375AWIR
VHP300AWIR

All dimensions in inches(mm)

A Instrument panel access door

B Package air inlet

C Access items:
Separator element & fill
Compressor oil filter 
Fuel filters
Dipstick
Engine oil fill
Coolant bottle fill

D Access items:
Fuel fill
Engine oil filter 
Fuel filter
Engine and compressor air filter

E Access items:
Radiator fill 

F Package air outlet 

G Track width

Summary of Contents for HP375AWIR

Page 1: ...nel who operate and maintain this machine C C N 22220321 US DATE SEPTEMBER 2003 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of tr...

Page 2: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm...

Page 3: ...STRUCTION MANUAL 54 MAINTENANCE Routine maintenance Lubrication Speed pressure regulation Torque settings table Compressor lubrication 65 MACHINE SYSTEMS Electrical system Piping instrumentation syste...

Page 4: ...mprovementsto products without notice and without incurring any obligation to make such changes or add such improvementsto products sold previously The intended uses of this machine are outlined below...

Page 5: ...train pertains to the Ingersoll Rand Engine and Airend combination The earlier of sixty 60 months from shipment to or the accumulation of 10 000 hours of service The starter alternator fuel injection...

Page 6: ...CATERPILLAR Months Hours Extended Coverage 12 unlimited Available at dealer CUMMINS 24 2000 Major components 3 yrs 10 000 hrs Available at dealer JOHN DEERE in compressors 24 2000 5 yrs 5000 hrs using...

Page 7: ...TS Months Hours Coverage Ingersoll Rand 6 No Limit Parts Only AIREND EXCHANGE Months Hours Extended Coverage Airend 12 2000 2 yrs 4000 hrs available from IR Note Actual warranty times may change Consu...

Page 8: ...anty is limited to defects in major components rotors housings gears and bearings and is automatically available when the following conditions are met 1 The original airend is returned assembled and u...

Page 9: ...his section keep a copy for your records and mail form to Ingersoll RandCompany P O Box 868 Mocksville North Carolina 27028 Attn Warranty Department Note Completion of this form validates the warranty...

Page 10: ...use Other specify Exploration Utility Contractor Model S N Unit S N Engine S N Date delivered Unit Hours Airend S N Truck S N Truck Engine S N SERVICING DISTRIBUTOR USER ACKNOWLEDGEMENT 1 The Purchas...

Page 11: ...not understand inform you supervisor GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition Mandatory Information Instructions Warning WARNING Electrical shock risk WARNING Pressurised component or syst...

Page 12: ...on and maintenance manual WARNING Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved WARNING Consult the operation an...

Page 13: ...speed limit No naked lights Do not open the service valve before the airhose is attached Use fork lift truck from this side only Emergency stop Tie down point Lifting point On power Off power Read th...

Page 14: ...ace any cracked protective shield Oil drain Engine Oil Fuel level point Pressure control Malfunction Battery charging condition Low pressure High pressure Engine malfunction High compressor temperatur...

Page 15: ...e if ignored Orange Background CAUTION 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...

Page 16: ...mph 105 km hr Do not operate without guard in place Rotating fan blade Can cause serious injury Access lifting bail from inside machine Falling off machine Can cause serious injury or death Door unde...

Page 17: ...fety Assure that decals are present on the machines Replace decals that are not readable FREE SAFETY DECALS This engine is equipped with an electric heater starting aid DO NOT USE ETHER ENGINE DAMAGE...

Page 18: ...hereof 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...

Page 19: ...or 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 a device or element of design has been remov...

Page 20: ...r 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 tha...

Page 21: ...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 25...

Page 22: ...ed 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 adjus...

Page 23: ...IR 9 110 HP375AWIR 10 105 VHP300AWIR 14 85 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK OR COMMENTS HOURMETER READING MAINT INSPECT DATE LOCATION CIT...

Page 24: ...h pressure as this can penetrate the skin and result in serious illness wear eye protection while cleaning unit with compressed air to prevent debris from injuring eye s Rotating fan blade can cause s...

Page 25: ...ion Avoid breathing exhaust fumes when working on or near the machine This machine may include such materials as oil diesel fuel antifreeze brake fluid oil air filters and batteries which may require...

Page 26: ...are in safe operating condition and tow bar is properly connected before towing Safety chains connections and their adjustment Where brakes and safety chains are fitted a Loop the chains onto the towi...

Page 27: ...5AWIR XP375AWIR HP375AWIR VHP300AWIR All dimensions in inches mm A Instrument panel access door B Package air inlet C Access items Separator element fill Compressor oil filter Fuel filters Dipstick En...

Page 28: ...rument panel access door B Package air inlet C Access items Separator element fill Compressor oil filter Fuel filters Dipstick Engine oil fill Coolant bottle fill D Access items Fuel fill Engine oil f...

Page 29: ...ge temperature 120 C 248 F Cooling system Oil injection Oil capacity 36 litres 9 5 GAL Maximum oil system temperature 120 C 248 F Maximum oil system pressure 8 6 bar 125 PSI 7 120 P425AWIR Maximum oil...

Page 30: ...of darkness ensure that the lights are functioning correctly where fitted Ensure that all transport and packing materials are discarded Ensure that the correct fork lift truck slots or marked lifting...

Page 31: ...only a No 2 D diesel fuel oil with a minimum octane number of 45 and a sulphur content not greater than 0 5 CAUTION When refuelling switch off the engine do not smoke extinguish all naked lights do no...

Page 32: ...Gauge Indicates amount of fuel in tank CONTROLS STANDARD 6 Power Switch Flip ON to activate systems prior to Starting Flip OFF to stop engine 7 Service Air Switch After warm up PUSH Provides full air...

Page 33: ...inlet filters need service 5 High Engine Coolant Temp Fault indicator lamp Indicates shutdown due to high engine water temperature 6 Spare 7 Low Fuel Level Fault indicator lamp Indicates shutdown due...

Page 34: ...1 CPRSR Malf 30 Engine Speed 2500 RPM 2 CPRSR Malf 30 Engine Crank Time Exceeded 3 CPRSR Malf 0 Intake Manifold Temperature 180 deg F 6 CPRSR Malf Engine Not Responding To Throttle Command 10 CPRSR M...

Page 35: ...hrottle B Input Voltage Low 29 3 Analog Throttle A Input Voltage High 4 Analog Throttle A Input Voltage Low 91 3 Multi state Throttle Input Voltage High 4 Multi state Throttle Input Voltage Low 100 1...

Page 36: ...nkshaft Position Input Pattern Error 970 31 Auxiliary Engine Shutdown Switch Active 971 31 External Engine Derate Switch Active 1076 0 Pump Control Valve Closure Too Long 1 Pump Control Valve Closure...

Page 37: ...eturns 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 7 At this point in the...

Page 38: ...oil to the compressor at low temperature never allow the discharge pressure to fall below 3 5 bar 50 psi DECOMMISSIONING When the machine is to be permanently decommissioned or dismantled it is impor...

Page 39: ...if the bio diesel fuel properties meet the latest edition of ASTM PS121 DIN 51606 or equivalent specification It has been found that bio diesel fuels may improve lubricity in concentrations up to a 5...

Page 40: ...below 5 C 40 F Grade No 1 D fuel is best suited for cold weather operation Diesel Fuel Additive IMPORTANT Treat fuel when outside temperature drops below 0_C 32_F For best results use with untreated f...

Page 41: ...oolant additive every 12 months IMPORTANT Only use coolant additive to replenish the coolant Do not use additive when the entire system is drained and refilled Consult the coolant supplier and follow...

Page 42: ...n Crankcase Vent Tube Check Air Intake Hoses Connections System Replace Fuel Filter Elements Bleed Fuel System Check Belt Tensioner and Belt Wear Check Engine Electrical Ground Connection Check Coolin...

Page 43: ...drain plug 3 Drain crankcase oil from engine while warm 4 Turn filter element using a suitable filter wrench to remove Discard oil filter element Important Filtration of oils is critical to proper lu...

Page 44: ...click is heard and a release of the retaining ring is felt A plug is provided with the new element for plugging the used element 10 Reconnect water sensor wiring if equipped 11 Open fuel shut off valv...

Page 45: ...belts for cracks fraying or stretched out areas Replace if necessary 2 To replace belt with automatic tensioner release tension on belt using a breaker bar and socket on tension arm To replace belt wi...

Page 46: ...ng Information Troubleshooting engine problems can be difficult In this section is a list of possible engine problems that may be encountered accompanied by possible causes and corrections The illustr...

Page 47: ...eck fuel tank Air in fuel line Bleed fuel line Cold weather Use cold weather starting aids Slow starter speed See Starter Cranks Slowly Crankcase oil too heavy Use oil of proper viscosity Improper typ...

Page 48: ...Reduce load Intake air restriction Service air cleaner Clogged fuel filter Replace filter elements Improper type of fuel Use proper fuel Overheated engine See Engine Overheats Below normal engine temp...

Page 49: ...horized servicing dealer Engine emits white smoke Improper type of fuel Use proper fuel Low engine temperature Warm up engine to normal operating temperature Defective thermostat Remove and check ther...

Page 50: ...y Incorrect grade of fuel Use correct grade of fuel High fuel consumption Improper type of fuel Use proper type of fuel Clogged or dirty air cleaner Service air cleaner Engine overloaded Reduce load I...

Page 51: ...Starter cranks slowly Low battery output See your authorized servicing dealer Crankcase oil too heavy Use proper viscosity oil Loose or corroded connections Clean and tighten loose connections Entire...

Page 52: ...tc can cause faulty signals to be sent to the ECU Storage Engine Storage Guidelines 1 Engines can be stored outside for up to three 3 months with no long term preparation IF COVERED BY WATERPROOF COVE...

Page 53: ...3 Install fan alternator poly vee belt if removed 4 Fill fuel tank 5 Perform all appropriate pre starting checks IMPORTANT DO NOT operate starter more than 30 seconds at a time Wait at least 2 minute...

Page 54: ...needs service 3 DO ALL the services within an interval section Write the number of hours from your service Records and the date in the spaces provided For a complete listing of all items to be perfor...

Page 55: ...of an EU number in the third line of the label signifies that the engine has been certified with the European Union countries per Directive 97 68 EC The emissions warranty does not apply to the EU co...

Page 56: ...umps C Fan Alternator Belts C Battery Connections Electrolyte C Tire Pressure and Surface C Wheel Lug Nuts C Hoses Oil Air Intake etc C Automatic Shutdown System C Air Cleaner System C Compressor Oil...

Page 57: ...e Related Parts C Oil Separator Element R Feed Pump Strainer Cleaning C Coolant Replacement R Valve Clearance Check C Lights running brake turn CBT Pintle Eye Bolts CBT Brakes C C Brake linkage C Emer...

Page 58: ...an be dangerous if incorrectly handled Before doing any work on the unit ensure that all pressure is vented from the system and that the machine cannot be started accidentally If the automatic blowdow...

Page 59: ...nning SCAVENGE LINE The scavenge line runs from the combined orifice drop tube in the separator tank to the orifice fitting located in the airend Examine the orifice check valve and hoses at every ser...

Page 60: ...the filler cap absorbing any released fluid with the cloth Do not remove the filler cap until all excess fluid is released and the engine cooling system fully depressurised WARNING Follow the instruc...

Page 61: ...arts should be replaced before the machine is put back into service TYRES TYRE TIRE PRESSURE See the GENERAL INFORMATION section of this manual RUNNING GEAR WHEELS Check the wheel nut torque 20 miles...

Page 62: ...most of the sediment will be in suspension and will therefore drain more readily CAUTION Some oil mixtures are incompatible and result in the formation of varnishes shellacs or lacquers which may be...

Page 63: ...Start the machine Refer to STARTING INSTRUCTIONS in the OPERATING INSTRUCTIONS section of this manual Adjust the service valve on the outside of the machine to maintain rated pressure at full speed If...

Page 64: ...HEAD MARKING TYPICAL RECTANGULAR TORQUE PATTERN CAPSCREW OR NUT THREAD SIZE AND PITCH TYPICAL SQUARE TORQUE PATTERN Nm FT LBF Nm FT LBF 1 4 20 11 8 16 12 5 16 18 24 17 33 25 3 8 16 42 31 59 44 7 16 14...

Page 65: ...12 9 HEAD MARKING TYPICAL RECTANGULAR TORQUE PATTERN CAPSCREW OR NUT THREAD SIZE AND PITCH TYPICAL SQUARE TORQUE PATTERN Nm FT LBF Nm FT LBF Nm FT LBF M6 X 1 0 11 8 15 11 18 13 M8 X 1 25 26 19 36 27 4...

Page 66: ...500 psi 50 F to 125 F 10 C to 52 C 10 F to 65 F 12 C to 18 C below 10 F 12 C IR XHP1001 IR XHP 505 Consult Factory IR XHP505 IR XHP1001 IR PERFORMANCE 500 IR PRO TEC 100 300 PSI RATED OPERATING PRESSU...

Page 67: ...p fault lamp POUT4 Engine fault lamp POUT5 Start relay POUT6 Spare POUT7 Hour meter POUT8 Spare PT1 Pressure transducer separator tank 0 500 PSIG PT2 Pressure transducer regulation system 0 100 PSIG P...

Page 68: ...LOG THROTTLE ENGINE CONTROLLER FIGURE 2 1 WEDGE TO ENGINE INTERFACE IR ENGINE CONTROLL PANEL HARNESS SOLENOID VALVES ENGINE ECM DIAGNOSTIC INTERFACE 24VDC HEATERS GUAGES HOURMETER CONTROL PANEL SWITCH...

Page 69: ...67 P425AWIR 7 120 XP375AWIR 9 110 HP375AWIR 10 105 VHP300AWIR 14 85 ENGINE CM TERMINATOR J1939 CAN COMMUNICATIONS SCHEMATIC FIGURE 2 3 ENGINE DIAGNOSTICS JACK WEDGE CONTROLLER TERMINATOR...

Page 70: ...ool Yellow Used to repair Deutsch connectors HDT 48 00 Deutsch Terminal Crimp Tool Used to crimp Deutsch connector terminals DD Deutsch Terminal Crimping Tool Used to crimp Deutsch connector terminals...

Page 71: ...ailable from electrical and electronic parts distributors 54729660 Weather Pack Terminal Removal Tool 54699632 Deutsch Terminal Removal Tool Blue 54699640 Deutsch Terminal Removal Tool Red 54699624 De...

Page 72: ...VHP300AWIR 14 85 54729728 PDA Service Tool 54699616 Deutsch Terminal Removal Tool 22073886 Packard Crimp Tool 22073878 Thermistor Simulator 54749635 Connector Repair Kit 54699657 Deutsch Terminal Rem...

Page 73: ...PROBE 2 36840841 SOLENOID VALVE 1 36853521 STARTER AND INLET HEATER RELAY 2 35610856 NEGATIVE BATTERY CABLE 1 35583582 POSITIVE BATTERY CABLE 1 35578194 ENGINE GROUND STRAP 1 54731427 FUEL LEVEL SENDE...

Page 74: ...eplace the fuel filter if necessary Switch failure Test the switches High compressor oil temperature Check the compressor oil level and oil cooler Check the fan drive Water present in fuel system Chec...

Page 75: ...essure too high Refer to SPEED AND PRESSURE RE GULATION AD JUSTMENT in the MAINTENANCE sec tion of this manual Incorrect setting of the regulator Adjust the regulator Faulty regulator Replace the regu...

Page 76: ...ING INSTRUCTIONS section of this manual CAUTION If the nylon tubes to the lubricator are disconnected then ensure that each tube is re connected in its original location GENERAL INFORMATION Oil capaci...

Page 77: ...enabled This will result inC operation at excessive horsepower levels causing overheating reduced engine life and reduced airend life CAUTION Excessively restricted filter elements may cause an incre...

Page 78: ...estriction indicators for the filters are mounted on the filter heads If so equipped an automatic restriction indicator located behind the filters will shut down the compressor if restriction exceeds...

Page 79: ...h part distinctly and in location relative to the other parts in the assembly The part number the description of the part and the quantity of parts required are shown on each illustration or on adjace...

Page 80: ...st sales office autonomous company or authorized distributor for inspection or repair it is important to include the serial number of the unit from which the parts were removed TERMS AND CONDITIONS ON...

Page 81: ...consequential incidental indirect special or punitive damages arising out of this order or any breach thereof or any defect in or failure of or malfunction of the parts hereunder whether based upon lo...

Page 82: ...Asia Pacific distributor please contact Ingersoll Rand Company 501 Sanford Avenue P O Box 868 Mocksville N C 27028 Telephone 800 633 5206 US Canada 305 222 0835 Latin America 65 860 6863 Asia Pacific...

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