Ingersoll-Rand HP375WIR Installation, Operation And Service Manual Download Page 3 | Manualshive

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Book: 22600498 (1/05)

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FOREWORD

This manual provides installation and operating instructions for field installation
of Auto Start capabilities for certain model air compressors.

Read these instructions before beginning the installation and check that all kit
parts are included. Assure all decals are attached.

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Summary of Contents for HP375WIR

Page 1: ...ed Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Ran...

Page 2: ...General Information And Operational Theory SECTION 4 Installation SECTION 5 Troubleshooting Procedures SECTION 6 Schematic Diagrams SECTION 7 Electrical Electronic Component Locations SECTION 8 Electr...

Page 3: ...stallation and operating instructions for field installation of Auto Start capabilities for certain model air compressors Read these instructions before beginning the installation and check that all k...

Page 4: ...k 22600498 1 05 4 SECTION 1 SAFETY Follow all safety instructions in the air compressor operator s manual and decals on the machine and those included with the kit below WARNING 22306617 NOTICE 365734...

Page 5: ...al schematics and component location information Section 7 contains electrical component locations Section 8 contains electrical connector information Section 9 contains the electrical parts list Sect...

Page 6: ...Book 22600498 1 05 6 SECTION 3 GENERAL INFORMATION And OPERATIONAL THEORY...

Page 7: ...698 Alarm Horn LS1 36785145 Terminal Strip TB1 22307706 Auto Manual Switch S1 54615091 Switch Bracket 22311823 Battery Charger 54715941 Battery Charger harness 22600514 Battery Charger Bracket 2232941...

Page 8: ...the two basic modules on the CAN network The CAN network supports the J1939 protocol as defined by the Society of Automotive Engineers SAE The machine wiring harness contains two stubs for CAN power...

Page 9: ...22600498 1 05 9 J1939 CAN COMMUNICATIONS SCHEMATIC P15 ENGINE DIAGNOSTICS JACK J8 R5 R4 P7 P11 P6 ENGINE CONTROLLER WEDGE CONTROLLER TERMINATOR TERMINATOR AUTO START OPTION CAN NODE WITH POWER FIGURE...

Page 10: ...VDC TB1 5 Machine running output 24 VDC TB1 7 Low fuel indication 24 VDC SECTION 5 of this manual provides schematic diagrams of the auto start system and wiring harness connections Auto Start Stop Op...

Page 11: ...dule will issue a shutdown condition to the machine controller A code 73 will be displayed on the control panel diagnostic display 5 If the engine does start the auto start module will issue a load co...

Page 12: ...Book 22600498 1 05 12 SECTION 4 INSTALLATION...

Page 13: ...access to drill the mounting holes Refer to figure 4 1 The mounting location is shown in the picture below Figure 4 1 Connect the wiring harness to the two connectors on the Auto Start Module P1 and...

Page 14: ...mponents Connect the harness wires TB1 1 to TB1 8 to the terminal strip refer to Figure 4 3 starting with TB 1 at the top left Mount the switch bracket and then mount the switch S1 into the bracket Re...

Page 15: ...e lock washer and nut are attached from the back of the panel to hold it in place Figure 4 5 Connect the wires from the harness branch labeled DS1 to the lamp Polarity is not important the wires can b...

Page 16: ...onto the threaded portion This will secure the horn in the hole Figure 4 6 The operating instructions decal 22313597 is attached just under the control panel door Refer to Figure 4 7 Figure 4 7 Insta...

Page 17: ...talled near the door handle on each of the machine s 2 doors as shown in Figure 4 9 Figure 4 9 The battery charger is installed on the cooler housing as shown in Figure 4 10 The charger is attached to...

Page 18: ...the charger output cable and then connects to the battery cable connectors that attach to the battery posts Ring tongue terminals are provided to connect under the screw clamps of the battery cable l...

Page 19: ...Book 22600498 1 05 19 SECTION 5 TROUBLESHOOTING PROCEDURES...

Page 20: ...list all possible problems The charts are designed to stimulate a thinking process that will lead to solution of the problem Basic Troubleshooting Steps Collect all facts concerning the problem Analyz...

Page 21: ...MACHINE FRAME SHEET METAL PIPING OR OTHER METAL COMPONENTS AS COMMON OR GROUND WHEN MAKING VOLTAGE OR FREQUENCY MEASUREMENTS Measuring Resistance Extra care must be taken when making resistance measur...

Page 22: ...come on Check F1 fuse Check operation of control panel switch Check battery voltage battery disconnect switch WEDGE system works OK but auto start does not function Ensure external pressure switch con...

Page 23: ...r to the Auto Start controller Step 2 Check J1939 CAN communications connections to Auto Start controller Explanation The WEDGE has received a fault from the Auto Start controller It has lost communic...

Page 24: ...le of cranking engine Step 2 Check machine fuel system filters fuel tank s and associated piping Batteries too weak to crank Restricted fuel system component Explanation The WEDGE has received a fault...

Page 25: ...Book 22600498 1 05 25 SECTION 6 SCHEMATIC DIAGRAMS...

Page 26: ...Book 22600498 1 05 26...

Page 27: ...Book 22600498 1 05 28...

Page 28: ...Book 22600498 1 05 29 SECTION 7 ELECTRICAL ELECTRONIC COMPONENT LOCATIONS...

Page 29: ...on baffle wall under auto start controller DS1 Located on front of machine above control panel TB1 Located on baffle wall below the auto start controller LS1 Located on front panel of machine above an...

Page 30: ...Book 22600498 1 05 31 SECTION 8 ELECTRICAL CONNECTOR INFORMATION...

Page 31: ...99582 Sensor Pin Terminal Deutsch 54699590 Harness Housing Deutsch 54750468 Sensor Housing Deutsch 54750476 Harness Housing Wedgelock Deutsch 54750484 Sensor Housing Wedgelock Deutsch 54750492 Pressur...

Page 32: ...g Wedgelock Deutsch 54750591 Heater Conn Wedgelock Deutsch 54750609 Engine OEM 50 Pin Conn Harness Pin Deutsch 54699608 J1939 CAN Cable Harness Socket Deutsch 54699566 Harness Housing Deutsch 54750633...

Page 33: ...667 54699558 54699632 22216667 54699582 54699640 22216675 54699590 54699640 22216675 54750500 Packard Metri Pack 54749643 12155975 54750674 54749643 12155975 54750526 Packard Weather Pack 54729660 121...

Page 34: ...ess troubleshooting Some examples of these are shown in Section 2 concerning multimeters Use of these adapters will prevent harness damage during testing The first item to perform during harness troub...

Page 35: ...4 Green 8 10 54699616 The wire is placed into the slot on the removal tool and the tool is slid along the wire inserted into the back of the connector Gently pull on the wire as the tool is pushed int...

Page 36: ...Book 22600498 1 05 37 SECTION 8...

Page 37: ...Book 22600498 1 05 38...

Page 38: ...Book 22600498 1 05 39 SECTION 9 ELECTRICAL PARTS LIST...

Page 39: ...LS1 Alarm Horn 36785145 TB1 Terminal Block 22307706 Wiring Harness 22149157 Switch Bracket 22311823 Battery Charger 54715941 Battery Charger Bracket 22329411 Battery Charger Harness 22327175 Operating...

Page 40: ...Book 22600498 1 05 41 SECTION 10 ALERTS AND SHUTDOWNS LIST...

Page 41: ...31 CPRSR Malf 20 0 2 5 Disch Temp RT2 Sensor Fault 32 CPRSR Malf 10 All Sep Tank Pressure PT1 Sensor Fault 33 CPRSR Malf All Separator Tank Pressure 20 PSI During Start Attempt Engine Will Not Crank 3...

Page 42: ...Rest 3 0 62 High Discharge Temp RT2 247 deg F High Comp Temp 3 All Notes CAN Derived Data 1 Max crank time 0 6 15 sec 7 8 30 sec 2 IQ equipped machines 3 ID 0 6 800 RPM 7 8 900 4 ID 0 6 1900 RPM 7 8...

Page 43: ...RSR Malf 0 All Low AE Oil Pressure HP1600 only 31 CPRSR Malf 20 0 2 5 Disch Temp RT2 Sensor Fault 32 CPRSR Malf 10 All Separator Tank Pressure PT1 Sensor Fault 33 CPRSR Malf All Separator Tank Pressur...

Page 44: ...t Temp 215 deg F High Engine Temp All Engine Coolant Temp 220 deg F High Engine Temp 10 All IQ Filter Restriction IQ Filt Rest 3 0 6 High Discharge Temp RT2 247 deg F High Comp Temp 3 All Notes 1 Max...

Page 45: ...31 CPRSR Malf 20 0 2 5 Disch Temp RT2 Sensor Fault 32 CPRSR Malf 10 All Separator Tank Pressure PT1 Sensor Fault 33 CPRSR Malf All Separator Tank Pressure 20 PSI during start attempt Engine will not c...

Page 46: ...ant Temp 215 deg F High Engine Temp All Engine Coolant Temp 220 deg F High Engine Temp 10 All IQ Filter Restriction IQ Filt Rest 3 0 6 High Discharge Temp RT2 247 F High Comp Temp 3 All Notes 1 Max cr...

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