Ingersoll-Rand HP375WJD Operating, Maintenance & Parts Manual Download Page 3

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Book 54722160 (8/02)

Foreword

Machine models represented in this manual may be used in various locations worldwide. Machines sold and

shipped into European common market countries requires that the machine display the EC Mark and conform to

various directives. In such cases, the design specification of this machine has been certified as complying with EC

directives. Any modification to any part is absolutely prohibited and would result in the CE certification and marking

being rendered invalid. A declaration of that conformity follows:

Declaration of Conformity

WITH EC DIRECTIVE

Ingersoll--Rand Company

Portable Compressor Division

P.O. Box 868

501 Sanford Avenue

Mocksville, North Carolina 27028

Declare that, under our sole responsibility for manufacture and supply, the product(s)

To which this declaration relates, is (are) in conformity with the provisions of the above

directives using the following principal standards

________________________________

Represented In EC By:

Ingersoll--Rand Company Limited

Standard Products Division

Swan Lane

Hindley Green

Wigan WN2 4EZ

United Kingdom

Issued at Mocksville on 1--1--95

Issued at Hindley Green on 1--1--95

________________________________

EN1012--1, EN29001, EN202, EN60204--1

PN8NTC2, EN 50081, EN50082

HP1300WCU

XP1400WCU

P1600WCU

XP900WCU

XHP900WCAT

XHP650WCAT

XHP750WCAT

XHP825WCAT

VHP825WCU

HP935WCU

XP1050WCU

HP825WCU

VHP750WCAT

VHP850WCAT

HP900WCAT

XP1000WCAT

98/37/EC

XHP1070CAT

NXP1300WCU

H. Seddon, Q.A. Manager

Ric Lunsford

Manager of Quality Control

HP375WJD

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

implied, regarding the Ingersoll--Rand products described herein. Any such warranties or other terms and

conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such

products, which are available upon request.

This manual contains instructions and technical data to cover all routine operation and scheduled maintenance

tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be

referred to an authorized Ingersoll--Rand service department.

Summary of Contents for HP375WJD

Page 1: ...INTENANCE PARTS MANUAL COMPRESSOR MODEL HP375WJD XP375WJD Code Revised 10 12 Doosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Rand Company in this manual is historical or nominative in nature and is not meant to suggest a current affiliat...

Page 2: ...nd services that consistently meet the requirements of our customers and each other 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: ...By Ingersoll Rand Company Limited Standard Products Division Swan Lane Hindley Green Wigan WN2 4EZ United Kingdom Issued at Mocksville on 1 1 95 Issued at Hindley Green on 1 1 95 ________________________________ EN1012 1 EN29001 EN202 EN60204 1 PN8NTC2 EN 50081 EN50082 HP1300WCU XP1400WCU P1600WCU XP900WCU XHP900WCAT XHP650WCAT XHP750WCAT XHP825WCAT VHP825WCU HP935WCU XP1050WCU HP825WCU VHP750WCAT...

Page 4: ... any obligation to make such changes or add such improvements to products sold previously Theintendedusesofthismachine areoutlined belowand examplesofunapprovedusage arealso given However Ingersoll Rand cannot anticipate every application or work situation that may arise If in doubt consult supervision This machine has been designed and supplied for above ground operation to be used for compressio...

Page 5: ...ION SECTION 3 NOISE EMISSION SECTION 4 GENERAL DATA SECTION 5 OPERATION SECTION 6 MAINTENANCE SECTION 7 LUBRICATION SECTION 8 TROUBLESHOOTING SECTION 9 PARTS ORDERING SECTION 10 PARTS LIST SECTION 11 OPTIONS PARTS LIST SECTION 12 ENGINE operation maintenance lubrication troubleshooting ...

Page 6: ...must be fitted and controlled by work procedures so that one machine cannot accidentally be pressurized or over pressurized by another Compressed air must not be used for a feed to any form of breathing apparatus or mask The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible If the discharged air ...

Page 7: ...ous burns Do not open radiator while hot Rotating fan blade can cause serious injury Do not operate without guard in place Use care to avoid contacting hot surfaces engine exhaust manifold and piping air receiver and air discharge piping etc Ether is an extremely volatile highly flammable gas USE SPARINGLY Do NOT use ETHER if unit has GLOW Plug starting aid Engine damage will result Never allow th...

Page 8: ... WARNING Flammable liquid Air gas flow or Air discharge Look forthese signs onmachines shippedtointernationalmarkets outside NorthAmerica whichpoint 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 handbrake and wheel chocks Diesel Fuel No open flame Do not breathe the compresse...

Page 9: ...nual Rough Service Designation Wet Location Operation WARNING Consult the operation and maintenance manual before performing any maintenance WARNING Before connecting the tow bar or when preparing to tow consult the operation and maintenance manual Replace any cracked protective shield On power Off power Emergency stop Do not use fork lift truck from this side Do not stack Do not operate with the ...

Page 10: ... and Maintenance manual before operation or maintenance of this machine is undertaken XX km h Pressurized component or system Do not exceed the speed limit Pressurized vessel Do not remove the Operating and Maintenance manual and manual holder from this machine Use fork lift truck from this side only 0_C WARNING For operating temperature below 0_C consult the operation and maintenance manual ...

Page 11: ...arkets 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 Discharged air can contain carbon monoxide or other contaminants DANGER Do not breathe this air Will cause serious injury or death Can cause serious injury or death Trapped air pressure Close se...

Page 12: ...th 105 km hr Rotating fan blade Can cause serious Do not operate without guard in place WARNING injury Falling off machine Can cause serious injury Access lifting bail from inside machine or death WARNING Door under pressure Can cause serious injury Use both hands to open door when machine is running WARNING attach safety device OSHA Valve at source of When using air tools Can cause serious WARNIN...

Page 13: ...ls are present on the machines Replace decals that are not readable FREE SAFETY DECALS CAUTION This engine is equipped with an electric heater starting aid DO NOT USE ETHER ENGINE DAMAGE WILL OCCUR High pressure air Can cause serious Relieve pressure before removing filler plugs caps fittings or covers injury or death WARNING COOLANT FILL INSTRUCTIONS Adding Do NOT remove radiator cap Top off at o...

Page 14: ...of twenty four 24 months from shipment to or the accumulation of 4 000 hours of service by the initial user For Air Ends the warranty against defects will include replacement of the complete Air End provided the original Air End is returned assembled and unopened C 1 Portable Compressor Airend Limited Optional Warranty The earlier of sixty 60 months from shipment to or the accumulation of 10 000 h...

Page 15: ...d 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 warrant...

Page 16: ...eere IN COMPRESSORS IN GENERATORS AS OF 1 1 01 24 24 2000 2000 5 yrs 5000 hours using OEM fluids filters with 250 deductible 2 yrs 4000 hours using IR fluids filters Deutz 24 2000 Available at dealer Ingersoll Rand 24 4000 5 years 10 000 hours when using genuine Ingersoll Rand fluids and parts Refer to operator s manual Kubota North America Only Western Europe Oceania Central South America Asia Mi...

Page 17: ...rranty is limited to defects in major components rotors housings gears bearings and is automatically available when the following three conditions are met 1 The original airend is returned assembled and unopened 2 Submissions of proof that Ingersoll Rand fluid filters and separators have been used Refer to the Operation and Parts manual for the correct fluids filters and separator ele ments requir...

Page 18: ...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 Ingersoll Rand Company Portable Compressor Division P O Box 868 Mocksville North Carolina 27028 Attn Warranty Department Note Completion of this form validates the warra...

Page 19: ...ectric water etc Utility Contractor SERVICING DISTRIBUTOR USER ACKNOWLEDGEMENT 1 The Purchaser has been instructed and or has read the manual and understands proper preventative maintenance general operation and safety precautions 2 The warranty and limitation 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 o...

Page 20: ...20 Book 54722160 8 02 Ingersoll Rand Company Portable Compressor Division P O Box 868 Mocksville North Carolina 27028 Attention Warranty Department fold ...

Page 21: ...the air intake system or parts thereof c enclosure or parts thereof 5 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 6 Operation of the compressor with any of the enclosure doors open Compressor Noise Emission Control Information A The removal or rendering inoperative other than for the purpose of maintenance repair or replacement of any noise control d...

Page 22: ...he 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 de sign assembly or in any part compon...

Page 23: ...E Enclosure Panels Enclosure panels should also be inspected at 100 hour operational intervals All panels that are warped punctured torn or otherwise deformed such that their noise containment function is reduced should be re paired 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 seati...

Page 24: ...24 Book 54722160 8 02 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK HOURMETER READING MAINT INSPECT DATE LOCATION CITY STATE WORK DONE BY NAME ...

Page 25: ... Speed rpm 1400 FLUID CAPACITIES U S Gallons litres Compressor Lubricant 9 5 36 0 Engine Lube including filter 3 5 13 2 Engine Coolant Radiator 5 5 20 8 Fuel Tank Clean DIESEL fuel 58 219 5 UNITS MEASUREMENTS WEIGHTS inches mm Overall Length 149 3807 Overall Height 68 1727 Overall Width 78 1 1984 Unit Weight pounds 4444 RUNNING GEAR Tire Size Load Range ST225 75 R15 D Towing Speed Maximum mph 65 m...

Page 26: ...i kPa 11 Fuel Level Gauge Indicates amount of fuel in tank Controls Standard 12 Power Switch Rotate ON to activate systems prior to Starting Rotate Off to stop engine 19 Service Air Button After warm up PUSH Provides full air pressure at the service outlet Optional Controls 13 Engine Speed Gauge Indicates engine speed 14 Discharge Air Temp Gauge Indicates in _F and _C Normal operating range 185_F ...

Page 27: ...nd rod A of air cylinder B fully retracted turn regulator adjustment screw clockwise until throttle airm C moves against full speed governor stop D 4 Insure that pressure is maintained at rated pressure then turn regulator adjustment screw counterclockwise until throttle arm C just begins to move Note Turning regulator adjustment screw clockwise will raise pressure at full speed 5 Close service va...

Page 28: ...e and or other components It is necessary to isolate the compressor package from the carrier base with a flexible mounting system Such a system must also prevent detachment of the package from the carrier base in the event the isola tors fail Contact Ingersoll Rand representative for flexible mounting kits Warranty does notcover failures attributable to mount ing of the compressor package to the c...

Page 29: ...e with doors open Extended exposure to loud noise can cause hearing loss Wear hearing protection whendoors or valve s are open Close the side doors to maintain a cooling air path and to avoid recirculation of hot air This will maximize the life of the engine and compressor and protect the hearing of surrounding personnel Be sure no one is IN or ON the compressor unit STARTING WARNING Under no circ...

Page 30: ...ce valve s CAUTION Never allow the machine to stand idle with pressure in the system EMERGENCY STOPPING In the event that the unit has to be stopped in an emergency TURN THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO THE 0 OFF POSITION RE STARTING AFTER AN EMERGENCY If the machine has been switched off because of a machine malfunction then identify and correct the fault before attempting to re ...

Page 31: ...y of the sight tube on the side of the receiver tank See the de cal beside the sight tube If the oil level is not in the OK range make appropriate corrections Add or Drain A totally filled sight tube in which the level is not visible indicates an over full condition and requires that oil be drained Compressor Oil This machine was factory filled with Ingersoll Rand Pro TecR Compressor Fluid Ingerso...

Page 32: ...r dirt dump on each air cleaner housing to ensure that they are not clogged NOTICE Holes or cracks down stream of the air cleaner housing will cause the restric tion indicators to be ineffective The air filters restricted sensor will automatically reset after the main power switch is flipped to OFF To service the air cleaners on all units proceed as fol lows 1 Loosen outer wing nut and remove with...

Page 33: ...clean fuel is either poured or pumped into the tank When filling the fuel tank on this unit by methods other than a pump and hose use a CLEAN non metallic funnel Every six months the drain plugs should be removed from the tanks so that any sediment or accumulated condensate may be drained When replacing the drain plugs make sure they are tightened securely BATTERY Heavy duty diesel cranking type b...

Page 34: ...of such a mixture is recommended for both summer and winter operation When using water alone be sure to add a reputable brand of rust inhibitor to prevent internal corrosion It is recommended to test the freezing protection of the coolant every six months or prior to freezing tempera tures Replenish with a fresh mixture every twelve months A drain for the system is located in the bottom radiator t...

Page 35: ...ing and cooling oil to preclude any possible damage from loss of oil Also the design of the filter prevents any wa shing off of any dirt during oil bypassing NOTICE The oil filter must be replaced every 500 hours of operation On new or overhauled units replace the element after the first 50 and 150 hours of oper ation thereafter service the oil filter every 500 hours To service the oil filters it ...

Page 36: ...een the rollers Then rotate the bearing to repeat this operation on the next segment Keep doing this until you have the entire bearing completely filled with grease Before installing bearing place a light coat of grease on the bearing cups which are pressed in the hub NOTICE Excessive grease in the hub or grease cap serves no purpose due to the fact that there is no way to force the grease into th...

Page 37: ...xcessive oil carry over may be caused by an oil logged separator element Do not replace element without first performing the following mainte nance procedure 1 Check oil level Maintain as indicated earlier in this section 2 Thoroughly clean scavenge line any orifice and check valve 3 Assure minimum pressure valve if so equipped has proper setting 4 Run unit at rated operating pressure for 30 to 40...

Page 38: ...the first week of use Every six months apply a multi purpose grease to the fittings on the brake actuator Electric Brake Adjustment Brakes should be adjusted 1 after the first 200 miles of operation when the brake shoes and drums have seated 2 at 3000 mile intervals 3 or as use and performance requires The brakes should be adjusted in the following manner 1 Jack up trailer and secure on adequate c...

Page 39: ... material left on cover or tank Install new gasket inner shell and new element Place a straightedge across top of element and mea sure from bottom of straightedge to bottom of ele ment See Fig 4 1 Reposition cover use care not to damage gaskets Replace cover mounting screws tighten in a criss cross pattern to 180 190 lbs ft Reconnect service line Reconnect hose Close service valve Start unit and l...

Page 40: ...edium wet coats of Duponts 222S Adhesion Promoter over the entire area to be painted with a 5 minute flash in between coats 9 To apply the texture coat use Duponts 1854S Tuffcoat Primer The proper technique to do this is to spray the Tuffcoat Primer using a pressure pot and use about 2 5 pounds of air pressure This will allow the primer to splatter causing the textured look Note you must be carefu...

Page 41: ... C Wheel Lug Nuts C Hoses oil air intake etc C Automatic Shutdown System Test C Air Cleaner System Visual C Compressor Oil Cooler Exterior C CLEAN Engine Radiator Exterior C CLEAN Fasteners Guards C Air Cleaner Elements WI Fuel Water Separator Element R Compressor Oil Filter Element B A Compressor Oil R Wheels bearings seals etc C C Engine Coolant Test C R Shutdown Switch Settings Test C Scavenge ...

Page 42: ...s or lacquers which may be insoluble Such deposits can cause se rious troubles including clogging of the filters Where possible do NOT mix oils of different types and avoid mixing differentbrands Atype or brand change is best made at the time of a complete oil drain and refill If the unit has been operated for the time hours men tioned above it should be completely drained of oil If the unit has b...

Page 43: ...ory Portable Compressor Fluid Chart SECTION 7 COMPRESSOR LUBRICATION 23_C to 52_C 10_F to 125_F 40_F to 125_F 40_C to 52_C Mil PRF 2104G SAE 10W IR Pro Tect IR Performance 500 Mil L 46167 IR XHP 505 10_F to 125_F 23_C to 52_C 65_F to 125_F 18_C to 52_C IR XHP1001 40_F to 65_F 40_C to 18_C IR Performance 500 Mil L 46167 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 Co...

Page 44: ...the compressor will still operate is it safe to continue operating it to make further checks B Do The Simplest Things First Most troubles are simple and easily corrected For example most complaints are low capacity which may be caused by too low an engine speed or compressor over heats which may be caused by low oil level Always check the easiest and most obvious things first following this simple...

Page 45: ...n of Cooling Air Loose Wire Connection Malfunctioning circuit board TROUBLE SHOOTING CHART Bold Headings depict the COMPLAINT Subheadings suggest the CAUSE Note Subheadings suggest sequence to follow troubleshooting Add CLEAN diesel Fuel See Complaint 10 Check coolant level If necessary Add See Complaint 3 and Complaint 4 Replace fan belt Wiggle wires at switches connector blocks Make repairs Repl...

Page 46: ...enoid Malfunctioning Relay Defective Safety Bypass Switch Add oil Relocate or reposition See Engine Oil Spec Change oil Replace element s See Trouble Shooting in Engine Manual Repair or replace Replace circuit Replace circuit board Replace circuit board Replace circuit board Replace circuit board Tighten or replace belt set Repair or replace connection Check electrolyte level Add if necessary Chec...

Page 47: ...efective Minimum Pressure Valve Defective Separator Element Wrong Air Filter Element Above spec limit Relocate or reposition unit Add oil Look for any leaks Check spec in this manual Clean exterior surfaces Move unit to cleaner environment Replace elements Change oil Tighten or replace belt set Reduce pressure to spec Close side doors Replace belly pan Replace thermostat in bypass valve Check fan ...

Page 48: ...oader Butterfly Valve Defective Safety Valve Defective Separator Element Ice in Regulation Lines Orifice Move unit to cleaner environment Install new element Read Page 13 in this manual Install proper element Inspect coupling If necessary replace coupling Read Page 15 in this manual Relocate or reposition unit Remove scavenge orifice Clean and Replace Remove scavenge tube Clean and Replace Remove ...

Page 49: ...d 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 adjacent page The quantities specified are the number of parts used per one assembly and are not necessarily the total number of parts used in the machine Where no quantity is specified the quantity is assumed to be one Each d...

Page 50: ...s also permanently stamped in the metal of the frame side rail c Always specify the number of the parts list pub lication d Always specify the quantity of parts required e Always specify the part number as well as the description of the part or parts exactly as it is given on the parts list illustration In the event parts are being returned to your nearest sales office autonomous company or author...

Page 51: ...no event be liable to the Purchaser any successors in in terest or any beneficiary of this order for any conse quential incidental indirect special or punitive dam ages 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 loss of use lost prof its or revenue interest lost goodwill work stoppage impairment of other g...

Page 52: ... Wheel Assembly Seperator Tank Electric Brake Shoes Electric Brake Wiring Running Gear Complete Exhaust Complete Air Intake Complete Fuel Tank Complete Battery Assembly Air Cleaner Assembly Inst Control Panel Standard Enclosure Complete Foam Insulation Complete Decal Location Service Air OTBV Oil Filter Mounting Minimum Pressure Valve Galvanneal Enclosure Complete Standard Wiring Trailer Wiring Un...

Page 53: ...0 C D 54742010 54641840 1 1 LIFTING BAIL PAN MIDDLE BELLY L M 36879492 96700893 8 2 SCREW HEX FLANGE M12 1 75 X 25 SCREW HEX M16 2 0 X 60 E F 54759113 36877579 1 2 EYE LIFTING BAIL FENDER N 96704630 2 NUT NYLOC M16 G H 36797652 36880623 10 2 SCREW TAPPING M06 1 0 X 12 COVER FLEXIBLE DRAWBAR END A B D E F H G J H K M N C L J Q R S Q P P 54772041 12 PLUG SNAP IN HOLE Q 92368687 8 SCREW TAPPING M06 1...

Page 54: ...EASE 96730395 36876621 8 1 SCREW HEX M12 1 75 X 50 DRAWBAR 35610377 35372432 2 2 CHAIN ASSEMBLY LOCK COUPLING 54443577 36757284 1 1 JACK SCREW CHANNEL PINTEL MTG 3 POSITION 35304047 95935003 8 16 NUT NYLOC M12 1 75 WASHER FLAT 35605187 35376094 1 2 PINTEL EYE 3 SCREW HEX M16 2 0 X 12 36026268 2 TIRE ASSEMBLY C D M E F N P G H Q R T B C E F G H J K L M N D Q P R S S 36879302 6 SCREW HEX FLANGE M16 ...

Page 55: ...315217 35379395 2 2 NUT SPINDLE CAP GREASE DUST 35316876 35316884 2 2 CONE INNER BEARING CUP INNER BEARING 35326958 35315340 2 2 HANGER FRONT BOLT SHACKLE 35390459 35318831 2 2 HUB STUDDED CUP OUTER BEARING 35315357 35326966 2 2 NUT TOP LOCK HANGER REAR J K C D L M E F S T G H U V 35315241 35315258 2 4 PLATE TIE NUT U BOLT 35361898 35315274 12 12 STUD NUT WHEEL N P Q R 35315365 35315373 2 2 BOLT K...

Page 56: ...AL NO ILLUST NO 3 02 DATE REV 35367051 2 LIGHT YELLOW CLEARANCE 35315944 1 SWITCH BREAKAWAY 37140365 35346337 1 1 SPLICE INSULATED LUG TERMINAL 35120005 92368687 40 5 WIRE 14 GA BLACK SCREW TAPPING M06 1 0 X 14 J K C D L M E F N P G H 54671557 2 LIGHT STOP TAIL TURN 36797652 2 SCREW TAPPING M06 1 0 X 12 J B M A C N M G F FURNISHED K L P P BY CUSTOMER H E D 36895860 1 LIGHT LICENSE 36782837 2 SCREW...

Page 57: ...22160 006 MANUAL NO ILLUST NO 07 01 DATE REV A A SECTION A A DEXTER A B C D E F H G 35391002 2 SPRING RETRACTOR 36895803 36895811 1 2 SHOE KIT BRAKE MAGNET KIT 36895829 1 LEVER KIT LH ACTUATING 35390913 35391010 2 2 LEVER PARKING BRAKE SCREW ASM ADJUSTING 35391069 35393727 2 2 PLUG ADJUSTING SLOT SPRING KIT ADJ SCREW J C D E F G H 36895837 1 LEVER KIT RH ACTUATING J ...

Page 58: ...160 08 02 Item CPN Qty Description A B 35318757 35282565 1 1 WHEEL 15 X 6 VALVE STEM Item CPN Qty Description TIRE WHEEL ASSEMBLY A 54722160 007 MANUAL NO ILLUST NO 07 01 DATE REV 36846319 1 TIRE ST225 75R15D A B C C ...

Page 59: ... 1 NUT NYLOC M12 1 75 CYLINDER PNEUMATIC 35328467 95923074 2 2 BEARING ROD END NUT JAM 5 16 24 N P Q R 96701461 2 SCREW HEX M06 1 0 X 25 W X Y Z 36877223 1 BRACKET AIR CYLINDER 95935029 1 WASHER FLAT 35370386 1 35356484 ELBOW MALE 1 8NPT X 3 8 TUBE TUBING 3 8 SYNFLEX L M P N A C E T U Q R S C E D G F J B Z H TO UNLOADER 29 Y X 96701396 4 WASHER FLT 96726435 4 SCREW HEX M08 1 25 X 20 96701479 2 SCR...

Page 60: ...on A B 22058259 35279025 1 4 MUFFLER SCREW TAPPING M08 1 25 X 20 Item CPN Qty Description EXHAUST COMPLETE 22058275 22058267 1 1 TUBE EXHAUST EXHAUST PIPE ASM 54738760 36881175 1 1 PIPE EXHAUST CLAMP EXHAUST C D E F A B C D E F G G H 35293059 2 CLAMP EXHAUST SEAL 35293059 3 G H CLAMP EXHAUST SEAL ...

Page 61: ...tem CPN Qty Description 36879492 36797652 4 10 SCREW HEX FLANGE M12 1 75 X 25 SCREW TAPPING M06 1 0 X 12 54637111 54637103 1 1 SUPPORT OIL COOLER SUPPORT RADIATOR 36895746 96702055 8 8 NUTSERT M08 SCREW HEX M08 1 25 X 20 54703558 54665781 1 1 BAFFLE LH COOLER SHROUD FAN 95934998 8 WASHER FLAT 36878262 1 GUARD FAN J K C D L M E F G H DRAWBAR END A B C E F J L D J G H M K ...

Page 62: ...OR CLAMP WORM GEAR 96702279 92368687 18 4 SCREW HEX M10 1 50 X 20 SCREW TAPPING M06 1 0 X 12 35360775 35285162 42 1 TUBING 5 16 GROMMET 35221639 54666334 4 1 CLAMP HOSE HOSE TOP RADIATOR B 54722160 011 MANUAL NO ILLUST NO 10 01 DATE REV DRAWBAR END J K C D L M E F G H A B C D D E K J G G H F L L L 54738893 1 OIL COOLER M N N 37 37 35140409 FOAM N 22060503 1 PLATE BAFFLE P 36797652 2 Q SCREW TAPPIN...

Page 63: ...DER STUD M16 2 0 X 55 35375385 4 SCREW HEX M16 2 0 X 40 96701750 4 NUT HEX M16 2 0 54636584 95955993 1 1 ORIFICE INJECTION CONNECTOR 1 31 SAE X 16 JIC 35589589 35588318 1 1 GASKET UNLOADER A E GASKET UNLOADER INLET MANUAL NO ILLUST NO J K C D L M E F N P G H Q R DRAWBAR END 35843168 96702048 1 4 FLANGE UNLOADER INLET SCREW HEX M08 1 25 X 16 35316587 35282292 1 14 ADAPTER BARBED 1 8 X 1 8 NPT TUBIN...

Page 64: ...29 2 ISOLATOR CENTER BOND MOUNT 96704630 95935052 2 4 NUT NYLOC M16 2 0 WASHER FLAT 35375591 2 SCREW HEX M16 2 0 30 AIREND COMPLETE A D H J G K F L F E B C M N R P 35322379 95364469 1 1 VALVE BLOWDOWN ELBOW 1 4 N P Q M 35369503 1 TEE 1 4NPT X 3 8 TUBE R 35356484 TUBING 3 8 SYNFLEX T S R R T Q R FROM SEP TK REGULATOR TO AIR CYLINDER 35373976 1 TEE 1 4 NPT X 3 8 TUBE S T U 36766756 2 ORIFACE MUFFLER...

Page 65: ...OUNT 96704630 95935052 2 4 NUT NYLOC M16 2 0 WASHER FLAT 35375591 2 SCREW HEX M16 2 0 30 AIREND COMPLETE A D H J G K F L F E B C M N R P 35322379 95364469 2 1 VALVE BLOWDOWN ELBOW 1 4 N P Q M 35369503 1 TEE 1 4NPT X 3 8 TUBE R 35356484 TUBING 3 8 SYNFLEX T S R R T Q U FROM SEP TK REGULATOR TO AIR CYLINDER 35373976 2 TEE 1 4 NPT X 3 8 TUBE S T U 36766756 2 ORIFACE MUFFLER 140 35114545 2 TEE STREET ...

Page 66: ...54643432 54469242 1 1 SPACER BEARING TAPER ROLLER 54680939 35313550 1 1 O RING ROTOR HOUSING INLET END BEARING CYLINDRICAL 95688289 54610779 1 1 KEY SQUARE FR SET GEAR 54654819 96716105 1 4 RETAINER BEARING MR INLET SCREW HEX HD M6 X 12 54611918 35295336 1 2 GEARCASE PIN DOWEL M16 X 40 P Q C D R S E F T U G H V W A B C E F G H J K L M N P Q D R S T U V 54686936 1 SPACER GEAR MR 96706262 8 SCREW HE...

Page 67: ...X HD M16 X 50 54635651 35600113 1 2 RETAINER FR BEARING BEARING TAPER ROLLER 54635644 39309117 1 2 RETAINER MR BEARING BEARING TAPER ROLLER 95643383 35355874 1 1 O RING BEARING CVR TO BH SET DISCHG END CLEAR SHIM 39312079 39312293 1 1 SHIM ROTOR END CLEARENCE 05 96716162 7 SCREW HEX HD M16 X 45 P Q C D R S E F T U G H V 39312301 1 39312319 96707377 1 2 SCREW HEX HD M16 X 150 35295336 54509203 2 1 ...

Page 68: ...ON SPRING BUSHING PISTON 36718427 35278555 1 1 BODY UNLOADER PLUG 35588193 35317197 1 1 PISTON UNLOADER DIAPHRAGM 35318914 35317213 1 1 SPRING PIN PIN UNLOADER 35321603 35317239 1 1 SPRING 35289057 35278589 1 1 PLUG O RING P Q C D R S E F T U G H V W 35321595 1 35279959 1 O RING 35836949 35271162 1 4 SCREW 96702287 35833227 6 1 SCREW HOUSING PISTON J X K L M N WASHER PISTON SCREW CAP COVER PISTON ...

Page 69: ...ST NO DRAWBAR END Item CPN Qty Description A B 36876753 35584242 1 1 BODY GASKET Item CPN Qty Description 35379940 36788164 1 1 SPRING PLUG 36876761 36876779 1 1 BODY COVER 36788172 1 SEAL 36782019 95022307 1 1 ELEMENT O RING 36786382 35288448 8 1 SCREW BALL J K C D L E F G H A B H J L F C G E D K ...

Page 70: ... 70 95938171 35227919 1 1 ELBOW 90 1 31 SAE HOSE 16 X 25 95992632 1 ELBOW 45 1 31 SAE J K C D L M E F G H 36880367 95954921 1 1 SUPPORT OIL FILTER UNION 1 31 SAE N 35279025 2 SCREW TAPPING M08 1 25 X 20 P 36876787 1 OTBV 1 31 SAE DRAWBAR END 95954913 1 REDUCER 1 62 SAE X 1 31FEM SAE 36897437 1 HEAD SINGLE FILTER Q R 36897346 1 ELEMENT OIL FILTER S H G Q P N A A J K D B A C E F L M S R T 95935037 2...

Page 71: ...V MINIMUM PRESSURE VALVE Item CPN Qty Description A B 35379973 35380708 1 1 BODY MIN PRESS VALVE CV ASSEMBLY Item CPN Qty Description 35380732 35380716 1 1 SPRING PISTON 35380724 35380757 1 1 O RING CAP C D E F G 35380740 1 SPRING 36789550 MIN PRESS VALVE ASM A B C D E F G ...

Page 72: ...OSED 3 4NPT VALVE MINIMUM PRESSURE 95953451 1 COUPLING 1 25 NPT 95208682 54698659 1 1 ADAPTER 1 50 NPT X 1 50 TUBE SERVICE 95279345 1 CONNECTOR 1 25 NPT J K C D L M E F G H 95950275 35612126 1 1 NIPPLE PIPE 1 25 NPT X 4 0 VALVE BALL 1 25 NPT N 95944104 1 ELBOW STREET 1 25 NPT P 95741088 1 ADAPTER FEMALE E G H Q C B A F 95242996 1 NIPPLE CLOSE Q D R S 95280541 1 PLUG HEX O RING 1 06 12 R 95928230 P...

Page 73: ...45 2 50 SAE 54680012 95954210 1 1 TUBE OTBV TO SEPTK TEE 3 4 NPT 54688015 95357976 1 1 HOSE DISCHARGE O RING 35295143 95934683 2 4 FLANGE HALF WASHER LOCK J K C D L M E F G H N P 96727557 36785012 8 2 SCREW HEX FLANGE M16 X 60 BRACKET SEPERATOR TANK LIFT Q R 95992632 1 ELBOW 45 1 31SAE 54731443 1 VLAVE SAFETY 200PSI 54764956 1 SWITCH ALARM 95049359 1 PLUG 1 8 NPT S 95928040 1 NIPPLE 3 4 NPT CLOSED...

Page 74: ...CVANGE TUBE 35279942 1 O RING 36840411 35282920 1 1 VALVE CHECK HOSE 4 JIC X 30 54627799 54629464 2 1 ELBOW SIGHT TUBE TUBE SIGHT J K C D L M E F S T G H U 35369347 1 CONN MALE 1 4 NPT X 3 8 TUBE 95944575 35579630 1 NIPPLE CLOSED 1 4 NPT PLUG 1 62 N P Q R SEPARATOR TANK COMPLETE G L H M E N D R S U U T B F C C A P 92877620 1 O RING 95973228 1 O RING Q TO UNLOADER VALVE 32 TO BLOWDOWN VALVE 30 E TO...

Page 75: ...ASM BUSHING NITRILE 35296342 6 CLAMP WORMGEAR M06 16 54720727 54721170 1 STRAP FUEL TANK STRAP FUEL TANK J K C D L M E F G H ENGINE FUEL FILTER 41 C N D A B L H M E K J H H F D 22 5 G H C C FUEL RETURN RAIL 36845493 1 FILTER IN LINE FUEL N S T R Q P U H F G RETURN PICKUP 35279025 SCREW TAPPING M08 1 25 X 20 4 P Q R S T U 35322395 1 SILENCER PNEUMATIC 1 4 NPT 35369339 CONN FEMALE 1 4 NPT X 3 8 TUBE...

Page 76: ...V Item CPN Qty Description A B 54692975 35393677 1 1 COVER AIR CLEANER VALVE DUST EJECTOR Item CPN Qty Description 54717152 54692967 1 1 ELEMENT SAFETY OPTIONAL BODY AIR CLEANER AIR CLEANER ASSEMBLY 54717145 1 ELEMENT PRIMARY 35393719 1 CAP PLUG D E C F A C D E OPTIONAL B F ...

Page 77: ...2 DATE REV 54667084 35314939 1 2 HOSE ENGINE AIR INTAKE INDICATOR RESTRICTION 96719851 2 SCREW HEX M12 1 75 X 16 MANUAL NO ILLUST NO C D E F G H DRAWBAR END AIR CLEANER ASM 54747977 1 SUPPORT AIR CLEANER 96702048 8 SCREW HEX M08 1 25 X 16 36897668 1 CLAMP T BOLT A C D F E J K B H G G J J 35365477 2 CLAMP T BOLT K 35374073 1 CLAMP T BOLT 54756044 ...

Page 78: ... B 35284801 35516582 1 1 CABLE GROUND CABLE POSITIVE BATTERY Item CPN Qty Description 92368687 36853232 4 1 SCREW TAPPING M06 1 0 X 12 TRAY BATTERY 36853257 95923298 1 2 ANGLE NUT HEX LOCK 25 20 36853265 36844264 2 1 WASHER PLASTIC BATERY 12 V 35610856 36860005 1 2 CABLE NEGATIVE BATTERY BOLT J J K C D E F G H B C D E H K G J F A ...

Page 79: ...INE CONTROL W1 S1 KEYSWITCH OPERATION SEQUENCE OFF 1 2 3 4 1 2 ON 1 2 3 4 CRANK 1 2 3 BYPASS S1 I II III M 2 3 4 B R6 1 S0L CF1 R3 1 G S1 1 R B L 87 30 87 30 86 85 IG R4 1 87 R6 86 R4 R Y U Y U R B R R R W N Y Y S N N R R B R I II III N N U R B CONTINUE NEXT PAGE IL1 D1 B P Y A IND LP B 36782456 1 BATTERY 35676169 1 DIODE D1 IL1 54774112 1 LAMP ALTERNATOR CHARGE ITEM COLOR B BLACK U BLUE N BROWN G...

Page 80: ...SS ENGINE CONTROL W1 S1 KEYSWITCH OPERATION SEQUENCE OFF 1 2 3 4 1 2 ON 1 2 3 4 CRANK 1 2 3 BYPASS S1 I II III M 2 3 4 B R6 1 S0L CF1 R3 1 G S1 1 R B D 87 30 87 30 86 85 R4 1 87 R6 86 R4 R Y U Y U R B R R R W N Y S N N R R I II III N N U R B CONTINUE NEXT PAGE IL1 D1 B P Y A IND LP B 36884264 1 BATTERY 35676169 1 DIODE D1 IL1 54774112 1 LAMP ALTERNATOR CHARGE ITEM COLOR B BLACK U BLUE N BROWN G GR...

Page 81: ... SWITCH DISCRG HIGH AIR TEMP SWITCH HIGH ENGINE TEMP TS2 TS3 54758008 1 HARNESS ENGINE CONTROL W1 LFS IL2 SV1 TS1 TS3 R5 B 86 85 h 3 R5 1 D TS2 30 87A 87 P 85 86 R3 PS1 FS FG S A C W Y N N O K R B R B R B K P K G K B K U N W G P N U B C B C A A C C S D3 D4 G U D C LOW F N E K U P U U 1 R B G K B 2 R B D C A B P CONTINUE PREVIOUS PAGE CONTINUE OPTIONS N N U R B FUEL IND LP ITEM COLOR B BLK U BLU N ...

Page 82: ... TAIL SIDE FRAME BRAKE BRAKE SIDE SIDE RED WHITE BROWN GREEN YELLOW BLUE N C WHITE BROWN GREEN YELLOW BLUE BLUE RED BREAKAWAY SWITCH BATT RIGHT LEFT BULB BULB BULB BULB 35676169 2 35676169 35676169 1 2 35676169 2 BRAKEAWAY SW 35315944 1 JUNCTION BOX 3 5 4 2 PLUG SOCKET WIRING CONNECTIONS 1 WHITE GROUND 2 YELLOW LEFT STOP TURN SIGNAL 3 4 GREEN RIGHT STOP TURN SIGNAL 5 BROWN TAIL CLEARANCE LIGHTS 6 ...

Page 83: ...19 54746845 1 1 PANEL INSTRUMENT DECAL WW INST PANEL 22070494 8 SCREW PLASTIC TAPPING G H J 54774104 54774096 1 1 KNOB NON REMOVABLE KEY GAUGE FUEL LEVEL 35370386 1 ELBOW MALE 1 8 NPT X 3 8 TUBE M N P 95935599 36882207 1 1 COUPLING 18 NPT X 3 4 GAUGE PRESSURE 150 PSI 54774112 1 MODULE 2 LIGHT WARNING Q R S A B C B C E M N F T D H J L Q P R S 22054159 2 NUT 4 40 PLASTIC T K 36920486 4 RIVET SS 19 D...

Page 84: ... NO 10 01 DATE REV 54718184 8 STRAP FOAM RETAINING 35337328 36881886 8 8 STUD BALL NUT HEX FLANGE M08 1 25 54639174 2 HINGE SIDE DOOR 35256445 54694831 12 1 RETAINER PUSHON 1 4 TURN PANEL REAR ACCESS 54697495 36793602 2 2 RAIL LH TOP LATCH SLAM DOOR 35256429 12 STUD 1 4 TURN DRAWBAR END J K C D L M E F G H N P 35600261 4 SPRING GAS A B M B B L B C N B H J K B C P D E G K G B H J F F B C B B E D Q ...

Page 85: ...TAPPING M08 1 25 X 20 PANEL RH SIDE N P Q R 54694823 54686209 2 1 PANEL LOWER SIDE PANEL FRONT END CAP 54767223 1 PANEL SMALL TOOLBOX W X E F G A G C K D C D G L K H A C D G BRACKET FRONT INTAKE N 54767488 1 PANEL TOOLBOX A B A M A A P 54720834 1 BAFFLE FRONT INTAKE Q R 35310622 1 PLUG 2 0 DIA HOLE 35285543 2 PLUG 1 5 DIA HOLE J A 54722160 033 MANUAL NO ILLUST NO 10 01 DATE REV X S T U V W 9593502...

Page 86: ...T NO 10 01 DATE REV 54718184 8 STRAP FOAM RETAINING 35337328 36881886 8 8 STUD BALL NUT HEX FLANGE M08 1 25 54639174 2 HINGE SIDE DOOR 35256445 54694831 12 2 RETAINER PUSHON 1 4 TURN PANEL REAR ACCESS 54743273 36793602 2 2 RAIL LH TOP LATCH SLAM DOOR 35256429 12 STUD 1 4 TURN DRAWBAR END J K C D L M E F G H N P 35600261 4 SPRING GAS A B M B B L B C N B H J K B C P D E G K G B H J F F B C B B E D Q...

Page 87: ... TAPPING M08 1 25 X 20 PANEL RH SIDE N P Q R 54743232 54686209 2 1 PANEL LOWER SIDE PANEL FRONT END CAP 54767223 1 PANEL SMALL TOOLBOX W X E F G A G C K D C D G L K H A C D G BRACKET FRONT INTAKE N 54767488 1 PANEL TOOLBOX A B A M A A P 54720834 1 BAFFLE FRONT INTAKE Q R 35310622 1 PLUG 2 0 DIA HOLE 35285543 2 PLUG 1 5 DIA HOLE J A 54722160 035 MANUAL NO ILLUST NO 10 01 DATE REV X S T U V W 959350...

Page 88: ...TER ACOUSTIC 54675061 54675020 1 1 PANEL REAR ROOF ACOUSTIC PANEL LOWER DOOR ACOUSTIC 54744826 1 PANEL INTR BAFFLE FRONT ACOUSTIC 54675046 54674973 1 2 PANEL UPPER DOOR ACOUSTIC PANEL REAR CORNER ACOUSTIC 54746516 54770524 2 1 PANEL REAR SIDE ACOUSTIC PANEL LWR SIDE ACOUSTIC J K C D L M E F G H 54744818 54674916 1 1 PANEL INTR BAFFLE SIDE ACOUSTIC PANEL FRONT END CAP ACOUSTIC N 54770490 2 PANEL TO...

Page 89: ...for each tool When using air tools attach safety Disconnected air hoses whip Can cause serious injury death DANGER WARNING WARNING 54568761 REV A Hot pressurized fluid Can cause serious burns Do not open radiator while hot 54568779 REV A Rotating fan blade Can cause serious injury Do not operate without guard in place 54568787 REV A Improper operation of this equipment Can cause serious injury or ...

Page 90: ...V A Combustible gas Can cause serious burns blindness or death Keep sparks and open flames away from batteries WARNING Item CPN Qty Description A B 54568779 54761556 1 1 WARNING ROTATING FAN LAMINATE WJD STD WIRING DIAGRAM Item CPN Qty Description 54568753 54568795 1 1 WARNING BATTERY 54604970 1 DECAL OIL FILL C D E WARNING HIGH PRESSURE C F H G B G H 54767900 36788982 1 1 LAMINATE TRAILER WIRING ...

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