Ingersoll-Rand HP375WJD Operating, Maintenance & Parts Manual
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Ingersoll-Rand HP375WJD Operating, Maintenance & Parts Manual

Ingersoll-Rand HP375WJD Operating, Maintenance & Parts Manual

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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.
Portable Air Compressor Division
P.O. Box 868 -- 501 Sanford Ave
Mocksville, N.C. 27028
Revised (10-12)
Book 54722160 (8/02)
OPERATING, MAINTENANCE,
PARTS MANUAL
COMPRESSOR MODEL
HP375WJD
XP375WJD
Code:
( )
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
1

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Summary of Contents for Ingersoll-Rand HP375WJD

  • Page 1 This manual must be available to the personnel who operate and maintain this machine. 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...
  • Page 2 QUALITY POLICY We will supply products and 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 HP935WCU XHP650WCAT VHP850WCAT NXP1300WCU P1600WCU XP1050WCU XHP750WCAT HP900WCAT HP375WJD XP900WCU HP825WCU XHP825WCAT XP1000WCAT To which this declaration relates, is (are) in conformity with the provisions of the above directives using the following principal standards EN1012- -1, EN29001, EN202, EN60204- -1...
  • Page 4 All components, accessories, pipes and connectors added to the compressed air system should be: S of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Ingersoll--Rand. S clearly rated for a pressure at least equal to the machine maximum allowable working pressure. S compatible with the compressor lubricant/coolant.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1 ....SAFETY SECTION 2 ....WARRANTY/REGISTRATION SECTION 3 ....NOISE EMISSION SECTION 4 .
  • Page 6 SECTION 1- - SAFETY SAFETY PRECAUTIONS Compressed air must not be used for a feed to any form of breathing apparatus or mask. General Information The discharged air contains a very small percentage Ensure that the operator reads and understands the of compressor lubricating oil and care should be taken decals and consults the manuals before maintenance to ensure that downstream equipment is compatible.
  • Page 7 This machine may include such materials as oil, diesel Use care to avoid contacting hot surfaces (engine fuel, antifreeze, brake fluid, oil/air filters and batteries exhaust manifold and piping, air receiver and air which may require proper disposal when performing discharge piping, etc.).
  • Page 8 SAFETY LABELS Look for these signs on machines shipped to international markets outside 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. Hot Surface Corrosion risk Lifting point...
  • Page 9 Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken. WARNING - - Maintain correct tire pressure. (Refer to the GENERAL INFORMATION section of this manual). WARNING: Consult the operation and maintenance manual before performing any maintenance. Rough Service Designation Wet Location Operation Do not stack...
  • Page 10 Oil Drain km/h WARNING undertake Do not exceed the speed limit. maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved. Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken Do not remove the Operating and Maintenance manual and manual holder from this machine.
  • Page 11 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. Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored.
  • Page 12 km/h WARNING WARNING Improper operation of this equipment. Collapsing jackstand. Can cause serious injury or death. Can cause serious injury. Read Operator’s Manual supplied with this machine before operation or Insert locking pin completely. servicing. Excessive towing speed. Modification or alteration of this machine. Can cause serious injury or death.
  • Page 13 CAUTION WARNING DO NOT USE ETHER. High pressure air. Can cause serious ENGINE DAMAGE WILL OCCUR. injury or death. This engine is equipped with an Relieve pressure before electric heater starting aid. removing filler plugs/caps, fittings or covers. NOTICE COOLANT FILL INSTRUCTIONS Adding: USE DIESEL Do NOT remove radiator cap.
  • Page 14 SECTION 2 - - Warranty Ingersoll--Rand, through its distributor, warrants that each item of equipment manufactured by it and delivered hereunder to the initial user will be free of defects in material and workmanship for a period of three (3) months from initial operation or six (6) months from the date of shipment to the initial user, whichever occurs first.
  • Page 15 Ingersoll- -Rand Platinum Drive Train Warranty (Optional) – Platinum drive 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 system and all electrical components are ex- cluded from the extended warranty.
  • Page 16 GENERAL WARRANTY INFORMATION GENERAL WARRANTY Extended Coverage Portable Compressor Package 1 year/2000 hours Airend 2 years/4000 hours 5 years/10,000 hours Limited warranty, major components (refer to operator’s manual). Portable Genset 8KW, 11KW, 20KVA Package 1 year/2000 hours None thru 575KVA Generator 2 years/4000 hours None...
  • Page 17 Extended Limited Airend Warranty Ingersoll--Rand Portable Compressor Division is pleased to announce the availability of extended limited airend warranty. Announcement of the extended warranty coincides with the introduction of PROSTECt Compressor Fluid. PROSTECt Compressor Fluid is an amber colored fluid specially formulated for Portable Compressors and is being provided as the factory filled fluid for all machines except ! XHP650/900/1070 models.

  • Page 18: Warranty/Registration

    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.
  • Page 19 WARRANTY REGISTRATION Selling Distributor Servicing Distributor 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) Construction--Heavy Asphalt Contractor Coal Mining...
  • Page 20 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Book 54722160 (8/02)

  • Page 21: Noise Emission

    SECTION 3 - - NOISE EMISSION This section pertains only to machines distributed within the United States. WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or re- placement, 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;...
  • Page 22 NOISE EMISSION CONTROL MAINTENANCE LOG COMPRESSOR MODEL SERIAL NO. USER UNIT NO. UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Engine Make & Model: Serial No.: Purchaser or Owner: Address: Date Purchased: The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations, specifically the following acts or the causing thereof: (1) the removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replace- ment, of any device or element of design incorporated into new compressor for the purpose of noise control prior...
  • Page 23 MAINTENANCE SCHEDULE ITEM AREA PERIOD Compressed Air Leaks As Detected Safety and Control Systems As Detected Acoustic Materials Daily Fasteners 100 hours Enclosure Panels 100 hours Air Intake & Engine Exhaust 100 hours Cooling Systems 250 hours Isolation Mounts 250 hours Engine Operation See Operator’s Manual Fuels &...
  • Page 24 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK HOURMETER MAINT/ LOCATION CITY/ WORK DONE BY READING STATE (NAME) INSPECT DATE Book 54722160 (8/02)

  • Page 25: General Data

    XP375WJD ..HP375WJD Air Delivery -- cfm (litres/sec) ......

  • Page 26: Maintenance

    CONTROL PANEL 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.
  • Page 27 SPEED and PRESSURE 36518066 Normally, regulation requires no adjusting, but if prop- 4. Insure that pressure is maintained at rated er adjustment is lost, proceed as follows: pressure, then turn regulator adjustment screw counterclockwise until throttle arm (C) just begins to Note: Refer to general data for machine rated speeds move.
  • Page 28 Such a system must also prevent detachment of the BEFORE TOWING package from the carrier base in the event the isola- tors fail. Contact Ingersoll--Rand representative for WARNING flexible mounting kits. Warranty does not cover failures attributable to mount- Failure to follow these instructions can cause ing of the compressor package to the carrier base un- severe injury or death.
  • Page 29 STARTING • Open manual blowdown valve to ensure pressure is relieved in receiver--separator system. Close valve in WARNING order to build up full air pressure and ensure proper oil circulation. Under no circumstances should volatitle liquids such as ETHER be used for starting this machine. .•...
  • Page 30 PUSH AFTER WARM UP RE- -STARTING AFTER AN EMERGENCY NOTE: In order to allow the machine to start at a If the machine has been switched off because of reduced load, a valve, which is operated by a button a machine malfunction then identify and correct the located on the instrument panel, is incorporated in fault before attempting to re--start.
  • Page 31 SECTION 6 - - MAINTENANCE GENERAL unusual environmental operating conditions exist, the schedule should be adjusted accordingly. In addition to periodic inspections, many of the compo- COMPRESSOR OIL LEVEL nents in these units require periodic servicing to pro- vide maximum output and performance. Servicing The oil level is most consistent when the unit is RUN- may consist of pre--operation and post-- operation pro- NING AT FULL LOAD and should be checked at this...
  • Page 32 * Bare Airend -- Pertains to major airend parts (rotors, housings, and bearings). ** Airend Components -- Pertains to auxiliary attachments to the bare airend (drive coupling, seals, pumps, valves, tubes, hoses, fittings and filter housing) The compressor oil must be replaced every 500 hours of operation or six (6) months, whichever comes first for models HP600 -- P1600.
  • Page 33 Every six months the drain plugs should be removed In the event the element is contaminated with dry dirt, from the tanks so that any sediment or accumulated oil or greasy dirt deposits,and a new element is not condensate may be drained. When replacing the available, cleaning can be accomplished by washing, drain plugs, make sure they are tightened securely.
  • Page 34 COMPRESSOR OIL COOLER The use of such a mixture is recommended for both summer and winter operation. When using water The compressor lubricating and cooling oil is cooled alone, be sure to add a reputable brand of rust inhibitor by means of the fin and tube--type oil cooler, located to prevent internal corrosion.
  • Page 35 NOTICE NOTICE The oil filter must be replaced every 500 hours of operation. On new or overhauled units, replace Piping systems operating at less than 150 psi the element after the first 50 and 150 hours of oper- (1050 kPa) may use a special nylon tubing. The as- ation;...
  • Page 36 NOTICE FASTENERS Excessive grease in the hub or grease cap serves Visually check entire unit in regard to bolts, nuts and no purpose due to the fact that there is no way to screws being properly secured. Spot check several capscrews and nuts for proper torque.
  • Page 37 RECEIVER- -SEPARATOR SYSTEMS NOTICE Excessive oil carry- -over may be caused by an oil- - WARNING logged separator element. Do not replace element without first performing the following mainte- High pressure air can cause severe injury or death nance procedure: from hot oil and flying parts.
  • Page 38 Adjust parking brakes after all brake shoes have Electric Brake Adjustment: been adjusted by: Brakes should be adjusted (1) after the first 200 miles 1. Turning knob on brake lever until lever is perpendic- of operation when the brake shoes and drums have ular to bracket when in “OFF”...
  • Page 39 *Place a straightedge across top of element and mea- OIL SEPARATOR ELEMENT sure from bottom of straightedge to bottom of ele- The life of the oil separator element is dependent upon ment (See Fig. 4.1). the operating environment (soot, dust, etc.) should be replaced every twelve months or 2000 Reposition cover (use care not to damage gaskets).
  • Page 40 To apply the texture coat, use Duponts EXTERIOR FINISH CARE 1854S Tuffcoat Primer. proper technique to do this is to spray the Tuffcoat This unit was painted and heat cured at the factory Primer using a pressure pot and use about with a high quality, thermoset polyester powder 2- -5 pounds of air pressure.
  • Page 41 MAINTENANCE SCHEDULE These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty or wet). Daily Weekly Monthly 3 MOS . 6 MOS. 12 MOS. SMALL UNITS (P100- -P600) 250 hours 500 hours 1000 hours LARGE UNITS (HP600- -P1600) 500 hours 1000 hours 2000 hours...
  • Page 42 SECTION 7 - - LUBRICATION GENERAL INFORMATION Lubrication is an essential part of preventive mainte- If the unit has been operated for the time/ hours men- nance, affecting to a great extent the useful life of the tioned above, it should be completely drained of oil. If unit.

  • Page 43: Lubrication

    RATED OPERATING PRESSURE SECTION 7 - - COMPRESSOR 350 PSI 100 - - 300 PSI 500 PSI 125_F LUBRICATION 50_C 40_C 104_F Portable Compressor Fluid Chart XHP505 XHP 1001 XHP1001 86_F 30_C Refer to these charts for correct compressor 65_F 20_C fluid required.

  • Page 44: Troubleshooting

    SECTION 8 - - Trouble Shooting INTRODUCTION B. Do The Simplest Things First Trouble shooting for a portable air compressor Most troubles are simple and easily corrected. is an organized study of a particular problem or example, most complaints are “low capacity” which may series of problems and a planned method of be caused by too low an engine speed or “compressor procedure for investigation and correction.
  • Page 45 TROUBLE SHOOTING CHART Bold Headings depict the COMPLAINT - - Subheadings suggest the CAUSE Note: Subheadings suggest sequence to follow troubleshooting. Corrective Action Unit Shutdown: Out of Fuel Add CLEAN diesel Fuel Compressor Oil Temp. Too High See Complaint 10 Engine Water Temp.
  • Page 46 Engine Oil Pressure Lamp Stays On: Corrective Action Low Oil Level Add oil. Out of Level >15 degrees Relocate or reposition. Wrong Lube Oil See Engine Oil Spec. Change oil. Clogged Oil Filter Element(s) Replace element(s). Engine Malfunctioning See Trouble Shooting in Engine Manual. Loose Wire Connection.
  • Page 47 Excessive Compressor Oil Temperature: Corrective Action Ambient Temp. > 125_F (52_C) Above spec limit. Out of Level > 15 degrees Relocate or reposition unit. Low Oil Level Add oil. Look for any leaks. Wrong Lube Oil Check spec in this manual. Dirty Cooler Clean exterior surfaces.
  • Page 48 Short Air Cleaner Life: Corrective Action Dirty Operating Conditions Move unit to cleaner environment. Inadequate Element Cleaning Install new element. Incorrect Stopping Procedure Read Page 13 in this manual. Wrong Air Filter Element Install proper element. Oil Pump Drive Coupling Inspect coupling.

  • Page 49: Parts Ordering

    SECTION 9 - - PARTS ORDERING location relative to the other parts in the assembly. The GENERAL part number, the description of the part and the quantity of parts required are shown on each This publication, which contains an illustrated parts illustration or on adjacent page.
  • Page 50 MARKINGS AND DECALS Always specify the number of the parts list pub- lication. NOTICE Always specify the quantity of parts required. Do not paint over safety warnings or instructional decals. If safety warning decals become illegible, Always specify the part number, as well as the immediately order replacements from the factory.
  • Page 51 Warranty: The Company warrants that parts man- any defect in, or failure of, or malfunction of the parts ufactured by it will be as specified and will be free from hereunder, whether based upon loss of use, lost prof- defects in materials and workmanship. The Compa- its or revenue, interest, lost goodwill, work stoppage, ny’s liability under this warranty shall be limited to the impairment of other goods, loss by reason of shut-...
  • Page 52 CONTENTS Frame Drawbar & Running Gear Running Gear Complete Electric Brake Wiring Electric Brake Shoes 15” Tire & Wheel Assembly Engine Complete Exhaust Complete Cooling Complete Airend Complete Airend Assembly Unloader Valve Oil Temperature Bypass Valve OTBV / Oil Filter Mounting Minimum Pressure Valve Service Air Seperator Tank...
  • Page 53 FRAME DRAWBAR END Item Description Item Description 36888055 SCREW, HEX FLANGE M12--1.75 X 30 54615208 FRAME ASSEMBLY 36879492 SCREW, HEX FLANGE M12--1.75 X 25 54667902 BUMPER 96700893 SCREW, HEX M16--2.0 X 60 54742010 LIFTING BAIL 54641840 PAN, MIDDLE BELLY 96704630 NUT, NYLOC M16 54759113 EYE, LIFTING BAIL...
  • Page 54 DRAWBAR & RUNNING GEAR DRAWBAR END Item Description Item Description 54625322 RUNNING GEAR 96701750 NUT HEX M16--2.0 36880599 SPACER, RUNNING GEAR 39179072 BOLT, M16--2.0 X 50 96730395 SCREW, HEX M12--1.75 X 50 36879211 NUT, HEX FLANGE M16--2.0 36876621 DRAWBAR 35609544 PIN, QUICK RELEASE 54443577 JACK, SCREW...
  • Page 55 RUNNING GEAR COMPLETE Item Description Item Description 54750997 BEAM, AXLE 35361898 STUD 35315126 SPRING, SLIPPER 35315274 NUT, WHEEL 35360734 U--BOLT 35326958 HANGER, FRONT 35315340 BOLT, SHACKLE 35316868 SEAL, GREASE 35316876 CONE, INNER BEARING 35315357 NUT, TOP LOCK 35326966 HANGER, REAR 35316884 CUP, INNER BEARING 35315365...
  • Page 56 ELECTRIC BRAKE WIRING FURNISHED BY CUSTOMER Item Description Item Description 36893634 GROMMET, SIDE LIGHT 35346337 LUG, TERMINAL 54761101 HARNESS, LIGHTING 35253038 CLAMP, 3/8 35367051 LIGHT, YELLOW CLEARANCE 37001252 CLAMP, SUPPORT 36895860 LIGHT, LICENSE 92368687 SCREW, TAPPING M06--1.0 X 14 36782837 SCREW, HEX SHEETMETAL #10 X 1.0 36797652 SCREW, TAPPING M06--1.0 X 12...
  • Page 57 ELECTRIC BRAKE SHOE DEXTER SECTION A - - A Item Description Item Description 35390830 PLATE ASM., LH BACKING 35391069 PLUG, ADJUSTING SLOT 35390848 PLATE ASM., RH BACKING 35393727 SPRING KIT, ADJ. SCREW & 36895803 SHOE KIT, BRAKE 35391002 SPRING, RETRACTOR 36895811 MAGNET KIT 36895829...
  • Page 58 TIRE & WHEEL ASSEMBLY Item Description Item Description 35318757 WHEEL,15 X 6 35282565 VALVE STEM 36846319 TIRE, ST225/75R15D MANUAL NO. - - ILLUST. NO. DATE/REV: 54722160--007 07/01 Book 54722160 (08/02) - - 57 - -...

  • Page 59: Engine

    ENGINE COMPLETE DRAWBAR END UNLOADER 29” Item Description Item Description 54757869 ENGINE 54749056 SPACER, FAN 54756739 BRACKET, STSD ENGINE 54731468 96701461 SCREW, HEX M06--1.0 X 25 96726435 SCREW, HEX M08--1.25 X 20 36888055 SCREW, HEX FLANGE M12--1.75 X 30 96701396 WASHER, FLT 36769032 NUT, HEX LOCK M06--1.0...

  • Page 60: Exhaust Complete

    EXHAUST COMPLETE Item Description Item Description 22058259 MUFFLER 35279025 SCREW, TAPPING M08--1.25 X 20 54738760 PIPE, EXHAUST 22058275 TUBE, EXHAUST 22058267 EXHAUST PIPE ASM. 36881175 CLAMP, EXHAUST 35293059 CLAMP, EXHAUST SEAL 35293059 CLAMP, EXHAUST SEAL MANUAL NO. - - ILLUST. NO. DATE/REV: 54722160--009 10/01...

  • Page 61: Cooling Complete

    COOLING COMPLETE DRAWBAR END G H M Item Description Item Description 54656749 BAFFLE, TOP 95934998 WASHER, FLAT 54703566 BAFFLE, RH COOLER 36879492 SCREW, HEX FLANGE M12--1.75 X 25 54637111 SUPPORT, OIL COOLER 36797652 SCREW, TAPPING M06--1.0 X 12 54637103 SUPPORT, RADIATOR 36895746 NUTSERT, M08 96702055...
  • Page 62 COOLING COMPLETE DRAWBAR END *37” *37” Item Description Item Description 54666342 HOSE, BOTTOM RADIATOR 54738893 OIL COOLER 54738737 BAFFLE, SPLITTER 36884948 BOTTLE, COOLANT RECOVERY 22056386 RADIATOR 96702279 SCREW, HEX M10--1.50 X 20 35296342 CLAMP, WORM GEAR 92368687 SCREW, TAPPING M06--1.0 X 12 35360775 42”...

  • Page 63: Airend Complete

    AIREND COMPLETE DRAWBAR END Item Description Item Description 42514505 AIREND ASM. 54642921 ADAPTER, UNLOADER 35842160 ELBOW, DISCHARGE 35060631 VALVE, UNLOADER 35575570 GASKET, AIREND DISCHARGE 35323450 STUD, M16--2.0 X 55 54764964 SWITCH, ALARM 96701750 NUT, HEX M16--2.0 35377621 CLAMP, SPRING 35589589 GASKET, UNLOADER / A--E 35375385 SCREW, HEX M16--2.0 X 40...
  • Page 64 AIREND COMPLETE DRAWBAR END TO AIR PRESS GAUGE *20” FROM SEP TK *30” TO AIR CYLINDER *29” TO START RUN VALVE *26” FROM SEP TK REGULATOR *32” PRIOR TO SERIAL NUMBER 328497 Item Description Item Description 35834779 COUPLING, CLUTCH 96704630 NUT, NYLOC M16--2.0 95220604 SCREW, SOCKET HEAD 3/8--16 X .75...
  • Page 65 AIREND COMPLETE DRAWBAR END TO AIR PRESS GAUGE *20” FROM SEP TK *30” R 23” 23” TO AIR CYLINDER *29” FROM SEP TK REGULATOR *32” TO START RUN VALVE *26” BEGIN WITH SERIAL NUMBER 328497 Item Description Item Description 35834779 COUPLING, CLUTCH 96704630 NUT, NYLOC M16--2.0...

  • Page 66: Airend Assembly

    AIREND ASSEMBLY DRAWBAR END Item Description Item Description 42495101 SET, ROTOR JACKSHAFT 96706254 SCREW, HEX HD M16 X 35 54509187 HOUSING, ROTOR 95939856 PLUG, HEX 1 5/16” 35609361 BEARING, CYLINDRICAL 54642921 ADAPTER, INLET 95223806 RING, EXTERNAL RETAINING 35358274 SCREW, SOC HD M16--2.0 X 25 54680939 O--RING, ROTOR HOUSING INLET END 54643432...
  • Page 67 AIREND ASSEMBLY DRAWBAR END Item Description Item Description 96705983 SCREW, HEX HD M10 X 35 96707377 SCREW, HEX HD M16 X 150 54523980 COVER, REAR BEARING 35295336 PIN, DOWEL M16 X 40 54643895 SPRING, WAVE 54509203 HOUSING, REAR BEARING 96710553 SCREW, HEX HD M16 X 50 54680921 0--RING, RH TO BH...
  • Page 68 UNLOADER ASSEMBLY DRAWBAR END Item Description Item Description 35318013 BUSHING, HOUSING 35833227 HOUSING, PISTON 35317205 WASHER 35588300 GASKET, PISTON 35322767 PIOSTON, SPRING 35591122 PLATE, VALVE 35318005 BUSHING, PISTON 36718427 BODY, UNLOADER 35588193 PISTON, UNLOADER 35278555 PLUG 35317197 DIAPHRAGM 35318914 SPRING, PIN 35317213 PIN, UNLOADER 35321603...

  • Page 69: Oil Temperature Bypass Valve

    OIL TEMPERATURE BYPASS VALVE DRAWBAR END Item Description Item Description 36876753 BODY 36786382 SCREW 35584242 GASKET 35288448 BALL 36876761 BODY 35379940 SPRING 36876779 COVER 36788164 PLUG 36788172 SEAL 36782019 ELEMENT 95022307 O--RING MANUAL NO. - - ILLUST. NO. DATE/REV: 54722160--018 07/01 Book 54722160 (08/02) - - 68 - -...

  • Page 70: Otbv / Oil Filter Mounting

    OTBV / OIL FILTER MOUNTING DRAWBAR END TOP OIL COOLER BOTTOM OIL COOLER SEPERATOR TANK AIR END Item Description Item Description 36786382 SCREW, M08--1.25 X 70 95955993 CONNECTOR, 1.31 SAE 36880367 SUPPORT, OIL FILTER 54679998 TUBE, OIL COOLER TOP 95954921 UNION, 1.31 SAE 95992848 ELBOW, 90 DEGREE...

  • Page 71: Minimum Pressure Valve

    MINIMUM PRESSURE VALVE Item Description Item Description 35379973 BODY, MIN PRESS VALVE 35380708 CV ASSEMBLY 35380732 SPRING 35380716 PISTON 35380724 O--RING 35380740 SPRING 35380757 36789550 MIN PRESS VALVE ASM. MANUAL NO. - - ILLUST. NO. DATE/REV: 54722160--020 07/01 Book 54722160 (08/02) - - 70 - -...

  • Page 72: Service Air

    SERVICE AIR DRAWBAR END Item Description Item Description 35576115 VALVE, 3/4 NPT BALL 35192178 CLAMP, SADDLE 95928172 ELBOW, STREET 3/4 NPT 54698667 SUPPORT, SERVICE PIPE 95928040 NIPPLE, CLOSED 3/4NPT 95953451 COUPLING, 1.25 NPT 36789550 VALVE, MINIMUM PRESSURE 95950275 NIPPLE, PIPE 1.25 NPT X 4.0 95208682 ADAPTER, 1.50 NPT X 1.50 35612126...
  • Page 73 SEPARATOR TANK COMPLETE Item Description Item Description 95954210 TEE, 3/4 NPT 54721345 ELEMENT, SEPARATOR 54620604 TANK, SEPARATOR 54764956 SWITCH, ALARM 54731443 VLAVE, SAFETY 200PSI 36888055 SCREW, HEX FLANGE M12--1.75 X 30 96727557 SCREW, HEX FLANGE M16 X 60 95944732 ELBOW, 45 2.50 SAE 36785012 BRACKET, SEPERATOR TANK LIFT 54688015...
  • Page 74 SEPARATOR TANK COMPLETE TO UNLOADER VALVE *32” TO BLOWDOWN VALVE *30” TO START RUN VALVE *26” TO OIL FILTER HEAD Item Description Item Description 95365094 ELBOW, 9/16 X --4 JIC 95773032 ADAPTER, .88 SAE 36896892 VLV, PRESS REG 200PSI (HP375) 35283464 ELBOW, 1/4 NPT X --4 JIC 36854149...

  • Page 75: Fuel Tank Complete

    FUEL TANK COMPLETE * 5” ENGINE FUEL FILTER * 22” FUEL RETURN RAIL PICKUP * 41” RETURN Item Description Item Description 54633938 TANK, FUEL 95916532 SCREW, FILLISTER HEAD 10--32 X .50 54720727 STRAP, FUEL TANK 54660089 CAP, FUEL 35363498 HOSE, .31 FUEL 36845493 FILTER, IN--LINE FUEL 35279025...

  • Page 76: Air Cleaner Assembly

    AIR CLEANER ASSEMBLY OPTIONAL Item Description Item Description 54692975 COVER, AIR CLEANER 54717152 ELEMENT, SAFETY (OPTIONAL) 35393677 VALVE, DUST EJECTOR 54692967 BODY, AIR CLEANER 54717145 ELEMENT, PRIMARY 35393719 CAP, PLUG DATE/REV: MANUAL NO. - - ILLUST. NO. 54722160--025 07/01 Book 54722160 (08/02) - - 75 - -...

  • Page 77: Air Intake Complete

    AIR INTAKE COMPLETE DRAWBAR END Item Description Item Description 54661889 AIR CLEANER ASM. 54667084 HOSE, ENGINE AIR INTAKE 54747977 SUPPORT, AIR CLEANER 35314939 INDICATOR, RESTRICTION 96702048 SCREW, HEX M08--1.25 X 16 96719851 SCREW, HEX M12--1.75 X 16 36897668 CLAMP, T--BOLT 35365477 CLAMP, T--BOLT 54756044...
  • Page 78 BATTERY COMPLETE DRAWBAR END Item Description Item Description 35284801 CABLE, GROUND 36844264 BATERY 12 V 35516582 CABLE, POSITIVE BATTERY 35610856 CABLE, NEGATIVE BATTERY 36853257 ANGLE 36860005 BOLT, J 92368687 SCREW, TAPPING M06--1.0 X 12 95923298 NUT, HEX LOCK .25--20 36853232 TRAY, BATTERY 36853265 WASHER, PLASTIC...

  • Page 79: Standard Wiring

    STANDARD WIRING S1 KEYSWITCH OPERATION SEQUENCE (1)------(2) ON (1)------(2)------(3) BYPASS (1)------(2)------(3)------(4) CRANK ITEM COLOR ALTRNTR BLACK CHARGE IND LP BLUE BROWN (86) (87) GREEN R3--1 GREY (30) (85) LIGHT GREEN ORANGE PINK (86) CONTINUE PURPLE NEXT PAGE (85) WHITE (30) YELLOW R6--1 (86)
  • Page 80 STANDARD WIRING S1 KEYSWITCH OPERATION SEQUENCE (1)------(2) ON (1)------(2)------(3) BYPASS (1)------(2)------(3)------(4) CRANK ITEM COLOR ALTRNTR BLACK CHARGE IND LP BLUE BROWN (86) (87) GREEN R3--1 GREY (30) (85) LIGHT GREEN ORANGE PINK (86) CONTINUE PURPLE NEXT PAGE (85) WHITE (30) YELLOW R6--1 (86)
  • Page 81 STANDARD WIRING (continued) ITEM COLOR LT GRN CONTINUE PREVIOUS PAGE CONTINUE OPTIONS (--) (86) (85) R5--1 (30) (87A) (87) (86) FUEL SENDER (85) FUEL IND LP Item Description Item Description 54368048 RELAY, START INHIBIT 35676169 DIODE 54368048 RELAY, LOW FUEL SHUTDOWN 35676169 DIODE GAUGE, FUEL...

  • Page 82: Trailer Wiring

    TRAILER WIRING SIDE RIGHT BRAKE TAIL / SIDE BREAKAWAY BATT SWITCH RIGHT STOP / TURN JUNCTION BOX WHITE WHITE LICENSE BROWN BROWN GREEN GREEN YELLOW YELLOW BLUE BLUE LEFT STOP / TURN FRAME BRAKE SIDE LEFT TAIL / SIDE PLUG / SOCKET WIRING CONNECTIONS 1 WHITE -- GROUND 2 YELLOW -- LEFT STOP/TURN SIGNAL 4 GREEN -- RIGHT STOP/TURN SIGNAL...
  • Page 83 INSTRUMENT PANEL ASSEMBLY Item Description Item Description 35370386 ELBOW, MALE 1/8 NPT X 3/8 TUBE 54749601 FRAME, WW INST PANEL 35369354 ELBOW, MALE 1/4 NPT X 3/8 TUBE 95935599 COUPLING, 18 NPT X 3/4 35302314 ADAPTER 36882207 GAUGE, PRESSURE 150 PSI 36783439 VALVE, 2--WAY START--RUN 36891216...

  • Page 84: Standard Enclosure Complete

    STANDARD ENCLOSURE COMPLETE DRAWBAR END B H J B H J Item Description Item Description 54642905 ROOF 35337328 STUD, BALL 36881886 NUT, HEX FLANGE M08--1.25 36797652 SCREW, TAPPING M06--1.0 X 12 54718184 STRAP, FOAM RETAINING 35256445 RETAINER, PUSHON 1/4 TURN 54694831 PANEL, REAR ACCESS 54639174...
  • Page 85 STANDARD ENCLOSURE COMPLETE DRAWBAR END E F G A C D *77” *77” C D G L S T U V W Item Description Item Description 36797652 SCREW, TAPPING M06--1.0 X 12 54767488 PANEL, TOOLBOX 54737622 BRACKET, FRONT INTAKE 54720834 BAFFLE, FRONT INTAKE 35310622 PLUG, 2.0 DIA HOLE...

  • Page 86: Galvanneal Enclosure Complete

    GALVANNEAL ENCLOSURE COMPLETE DRAWBAR END B H J B H J Item Description Item Description 54743240 ROOF 35337328 STUD, BALL 36881886 NUT, HEX FLANGE M08--1.25 36797652 SCREW, TAPPING M06--1.0 X 12 54718184 STRAP, FOAM RETAINING 35256445 RETAINER, PUSHON 1/4 TURN 54694831 PANEL, REAR ACCESS 54639174...
  • Page 87 GALVANNEAL ENCLOSURE COMPLETE DRAWBAR END A C D *77” *77” C D G L T U V W Item Description Item Description 36797652 SCREW, TAPPING M06--1.0 X 12 54767488 PANEL, TOOLBOX 54737622 BRACKET, FRONT INTAKE 54720834 BAFFLE, FRONT INTAKE 35337328 STUD, BALL 35310622 PLUG, 2.0 DIA HOLE...

  • Page 88: Foam Insulation Complete

    FOAM INSULATION COMPLETE Item Description Item Description 54675020 PANEL, LOWER DOOR ACOUSTIC 54770524 PANEL, LWR SIDE ACOUSTIC 54675046 PANEL, UPPER DOOR ACOUSTIC 54745518 PANEL, REAR SPLITTER ACOUSTIC 54770490 PANEL, TOP LWR SIDE ACOUSTIC 54675053 PANEL, FRONT ROOF ACOUSTIC 54674916 PANEL, FRONT END CAP ACOUSTIC 54675079 PANEL, MIDDLE ROOF ACOUSTIC 54744826...

  • Page 89: Decal Location

    DECAL LOCATION WARNING WARNING DANGER WARNING Trapped air pressure. Hot pressurized fluid. Disconnected air hoses whip. Can cause serious injury or Can cause serious injury death. Can cause serious burns. death. Close service valve and When using air tools attach safety operate tool to vent trapped device (OSHA Valve) at source of Do not open radiator while...
  • Page 90 DECAL LOCATION WARNING Rotating fan blade. Can cause serious injury. Do not operate without guard in place. 54568779 REV. A WARNING Combustible gas. Can cause serious burns, blindness or death. Keep sparks and open flames away from batteries. 54568753 REV. A WARNING High pressure air.

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