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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...
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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.
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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...
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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.
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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.
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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.).
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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...
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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...
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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.
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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.
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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.
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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.
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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.
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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.
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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...
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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.
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.
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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...
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;...
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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...
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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 &...
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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)
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.
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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.
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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.
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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. .•...
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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.
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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...
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* 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.
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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.
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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.
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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;...
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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.
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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.
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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”...
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*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).
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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.
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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...
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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.
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.
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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.
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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.
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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.
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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.
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.
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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.
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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-...
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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...
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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...
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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...
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)
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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)
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...
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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...
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...
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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...
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...
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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...
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...
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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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