OPERATING, MAINTENANCE,

PARTS MANUAL

COMPRESSOR MODELS

HP1300WCU HP1600WCU

Code: C Code:

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.

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
Portable Power to Ingersoll-Rand Company in this manual is historical or nominative
P.O. Box 868 -- 501 Sanford Ave in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
Mocksville, N.C. 27028 either.

Book 54757919 (5/02) (1)

Revised (09-12)
 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.

Book 54757919 (5/02) (2)

 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:

Book 54757919 (5/02) (3)

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 Directives

98/37/EC, 93/68/EEC, 89/336EEC

Ingersoll--Rand Company Ingersoll--Rand Company Limited

P.O. Box 868 We Swan Lane, Hindley Green
501 Sanford Avenue Wigan WN2 4EZ
Mocksville, North Carolina 27028 Represented In EC By: United Kingdom

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

10/370 25/300
10/455 25/330
To which this declaration relates, is (are) in conformity with the provisions of the above
directives using the following principal standards

EN1012--1, EN29001, EN292, EN60204--1

PN8NTC2, EN 50081, EN50082

Issued at Mocksville on 1--1--02 Issued at Hindley Green on 1--1--02

________________________________ ________________________________

Ric Lunsford
Manager of Quality Control H. Seddon, Q.A. Manager

EC Pressure Equipment Directive and Related Regulations

We declare that this product has been assessed according to the Pressure Equipment Directive (97/23/EC)
and, in accordance with the terms of this Directive, has been excluded from the scope of this Directive.
It may carry “CE” marking in compliance with other applicable EC Directives.
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.

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.
S accompanied with instructions for safe installation, operation and maintenance.

Details of approved equipment are available from Ingersoll--Rand Service departments.

The use of repair parts other than those included within the Ingersoll--Rand approved parts list may create
hazardous conditions over which Ingersoll--Rand has no control. Therefore, Ingersoll--Rand cannot be held
responsible for equipment in which non--approved repair parts are installed.

Ingersoll--Rand reserves the right to make changes and improvements to products without notice and without
incurring any obligation to make such changes or add such improvements to products sold previously.

The intended uses of this machine are outlined below and examples of unapproved usage are also 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 compression of normal
ambient air containing no additional gases, vapors or particles within the ambient temperature range specified in
the general data section of this manual.

This machine should not be used:

A. For direct or indirect human consumption of the compressed air.

B. Outside the ambient temperature range specified in the general data section of this manual.

C. When an actual or foreseeable risk of hazardous levels of flammable gases or vapors exists.

D. With other than Ingersoll--Rand approved components.

E. With guards, or controls or switches missing or disabled.

F. For storage or transportation of materials inside or on the enclosure.

This company accepts no responsibility for errors in translation of this manual from the original English version.

You as the customer are expected to provide certain service and maintenance items. Your Ingersoll--Rand dealer
will provide all other more detailed service and maintenance items on a special preventive maintenance schedule
for each machine. It is very important that the minimum service and maintenance requirements explained in this
manual be performed at the required intervals. Exceeding these intervals may reduce the reliability of the machine.

The purpose of this manual is to train the operator with functions, operation, and basic service and maintenance
requirements of the compressor. During the preparation of this manual, every effort was made to ensure the
adequacy and accuracy of the contents.
Book 54757919 (5/02) (5)
Your Ingersoll--Rand dealer will assist with setup and initial startup of the compressor. He will also provide brief
operating and service instructions and will insure that a copy of this manual is included with the machine. Before
starting the compressor, this manual and instructions should be carefully read to obtain a thorough knowledge of
the duties to be performed. Please take pride in the compressor, keep it clean, and in good mechanical condition.

To enable proper maintenance records, Ingersoll--Rand provides a Noise Emission Control Maintenance Log Book
(PCD Form 685) with each compressor shipped from the factory. This Log Book contains a recommended
schedule and space so that the serviceman can note what service and maintenance was done, by whom, where,
and when.

Book 54757919 (5/02) (6)

 TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . SAFETY

SECTION 2 . . . . . . . . . . . . . . . . . . . WARRANTY/REGISTRATION

SECTION 3 . . . . . . . . . . . . . . . . . . . GENERAL DATA

SECTION 4 . . . . . . . . . . . . . . . . . . . OPERATION

SECTION 5 . . . . . . . . . . . . . . . . . . . MAINTENANCE

SECTION 6 . . . . . . . . . . . . . . . . . . . LUBRICATION

SECTION 7 . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING

SECTION 8 . . . . . . . . . . . . . . . . . . . ELECTRICAL

SECTION 9 . . . . . . . . . . . . . . . . . . . SYSTEM DIAGRAMS

SECTION 10 . . . . . . . . . . . . . . . . . PARTS ORDERING

SECTION 11 . . . . . . . . . . . . . . . . . . PARTS LIST

SECTION 12 . . . . . . . . . . . . . . . . . ENGINE (operation, maintenance,

lubrication, troubleshooting)

Book 54757919 (5/02) (7)

 SECTION 1-- SAFETY
SAFETY PRECAUTIONS Compressed air must not be used for a feed to any
form of breathing apparatus or mask.
General Information

Ensure that the operator reads and understands the The discharged air contains a very small percentage
decals and consults the manuals before maintenance of compressor lubricating oil and care should be taken
or operation. to ensure that downstream equipment is compatible.

Ensure that the Operation and Maintenance manual, If the discharged air is to be ultimately released into a
and the manual holder if equipped, are not removed confined space, adequate ventilation must be pro-
permanently from the machine. vided.

Ensure that maintenance personnel are adequately When using compressed air, always use appropriate
trained, competent and have read the manuals. personal protective equipment.

Make sure that all protective covers are in place and All pressure containing parts, especially flexible hoses
that the canopy/doors are closed during operation. and their couplings, must be regularly inspected, be
free from defects and be replaced according to the
The specification of this machine is such that the ma- Manual instructions.
chine is not suitable for use in flammable gas risk
areas. If such an application is required then all local Avoid bodily contact with compressed air.
regulations, codes of practice and site rules must be
observed. To ensure that the machine can operate in Never operate unit without first observing all safety
a safe and reliable manner, additional equipment such warnings and carefully reading the operation and
as gas detection, exhaust spark arrestors, and intake maintenance manual shipped from the factory with
(shut--off) valves may be required, dependent on local this machine.
regulations or the degree of risk involved. Never operate the engine of this machine inside a
building without adequate ventilation. Avoid breathing
Air discharged from this machine may contain carbon exhaust fumes when working on or near the machine.
monoxide or other contaminants which will cause seri- Do not alter or modify this machine.
ous injury or death. Do not breathe this air.
A battery contains sulfuric acid and can give off gases
Compressed air can be dangerous if incorrectly han- which are corrosive and potentially explosive. Avoid
dled. Before doing any work on the unit, ensure that all contact with skin, eyes and clothing. In case of contact,
pressure is vented from the system and that the ma- flush area immediately with water.
chine cannot be started accidentally. Exercise extreme caution when using booster battery.
To jump battery, connect ends of one booster cable to
Ensure that the machine is operating at the rated pres-
the positive (+) terminal of each battery. Connect one
sure and that the rated pressure is known to all rele-
end of other cable to the negative (--) terminal of the
vant personnel.
booster battery and other end to a ground connection
All air pressure equipment installed in or connected to away from dead battery (to avoid a spark occurring
the machine must have safe working pressure ratings near any explosive gases that may be present). After
of at least the machine safety valve rating. starting unit, always disconnect cables in reverse or-
der.
If more than one compressor is connected to one com-
mon downstream plant, effective check valves and Never operate unit without first observing all safety
isolation valves must be fitted and controlled by work warnings and carefully reading the operation and
maintenance manual shipped from the factory with
procedures, so that one machine cannot accidentally
this machine.
be pressurized or over pressurized by another.

Book 54757919 (5/02) (8)

This machine may include such materials as oil, diesel
fuel, antifreeze, brake fluid, oil/air filters and batteries Use care to avoid contacting hot surfaces (engine
which may require proper disposal when performing exhaust manifold and piping, air receiver and air
maintenance and service tasks. Contact local authori- discharge piping, etc.).
ties for proper disposal of these materials.
Ether is an extremely volatile, highly flammable gas.
High Pressure Air can cause serious injury or death.
USE SPARINGLY! Do NOT use ETHER if unit has
Relieve pressure before removing filler plugs/caps, fit-
GLOW Plug starting aid. Engine damage will result.
tings or covers.

Air pressure can remain trapped in air supply line Never allow the unit to sit stopped with pressure in the
which can result in serious injury or death. Always receiver--separator system. As a precaution, open the
carefully vent air supply line at tool or vent valve before manual blowdown valve.
performing any service.
Never operate unit with guards, covers or screens
This machine produces loud noise with the doors open
removed. Keep hands, hair, clothing, tools, blow gun
or service valve vented. Extended exposure to loud
tips, etc. well away from moving parts.
noise can cause hearing loss. Always wear hearing
protection when doors are open or service valve is Make sure wheels, tires and tow bar connectors are in
vented. safe operating condition and tow bar is properly
connected before towing.
Never inspect or service unit without first disconnect-
ing battery cable(s) to prevent accidental starting.
Whenever the machine is stopped, air will flow back
Do not remove the pressure cap from a HOT radiator. into the compressor system from devices or systems
Allow radiator to cool down before removing pressure downstream of the machine unless the service valve
cap. is closed. Install a check valve at the machine service
valve to prevent reverse flow in the event of an
Do not use petroleum products (solvents or fuels) un-
unexpected shutdown when the service valve is open.
der high pressure as this can penetrate the skin and
result in serious illness. wear eye protection while
Hazardous Substance Precaution
cleaning unit with compressed air to prevent debris
from injuring eye(s). The following substances are used in the manufacture
of this machine and may be hazardous to health if used
Disconnected air hoses whip and can cause serious
incorrectly.
injury or death. Always attach a safety flow restrictor
to each hose at the source of supply or branch line in Precaution: Avoid ingestion, skin contact and
accordance with OSHA Regulation 29CFR Section breathing fumes for the following substances:
1926.302(b). Antifreeze, Compressor Oil, Engine Lubricating Oil,
Preservative Grease, Rust Preventative, Diesel Fuel
Hot pressurized fluid can cause serious burns. Do not and Battery Electrolyte.
open radiator while hot.
The following substances may be produced during the
Rotating fan blade can cause serious injury. Do not operation of this machine and may be hazardous to
operate without guard in place. health:

Avoid build--up of Engine Exhaust Fumes in confined

spaces.

Avoid breathing Exhaust Fumes.

Avoid breathing Brake Lining Dust during mainte-

nance.

Book 54757919 (5/02) (9)

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.

Corrosion risk Hot Surface

Lifting point

WARNING: Electrical shock risk. Parking Brake No open flame

Diesel Fuel.
No open flame.
Do not operate the machine Lifting point
without guard being fitted.

WARNING -- Flammable liquid. When parking use prop stand,

handbrake and wheel chocks. Air/gas flow or Air discharge.

WARNING -- Hot and harmful exhaust gas. Tie down point Do not breathe the compressed
air from this machine.

Book 54757919 (5/02) (10)

 Read the Operation and Maintenance
manual before operation or maintenance
of this machine is undertaken.
X,X BAR

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

Replace any cracked

Do not use fork lift truck from this side protective shield.

On (power).

Off (power).
Do not operate with the doors or enclosure
open.

WARNING -- Before connecting the tow bar or

when preparing to tow, consult the operation
and maintenance manual. Emergency stop.

Book 54757919 (5/02) (11)

 Oil Drain

XX
km/h

WARNING -- Do not undertake any

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

0_C before operation or maintenance of this
machine is undertaken

Do not remove the Operating and Maintenance

WARNING -- For operating temperature below manual and manual holder from this machine.
0_C, consult the operation and maintenance
manual.

Pressurized vessel. Use fork lift truck from this side only. Pressurized component or system.

Book 54757919 (5/02) (12)

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.

(Red Background)

Indicates the presence of a hazard which CAN

! cause serious injury, death or property damage,

if ignored.
(Orange Background)

Indicates the presence of a hazard which WILL or

can cause injury or property damage, if ignored.

(Yellow Background)

Indicates important set--up, operating or maintenance

information.

(Blue Background)

DANGER WARNING
Trapped air pressure.
Can cause serious
injury or death.
Close service valve and
operate tool to vent
trapped air before
Discharged air can contain carbon performing any service.
monoxide or other contaminants.
Will cause serious injury or death.
Do not breathe this air.

WARNING
WARNING
High pressure air.
Hot pressurized fluid. Can cause serious
Can cause serious injury or death.
burns.

Do not open radiator Relieve pressure before

removing filler plugs/caps,
while hot. fittings or covers.

Book 54757919 (5/02) (13)

 105
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.
Modification or alteration of this machine. Excessive towing speed.
Can cause serious injury or death. Can cause serious injury
Do not alter or modify this machine or death.
without the express written consent of
the manufacturer. Do NOT exceed 65 mph
(105 km/hr.)

WARNING WARNING
Falling off machine.
Rotating fan blade.
Can cause serious Can cause serious injury
injury. or death.

Do not operate without

guard in place.
Access lifting bail from
inside machine.

WARNING WARNING
Disconnected air hoses whip.
Door under pressure.
Can cause serious
Can cause serious injury. injury or death.
When using air tools
Use both hands to open door attach safety device
when machine is running. (OSHA Valve) at source of
WARNING air supply for each tool.

CAUTION WARNING
DO NOT WELD. Combustible gas.
ELECTRONIC DAMAGE Can cause serious burns, +
WILL OCCUR. blindness or death.
This engine is equipped with an
electronic engine controller and Keep sparks and open
other electronic components. flames away from batteries.

Book 54757919 (5/02) (14)

 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
USE DIESEL
COOLANT FILL INSTRUCTIONS
Adding:
Do NOT remove radiator cap. Top off at overflow

FUEL ONLY
reservoir. Use same anti--freeze mixture as in
radiator.
Replacing:
With system cool, remove radiator cap. Drain
coolant and close drain. At radiator, refill system.
Replace radiator cap. At reservoir, fill to “Hot” level.
Run for 30 minutes. Stop and allow to cool.
At reservoir, add coolant as necessary to reach
“Cold” level.

FREE SAFETY DECALS!

To promote communication of Safety Warnings on
products manufactured by the Portable Compressor
Division in Mocksville, N.C., Safety Decals are available
free of charge. Safety decals are identified by the decal
heading: DANGER, WARNING or CAUTION.

Decal part numbers are on the bottom of each decal and

are also listed in the compressor’s parts manual. Submit
orders for Safety Decals to the Mocksville Parts Service
Department. The no charge order should contain only
Safety Decals. Help promote product safety! Assure that
decals are present on the machines. Replace decals that
are not readable.

Book 54757919 (5/02) (15)

 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.

With respect to the following types of equipment, the warranty period enumerated below will apply in lieu of the
foregoing warranty period.

A. Aftercoolers -- The earlier of nine (9) months from date of shipment to or six (6) months from start up by
initial user.

B. Portable Compressors, Portable Generator Sets (GENSET) 8KW, 11KW, 20KVA thru 575KVA, Portable
Light Towers and Air Dryers -- The earlier of twelve (12) months from shipment to or the accumulation of
2,000 hours of service by the initial user.
3.5KW thru 7.0KW and 10KW– The earlier of twelve (12) months from shipment to or the accumulation of
2,000 hours of service by the initial user, whichever occurs first. Ingersoll--Rand will provide a new part or re-
paired part, at it’s election, in place of any part which is found to be defective in material or workmanship during
the period described above. Labor cost to replace the part is the responsibility of the user.

C. Portable Compressor Air Ends -- The earlier 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 hours of service. The optional warranty is limited to defects in rotors, hous-
ings, bearings and gears and provided all the following conditions are met:
1. The original air end is returned assembled and unopened.
2. Continued use of genuine Ingersoll--Rand parts, fluids, oil and filters.
3. Maintenance is performed at prescribed intervals.
Oil--Free airends are fee--based and may require a maintenance agreement. Formal enrollment is
required.

D. Genset Generators 8KW, 11KW, 20KVA thru 575KVA -- The earlier of twenty--four (24) months from ship-
ment to or the accumulation of 4,000 hours of service by the initial user.
3.5KW thru 7.0KW and 10KW -- The earlier of twelve (12) months from shipment to or the accumula-
tion of 2,000 hours of service.

E. Portable Light Tower Generators-- The earlier of twelve (12) months from shipment to or the accumulation
of 2,000 hours of service by the initial user. Light Source model only, the earlier of twenty--four (24) months
from shipment to or the accumulation of 4,000 hours of service.

F. Ingersoll--Rand Engines -- The earlier of twenty--four (24) months from shipment to or the accumulation of
4,000 hours of service.

Book 54757919 (5/02) (16)

G. 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. The airend seal and drive coupling are included in the warranty (airend
drive belts are not included). The optional warranty is automatically available when meeting the following con-
ditions:

1. The original airend is returned assembled and unopened.

2. Continued use of genuine Ingersoll--Rand parts, fluids, oil and filters.
3. Maintenance is performed at prescribed intervals.

It is the obligation of the user to provide verification that these conditions have been satisfied when submitting
warranty claims.

F. Spare Parts– Six (6) months from date of shipment.

Ingersoll--Rand will provide a new part or repaired part, at its election, in place of any part which is found upon
its inspection to be defective in material and 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 warrantees do not apply to failures occurring as a result of abuse; misuse, negligent repairs, corrosion,
erosion and normal wear and tear, alterations or modifications made to the product without express written consent
of Ingersoll--Rand; or failure to follow the recommended operating practices and maintenance procedures as pro-
vided in the product’s operating and maintenance publications.

Accessories or equipment furnished by Ingersoll--Rand, but manufactured by others, including, but not limited to,
engines, tires, batteries, engine electrical equipment, hydraulic transmissions, carriers, shall carry whatever war-
ranty the manufacturers have conveyed to Ingersoll--Rand and which can be passed on to the initial user.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT OF
TITLE),AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.

Book 54757919 (5/02) (17)

 GENERAL WARRANTY INFORMATION
GENERAL WARRANTY Extended Coverage
Portable Compressor Package 1 year/2000 hrs
Airend 2 yrs/4000 hrs 5 yrs/10,000 hrs
Limited warranty, major components
(refer to operator’s manual).

Portable Genset 8kW, 11KW, Package 1 yr/2000 hrs None

20KVA thru 575KVA
Generator 2 yrs/4000 hrs None

Portable Genset 3.5KW thru Package 1 yr/2000 hrs (parts only) None
7.0KW and 10KW
Generator 1 yrs/2000 hrs (parts only) None

Light Tower Package 1 yr/2000 hrs

Generator 1 yr/2000 hrs 2 years/4000 hours, for Lightsource
introduced 8/16/99.

ENGINES
CATERPILLAR Months Hours Extended Coverage
12 unlimited Available at dealer
CUMMINS 24 2000 Major components 3 yrs/10,000 hrs
Available at dealer
JOHN DEERE (in compressors) 24 2000 5 yrs/5000 hrs using OEM fluids and filters with
$250 deductible

(in generators as of 1/1/01) 24 2000 2 yrs/4000 hrs using IR fluids and filters

DEUTZ 24 2000 Available at dealer

INGERSOLL--RAND 24 4000 5 yrs/10,000 hrs when using genuine Ingersoll--
Rand fluids and parts. Refer to operator’s manu-
al.
KUBOTA (North America only) 24 2000 Major components 36 mo/3000 hrs (parts only)
(Western Europe & Oceania) 24 2000 None
(Central & South America, Asia, Middle East & 12 1000 None
Africa)
MITSUBISHI 24 2000 2 yrs/4000 hrs using IR fluids & filters
VOLVO 24 2000 2 yrs/4000 hrs using ir fluids & filters
HONDA 12 unlimited None
VANGUARD 24 unlimited None

PARTS
Months Hours Coverage
Ingersoll--Rand 6 No Limit Parts Only

AIREND EXCHANGE
Months Hours Extended Coverage
Airend 12 2000 hours 2 yrs/4000 hrs -- available from
IR.

Note: Actual warranty times may change. Consult the manufacturer’s warranty policy as shipped with each new
product.
Book 54757919 (5/02) (18)
 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.

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 warranty.

Book 54757919 (5/02) (19)

Selling Distributor Servicing Distributor WARRANTY REGISTRATION
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 Other Mining

(highway, excavation, etc.)

Construction--Light Government Quarry Shallow Oil & Gas

(carpentry, plumbing, pools, (municipal, state,
mason, etc.) county, etc.)

Rental Building Contractor Waterwell Utility Company

(rental center, rental fleet, etc.) (gas, electric, water, etc.)

Industrial (plant use) Other Exploration Utility Contractor

specify __________

Model Unit S/N Engine S/N Date Delivered

Unit--Hours Airend S/N Truck S/N Truck Engine S/N

SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT

1. The 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 owner/user shall notify Ingersoll--Rand of such
use so that Ingersoll--Rand may arrange for appropriate nuclear liability protection from the owner--licensee of the
facility.
4. Ingersoll--Rand reserves the right to make design changes or modifications of Ingersoll--Rand products at anytime
without incurring any obligation to make similar changes or modifications on previously sold units.

Book 54757919 (5/02) (20)

 Attention: Warranty Department

Mocksville, North Carolina 27028

P.O. Box 868
Portable Compressor Division
Ingersoll- Rand Company

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
fold

Book 54757919 (5/02) (21)

 SECTION 3 -- GENERAL DATA
UNIT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . HP1600WCU . . . . . . . . . . . . . . . . . . . . . . . . . . HP1300WCU

Air Delivery -- cfm (litres/sec) . . . . . . . . . . . . . . . . 1600 (756 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 (614)

COMPRESSOR
Rated Operating Pressure -- psi (kPa) . . . . . . . . 80--150 (552--1034) . . . . . . . . . . . . . . . . . . . . .

ENGINE (Diesel)
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QSX--15
Rated Horsepower at 1800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC
Full Load Speed -- rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
No Load Speed -- rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

FLUID CAPACITIES -- U.S. Gallons (litres)

Compressor Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 (208)
Engine Lube (including filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 (40)
Engine Coolant (Radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 (57.5)
Fuel Tank (Clean DIESEL fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 (870)

UNITS MEASUREMENTS/WEIGHTS . . . . . HSRG . . . . . . . . . . . Wagon RG . . . . . . . . . . . . . . LRG

Feet (Meters)

Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . 24.2 (7.4) . . . . . . . . 19.0 (5.79) . . . . . . . . . . . . . . 19.0 (5.79)

Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . 8.33 (2.54) . . . . . . . 8.33 (2.54) . . . . . . . . . . . . . . 7.25 (2.21)
Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 (2.29) . . . . . . . . 7.5 (2.29) . . . . . . . . . . . . . . . 7.5 (2.29)
Gross Weight -- pounds (kg) . . . . . . . . . . . . . 17,200 (7810) . . . . 17,200 (7810) . . . . . . . . . . . 16,700 (7590)
(including fluids--no fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . est . . . . . . . . . . . . . . . . . . est

RUNNING GEAR

Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215/75R17.5H . . . 215/75R17.5H . . . . . . . . . . NA

Towing Speed (Maximum) mph . . . . . . . . . . . 65 . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . NA
Inflation Pressure . . . . . . . . . . . . . . . . . . . . . . . 125 psig . . . . . . . . . 125 psig . . . . . . . . . . . . . . . . NA

EXPENDABLE SERVICE PARTS

Part Number Description Where Used Quantity

36860336 . . . . . . . . . . . . . . Filter, Oil . . . . . . . . . . . . . . . . . . . Airend . . . . . . . . . . . . . . . . . . . . . . 2
36754406 . . . . . . . . . . . . . . Separator, Oil HP . . . . . . . . . . . . Airend . . . . . . . . . . . . . . . . . . . . . . 1
36864361 . . . . . . . . . . . . . . Filter, Inlet Primary . . . . . . . . . . Engine & AE inlet . . . . . . . . . . . . 2
36864379 . . . . . . . . . . . . . . Filter, Inlet Secondary . . . . . . . . Engine & AE inlet . . . . . . . . . . . . 2
54662028 . . . . . . . . . . . . . . Filter Oil, Engine . . . . . . . . . . . . QSX15 . . . . . . . . . . . . . . . . . . . . . 1
54662051 . . . . . . . . . . . . . . Filter Coolant, Engine . . . . . . . . QSX15 . . . . . . . . . . . . . . . . . . . . . 1
54662036 . . . . . . . . . . . . . . Filter Fuel, Engine . . . . . . . . . . . QSX15 . . . . . . . . . . . . . . . . . . . . . 1

CAUTION: Any departure from the specifications may make this equipment unsafe.

Book 54757919 (5/02) (22)

 SECTION 4 -- OPERATING INSTRUCTIONS
6. High Engine Coolant Temp: Fault indicator
lamp. Indicates shutdown due to high engine
19
f E STOP
7.
water temperature.
Restricted IQ Air Filters: Fault indicator
Control Panel 1
lamp. Indicates shutdown due to high Pon IQ
20 air filters (if equipped).
\\ \ \
2 3
8. Low Fuel Level: Fault indicator lamp.
4 5
Indicates shutdown due to low fuel level.
6 Lamp blinks at low fuel warning.
7
8
9. Compressor Malfunction: Fault indicator
9 21 lamp. Indicates shutdown due to compressor
10
11 \\ \ \ system fault. Refer to Fault Code List.
10. Low Battery Voltage: Alarm indicator lamp.
12 Indicates battery or charging system requires
22 service.
11. Engine Malfunction: Engine Fault code.
Refer to service card or engine manual for
codes and service requirements.
23 12. Malfunction Code (4 Digit): Compressor or
18
\\ \ \ engine fault. Refer to manual for list of codes
and service requirements.
13. Ether Inject: Injects a measured shot of ether
for aid in cold weather starting of engine.
Caution: Use Sparingly.
14. Panel Light Switch: Controls panel lamp # 1.
14
15. Service Air Switch: Momentary contact
16 switch. Allows engine to warm up at low
15 17 compressor pressure.
13
16. Main Power Control Switch: ON/OFF Start
OPERATING CONTROLS AND INSTRUMENTS Switch.
The operating controls and instruments are arranged
17. Heaters: ON/OFF Power Switch for
on the control panel as shown on previous page. A
description of each panel device is as follows: regulation and IQ heaters. Prevents freeze up
in cold weather.
1. Panel Light: Illuminates PHE instrument and 18. Hourmeter: Indicates machine operating
control panel controlled by Switch 14. hours.
2. High Compressor Temp: Fault indicator 19. E--STOP: Emergency Stop Push Button (ESA
lamp. Indicates shutdown due to high units only). Push to stop, turn to release.
compressor temperature. 20. Discharge Air Pressure Gage: Indicates
3. Low Radiator Coolant Level: Alarm pressure in receiver tank, normally from 0
indicator lamp. Indicates engine coolant psi(kPa) to the rated pressure of the machine.
needs service. 21. Engine Tachometer: Indicates engine speed
4. Low Engine Oil Pressure: Fault indicator in RPM from 0 when stopped to full speed.
lamp. Indicates shutdown due to low engine 22. Systems Gage: Engine Water Temp
oil pressure. Compressor Oil Temp
5. Restricted Air Filter: Alarm indicator lamp. Engine Oil Pressure
Indicates engine/compressor air inlet filters Battery Voltage
need service. 23. Fuel Level Gage: Indicate fuel level in tank.

Book 54757919 (5/02) (23)

 WARNING SETTING UP (ALL UNITS)

Do not climb on top of unit. Place the unit in an open, well--ventilated area. Posi-
tion as level as possible. The design of these units
LIFTING UNIT permits a maximum 15 degree limit on out--of--level
Central Lifting Bail operation.
-- Hoist/crane per machines gross weight
(see general data) When the unit is to be operated out--of--level it is im-
portant: (1) to keep the engine crankcase oil level
BEFORE TOWING near the high level mark (with the unit level), and (2)
Ensure that the tires, wheels and running gear are in to have the compressor oil level gauge show no
good condition and secure.
more than mid--scale (with the unit running at full
Wagon Style Running Gear
load). Do not overfill either the engine crankcase or
S Do not tow this unit in exess of 20 mph (32km/hr).
the compressor lubricating oil system.
S Use a tow vehicle whose towing capacity is greater
than the gross weight of this unit. (see general data).
Chock wheels or set parking brake.
S Machine is not designed to be Highway Towable.
S Set parking brake or chock wheels before This unit is equipped with on--board fuel tanks with
disconnecting from towing vehicle. a total capacity of 230 gallons which provides 10
S Optional Parking Brake -- located beside towbar hours of full load operation.
on front of unit, if equipped.
Compressor Mounting
High Speed Running Gear Portable compressors, which are modified to re-
move the running gear and mount the machine di-
S Use jack to raise or lower lunette eye. rect to trailers, truck beds or frames, etc. may experi-
S Use tow vehicle whose towing capacity is greater ence failure of the enclosure, frame, and/or other
than the gross weight of this unit (see general data). components. It is necessary to isolate the compres-
sor package from the carrier base with a flexible
S Do not tow this unit in excess of 65 mph. mounting system. Such a system must also prevent
S Place wheel chocks under tires before detachment of the package from the carrier base in
disconnecting from towing vehicle. the event the isolators fail. Contact Ingersoll--Rand
representative for flexible mounting kits.
S When raising or lowering lunette eye, always
stand to one side. Warranty does not cover failures attributable to
mounting of the compressor package to the carrier
Wheel Chock -- HSRG base unless it is an Ingersoll--Rand provided sys-
-- Located inside of front towbar tem.
-- Secure unit with chocks before disconnecting
drawbar from tow vehicle.

Book 54757919 (5/02) (24)

 WARNING
WARNING
Combustible gas can cause severe burns,
Do not connect the air discharge on this unit blindness or death. Keep sparks and open flame
onto a common header with any other unit of any away from battery.
description, or any other source of compressed
air, without first making sure a check--valve is • Check the compressor lubricating oil level. The
used between the header and the unit. If this unit proper oil level is labeled on the compressor sump
is connected in parallel with another unit of sight glass.
higher discharge pressure and capacity, a safety • Check engine oil level. The proper level is
hazard could occur in a back--flow condition. labeled on the engine dipstick. Add oil when
required. Do not overfill.
• To jump--start, connect the positive
WARNING booster/charger cable to the 24VDC positive (+)
terminal of the battery. Then connect the negative
Unrestricted air flow from a hose will result in a
booster/charger cable to the engine block...Not to
whipping motion of the hose which can cause
the negative (--) terminal of the weak battery. After
serious injury or death. A safety device must be
starting, disconnect the negative (--) cable from
attached to the hose at the source of supply to
engine block; then from the booster battery/charger.
reduce pressure in case of hose failure or other
Disconnect positive (+) cable from both batteries.
sudden pressure release. Reference: OSHA
regulation 29 CFR Section 1926.302 (b).
WARNING
Air hose restraining cable installation:
Do not remove the cap from a HOT engine
Secure hose restraining cable at each end to prevent radiator. The sudden release of pressure from a
accidental hose whipping. At the machine--side of the heated cooling system can result in a loss of
air hose, install and secure one end of the hose coolant and possible severe personal injury.
restraining cable on the 3” nipple on the inlet side of the
3” service valve. Install the other end of the hose
restraining cable over the main hose connector.
Install suitable 3” air hose between service valve on WARNING
unit and point of air use. The air hose must be rated for
Hot pressurized fluid can cause serious burns.
outdoor use and for pressurized air service. Minimum Do not open radiator while hot.
rating is 250_F (121_C) and 200 psig (HP) or 425 psig
Check coolant to assure coolant level is at minimum
(XHP).
level when the unit is cold.

BEFORE STARTING Check engine coolant level by removing the radiator

top cap and looking for coolant in the filler neck of
Open service valves.
the radiator. Add coolant as required. Insure that
Inspect the complete installation including remote fuel radiator cap is installed properly and tightened.

lines (if any) and air hose routing and connections. Note: This machine will not allow engine starting if
engine coolant is low.
Check battery for proper connections and condition.

Book 54757919 (5/02) (25)

NOTICE: If the appropriate mixture of antifreeze is
not used during freezing temperatures, failure to STARTING --
drain the engine may cause costly engine damage.
Never use water only as corrosion inhibitors are NOTICE
required in engine coolant fluid.
This unit is equipped with a battery disconnect
switch which removes power from the machine
controller for long term storage. The switch is lo-
CAUTION cated on the side of the engine near the battery.
This switch must be turned ON to provide power
No smoking, sparks, or open flame near fuel. to the control panel for starting this unit.

Check the fuel level. Add only CLEAN DIESEL fuel 1. Turn the keyswitch to the “ON” position (first
for maximum service from the engine. Refer to the position). All diagnostic lamps and the LED
Engine Operator’s Section for fuel specifications. display will light for two (2) seconds. Then all
lamps should go off except for
ALTERNATOR NOT CHARGING and LOW
NOTICE ENGINE OIL PRESSURE.
2. In freezing weather (below 32_F/0_C), flip
To minimize condensation (water) in the fuel
HEATERS switch “ON” and wait sixty (60
tank, it is recommended to fill the tank at the end
seconds). This applies heat to the control
of each day.
system components for easier starting.
Leave this switch “ON” while operating at
WARNING these temperatures.
3. When the keyswitch is turned to “START”
This machine produces loud noise with doors the engine starter will be engaged. Do not
open. Extended exposure to loud noise can operate the engine starter motor for
cause hearing loss. Wear hearing protection more than ten (10) seconds without
when doors or valve(s) are open. allowing at least one minute cooling time
• Close the side doors to maintain a cooling air between start attempts.
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.

• Make sure no one is IN or ON the compressor

unit.

Book 54757919 (5/02) (26)

 CAUTION
Operation -- Unloaded
Ether is an extremely volatile, high flammable
gas. Use Sparingly! If too much is injected, the If there is no air demand at 1200 RPM (Pressure rises
uncontrolled explosion may result in costly above the unload point prssure), the compressor will
damage to the engine. unload by closing the inlet valve. The unit then runs at
1200 RPM unloaded with no air delivery. If air demand
increases (pressure falls to below the load point
4. In cold weather, as required, press the
pressure), the compressor reloads to meet the
ETHER INJECT button once or twice only
required air demand.
while the engine is cranking. This injects a
measured amount of ETHER to the engine.
5. Following a successful start, the engine will STOPPING
accelerate to idle speed of 1200 RPM for S Close air service valve(s).
warm--up. Compressor discharge pressure S Allow the unit to run at “no load” for 3 to 5 minutes
will be maintained at 60 psi during warm--up. to reduce the engine temperatures.
6. Press the LOAD button. The engine will S Turn the keyswitch to the “OFF” position.
increase speed up to 1800 rpm until the
pressure reaches the desired set point.

NORMAL OPERATION NOTICE

The Operator may observe and monitor operating
parameters using the gages on the panel. In the event Once the engine stops, the automatic blowdown
the machine controller detects a parameter outside valve will continue to relieve all pressure from
normal operating limits, the unit will shutdown. the check valve to discharge valve piping.

In the event the machine controller detects a

parameter at a dangerously high or low level, the
NOTICE
machine will be automatically be stopped with the Failure to allow turbo cool down prior to
cause of the SHUTDOWN shown on the diagnostic stopping can cause turbocharger damage.
lights.

Delivered air volume at set point pressure is WARNING

accomplished by two methods:
Even after pressure is relieved from the piping
1). The compressor is loaded (inlet valve fully open or system, any air supply line from the compressor
modulated partially open), or unloaded (inlet valve to a tool or machine could remain under
fully closed). pressure and cause serious personal injury or
death. After the compressor stops, carefully
2) Engine speed varies between 1200 RPM and 1800
open a valve at any tool or machine to exhaust
RPM while compressor is loaded to match the
the pressure in any line prior to removal or
required volume flow.
servicing.
Operation -- Loaded

Assume engine has been started and is running in the CAUTION

unload state at 1200 RPM. If there is air demand
(pressure falls below the load point pressure), Never allow the unit to sit stopped with pressure
compressor will load at 1200 RPM by opening the inlet in the receiver--separator system. As a
valve. As air demand rises and falls, engine speed is precaution, open the service valve.
controlled between 1200 RPM and 1800 RPM to
match the required flow while maintaining rated
pressure.
Book 54757919 (5/02) (27)
IQ System IQ SYSTEM OPERATION X TO AFTERCOOLER

The IQ System is a complete, self--contained system AFTER--

COOLER
which provides cooler, cleaner air than from a
standard portable compressor. The system utilizes an
integral aftercooler, high--efficiency filtration, and a
patented condensate disposal system to provide the

X
cool, clean air. The condensate disposal system FILTERS W/S

injects all liquid condensed from the moisture

separator and filters into the engine exhaust system
where it is vaporized by heat. This eliminates the need
CLOSED
for collecting the condensate, and the added cost of
disposing of the condensate, which is often regulated
by local, state, and/or federal regulations. IQ AIR

When equipped with the low ambient feature, the IQ

STANDARD OPERATION
System automatically adjusts movable louvers to con- X

trol airflow through the aftercooler, ensuring that the AFTER--

COOLER

compressed air temperature always remains above

freezing temperatures (typically 45ºF) at any ambient
temperature down to --20ºF. This prevents the need
for 120V AC heat tracing systems, or any manual ad-
FILTERS W/S
justment to prevent freezing of the compressed air
system. All drain points for the condensate handling
system are heated with 24VDC heat tracing, which is
integral to the compressor heater system. SERVICE AIR

Theory of Operation
The compressed air exits the separator tank through CLOSED

the top cover piping, and can then travel along one of REV.A 22054365

two paths, selectable via manual valving. At the bottom of the moisture separator and both filters
are strainers and constant--bleed orifices, which are
One path allows Standard Operation, which bypasses sized to allow the maximum flow of condensate while
the IQ System, and delivers air quality equivalent to a minimizing compressed air loss.
standard oil--flooded portable compressor. If the IQ The condensate lines are then piped together, and the
System is enabled by proper setting of the selector condensate is injected at a single point into the engine
valve, the compressed air first enters the aftercooler. exhaust piping. The compressed air then travels
The aftercooler is cooled by the incoming compressor through the minimum pressure valve, and out through
package air, which is controlled by movable louvers the service air valve. The air pressure gauge on the
mounted on the aftercooler (if equipped with low ambi- instrument panel indicates the pressure inside the
ent option). At most conditions, the louvers are fully separator tank. A service air pressure gauge is lo-
open, and maximum aftercooling is available. The cated inside the front door of the compressor on the fil-
compressed air and condensate (water with a small ter support.
amount of compressor lubricant) exits the aftercooler If the IQ System is bypassed (Standard Operation se-
and enters the moisture separator, where most of the lected), the delivered air pressure will be approximate-
condensate is removed. The compressed air then ly equal to the separator tank pressure. If the IQ Sys-
flows through two stages of filtration, where the aero- tem operation is selected, the delivered air pressure
sol water and oil is removed down to approximately will be slightly less, depending on the restriction of the
0.01 ppm, and all particulates are removed down to filters.
0.01 micron.

Book 54757919 (5/02) (28)

 CAUTION

Excessively restricted filter elements may cause

CAUTION an increase in the amount of aerosol water and oil
carryover, which could result in damage to down-
The compressor regulation system is adjusted to stream equipment. Normal service intervals
maintain regulated pressure at the separator tank. should not be exceeded.
DO NOT adjust regulation to provide full regula-
tion pressure at the service valve when the IQ Sys-
tem is enabled. This will result in operation at ex-
cessive horsepower levels, causing overheating, Weekly Maintenance:
reduced engine life, and reduced airend life. S Remove Y--strainer screens at the bottom of the
moisture separator and both filters and clean out any
residue.
Low Ambient Option Operation S Verify that the orifices below the Y--strainers are not
clogged.
When the ambient temperature falls to the point that
the aftercooler outlet temperature is approaching S Verify that the piping from the orifice purge points to
45ºF, the Temperature Control Unit (TCU), mounted the exhaust system is not clogged.
on the rear of the control panel, will automatically ad-
just the louvers to control the cooling airflow through
the aftercooler.

In the event that the unit is operating under abnormal

CAUTION
conditions (i.e., an enclosure door open) which would
cause excessive cooling of the aftercooler, a tempera- Blockage of the Y--strainers, orifices, or piping can
ture sensor in the aftercooler outlet header will signal result in flooding of the vessels with condensate.
the TCU to further close the louvers if the compressed If flooding occurs, excessive condensate may en-
air temperature falls to approximately 36ºF or lower. ter the air stream and could result in damage to
downstream equipment.
There are no user selectable or serviceable compo-
nents in the TCU. Contact Ingersoll--Rand Service if
any abnormal operation of the freeze protection con-
trol system occurs. Yearly Maintenance:
The normal maintenance interval on the primary and
secondary IQ System filters is one year, or earlier if
MAINTENANCE pressure drop becomes excessive. Restriction indica-
tors for the filters are mounted on the filter support in-
Daily Maintenance:
side the front door, and will shut down the compressor
Verify, during full--load (maximum compressed air de- if restriction exceeds recommended values.
livery) that the IQ System filter restriction indicators do
not show excessive restriction. Restriction indicators
for the filters are mounted inside the control panel, and CAUTION
will shut down the compressor if restriction exceeds
recommended values. Excessively restricted filter elements may cause
an increase in the amount of aerosol water and oil
carryover, which could result in damage to down-
stream equipment. Normal service intervals
should not be exceeded.

Book 54757919 (5/02) (29)

Filter Replacement
S With engine stopped, ensure pressure is relieved S Put a small amount of petroleum jelly or other
from air system. non--synthetic grease on the element o--ring to aid
S Remove all wires and hoses connected to drains on installation into the filter head.
bottom of each filter housing. Inspect fittings and
hoses for any blockage. Clean if necessary.
S Replace housing making sure to not overtighten.

S Using a chain wrench or similar tool, loosen the

housing. The housing should be removed by hand S Repeat the above procedure on the remaining filter
after loosening, taking care to prevent the housing element.
from falling to the floor panel.

S Reconnect all wires and hoses to drains on bottom

S Lower the housing to floor panel and lean it against of each filter housing.
the airend. Remove and replace the filter element,
being careful not to damage outer wrap.

Verify the part number of new element vs. old

element, as the two IQ filters are of different media.

Book 54757919 (5/02) (30)

 Pressure Regulation
H 4. Insure that pressure is maintained at rated
pressure, then turn regulator adjustment
screw (H) counterclockwise until engine
G speed just begins to be reduced.

Note: Turning regulator adjustment screw (H)

PR clockwise will raise pressure at full speed.

5. Close service valve (engine will slow to no

load or idle speed).

6. If necessary, repeat steps 3 and 4.

US
7. At pressure regulator (PR) tighten lock nut
(G).

8. To adjust the unloaded pressure to any

pressure between 80 PSI (550 kPa) and
the rated operating pressure, turn adjust-
ment screw (H) of pressure regulator (PR)

IU to obtain desired discharge pressure at full

load engine speed. Always lock and protect
22054399 pressure setting of adjusting screw (H) with
locknut (G).

Normally, regulation requires no adjusting, but if proper

adjustment is lost, proceed as follows:
9. Ensure unloader solenoid (US) acts to hold
Before Starting Unit -- pressure in inlet unloader (IU) after shut-
1. Atop separator cover at pressure regulator (PR) down. After start--up, the compressor
loosen locknut (G) counterclockwise. Turn ad- controller will open unloader solenoid (US).
justment screw counterclockwise on full turn.

After Starting Unit --

2. Allow unit to warm up, then push “Service Air
Switch” on control panel.

3. Open and adjust service valve on outside of the

unit to obtain the rated operating pressure on
the discharge pressure gauge.

Note: If the rated operating pressure cannot be main-

tained with engine at full load speed, turn regulator
adjustment screw (H) clockwise and adjust service
valve until engine maintains rated full load speed.

Book 54757919 (5/02) (31)

 SECTION 5 -- MAINTENANCE
GENERAL COMPRESSOR OIL LEVEL
In addition to periodic inspections, many of the The oil level is most consistent when the unit is
components in these units require periodic servicing running unloaded and should be checked at this
to provide maximum output and performance. time.The oil level should be between the high/low
Servicing may consist of pre--operation and indicators on the sight glass located on the side of
post--operation procedures to be performed by the the receiver tank.
operating or maintenance personnel. The primary
function of preventive maintenance is to prevent COMPRESSOR OIL
failure, and consequently, the need for repair.
This machine was factory filled with Ingersoll--Rand
Preventive maintenance is the easiest and the least
Fluid.
expensive type of maintenance. Maintaining your
unit and keeping it clean at all times will facilitate
servicing. By continued use of Ingersoll--Rand compressor
fluids and filters, optional warranty will be extended
for the base airend (rotors, housings, gears and
bearings) when substantiated with proof of
CONTAINMENT BASE conformance to recommended maintenance
This unit uses a containment base large enough to intervals and purchase of OEM Ingersoll--Rand
hold the fluid contents of the engine oil, coolant, fuel filters and fluids.
or compressor oil systems.
Drain plugs are located at strategic positions in this Optional Warranty -- The earlier of 60 months from
base to drain accumulated fluids and also to allow shipment to, or the accumulation of 10,000 hours of
access to system drain plugs in the fuel tanks and service by the initial user. The optional warranty is
compressor oil resevoir for flushing. limited to defects in major components (rotors,
A central drain system is provided for normal service housings and bearings), and is automatically
of engine, fuel, or compressor system. available to the original user when he meets the
following two conditions:
The containment base should be drained and
flushed monthly or following any fluid discharge into
the base.
1. Submissions of proof that Ingersoll--Rand fluid,
filters and separators have been used. Refer to the
SCHEDULED MAINTENANCE
Operation and Parts manual for the correct fluids,
The maintenance schedule is based on normal
filters and separator elements required.
operation of the unit. This page can be reproduced
and used as a checklist by the service personnel. In
2. Submission of proof that maintenance intervals
the event unusual environmental operating
have been followed.
conditions exist, the schedule should be adjusted
accordingly.

WARRANTY TIME *BARE AIREND **AIREND COMPONENTS

STANDARD 2 yrs/4000 hrs 100% parts and labor 100% parts and labor

Book 54757919 (5/02) (32)

Bare Airend -- Pertains to major airend parts (rotors, 3. Wipe inside of air cleaner housing with a
housings, and bearings). clean, damp cloth to remove any dirt
accumulation, especially in the area where
Airend Components -- Pertains to auxiliary the element seals against the housing.
attachments to the bare airend (drive coupling,
seals, pumps, valves, tubes, hoses, fittings and filter 4. If a new air filter element is to be used check
housing). it closely for shipping damage. To reset the
signal indicator in the special wing nut, apply
The compressor oil must be replaced every 1000 suction to the red window.
hours of operation or six (6) months, whichever 5. Install cleaned or new elements in the
comes first. reverse order to the above. Tighten wing
nuts firmly and replace cotter pin.
Refer to the fluids and lubricants chart for ambient 6. Inspect to ensure that the end cap seals
temperature ranges and specifications, in the tightly 360 degrees around the air cleaner
lubrication section of this manual. body.

The air cleaner system (housing and piping) should

Refer to the fluids and lubricants chart for ambient be inspected every month for any leakage paths or
temperature ranges and specifications in the inlet obstructions. Make sure the air cleaner
lubrication section of this manual. mounting bolts and clamps are tight. Check the air
cleaner housing for dents or damage which could
AIR CLEANER lead to a leak. Inspect the air transfer tubing from the
This unit is equipped with an AIR FILTERS air cleaner to the compressor and the engine for
RESTRICTED lamp on the instrument panel. holes. Make sure that all clamps and flange joints
are tight.
When this message is viewed, both the engine and
airend filters should be replaced.
GAUGES
Also, each week, squeeze the rubber valve The instruments or gauges are essential for safety,
(precleaner dirt dump) on each air cleaner housing maximum productivity and long service life of the
to ensure that they are not clogged. machine. Inspect the gauges and test any
diagnostic lamps prior to start--up. During operation
observe the gauges and any lamps for proper
NOTICE: Holes or cracks downstream of the air functioning. Refer to Operating Controls for the
cleaner housing will cause the restriction indicators normal readings.
to be ineffective.
FUEL TANK
This unit is equipped with dual tanks that can be filled
To service the air cleaners on all units proceed as from either side. Using clean fuel in the fuel tanks is
follows: important and every precaution should be taken to
ensure that only clean fuel is either poured or
1. Loosen outer wing nut and remove with pumped into the tank. When filling the fuel tank on
outer element. Inspect red window on this unit, by methods other than a pump and hose,
special inner wing nut to find small dot. If dot use a CLEAN non--metallic funnel.
is not visible, remove cotter pin and special
wing nut and inner (safety) element.
2. Inspect air cleaner housing for any condition
that might cause a leak and correct as
necessary.

Book 54757919 (5/02) (33)

Every six months the drain plugs should be removed The engine cooling system is filled at the factory with
from the tanks so that any sediment or accumulated a 50/50 mixture of water and ethylene glycol. This
condensate may be drained. When replacing the permanent type antifreeze contains rust inhibitors
drain plugs, make sure they are tightened securely. and provides protection to --35° F (--37°C).

BATTERY The use of such a mixture is recommended for both

Heavy--duty, diesel cranking type batteries were summer and winter operation. When using water
installed at the factory and these should be alone, be sure to add a reputable brand of rust
inspected weekly. Keep the battery posts--to--cable inhibitor to prevent internal corrosion.
connections clean, tight and lightly coated with a
grease. Also the electrolyte level in each cell should It is recommended to test the freezing protection of
cover the top of the plates. If necessary, top--up with the coolant every six months or prior to freezing
clean distilled water. temperatures. Replenish with a fresh mixture every
twelve months. A drain for the system is located in
the bottom radiator tank.
COMPRESSOR OIL and FUEL COOLERS
Each month, inspect the radiator exterior for
The coolers are cooled by means of the fin and
obstructions (dirt, bugs, etc.). If present, blow water
tube--type oil cooler. The compressor oil and fuel
or compressed air containing a nonflammable
flow internally through the core sections. Fluid is
solvent between the fins in a direction opposite the
cooled by the air stream from the cooling fan flowing
normal air flow. Should the radiator be clogged
past the core section. When grease, oil and dirt
internally, standard automotive practices should be
accumulate on the exterior surfaces of the coolers,
followed.
their efficiency is impaired.

ENGINE CHARGE AIR COOLER

Each month it is recommended that the coolers be
cleaned by directing compressed air which contains This cooler is a fin and tube--type oil cooler. The
a nonflammable safety solvent through the core of engine intake air flows internally through the core
the coolers. This should remove the accumulation of section. It is cooled by the air stream from the cooling
grease, oil and dirt from the exterior surfaces of the fan flowing past the core section. When grease, oil
cooler core so that the entire cooling area can and dirt accumulate on the exterior surfaces of the
transmit the heat of the fluid to the air stream. cooler, efficiency is impaired.

If foreign deposits, such as sludge and lacquer, Each month it is recommended that the cooler be
accumulate in the coolers, high temperature is likely cleaned by directing compressed air which contains
to occur, causing shut down of the unit. a nonflammable safety solvent through the core of
the cooler. This should remove the accumulation of
grease, oil and dirt from the exterior surfaces of the
RADIATOR
cooler core so that the entire cooling area can
WARNING transmit the heat of the fluid to the air stream.
Ensure that the air connections do not leak. Leaks or
Do not remove the cap from a HOT engine loss of cooling will result in low engine power.
radiator. The sudden release of pressure from a
heated cooling system can result in serious
personal injury.

Book 54757919 (5/02) (34)

ENGINE CRANKCASE VAPOR CONDENSATE
The engine is equipped with a system to collect
NOTICE
engine crankcase vapor condensate (oil and water) Piping systems operating at less than 150 psi
for disposal. Check the collection bottle near the (1050 kPa) may use a special nylon tubing. The
engine oil pan before starting the unit. If the bottle is associated fittings are also of a special
more than half full, remove it and empty the contents “push--in” design.
in a proper waste container. Replace the empty
bottle on the unit.
Pulling on the tubing will cause the inner sleeve to
withdraw and compress, thus tightening the
connection. The tubing can be withdrawn only while
WARNING
holding the sleeve against the fitting. The tubing can
Do not allow the bottle to overflow. Engine be removed and replaced numerous times without
damage may result. losing its sealing ability.

HOSES To install the nylon tubing, make a mark (with tape or

grease pencil) approximately 7/8 inch from the end
Each month it is recommended that all of the intake
of the tubing. Insert the tubing into the sleeve and
lines to and from the air cleaners, the charge air
“push--in” past the first resistance to the bottom. The
coolers, the engine cooling system hoses and all of
the flexible hoses used for air, oil, and fuel be mark should be approximately 1/16 inch from the
inspected. sleeve, for the 3/8 inch O.D. tubing; 1/8 inch for the
0.25 inch O.D. tubing. This will ensure that the
tubing is fully engaged in the sealing mechanism.
To prevent leaks, regular inspection of these
connections for wear or deterioration is a definite
“must” if regulator servicing of the air cleaners is not
to prove futile.
COMPRESSOR OIL FILTERS
Premature wear of both the engine and compressor The compressor lubrication oil systems include
is ASSURED if dust--laden air is permitted to enter spin--on, throw away type oil filters, each with an
the engine or the compressor. internal bypass valve. With a clean, new filter
element, all of the oil flows through the full element
The flexible hoses used in the fuel, oil and air lines area, from the outside/inside. As each element
on these units are primarily used for their ability to becomes contaminated with dirt, a pressure
accommodate relative movement between differential is created in the filter housing between
components. It is extremely important they be the oil inlet and outlet ports. As this differential
periodically inspected for wear and deterioration. approaches 25 psi (175 kPa), the bypass valve
Clamps are used to prevent hose cover abrasion starts to open, thus permitting a small quantity of oil
through vibration. This abrasion may occur when to bypass the filter. As the contaminants continue to
two hose lines cross, or when a hose line rubs build up, more and more of the oil bypasses the filter
against a fixed point; therefore, it is necessary that media itself.
all clamps be replaced if missing. It is also important
the operator does not use the hoses as convenient
hand hold or steps. Such use can cause early cover
wear and hose failure.

Book 54757919 (5/02) (35)

This bypass does not provide any filtration but does 5. Install new filter by turning element clockwise
allow a maximum flow of compressor lubricating oil until gasket makes initial contact. Tighten an
to preclude any possible damage from loss of oil. additional 1/2 to 3/4 turn.
Also the design of the filter prevents any washing--off
of any dirt during oil bypassing. 6. Start unit and allow to build up to rated pressure.
Check for leaks before placing unit back into service.

NOTICE FASTENERS
The oil filter must be replaced every 1000 hours Visually check entire unit in regard to bolts, nuts and
of operation. screws being properly secured. Spot check several
capscrews and nuts for proper torque. If any are
To service the oil filters it will first be necessary to found loose, a more thorough inspection must be
shut the unit down. Wipe off any external dirt and oil made. Take corrective action.
from the exterior of the filter to minimize any
contamination from entering the lubrication system. COMPRESSOR OIL
Proceed as follows: The lubricating and cooling oil must be replaced
every 1000 hours of operation or six (6) months,
whichever comes first.
WARNING
High pressure air can cause severe injury or
death from hot oil and flying parts. Always
relieve pressure before removing caps, plugs, ENGINE COOLING FAN DRIVE
covers or other parts from pressurized air
The heat exchanger or cooling fan is driven by a
system.
single belt arrangement from the engine. Inspect the
cooling fan belt weekly. These belts should be
1. Open the service air valve(s) to ensure that maintained at the proper tension by the auto tension
system is relieved of all pressure. Close the valve(s). system on the engine.

2. Turn the spin--on filter element

EXTERIOR FINISH CARE
counterclockwise to remove it from the filter housing.
Inspect the filter element and then discard. This unit was painted and heat cured at the factory
with a high quality, thermoset polyester powder
coating. The following care will ensure the longest
Note: If there is any indication of formation of
possible life from this finish.
varnishes, shellacs or lacquers on the oil filter
element, it is a warning the compressor lubricating
oil has improper characteristics and should be 1. If necessary to remove dust, pollen, etc.
immediately changed. from housing, wash with water and soap
or dish washing liquid detergent. Do not
scrub with a rough cloth, pad, etc.
3. Inspect the oil filter head to be sure the gasket
was removed with the oil filter element. Clean the 2. If grease removal is needed, a fast
gasket seal area on the oil filter head. evaporating alcohol or chlorinated
solvent can be used. Note: This may
cause some dulling of the paint finish.
Installing a new oil filter element when the old gasket
remains on the oil filter head will cause an oil leak
and can cause property damage.

4. Lubricate the new filter gasket with the same oil

being used in the machine.

Book 54757919 (5/02) (36)

3. If the paint has faded or chalked, the use 10. Apply any of Duponts Topcoat Finishes
of a commercial grade, non--abrasive car such as Imront or Centarit according
wax may partially restore the color and to the label instructions.
gloss.

Note: To re--topcoat the textured surfaces

when sheet metal repairs are not
necessary, follow steps 1, 2, 4, 5, 6, 8 and
10.

Field Repair of Texture Paint

1. The sheet metal should be washed and
clean of foreign material and then
thoroughly dried.

2. Clean and remove all grease and wax

CAUTION
from the area to be painted using S Any unauthorized modification or failure to
Duponts 3900S Cleaner prior to sanding. maintain this equipment may make it unsafe and out
of factory warranty.
3. Use 320 grit sanding paper to repair any
scratches or defects necessary. S If performing more than visual inspections,
disconnect battery cables and open manual
4. Scuff sand the entire area to be painted blowdown valve.
with a red scotch brite pad.
S Use extreme care to avoid contacting hot
surfaces (engine exhaust manifold and piping, air
5. Wipe the area clean using Duponts
receiver and air discharge piping, etc.).
3900S.
6. Blow and tack the area to be painted.
S Never operate this machine with any guards
7. Apply a smooth coat of Duponts 1854S removed.
Tuffcoat Primer to all bare metal areas
and allow to dry.
S Inch and metric hardware was used in the
design and assembly of this unit. Consult the parts
8. Apply 2 medium -- wet coats of Duponts manual for clarification of usage.
222S Adhesion Promoter over the entire
area to be painted, with a 5 minute flash Notice: Disregard any maintenance pertaining to
in between coats. components not provided on your machine.
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.
NOTICE
This will allow the primer to splatter
causing the textured look. Note: you Drain the frame after power--washing/cleaning or
must be careful not to put too much heavy rains.
primer on at one time, this will effect the
amount of texture that you are trying to
achieve. Allow the texture coat to flash
for 20 minutes or until dry to touch.

Book 54757919 (5/02) (37)

 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
**Hydraulic Oil Level C R
Compressor Oil Level C
Engine Oil Level C
**Radiator Coolant Level C
Gauges/Lamps C
Air Cleaner Service Indicators C
Fuel Tank (fill at end of day) C DRAIN
**Fuel/Water Separator DRAIN C
Air Cleaner Precleaner Dumps C
Fan/Alternator Belts C
Battery Connections/Electrolyte C
**Tire Pressure and Surface C
**Wheel Lug Nuts C
Hoses (oil, air, intake, etc.) C
Automatic Shutdown System 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 Orifice & related parts CLEAN
Oil Separator Element R
**Lights (running, brake, & turn) CBT
**Pintle Eye Bolts CBT
Engine (oil changes, oil & fuel filters, etc) R

**Disregard if not appropriate for this particular machine.

*NXP Units -- consult manual

R=replace, C=check (adjust if necessary), WI=OR when indicated, CBT = check before towing.

A = Small Units

B = Large Units

Refer to specific sections of the operator’s manual for more information.

Book 54757919 (5/02) (38)
 SECTION 6 -- LUBRICATION

GENERAL INFORMATION

Lubrication is an essential part of preventive mainte-

nance, affecting to a great extent the useful life of the
unit. Different lubricants are needed and some compo- If the unit has been operated for the time/ hours men-
nents in the unit require more frequent lubrication than tioned above, it should be completely drained of oil. If
others. Therefore, it is important that the instructions the unit has been operated under adverse conditions,
regarding types of lubricants and the frequency of their or after long periods in storage, an earlier change peri-
application be explicitly followed. Periodic lubrication od may be necessary as oil deteriorates with time as
of the moving parts reduces to a minimum the possibil- well as by operating conditions.
ity of mechanical failures.

The Preventive Maintenance Schedule shows those WARNING

items requiring regular service and the interval in
which they should be performed. A regular service
High pressure air can cause severe injury or death
program should be developed to include all items and
from hot oil and flying parts. Always relieve pres-
fluids. These intervals are based on average
sure before removing caps, plugs, covers or other
operating conditions. In the event of extremely severe
parts from pressurized air system. Ensure the fol-
(hot, cold, dusty or wet) operating conditions, more
lowing conditions are met:
frequent lubrication than specified may be necessary.
Details concerning lubrication of the running gear are
in Maintenance Section. -- Discharge air pressure gauge reads zero (0).
-- No air discharging from an “open” manual blow-
down valve.
All filters and filter elements for air and compressor lu-
bricant must be obtained through Ingersoll--Rand to
assure the proper size and filtration for the compres- An oil change is good insurance against the accumula-
tion of dirt, sludge, or oxidized oil products.
sor.

Completely drain the reservoir, piping, and cooler. If

the oil is drained immediately after the unit has been
COMPRESSOR OIL CHANGE run for some time, most of the sediment will be in sus-
pension and, therefore, will drain more readily. Howev-
er, the fluid will be hot and care must be taken to avoid
These units are normally furnished with an initial sup-
contact with the skin or eyes.
ply of oil sufficient to allow operation of the unit for
approximately 6 months or 1000 hours, whichever
comes first. If a unit has been completely drained of all
After the unit has been completely drained of all old
oil, it must be refilled with new oil before it is placed in
fluid, close the drain valve, install new oil filter ele-
operation. Refer to specifications in Lubrication Table.
ments. Add oil in the specified quantity at the filler
plug. Tighten the filler plug and run the machine to cir-
NOTICE culate the oil. Check the oil level. DO NOT OVERFILL.
Some oil types are incompatible when mixed and re-
sult in the formation of varnishes, shellacs, or lacquers NOTICE
which may be insoluble. Such deposits can cause se- Ingersoll--Rand provides compressor oil specifically
rious troubles including clogging of the filters. Where formulated for Portable Compressors and requires the
possible, do NOT mix oils of different types and avoid use of these fluids in order to obtain extended limited
mixing different brands. A type or brand change is best airend warranty.
made at the time of a complete oil drain and refill.

Book 54757919 (5/02) (39)

 RATED OPERATING PRESSURE

COMPRESSOR 100 -- 300 PSI 350 PSI 500 PSI

125_F
LUBRICATION 50_C

40_C 104_F IR IR IR

Portable Compressor Fluid Chart XHP505 XHP 1001 XHP1001

30_C 86_F

Refer to these charts for correct compressor IR IR

PER FORMANCE 20_C 65_F
fluid required. Note that the selection of fluid is 500
PRO--TECt

dependent on the design operating pressure

10_C 50_F
of the machine and the ambient temperature
expected to be encountered before the next oil
0_C 32_F IR IR
change. PERFORMANCE
500
XHP505

--10_C 14_F

10_F
--20_C
Design Operating Ambient --10_F
Specification
Pressure Temperature --30_C --22_F

100 psi to 300 psi --10_F to 125_F IR Pro--Tect

--40_C --40_F consult
(--23_C to 52_C) Mil –PRF 2104G SAE 10W factory

100 psi to 300 psi --40_F to 125_F IR Performance 500

(--40_C to 52_C) Mil--L--46167

350 psi --10_F to 125_F IR XHP 505

(--23_C to 52_C)

65_F to 125_F IR XHP1001

(18_C to 52_C)

--40_F to 65_F IR Performance 500

(--40_C to 18_C) Mil--L--46167

500 psi 50_F to 125_F IR XHP1001

(10_C to 52_C)

10_F to 65_F IR XHP 505

(--12_C to 18_C) Recommended Ingersoll--Rand Fluids -- Use of these
fluids with original I--R filters can extend airend warranty.
below 10_F Consult Factory Refer to operator’s manual warranty section for details
(--12_C) or contact your I--R representative.

Recommended Fluid 1 Gal. (3.8 Litre) 5 Gal. (19.0 Litre) 55 Gal. (208.2 Litre)
IR Pro--Tect 36899698 36899706 36899714
IR XHP 505 35365188 35365170
IR Performance 500 35382928 35382936 35382944
IR XHP1001 35612738 35300516

Premium grade oils API, CG --4 or CH--4 are recommended for the QSX15 engine.

Book 54757919 (5/02) (40)

 SECTION 7 -- Trouble Shooting
INTRODUCTION B. Do The Simplest Things First
Trouble shooting for a portable air compressor
is an organized study of a particular problem or Most troubles are simple and easily corrected. For
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. over-- heats” which may be caused by low oil level.
The trouble shooting chart that follows
includes some of the problems that an Always check the easiest and most obvious things first;
operator may encounter during the operation following this simple rule will save time and trouble.
of a portable compressor.

The chart does not attempt to list all of the Note: For trouble shooting electrical problems, refer to
troubles that may occur, nor does it attempt to the Wiring Diagram Schematic found in Parts List
give all of the answers for correction of the Section.
problems. The chart does give those problems
that are most apt to occur. To use the trouble
shooting chart:
C. Double Check Before Disassembly
A. Find the “complaint” depicted as a bold The source of most compressor troubles can be traced
heading. not to one component alone, but to the relationship of one
component with another. Too often, a compressor can be
B. Follow down that column to find the po- partially disassembled in search of the cause of a certain
tential cause or causes. The causes are trouble and all evidence is destroyed during disassembly.
listed in order (1,2,3 etc.) to suggest an Check again to be sure an easy solution to the problem
order to follow in trouble shooting. has not been overlooked.

D. Find And Correct Basic Cause

After a mechanical failure has been corrected, be sure to

locate and correct the cause of the trouble so the same
ACTION PLAN failure will not be repeated. A complaint of “premature
breakdown” may be corrected by repairing any improper
A. Think Before Acting wiring connections, but something caused the defective
wiring. The cause may be excessive vibration.
Study the problem thoroughly and ask yourself
these questions:

(1) What were the warning signals that preceded

the trouble?
(2) Has a similar trouble occurred before?
(3) What previous maintenance work has been
done?
(4) If the compressor will still operate, is it safe to
continue operating it to make further checks?

Book 54757919 (5/02) (41)

 A list of compressor and engine faults is attached with
General Information the placards inside the machine control panel and pro-
vided in this section. The table of Alert/Sutdown condi-
tions in this section also lists the compressor fault
The WEDGE controller records and displays diagnos- codes and a list of the engine fault codes is provided.
tic fault codes for the compressor system and the elec-
tronic engine. These codes are displayed on the The engine diagnostic fault codes can also be read
4--digit LED display on the machine control panel. Two with the manufacturer’s service tool. A service tool
of the ten LED diagnostic lamps on the control panel connector is mounted on the engine. This connector
are used with fault codes display. One lamp is desig- provides a connection to the J1939 CAN network. For
nated “Engine Fault” and the other “Compressor advanced engine troubleshooting, it is recommended
Fault”. When the engine fault lamp is on, all codes dis- that the manufacturer’s service tools be used with ac-
played are engine faults. When the compressor fault companying service literature.
lamp is on, all codes displayed are compressor or
package related faults.

FAULT CODE DESCRIPTION (QSX15 ENGINE FAULT CODES)

111 Engine Control Module -- Critical Internal Failure
115 Engine Speed/Position Sensor Circuit -- Lost both signals from Magnetic Pickup Sensor
121 Engine Speed/Position Sensor Circuit -- Lost one or two signals from Magnetic PU Sensor
122 Intake Manifold Pressure Sensor #1 Circuit -- Shorted High
123 Intake Manifold Pressure Sensor #1 -- Circuit -- Shorted Low
135 Engine Oil Pressure Sensor Circuit -- Shorted High
141 Engine Oil Pressur Sensor Circuit -- Shorted Low
143 Engine Oil Pressure Low -- Warning
144 Engine Coolant Temperature Sensor Circuit -- Shorted High
145 Engine Coolant temperature Sensor Circuit -- Shorted Low
151 Engine Coolant temperature High -- Critical
153 Intake Manifold Temperature Sensor #1 Circuit Shorted Low
154 Intake Manifold Temperature Sensor #1 Circuit Shorted High
155 Intake Manifold Temperature #1 High -- Critical
186 Sensor Supply Voltage #2 Circuit -- Shorted Low
212 Engine Oil Temperature Sensor Circuit -- Shorted High
213 Engine Oil Temperature Sensor Circuit -- Shorted Low
214 Engine Oil Temperature High -- Critical
221 Ambient Air Pressure Sensor Circuit -- Shorted High
222 Ambient Air Pressure Sensor Circuit -- Shorted Low
223 Engine Oil Burn Valve Solenoid Circuit -- Shorted Low
227 Sensor Supply Voltage #2 Circuit -- Shorted High
234 Engine Speed High -- Critical
235 Engine Coolant Level Low -- Critical
241 Vehicle Speed Sensor Circuit -- Data Incorrect
245 Fan Clutch Circuit -- Shorted Low
254 Fuel Shutoff Valve Circuit -- Shorted Low
255 Fuel Shutoff Valve Circuit -- Shorted High
259 Fuel Shutoff Valve -- Stuck Open
284 Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit -- Shorted Low
Book 54757919 (5/02) (42)
FAULT CODE DESCRIPTION
285 SAE J1939 Multiplexing PGN Timeout Error
286 SAE J1939 Multiplexing Configuration Error
287 SAE J1939 Multiplexing Remote Throttle Error
295 Ambient Air Pressure Sensor Circuit -- Data Incorrect
299 Engine Shutdown Commanded By J1939
311 Injector Solenoid Valve Cylinder #1 Circuit Grounded Circuit
312 Injector Solenoid Valve Cylinder #5 Circuit Grounded Circuit
313 Injector Solenoid Valve Cylinder #3 Circuit Grounded Circuit
314 Injector Solenoid Valve Cylinder #6 Circuit Grounded Circuit
314 Injector Solenoid Valve Cylinder #2 Circuit Grounded Circuit
319 Real Time Clock -- Power Interrupt
341 Engine Control Module -- Data Lost
343 Engine Control Module -- Warning Internal Hardware Failure
346 Engine Control Module -- Warning Software Error
352 Sensor Supply Voltage #1 -- Circuit -- Shorted Low
378 Fueling Actuator #1 Circuit -- Open Circuit
379 Fueling Actuator #1 Circuit -- Grounded Circuit
386 Sensor Supply Voltage #1 Circuit -- Shorted High
394 Timing Actuator #1 Circuit -- Open Circuit
395 Timing Actuator #1 Circuit -- Grounded Circuit
396 Fueling Actuator #2 Circuit -- Open Circuit
397 Fueling Actuator #2 Circuit -- Grounded Circuit
398 Timing Actuator #2 Circuit -- Open Circuit
399 Timing Actuator #2 Circuit -- Grounded Circuit
415 Engine Oil Pressure Low -- Critical
418 Water In Fuel Indicator High -- Maintenance
422 Engine Coolant Level Sensor Circuit -- Data Incorrect
426 SAE J1939 Datalink -- Cannot Transmit
428 Water in Fuel Sensor Circuit -- Shorted High
429 Water in Fuel Sensor Circuit -- Shorted Low
433 Intake Manifold Pressure Sensor Circuit -- Data Incorrect
434 Power Lost Without Ignition OFF
435 Engine Oil Pressure Sensor Circuit -- Data Incorrect
441 Battery #1 Voltage Low -- Warning
442 Battery #1 Voltage High -- Warning
449 Fuel Pressure High -- Warning
451 Injector Metering Rail #1 Pressure Sensor Circuit -- Shorted High
452 Injector Metering Rail 31 Pressure Sensor Circuit -- Shorted Low
466 Turbocharger #1 Wastegate Control Circuit -- Data Incorrect
482 Fuel Pressure Low -- Warning
483 Injector Metering Rail #2 Pressure Sensor Circuit -- Shorted High
484 Injector Metering Rail #2 Pressure Sensor Circuit -- Shorted Low
485 Injector Metering Rail #2 Pressure High -- Warning

Book 54757919 (5/02) (43)

FAULT CODE DESCRIPTION
486 Injector Metering Rail #2 Pressure Low -- Warning
496 Engine Speed/Position Sensor #2 (Camshaft) Supply Voltage
546 Fuel Delivery Pressure Sensor Circuit -- Shorted High
547 Fuel Delivery Pressure Sensor Circuit -- Shorted Low
553 Injector Metering Rail #1 Pressure High -- Warning
581 Fuel Supply Pump Inlet Pressure Sensor Circuit -- Shorted High
582 Fuel Supply Pump Inlet Pressure Sensor Circuit -- Shorted Low
583 Fuel Supply Pump Inlet Pressure Low -- Warning Level
595 Turbocharger #1 Speed High -- Warning Level
596 Electrical Charging System Voltage High -- Warning Level
597 Electrical Charging System Voltage Low -- Warning Level
598 Electrical Charging System Voltage Low -- Critical Level
611 Engine Hot Shutdown
753 Engine Speed/Position #2 Cam Sync Error
754 Injector Metering Rail #1 Pressure Malfunction
758 Injector Metering Rail #2 Pressure Malfunction
951 Cylinder Power Imbalance Between Cylinders

Book 54757919 (5/02) (44)

ALERT/SHUTDOWN CONDITIONS Software V1.10

ALERT SHUTDOWN
LIGHT CODE LIGHT DELAY
CODE (BLINKS) (STEADY) (sec)

Low Engine Speed (RPM<800) 1 CPRSR Malf. 30

High Engine Speed (RPM >1900) 2 CPRSR Malf. 30
Engine Crank Time Exceeded 3 CPRSR Malf. 0
Low Fuel Level Fuel Level Fuel Level 3

Engine Oil Temperature > 252 deg. F 5 CPRSR Malf.

Intake Manifold Temperature > 180 deg. F 6 CPRSR Malf.
High Discharge Temp. (RT2>247 deg. F) High Comp Temp. 3
Low AE Oil Pressure (HP1600 only) 31 CPRSR Malf. 3
Disch. Temp (RT2) Sensor Fault 32 CPRSR Malf. 10
High Separator Tank 50 CPRSR Malf. 3
Temp (RT1>247 deg.F)
Machine ID Not Valid 51 CPRSR Malf. 0
IQ Filter Restriction IQ Filt. Rest 3
Sep. Tank Temp (RT1) Sensor Fault 53 CPRSR Malf. 10
Sep. Tank Pressure (PT1) 33 CPRSR Malf.
Sensor Fault

Reg. System Pressure PT2) Sensor Fault 54 CPRSR Malf.

Air Filter Restriction Soiled Filter

Low Battery Voltage Battery
Charging
Condition
Serial Comm. Problem 70 CPRSR Malf.
CAN Bus Problem 71 CPRSR Malf.
Engine Coolant Temp > 215 deg. F High Engine
Temp
Engine Oil Pressure < 10 psi Low Engine
Oil Pressure
Separator Tank Pressure > 20 psi during 34 CPRSR Malf. 0
start attempt (engine will not crank)
Engine Temp > 220 deg. F High Engine Temp 10

Book 54757919 (5/02) (45)

 TROUBLE SHOOTING CHART
Bold Headings depict the COMPLAINT -- Subheadings suggest the CAUSE
Note: Subheadings suggest sequence to follow troubleshooting.

1. Unit Shutdown: Corrective Action

Out of Fuel Add CLEAN diesel Fuel
Compressor Oil Temp. Too High See Complaint 10
Engine Water Temp. Too High Check coolant level. If necessary, Add.
Engine Oil Pressure Too Low See Complaint 3 and Complaint 4.
Broken Engine Fan Belt Replace fan belt.
Loose Wire Connection Wiggle wires at switches & connector blocks. Make repairs.
Low Fuel Level Shutdown Replace fuel sender.
Defective Sensor Replace sensor.
Malfunctioning Relay Replace relay.
Blown Fuse Replace fuse.
Engine Malfunctioning See Trouble Shooting in Engine Manual.
* Airend Malfunctioning See Complaint 10.

2. Won’t Start/Run:
Low Battery Voltage Check electrolyte level. Check connections.
Blown Fuse Replace fuse.
Malfunctioning Start Switch Replace switch.
Clogged Fuel Filters Service filters. See Engine Operator’s Manual.
Out of Fuel Add CLEAN fuel.
Compressor Oil Temp. Too High See Complaint 10.
Engine Water Temp. Too High Check fluid level. If necessary, Add.
Engine Oil Pressure Too Low See Complaint 3 and Complaint 4.
Loose Wire Connection Repair or replace connection.
Defective Sensor Replace sensor.
Malfunctioning Relay Replace relay.
Engine Malfunctioning See Trouble Shooting in Engine Manual.
Airend Malfunctioning See Complaint 10.

3. High Engine Temperature

Broken Engine Fan Belt Replace fan belt set.

* Ambient Temp. >115_F Above spec limit.

Dirty Operating Conditions Move unit to cleaner environment.
Dirty Cooler Clean exterior of cooler.
* Out of Level >15 degrees Relocate or reposition unit.
Operating Pressure Too High Reduce pressure to spec.
Recirculation of Cooling Air Close side doors.
Loose Wire Connection Repair or replace.

* : > = greater than, < = less than

Book 54757919 (5/02) (46)

4. Low Engine Oil Pressure 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. Repair or replace.

5. Alternator Low Voltage

Loose or Broken Belts Tighten or replace belt set.
Loose Wire Connection Repair or replace connection.
Low Battery Voltage Check electrolyte level. Add if necessary.
Check connectors. Clean & tighten.
Recharge battery.
Malfunctioning Alternator Repair or replace alternator.

6. High Compressor Discharge Temperature: Corrective Action

Ambient Temp. > 115_F 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.
Dirty Operating Conditions Move unit to cleaner environment.
Clogged Oil Filter Elements Replace elements. Change oil.
Loose or Broken Belts Tighten or replace belt set.
Operating Pressure Too High Reduce pressure to spec.
Recirculation Of Cooling Air Close side doors. Replace belly pan.
Malfunctioning Thermostat Replace thermostat in bypass valve.
Malfunctioning Fan Check fan belt tension. Tighten or replace belt set.
Defective Oil Cooler Relief Valve Replace valve.
Defective Minimum Pressure Valve Repair or replace valve.
Blocked or Restricted Oil Lines Clean by flushing or replace.
Airend Malfunctioning See Complaint 11, 12, 13, 15, 16 or 18.

Add

7. Engine RPM Down:

Clogged Fuel Filter (primary) Replace primary filter. Replace final filter. Drain
tanks. Add CLEAN fuel.
Operating Pressure Too High Reduce pressure to spec limit.
Dirty Air Filter Clean or replace elements.
Wrong Air Filter Element Install correct element.
Engine Malfunctioning See Trouble Shooting in Engine Manual.
Airend Malfunctioning Refer to Factory.

Book 54757919 (5/02) (47)

 Corrective Action
8. Excessive Vibration:
Rubber Mounts, Loose or Damaged Tighten or replace.
Defective Fan Replace fan.
Drive Coupling Defective Replace coupling.
Engine Malfunctioning See Trouble Shooting in Engine Manual.
Airend Malfunctioning See Complaint 15 and 17.
Engine idle speed too low. See Engine Manual.

9. Low CFM:
Dirty Air Filter Clean or replace elements.
Incorrect Linkage Adjustment Make adjustment per Section 6.
Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve. Make adjustment per Section 6.

Wrong Air Filter Element Install correct element.

10. Short Air Cleaner Life:

Dirty Operating Conditions Move unit to cleaner environment.
Inadequate Element Cleaning Install new element.
Incorrect Stopping Procedure Read procedure in this manual.
Wrong Air Filter Element Install proper element.

11. Will Not Unload:

Malfunctioning Inlet Butterfly Valve Inspect valve fit. Re--adjust per Section 6.
Ice in Regulation Lines/Orifice Apply heat to line(s) and or orifice.
Load Solenoid Leak Replace load solenoid.
Plugged Vent Leak Clean and/or replace.

12. Safety Valve Relieves:

Operating Pressure Too High Reduce pressure to spec limit.
Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve fit. Readjust per Section 6.
Defective Safety Valve Replace safety valve.
Unit Will Not Unload Fast Enough Apply heat to lines and/or orifice.

Book 54757919 (5/02) (48)

 SECTION 8 -- ELECTRICAL
GENERAL INFORMATION AND OPERATIONAL
THEORY
Software versions under 2.0 use the frequency throttle
General to communicate with the engine. A square wave fre-
The HP1600/1300 machine has an electronic monitor quency signal from 150 Hz to 375 Hz is sent from the
and control system to provide discharge air pressure WEDGE controller to the engine controller.
control and engine and package monitor functions.
The system uses the WEDGE controller to perform The signal is linear from 150 Hz at engine idle (1200
these functions. The electrical system connects all the RPM) to 375 Hz at maximum run speed (1800 RPM).
necessary switches, sensors and transducers to the
Figure 8--2 shows the signals between the engine con-
WEDGE controller in order for it to perform the monitor
troller and the WEDGE controller.
and control functions.
Sensors and Transducers
WEDGE Controller The electronics system contains sensors and trans-
The WEDGE controller is the heart of the machine ducers that are used to collect process data from the
monitor and control system. It provides data collection, compressor. The temperature is measured by a ther-
alarming and control functions for compressor opera- mister. This device exhibits a change in resistance as
tions. It is a microcontroller based unit with analog and the temeprature changes. The resistance causes an
digital inputs and outputs. input voltage change to the WEDGE controller input
and is interpreted as a temperature change.
The WEDGE controller is attached to the back of the
control panel. The LED annunciators are part of the The electronics system also uses pressure transduc-
front panel of the WEDGE. They can be seen through ers to measure process pressure changes. These de-
the laminate on the front of the control panel. The vices have an output signal of .45 VDC to 4.5 VDC,
WEDGE is attached to the control panel with four #10 corresponding to 0 psi and the maximum measured
size nuts. psi for a particular device. The maximum pressure
transducer ranges are 100 or 225 psi. The 100 and
The first function of the WEDGE is to scan all analog 225 psi devices are gauge rpessure devices. These
and digital inputs at a fixed interval. These inputs are transducers are provided with 5VDC excitation to pow-
scanned every 50 milliseconds. The analog values er the device. These are three wire devices: excita-
are then compared against minimum and maximum tion, signal and ground (return) connections.
values and an ALERT or SHUTDOWN is issued, if a
value is out of range. The various ALERTS and SHUT- Digital Inputs and Outputs
DOWNS are listed in this section. The WEDGE controller scans digital inputs such as
switch contacts. These are either “ON” (24VDC) or
The second function of the WEDGE controller is ma- “OFF” (0 VDC). These digital inputs are connected to
chine discharge pressure control. The WEDGE moni- switches within the package such as the key start
tors the regulation system air pressure and varies the switch, air filter switches and IQ filter switches.
engine throttle to maintain the setpoint discharge air-
pressure. The setpoint pressure is set using the regu- The WEDGE controller provides 24 VDC digital out-
lator on the separator tank. puts to control solenoids, start compressor and DC
heaters. These are 24 VDC “ON” and O VDC “OFF”.
The third function of the WEDGE controller is to com- They are current limited and short circuit protected.
municate with the diesel engine via the J1939 CAN
network. The WEDGE controller provides the engine
throttle setting (software versions 2.0 and greater) to
the engine controller via the J1939 CAN Network and
retrieves diagnostic information from the engine.

Book 54757919 (5/02) (49)

Controller Outputs: Figure 8--2 shows the connections between the
The WEDGE controller has three different types of out- WEDGE controller and the engine controller.
puts: frequency, pulse width modulated (PWM) and 24
VDC digital (ON / OFF). The frequency output is used J1939 Data Link -- The CAN network is a single pair
as a throttle signal for the engine (software versions shielded cable within the W1 main harness. Figure
less than 2.0). 8--3 shows a layout of the CAN harness or “backbone”
as it is referred to. The termination resistors (Termina-
The WEDGE controller varies the frequency from 150 tor) are important to prevent reflections on the trans-
Hz to 375 Hz, corresponding to 1200 to 1800 rpm. The mission line and must be in place for the network to
frequency signal is a 50% duty cycle, 24VDC, square function properly. The shield from the cable is con-
wave. This throttle signal is used with the Cummins en- nected to the machine metal at the WEDGE controller
gine. end.

The PWM signal is used as a throttle signal for the The connection must be properly made with good met-
Caterpillar engine. It has a base frequency of 500 Hz al to metal contact between the wire terminal and the
and the duty cycle varies from 10% to 90%. machine metal.

The engine diagnostics connector is located on the left

Pressure Control side of the engine. This is used to connect the engine
The discharge pressure is controlled by manipulating manufacturer’s service tools to the CAN network. This
the engine speed and compressor inlet valve position. connector also provides 24 VDC power to these ser-
The inlet valve position is controlled pneumatically and vice tools.
the engine speed is determined by the WEDGE con-
Electrical System
troller. The WEDGE measures the pneumatic system
The electrical system consists of the wiring harnesses
regulation pressure and computes an engine throttle
and associated electrical devices such as relays,
setting. This throttle setting is sent to the engine via
switches, lights, solenoids and alarm horn.
the frequency throttle, PWM or J1939 throttle, depend-
The electrical system consists of the wiring harnesses
ing on which technique is used. The engine controller
and associated electrical devices such as relays,
will control engine speed to this throttle setting.
switches, lights, solenoids and alarm horn. There are
Electronic Engine two wiring harnesses in the HP1600 machine. They
The HP1600/1300 machine contains an emissions are as follows:
certified diesel engine. In order to meet the emissions
requirements, the engine has an electronic control 54654918 W1 Chassis Main Wiring Harness
system.
22060594 Control Panel Wiring Harness
The control system handles all monitor, alarm and
control functions for the engine. The WEDGE control- The schematic diagrams show the connections for
ler communicates with the engine controller over the these harnesses. Figure 8--1 is a system diagram
J1939 CAN network. showing harness connection with devices and control-
lers.
The WEDGE controller sends throttle settings to the
engine (software versions 2.0 and greater) and re- The electrical circuits are protected using ATC style
ceives diagnostic and run time data from the engine fuses. A fuse should only be replaced with one of the
over the J1939 CAN network. A frequency throttle in- same rating. Replacing a fuse with one of a large rat-
terface with the engine is used for software versions ing could lead to harness damage. If a fault occurs and
earlier than 2.0. the circuit does not have the appropriate size fuse,
wires could be burned in the harness and damage oth-
er circuits.

Book 54757919 (5/02) (50)

 HP--XHP VIKING HARNESS SYSTEM SCHEMATIC

SOLENOID VALVES

CONTROL PANEL SWITCHES 24VDC HEATERS

Book 54757919 (5/02)

SPEED SENSOR

FUEL LEVEL SWITCH

ENGINE ECM DIAGNOSTIC
WEDGE HOURMETER
INTERFACE
PRESSURE TRANSDUCERS
Controller

CONTROL PANEL HARNESS

GAUGES TEMPERATURE SENSORS
ESTOP SWITCHES

(51)
BATTERY STARTING AND
CHARGING SYSTEM

P4

W1 W1
W1

W1
P1

FIGURE 8--1
 WEDGE TO ENGINE INTERFACE
CUMMINS ENGINE

Book 54757919 (5/02)

J2--46 CAN HI J1--34

J2--37 CAN LO J1--35 WEDGE

CUMMINS
J2--36 CANSHLD J1--1
CONTROLLER
CM570
J1--37

(52)
ENGINE
CONTROLLER
KEY SWITCH
J2--38 J1--24

J3--22 FREQ -- THT + J1--38

RANGE = 150 Hz (1200 RPM) to 375 Hz (1800 RPM) AT 24VDC
J3--16 J1--31
FREQ -- THT --

FIGURE 8--2
 HP--XHP VIKING J1939 CAN COMMUNICATIONS SCHEMATIC

Book 54757919 (5/02)

ENGINE CONTROLLER WEDGE
CONTROLLER

P6 R4 R5
P11
TERMINATOR TERMINATOR

(53)
P15 P7
CAN NODE WITH POWER AUTO START OPTION

FIGURE 8--3
J8
ENGINE DIAGNOSTICS JACK
 KEY ELECTRICAL COMPONENTS FUNCTION

PT1:
PT1 is a 0--225 psi gauge pressure transducer that measures discharge air pressure.

PT2:
PT2 is a 0--100 psi gauge pressure transducer that measures regulation system pressure.

U1:
U1 is resistive level detector that measures the fuel level in the fuel tank.
It provides a continuous reading of fuel level. It also has a switch for low fuel level and low fuel shutdown.
These switches connect to WEDGE.

RT1:
RT1 is a 10K ohm Thermistor temperature sensor that measures separator tank temperature.
Its range is --30 to 255_ F.

RT2:
RT2 is a 10K ohm Thermistor temperature sensor that measures airend discharge temperature.
Its range is --30 to 255_F.

K1:
K1 is SPST, 24VDC relay used to activate the engine starter.

K2:
K2 is a SPDT, 24VDC relay used to activate the start compressor.

K3:
K3 is a SPDT, 24VDC relay used to power the IQ system.

Book 54757919 (5/02) (54)

ELECTRICAL PARTS LIST
Ref Designator Description Part Number
IQ Wiring Harness 54757224
U2 Coolant Level Switch 54474572
Battery Disconnect Switch 36896975
PT1 0--225 psi pressure transducer 54496973
PT2 0--100 psi Pressure Transducer 36920825
K2 Relay, 24VDC SPDT 36892362
G2 Mag Speed Sensor 36785319
RT1 Thermistor Temperature Sensor 36898922
L1 Start / Run Solenoid Valve 36842300
L2 Unloader Solenoid Valve 36842318
S10, S11 Air Filter Switch 36847838
RP1 Engine Oil Press Sender 36870608
RT3, RT4 Temperature Sender 36841138
S9 Airend Oil Press Switch 36757581
S14 Safety Valve Press Switch 36757581
B2 Startup Compressor 36850691
K1 Auxiliary Start Relay 35577873
R3 Control Orifice Heater 36841526
R1 Regulator Heater 36864677
R2 Machine ID Plug 54765953
U1 Fuel Level Sender (Wagon) 54672803
(High Speed) 54672811
D1--D4 Diode 35376169

WEDGE Controller 54688411

W1 Chassis Harness 54654918
W1 Control Panel Harness 22060594
Negative Battery Cable 54765367
Positive Battery Cable 54765375
Positive Jumper Cable 54765383
Battery Jumper 35128982
F2, F3 10 Amp ATC Fuse 22071591
F4 15 Amp Fuse 22071575
F1 20 Amp Fuse 36792083

IQ Heater Harness 54775887

IQ Orifice Heaters 36841526
Actuator 36898310
RT5 Thermistor Temperature Sensor 36898922
K3 Relay, 24VDC SPDT 36892362
TCU Controller 36920643
S12 Filter Switch 36899615
S13 Filter Switch 36899599

Book 54757919 (5/02) (55)

 TROUBLE SHOOTING FLOW CHART

Control panel key is turned to “ON” position, Check F1 fuse

WEDGE controller annunciator lamps and 4 Check operation of switch S1
digit LED display do not come on Check wiring from S1 to WEDGE controller
Check battery voltage, ensure battery dis-
connect switch is turned ON

B
J1939 CAN communications not working –
WEDGE controller annunciator lamps & 4
Check for 24VDC key switch at engine, CAN
digit LED display initialize OK but alternator
network wiring problem
lamp and engine oil pressure lamps do not
Ensure 24VDC power to engine ECM
blink.
Check connector pins

B
Ensure key switch (24VDC) at engine
Engine cranks but will not start Frozen fuel cooler or associated piping
Estop button pressed (ESA units) or
Estop jumpers not making connection
Clear active engine fault code

B
Check switch S1
Engine does not crank when key turned to
Check relay K1
crank position
Check starter solenoid
Check starter motor
Check WEDGE output to K1 relay
Check battery voltage

Compressor fails to load

when “Service Air” switch pressed Check Run/Start valve operation
Verify frequency throttle signal at engine
Check “Service Air” switch operation

Book 54757919 (5/02) (56)

 Replace this sheet with
11 x 17 System Schematic
Sheet 1 of 5

Book 54757919 (5/02) (57)

 Replace this sheet with
11 x 17 System Schematic
Sheet 2 of 5

Book 54757919 (5/02) (58)

 Replace this sheet with
11 x 17 System Schematic
Sheet 3 of 5

Book 54757919 (5/02) (59)

 Replace this sheet with
11 x 17 System Schematic
Sheet 4 of 5

Book 54757919 (5/02) (60)

 Replace this sheet with
11 x 17 System Schematic
Sheet 5 of 5

Book 54757919 (5/02) (61)

ALERT/SHUTDOWN CONDITIONS Software V1.01

ALERT SHUTDOWN
LIGHT CODE LIGHT DELAY
CODE (BLINKS) (STEADY) (sec)

Low Engine Speed (RPM<800) 1 CPRSR Malf. 30

High Engine Speed (RPM >1900) 2 CPRSR Malf. 30
Engine Crank Time Exceeded 3 CPRSR Malf. 0
Low Fuel Level Fuel Level Fuel Level 3

Engine Oil Temperature > 252 deg. F 5 CPRSR Malf.

Intake Manifold Temperature > 180 deg. F 6 CPRSR Malf.
High Discharge Temp. (RT2>247 deg. F) High Comp Temp. 3
Low AE Oil Pressure (HP1600 only) 31 CPRSR Malf. 3
Disch. Temp (RT2) Sensor Fault 32 CPRSR Malf. 10
High Separator Tank 50 CPRSR Malf. 3
Temp (RT1>247 deg.F)
Machine ID Not Valid 51 CPRSR Malf. 0
IQ Filter Restriction IQ Filt. Rest 3
Sep. Tank Temp (RT1) Sensor Fault 53 CPRSR Malf. 10
Sep. Tank Pressure (PT1) 33 CPRSR Malf.
Sensor Fault

Reg. System Pressure PT2) Sensor Fault 54 CPRSR Malf.

Air Filter Restriction Soiled Filter

Low Battery Voltage Battery
Charging
Condition
Serial Comm. Problem 70 CPRSR Malf.
CAN Bus Problem 71 CPRSR Malf.
Engine Coolant Temp > 215 deg. F High Engine
Temp
Engine Oil Pressure < 10 psi Low Engine
Oil Pressure
Separator Tank Pressure > 20 psi during 34 CPRSR Malf. 0
start attempt (engine will not crank)
Engine Temp > 220 deg. F High Engine Temp 10

Book 54757919 (5/02) (62)

ALERT/SHUTDOWN CONDITIONS Software V1.22

ALERT SHUTDOWN
LIGHT CODE LIGHT DELAY
CODE (BLINKS) (STEADY) (sec)

Low Engine Speed < 1000 RPM 1 CPRSR Malf. 10

High Engine Speed >1900 RPM 2 CPRSR Malf. 30
Engine Crank Time Exceeded 3 CPRSR Malf. 0
Engine Oil Temperature > 252 deg. F 5 CPRSR Malf.
Intake Manifold Temperature > 180 deg. F 6 CPRSR Malf.
Low AE Oil Pressure (HP1600 only) 31 CPRSR Malf. 3
Disch. Temp (RT2) Sensor Fault 32 CPRSR Malf. 10
Separator Tank (PT1) Sensor Fault 33 CPRSR Malf.

Separator Tank Pressure >20 PSI during

start attempt (Engine will not crank) 34 CPRSR Malf. 0
Machine Over Pressure 35 CPRSR Malf. 1
Safety Valve Open 36 CPRSR Malf. 0
Sep. Tank Temp > 247 degrees F 50 CPRSR Malf. 3
Machine ID Not Valid 51 CPRSR Malf. 0
Sep. Tank Temp. (Rt1) Sensor Fault 53 CPRSR Malf. 10
Reg. System Pressure (PT2)
Sensor Fault 54 CPRSR Malf.
Serial Comm. Problem 70 CPRSR Malf.
CAN Bus Problem 71 CPRSR Malf.

Dedicated Lights:
Low Fuel Level Fuel Level Fuel Level 3
Air Filter Restriction Soiled Filter
Low Battery Voltage Battery
Charging
Condition
Engine Oil Pressure < 18 PSI Low Engine
Oil Pressure
Engine Coolant Temperature High Engine
> = 215 deg F. Temp
Engine Coolant Temperature High Engine Temp 10
> = 220 deg F.
IQ Filter Restriction IQ Filter Restriction 3
High Discharge Temp. (RT2 > 247 deg. F) High Comp. Temp. 3

CAN Derived Data =

Book 54757919 (5/02) (63)

FAULT CODES FOR QSX15 CUMMINS ENGINE

Fault Code Description

111 Engine Control Module -- Critical Internal Failure

115 Engine Speed/Position Sensor Circuit -- Lost both signals from Magnetic Pickup Sensor

121 Engine Speed/Position Sensor Circuit --

Lost One of Two Signals From the Magnetic Pickup Sensor

122 Intake Manifold Pressure Sensor #1 Circuit -- Shorted High

123 Intake Manifold Pressure Sensor #1 Circuit -- Shorted Low

135 Engine Oil Pressure Sensor Circuit -- Shorted High

141 Engine Oil Pressure Sensor Circuit -- Shorted Low

143 Engine Oil Pressure Low -- Warning

144 Engine Coolant Temperature Sensor Circuit -- Shorted High

145 Engine Coolant Temperature Sensor Circuit -- Shorted Low

147 Frequency throttle signal low (see note 1)

151 Engine Coolant Temperature High -- Critical

153 Intake Manifold Temperature Sensor #1 Circuit -- shorted High

154 Intake Manifold Temperature Sensor #1 Circuit -- Shorted Low

155 Intake Manifold Temperature #1 High -- Critical

186 Sensor Supply Voltage #2 Circuit -- Shorted Low

212 Engine Oil Temperature Sensor Circuit -- Shorted High

213 Engine Oil Temperature Sensor Circuit -- Shorted Low

214 Engine Oil Temperature High -- Critical

221 Ambient Air Pressure Sensor Circuit -- Shorted High

222 Ambient Air Pressure Sensor Circuit -- Shorted Low

223 Engine Oil Burn Valve Solenoid Circuit -- Shorted Low

227 Sensor Supply Voltage #2 Circuit -- Shorted High

Book 54757919 (5/02) (64)

234 Engine Speed High -- Critical

235 Engine Coolant Level Low -- Critical

241 Vehicle Speed Sensor Circuit -- Data Incorrect

245 Fan Clutch Circuit -- Shorted Low

254 Fuel Shutoff Valve Circuit -- Shorted Low

255 Fuel Shutoff Valve Circuit -- Shorted High

259 Fuel Shutoff Valve -- Stuck Open

284 Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit -- Shorted Low

285 SAE J1939 Multiplexing PGN Timeout Error

286 SAE J1939 Multiplexing Configuration Error

287 SAE J1939 Multiplexing Remote Throttle Error

295 Ambient Air Pressure Sensor Circuit -- Data Incorrect

299 Engine Shutdown Commanded By J1939

311 Injector Solenoid Valve Cylinder #1 Circuit -- Grounded Circuit

312 Injector Solenoid Valve Cylinder #5 Circuit -- Grounded Circuit

313 Injector Solenoid Valve Cylinder #3 Circuit -- Grounded Circuit

314 Injector Solenoid Valve Cylinder #6 Circuit -- Grounded Circuit

315 Injector Solenoid Valve Cylinder #2 Circuit -- Grounded Circuit

319 Real Time Clock -- Power Interrupt

341 Engine Control Module -- Data Lost

343 Engine Control Module -- Warning Internal Hardware Failure

346 Engine Control Module -- Warning Software Error

352 Sensor Supply Voltage #1 Circuit -- Shorted Low

378 Fueling Actuator #1 Circuit -- Open Circuit

379 Fueling Actuator #1 Circuit -- Grounded Circuit

386 Sensor Supply Voltage #1 Circuit -- Shorted High

394 Timing Actuator #1 Circuit -- Open Circuit

395 Timing Actuator #1 Circuit -- Grounded Circuit

396 Fueling Actuator #2 Circuit -- Open Circuit

397 Fueling Actuator #2 Circuit -- Grounded Circuit

Book 54757919 (5/02) (65)

398 Timing Actuator #2 Circuit -- Open Circuit

399 Timing Actuator #2 Circuit -- Grounded Circuit

415 Engine Oil Pressure Low -- Critical

418 Water In Fuel Indicator High -- Maintenance

422 Engine Coolant Level Sensor Circuit -- Data Incorrect

426 SAE J1939 Datalink -- Cannot Transmit

428 Water In Fuel Sensor Circuit -- Shorted High

429 Water In Fuel Sensor Circuit -- Shorted Low

433 Intake Manifold Pressure Sensor Circuit -- Data Incorrect

434 Power Lost Without Ignition Off

435 Engine Oil Pressure Sensor Circuit -- Data Incorrect

441 Battery #1 Voltage Low -- Warning

442 Battery #1 Voltage High -- Warning

449 Fuel Pressure High -- Warning

451 Injector Metering Rail #1 Pressure Sensor Circuit -- Shorted High

452 Injector Metering rail#1 Pressure Sensor Circuit -- Shorted low

466 Turbocharger #1 Wastegate Control Circuit -- Data Incorrect

482 Fuel Pressure Low -- Warning

483 Injector Metering Rail #2 Pressure Sensor Circuit -- Shorted High

484 Injector Metering Rail #2 Pressure Sensor Circuit -- Shorted Low

485 Injector Metering Rail #2 Pressure High -- Warning

486 Injector Metering Rail #2 Pressure Low -- Warning

496 Engine Speed/Position Sensor #2 (Camshaft) Supply Voltage

546 Fuel Delivery Pressure Sensor Circuit -- Shorted High

547 Fuel Delivery Pressure Sensor Circuit -- Shorted Low

553 Injector Metering Rail #1 Pressure High -- Warning

581 Fuel Supply Pump Inlet Pressure Sensor Circuit -- Shorted High

582 Fuel Supply Pump Inlet Pressure Sensor Circuit -- Shorted Low

583 Fuel Supply Pump Inlet Pressure Low -- Warning Level

Book 54757919 (5/02) (66)

595 Turbocharger #1 Speed High -- Warning Level

596 Electrical Charging System Voltage High -- Warning Level

597 Electrical Charging System Voltage Low -- Warning Level

598 Electrical Charging System Voltage Low -- Critical Level

611 Engine Hot Shutdown

753 Engine Speed/Position #2 Cam Sync Error

755 Injector Metering Rail #1 Pressure Malfunction

758 Injector Metering Rail #2 Pressure Malfunction

951 Cylinder Power Imbalance Between Cylinders

Notes:
1. Code 147 will be logged each time the compressor controller stops
the engine. This is an operational fault and does not indicate any engine fault.

Book 54757919 (5/02) (67)

 SECTION 10 -- PARTS ORDERING
GENERAL A series of illustrations show each part distinctly and in
location relative to the other parts in the assembly. The
This publication, which contains an illustrated parts part number, the description of the part and the
breakdown, has been prepared as an aid in locating quantity of parts required are shown on each
those parts which may be required in the maintenance illustration or on adjacent page. The quantities
of the unit. All of the compressor parts, listed in the specified are the number of parts used per one
parts breakdown, are manufactured with the same assembly and are not necessarily the total number of
precision as the original equipment. For the greatest parts used in the machine. Where no quantity is
protection always insist on genuine Ingersoll--Rand specified the quantity is assumed to be one.
Company parts for your compressor.
Each description of a part is based upon the “noun
first” method, i.e., the identifying noun or item name is
NOTICE always the first part of the description. The noun name
Ingersoll--Rand Company can bear no responsibility is generally followed by a single descriptive modifier.
for injury or damages resulting directly from the use of The descriptive modifier may be followed by words or
non--approved repair parts. abbreviations such as upper, lower, inner, outer, front,
rear, RH, LH, etc. when they are essential.
Ingersoll--Rand Company service facilities and parts
are available worldwide. There are Ingersoll-- Rand In referring to the rear, the front or to either side of the
Company Construction Equipment Group Sales Of- unit, always consider the drawbar end of the unit as
fices and authorized distributors located in the princi- the front. Standing at the rear of the unit facing the
pal cities of the United States. In Canada our custom- drawbar (front) will determine the right and left sides.
ers are serviced by the Canadian Ingersoll--Rand
Company, Limited. There are also Ingersoll--Rand In- FASTENERS
ternational autonomous companies and authorized
distributors located in the principal cities throughout Both SAE/inch, ISO/metric hardware have been used
the free world. in the design and assembly of these units. In the
disassembly and reassembly of parts, extreme care
Special order parts may not be included in this manual. must be taken to avoid damaging threads by the use of
Contact the Mocksville Parts Department with the unit wrong fasteners. In order to clarify the proper usage
serial number for assistance with these special parts. and for exact replacement parts, all standard
fasteners have been identified by part number, size
and description. This will enable a customer to obtain
DESCRIPTION
fasteners locally rather than ordering from the factory.
The illustrated parts breakdown illustrates and lists the
These parts are identified in tables that will be found at
various assemblies, subassemblies and detailed parts the rear of the parts illustrations. Any fastener that has
which make up this particular machine. This covers not been identified by both part number and size is a
the standard models and the more popular options specially engineered part that must be ordered by part
that are available. number to obtain the exact replacement part.

Book 54757919 (5/02) (68)

MARKINGS AND DECALS c. Always specify the number of the parts list pub-
lication.
NOTICE
d. Always specify the quantity of parts required.
Do not paint over safety warnings or instructional
decals. If safety warning decals become illegible, e. Always specify the part number, as well as the
immediately order replacements from the factory. description of the part, or parts, exactly as it is
given on the parts list illustration.
Part numbers for original individual decals and their
mounting locations are shown within Parts List In the event parts are being returned to your nearest
Section. These are available as long as a particular sales office, autonomous company or authorized dis-
model is in production. tributor, for inspection or repair, it is important to in-
clude the serial number of the unit from which the parts
Afterwards, service sets of exterior decals and current
were removed.
production safety warning decals are available.
Contact the Product Support Group at Mocksville for TERMS AND CONDITIONS ON PARTS ORDERS
your particular needs and availability.
Acceptance: Acceptance of an offer is expressly lim-
HOW TO USE PARTS LIST
ited to the exact terms contained herein. If purchaser’s

a. Turn to Parts List. order form is used for acceptance of an offer, it is ex-
pressly understood and agreed that the terms and
b. Locate the area or system of the compressor in conditions of such order form shall not apply unless ex-
which the desired part is used and find illustration pressly agreed to by Ingersoll--Rand Company (“Com-
page number. pany”) in writing. No additional or contrary terms will
be binding upon the Company unless expressly
c. Locate the desired part on the illustration by visu-
al identification and make note of part number agreed to in writing.
and description.
Taxes: Any tax or other governmental charge now or
HOW TO ORDER hereafter levied upon the production, sale, use or ship-
ment of material and equipment ordered or sold is not
The satisfactory ordering of parts by a purchaser is included in the Company’s price and will be charged to
greatly dependent upon the proper use of all available and paid for by the Purchaser.
information. By supplying your nearest sales office,
autonomous company or authorized distributor, with Shipping dates shall be extended for delays due to
complete information, you will enable them to fill your acts of God, acts of Purchaser, acts of Government,
order correctly and to avoid any unnecessary delays. fires, floods, strikes, riot, war, embargo, transportation
shortages, delay or default on the part of the Compa-
In order that all avoidable errors may be eliminated,
ny’s vendors, or any other cause beyond the Compa-
the following instructions are offered as a guide to the
purchaser when ordering replacement parts: ny’s reasonable control.

a. Always specify the model number of the unit as Should Purchaser request special shipping instruc-
shown on the general data decal attached to the tion, such as exclusive use of shipping facilities, in-
unit. cluding air freight when common carrier has been
quoted and before change order to purchase order
b. Always specify the serial number of the unit. can be received by the Company, the additional
THIS IS IMPORTANT. The serial number of the
charges will be honored by the Purchaser.
unit will be found stamped on a plate attached to
the unit. (The serial number on the unit is also
permanently stamped in the metal of the frame
side rail.)
Book 54757919 (5/02) (69)
Warranty: The Company warrants that parts ages arising out of this order or any breach thereof, or
manufactured by it will be as specified and will be free any defect in, or failure of, or malfunction of the parts
from defects in materials and workmanship. The hereunder, whether based upon loss of use, lost prof-
Company’s liability under this warranty shall be limited its or revenue, interest, lost goodwill, work stoppage,
to the repair or replacement of any part which was de- impairment of other goods, loss by reason of shut-
fective at the time of shipment provided Purchaser no- down or non-- operation, increased expenses of op-
tifies the Company of any such defect promptly upon eration or claims of customers of Purchaser for service
discovery, but in no event later than three (3) months interruption whether or not such loss or damage is
from the date of shipment of such part by the Compa- based on contract, warranty, negligence, indemnity,
ny. The only exception to the previous statement is the strict liability or otherwise.
extended warranty as it applies to the special airend
exchange program. AIREND EXCHANGE PROGRAM
Your Ingersoll--Rand Company Construction Equip-
Repairs and replacements shall be made by the Com-
ment Group Sales Offices and authorized distributors
pany F.O.B. point of shipment. The Company shall not
as well as Ingersoll--Rand International autonomous
be responsible for costs of transportation, removal or
companies and authorized distributors now
installation.
have an airend exchange program to benefit portable
compressor users.
Warranties applicable to material and equipment sup-
plied by the Company but wholly manufactured by oth-
On the airend exchange program the exchange
ers shall be limited to the warranties extended to the
price is determined by the age and condition of the
Company by the manufacturer which are able to be
airend and may be classified by one of the follow-
conveyed to the Purchaser.
ing categories.

Delivery: Shipping dates are approximate. The Com-

pany will use best efforts to ship by the dates specified; Category “A”: The airend must not be over two years

however, the Company shall not be liable for any delay old and must have reusable rotor housing(s) and ro-

or failure in the estimated delivery or shipment of ma- tor(s).

terial and equipment or for any damages suffered by Category “B”: The airend must be between two and

reason thereof. five years old and returned with two or more reusable
major castings.
The company makes no other warranty or representa- Category “C”: The airend must be over five years old.
tion of any kind whatsoever, expressed or implied, ex- Your nearest sales office, autonomous company or
cept that of title, and all implied warranties, including authorized distributor must first contact the Parts Ser-
any warranty of merchantability and fitness for a par- vice Department at the factory at which your portable
ticular purpose, are hereby disclaimed. air compressor was manufactured for an airend ex-
change number. The airend must be tagged with this
Limitation of Liability: preassigned number and returned to the factory pre-
The remedies of the Purchaser set forth herein are ex- paid. The airend must be intact, with no excluded
clusive, and the total liability of the Company with re- parts, otherwise the exchange agreement may be
spect to this order whether based on contract, warran- cancelled. The warranty on an exchange or factory re-
ty, negligence, indemnity, strict liability or otherwise, built airend is 365 days.
shall not exceed the purchase price of the part upon Airends being returned to the factory in connection
which such liability is based. The Company shall in no with a WARRANTY CLAIM must be processed
event be liable to the Purchaser, any successors in in- through the Customer Service Department. If re-
terest or any beneficiary of this order for any conse- turned without a Warranty MRR (Material Return Re-
quential, incidental, indirect, special or punitive dam- quest) Number, no warranty claim will be considered.
Book 54757919 (5/02) (70)
 VIKING ELECTRICAL COMPONENTS
I--R Part Number Quantity per Mach Description

54757224 1 IQ Wiring Harness

54474572 1 Coolant Level Switch
36896975 1 Battery Disconnect Switch
54765946 1 0--500 psi Pressure Transducer

36920825 1 0--100 psi Pressure Transducer

36892362 1 24V Sealed Relay
36785319 1 Mag Speed Sensor
36898922 2 Thermistor Temperature Probe
36842300 1 Start/Run Solenoid Valve

36842318 1 Compressor Solenoid Valve

36847838 2 Air Filter Switch
36870608 1 Engine Oil Pressure Sender
36841138 2 Eng & Comp Temp Sender
36757581 1 Comp Oil Pressure Switch

36850691 1 Startup Compressor

35577873 1 Auxilary Start Relay
54720701 1 Eng Temp Sender Adaptor
36841526 1 Control Heater
36864677 1 Regulator Heater
54765367 1 Negative Battery Cable
54765375 1 Positive Battery Cable
54765383 1 Positive Jumper Battery Cable
35128982 1 Battery Jumper

35578194 1 Frame Ground Strap

35293075 1 Engine Ground Strap
54672803 (Wagon) 1 Fuel Level Sender
54672811 (High Speed) 1 Fuel Level Sender
22073894 1 WEDGE Controller
54654918 1 W1 Chassis Harness

54765953 1 Machine ID Plug

36898310 1 Louver Actuator
36920643 1 TCU Controller
36899599 1 IQ Filter Switch
36899615 1 IQ Filter Switch
54775887 1 IQ Heater Harness
36792083 2 20 AMP ATC Fuse
22071591 2 10 AMP ATC Fuse

Book 54757919 (5/02) (71)

SERVICE TOOLS
Electronic Systems
The following special tools are recommended to perform service procedures in this manual.
The tools can be purchased from Ingersoll Rand or equivalent substitutes can be used.

Tool Tool Description

Fluke 87 Digital Multimeter
Used to Measure electrical circuits:
volts, ohms amps
54729660 Weather--Pack Terminal Removal Tool
Used to repair Packard Electric Weather--Pack
Connectors
54729678 Deutsch Terminal Removal Tool (Blue)
Used to repair Deutsch connectors
54729686 Deutsch Terminal Removal Tool (Red)
Used to repair Deutsch connectors
54729694 Deutsch Terminal Removal Tool (Yellow)
Used to repair Deutsch connectors
HDT--48--00 Deutsch Terminal Crimp Tool
Used to crimp Deutsch connector terminals
DD Deutsch Terminal Crimping Tool
Used to crimp Deutsch connector terminals
54729710 Electrical Contact Cleaner
Used to clean electrical contacts and connectors
54729728 PDA Service Tool
Palm Pilot based service tool used to connect to Intellisys (SGP) Controller
to load software and extract service information
22073886 Packard Crimp Tool
Used to crimp Packard connector terminals
22073878 Thermistor Simulator Plug
Used to test thermister circuits
54699616 Deutsch Terminal Removal Tool
Used to repair Deutsch connectors
54699657 Deutsch Terminal Removal Tool
Used to repair Deutsch connectors
54749643 Packard Metri--Pack Terminal Removal Tool
Used to repair Metri--Pack connectors
54749635 Connector Repair Kit
Used to make connector repairs

Book 54757919 (5/02) (72)

 SERVICE TOOLS
Tool No. Tool Description Tool Illustration

Fluke 87 Digital Multimeter

Available from electrical and electronic
parts distributors.

54729660 Weather--Pack Terminal Removal Tool

54699632 Deutsch Terminal Removal Tool (Blue)

54699640 Deutsch Terminal Removal Tool (Red)

54699624 Deutsch Terminal Removal Tool (Yellow)

DT--RT1 Crimp Tool for Deutsch Pins Crimp

Available from:
Ladd Industries (800--223--1236)

Book 54757919 (5/02) (73)

54729710 Electrical Contact Cleaner

54729728 PDA Service Tool

54699616 Deutsch Terminal Removal Tool

22073886 Packard Crimp Tool

22073878 Thermistor Simulator

54749635 Connector Repair Kit

Book 54757919 (5/02) (74)

54699657 Deutsch Terminal Removal Tool

54749643 Packard Metri--Pack Removal Tool

Book 54757919 (5/02) (75)

 INDEX
FRAME ASSEMBLY ( FAST TRACK )
FRAME ASSEMBLY ( WAGON WHEEL )
RUNNING GEAR ASSEMBLY ( FAST TRACK )
RUNNING GEAR ASSEMBLY ( WAGON WHEEL )
ENGINE ASSEMBLY
EXHAUST COMPLETE
AIR END COMPLETE
AIR END ASSEMBLY
UNLOADER ASSEMBLY
STARTING AID ASSEMBLY
RADIATOR AND PIPING ASSEMBLY
FUEL TANK ASSEMBLY
AIR INTAKE ASSEMBLY
SEPARATOR TANK ASSEMBLY
AIR PIPING
OIL PIPING
MINIMUM PRESSURE / CHECK VALVE
OIL TEMPERATURE BYPASS VALVE
INSTRUMENT / CONTROL PANEL
BATTERY AND MOUNTING
ENCLOSURE ASSEMBLY
ACOUSTIC ASSEMBLY
WIRING DIAGRAM
PARKING BRAKE ASSEMBLY
SEPARATOR AIR PIPING
AIR CHARGE PIPING
IQ AIR PIPING
IQ COOLER PIPING
IQ FILTER PIPING
IQ INDICATOR PIPING
CENTRAL DRAIN PIPING
DECAL LOCATION
RECOMENDED SPARE PARTS LIST

Book 54757919 (7/02) (62)

FAST TRACK FRAME ASSEMBLY

C B

ITEM CPN QTY DESCRIPTION CPN QTY DESCRIPTION

A 54760202 1 FRAME ASSEMBLY LESS RUNNING GEAR OPTION ( PARTS )

B 54542543 1 BAIL , LIFTING 22053870 2 MIDDLE SUPPORT ASSEMBLY
C 96720610 4 SCREW 22053888 4 LARGE EDGE SUPPORT ASSEMBLY
96727896 4 SCREW ( THRU EDGE ASSY. TO FRAME )
36879203 4 NUT ( THRU EDGE ASSY. TO FRAME )
36879492 8 SCREW ( THRU SIDES OF EDGE SUPPORTS )
36879203 8 NUT ( THRU SIDES OF EDGE SUPPORTS )
22054118 2 LARGE FRONT SUPPORT ASSY.
95939914 8 SCREW ( THRU SLOTS OF THE SUPPORT )
95941084 8 NUT ( TO SCREWS THRU SUPPORTS )
54594098 1 TANK , R.H. FUEL
35279025 24 SCREW ( FUEL TANKS TO FRAME )
54594080 1 TANK , L.H. FUEL
22060156 1 HOSE ASSY. ( FUEL COOLER TOP TO L.H. TANK )
35136548 1 HOSE ASSY. ( R.H. TANK PICK--UP TO ENGINE )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 2 12/01 B

Book 54757919 (7/02) (63)

WAGON WHEEL FRAME ASSEMBLY

C B

ITEM CPN QTY DESCRIPTION CPN QTY DESCRIPTION

A 54501796 1 FRAME ASSEMBLY LESS RUNNING GEAR OPTION ( PARTS )

B 54542543 1 BAIL , LIFTING 22051304 4 SUPPORT ( BETWEEN FRAME )
C 96720610 4 SCREW 39179072 16 BOLT ( SUPPORTS TO FRAME )
96701750 16 NUT ( SUPPORTS TO FRAME )
22053706 2 CROSSMEMBER ( BETWEEN SUPPORTS )
39179072 8 BOLT ( CROSSMEMBER TO SUPPORT LEGS )
96701750 8 NUT ( CROSSMEMBER TO SUPPORT LEGS )
54594114 1 TANK , R.H. FUEL TANK
35279025 12 SCREW ( FUEL TANK TO FRAME )
54594106 1 TANK , L.H. FUEL TANK
22060149 1 HOSE ASSEMBLY ( FUEL COOLER TOP TO L.H. TANK )
35325083 1 HOSE ASSEMBLY ( RH FUEL PICK--UP TO ENGINE )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 3 12/01 B

Book 54757919 (7/02) (64)

HIGH SPEED RUNNING GEAR

N P R

G H J
K L M
A
F

B C D

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36880235 2 HANGER , REAR

B 36880219 2 BAR , EQUALIZER
C 36880243 2 BOLT , EQUALIZER
D 36880250 2 LOCKNUT
E 36880193 2 HANGER , CENTER
F 36880284 4 SPRING , LEAF
G 36880201 2 HANGER , FRONT
H 36880227 8 BOLT , SHACKLE
J 35336700 8 LOCKNUT
K 36880136 4 BOLT
L 95935011 4 WASHER
M 95077608 4 LOCKNUT
N 35144336 8 SCREW
P 36880151 4 BUMPER , RUBBER
Q 36880144 1 JACK , DROPLEG
R 36880128 1 EYE , PINTLE

MANUAL NO. DRAWING NO. DATE / REV:

54757919 4 08/01 A

Book 54757919 (7/02) (65)

HIGH SPEED RUNNING GEAR

X Y

P Q R S T U V W

E F G H J K L M N
C D

A B

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36877991 4 TIRE
B 22077515 4 WHEEL
36878049 4 CLAMP , PLATE
C 35272150 8 STUD
D 36880276 8 NUT
E 36853091 4 NUT
F 36853109 2 WASHER
G 36853117 2 WASHER , LOCK
H 36851624 1 INNER BEARING CUP
J 36851616 1 OUTER BEARING CUP
K 36851608 1 INNER BEARING
L 36851590 1 OUTER BEARING
M 36851632 1 SEAL
N 36776813 8 CAP , DUST
P 36880268 4 HUB ASSEMBLY
Q 36880292 2 L.H. ELECTRIC BRAKE
R 36880300 2 R.H. ELECTRIC BRAKE
S 36880318 4 SHIELD , BOTTOM DUST
T 36880326 4 SHIELD , TOP DUST
U 36880334 7 BOLT
V 95939955 7 WASHER , LOCK
W 36880342 7 LOCKNUT
X 35603190 2 CHOCK , WHEEL
Y 35333830 2 STRAP , RUBBER

MANUAL NO. DRAWING NO. DATE / REV:

54757919 5 01/02 B

Book 54757919 (7/02) (66)

HIGH SPEED RUNNING GEAR

M N P Q

C D E F G H J

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36895860 1 LIGHT , LICENSE PLATE

B 36922144 1 3 LIGHT ASSEMBLY
C 36788081 2 STOP , TURN AND TAIL LIGHT
D 36787968 6 GROMMET ( USE ON ITEM C & E )
E 36859320 4 STOP , TURN AND TAIL LIGHT
F 35367051 4 YELLOW LIGHT
G 36893642 2 GROMMET ( USE ON ITEM F )
H 36893634 2 GROMMET ( USE ON ITEM F )
J 35367044 4 RED CLEARANCE LIGHT
K 36894129 1 7--WAY CONNECTOR
L 36896306 1 ID BRACKET
M 36880169 2 PLATE , U--BOLT
N 36880177 4 U--BOLT
P 36880185 8 NUT
Q 95934741 8 WASHER , LOCK

MANUAL NO. DRAWING NO. DATE / REV:

54757919 6 08/01 A

Book 54757919 (7/02) (67)

FAST TRACK WIRING

RH REAR BOTTOM
CLEARANCE LAMP

BRN--14

RH TAIL
LAMP

RH TURN
LAMP
RH FRONT RH REAR
CLEARANCE LAMP CLEARANCE LAMP

RH STOP
LAMP

WHT--14 RH TAIL
LAMP
BRN--14

BRN--14
LIGHT GROUND

RED--14

BRN--14 WHT--14
REAR IDENTIFICATION LAMP

BRN--14

LICENSE LAMP
LH FRONT
CLEARANCE LAMP
LH REAR LH TAIL
CLEARANCE LAMP LAMP

WHT--14
LH STOP
BRN--14 BRN--14 LAMP
BRN--14
1 LH TAIL
6 BRN--14 LAMP
5 GRN--14
LH TURN
3 YEL--14 LAMP
4 RED--14
2 BLK--14 AUX CONN
7 BLU--14 ELEC BRAKE CONN BRN--14

RECEPTACLE LH REAR BOTTOM

CLEARANCE LAMP

MANUAL NO. DRAWING NO. DATE / REV:

54757919 7 08/01 A

Book 54757919 (7/02) (68)

FAST TRACK WIRING

GROUND ( WHITE ) TAIL,LICENSE PLATE & CLEARANCE LAMP

( BROWN )

AUX CLEARANCE ( BLACK )

1
LEFT TURN ( YELLOW ) RIGHT TURN ( GREEN )
2 7 6

5
3
4
ELECTRIC BRAKES IF EQUIPPED
( BLUE )
STOP ( RED )

STOP,TAIL & TURN LIGHT OPTION

( AS VIEWED FROM REAR OF SOCKET )

LIST OF MATERIALS
CKT TERMINATION A TYPE SIZE TERMINATION B TYPE SIZE GAUGE LENGTH COLOR
1 RECEPTACLE 1 E GROUND A 1/4 14 46 WHT
2 RECEPTACLE 6 E SPLICE 1 D 14 24 BRN
3 SPLICE 1 LH FRT CLEARANCE B 14 95 BRN
4 LH FRT CLEAR W/CKT 3B RH FRT CLEARANCE B 14 89 BRN
5 SPLICE 1 W/CKT 3A SPLICE 2 D 14 218 BRN
6 RECEPTACLE 3 E RH TURN G 14 342 YEL
7 RECEPTACLE 5 E LH TURN G 14 255 GRN
8
9
10 RH TURN/TAIL W/CKT 27B RH REAR CLEAR BOT B 14 22 BRN
11
12 SPLICE 2 LH REAR CLEARANCE B 14 19 BRN
13 LH REAR CLEAR W/CKT 12B LH REAR TOP CLEAR B 14 74 BRN
14 LH REAR TOP CLEAR W/CKT 13B REAR ID W/CKT 15A B 14 61 BRN
15 R ID W/CKT 14B RH REAR TOP CLEAR B 14 56 BRN
16 SPLICE 2 W/CKT 12A LICENSE LAMP B 14 31 BRN
17 SPLICE 2 W/CKT 12A LH TURN/TAIL G 14 13 BRN
18 RECEPTACLE 4 E LH STOP LAMP G 14 261 RED
19 LIGHT GRD W/CKT 24A LIGHT GROUND 14 36 WHT
20 LEFT STOP LAMP W/CKT 18B RIGHT STOP LAMP G 14 99 RED
21 RECEPTACLE 7 E ELECTRIC BRAKES 14 29 BLU
22 LEFT TURN GRD LH ST/GRD W/CKT 23A G 14 30 WHT
23 LEFT STOP GRD RT ST/GRD W/CKT 24A G 14 99 WHT
24 RIGHT STOP GRD RH TURN GRD G 14 30 WHT
25 LH TURN/TAIL W/CKT 17B LEFT STOP/TAIL G 14 30 BRN
26 LH STOP/TAIL W/CKT 25B RIGHT STOP/TAIL G 14 99 BRN
27 RH STOP/TAIL W/CKT 26B RIGHT TURN/TAIL G 14 30 BRN
28 RECEPTACLE 2 E AUX B 14 29 BLK

MANUAL NO. DRAWING NO. DATE / REV:

54757919 8 08/01 A

Book 54757919 (7/02) (69)

WAGON WHEEL RUNNING GEAR

V
M

G
W
K L
X Y

F J

Z H

A2 A1

A3

D A4
Q
R
C P
A8 A9
A A1

A5 B

A6 S

A7 T

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36504389 2 ROD , TIE X 95934956 2 WASHER

B 36140730 2 NUT , JAM Y 36719557 1 DRAWBAR
C 35588961 2 BALL JOINT , OUTER Z 35107168 1 PIN , HINGE
D 35221894 2 FITTING , LUBE A1 95201455 2 PIN , COTTER
E 36753259 1 AXLE , FRONT A2 36753242 1 ARM , CENTER
F 95717369 1 PIN , ROLL A3 35588953 2 BALLJOINT , INNER
G 35221894 1 FITTING , LUBE A4 35140722 2 NUT , JAM
H 95338554 2 PIN , ROLL A5 36719219 1 LATCH
J 95239927 4 WASHER A6 35141167 1 SPRING
K 36851566 1 L.H. KNUCKLE ASSEMBLY A7 95098703 2 PIN , ROLL
L 36851574 1 R.H. KNUCKLE ASSEMBLY A8 36851376 1 FRONT AXLE ASSEMBLY
M 95673042 2 PIN , ROLL A9 36851384 1 REAR AXLE ASSEMBLY
N 35319045 2 PIN , KING B1 36853042 2 TIE ROD ASSEMBLY
P 95018982 2 PIN , COTTER ( INCLUDES A,B,C,A3,A4 )
Q 36719169 2 BRACKET 22077515 4 WHEEL
R 36719466 2 SPRING 36877991 4 TIRE
S 36719177 2 BRACKET 36878049 4 RING , CLAMP
T 35111590 2 BOLT , SHACKLE
U 95318556 2 FITTING , LUBE
V 35588755 1 PIN , CENTER
W 95717377 2 PIN , ROLL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 9 01/02 B

Book 54757919 (7/02) (70)

WAGON WHEEL RUNNING GEAR

B C

Y
A

D Z

H
A3
G

X H

E
A1

A2

W
F K

A4

S L

U
N

M
R
P
A5

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 95318556 2 FITTING , LUBE X 36776839 2 FLANGE , BRAKE MTG

B 35588839 2 RIVET Y 36719177 2 BRACKET
C 35589241 2 PLATE , CLAMP Z 36719169 2 BRACKET
D 35111566 8 NUT A1 36851608 2 INNER BEARING
E 36851640 1 AXLE , REAR A2 36851624 2 INNER RACE
F 36719466 2 SPRING A3 36851632 2 SEAL
G 35111590 2 BOLT , SHACKLE A4 36776821 8 NUT , STUD
H 95018982 2 PIN , COTTER A5 36853117 2 WASHER , LOCK
J 35834621 4 U--BOLT
K 36851665 2 HUB ASSEMBLY ( INCLUDES ITEMS N, L, A2 )
L 36764983 8 STUD
M 36851590 2 OUTTER BEARING
N 36851616 2 OUTER RACE
P 36853109 2 WASHER , FLAT
Q 36853091 2 NUT
R 36776813 2 CAP , GREASE
S 95272902 2 PIN , COTTER
T ---------------- 1 PARKING BRAKE ASSEMBLY
U 36A2D326Z1 8 BOLT
V 95934741 8 WASHER , FLAT
W 95916573 8 NUT

MANUAL NO. DRAWING NO. DATE / REV:

54757919 10 08/01 A

Book 54757919 (7/02) (71)

ENGINE ASSEMBLY

M
D

J
C

H G

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 95940920 6 SCREW
B 36884047 1 FAN ASSEMBLY
ENGINE FILTERS
C 54409339 1 SPACER , FAN
35362243 ENGINE FUEL FILTER
D 54661533 1 ENGINE , QSX--15 CUMMINS
E 35297340 1 NUT 35362235 ENGINE OIL FILTER
F 35584556 1 MOUNT , RUBBER 35362268 ENGINE WATER SEPARATOR FILTER
G 35273937 1 WASHER
35362250 PRIMARY FUEL FILTER
H 35297340 2 NUT
J 54570122 1 BRACKET , ENGINE
K 96700919 1 SCREW
L 95935011 2 WASHER
M 36763670 2 SCREW

MANUAL NO. DRAWING NO. DATE / REV:

22063556 11 09/01 A

Book 54757919 (7/02) (72)

EXHAUST ASSEMBLY

L
J

E F N H

D E F
B

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54603774 1 PIPE , ENGINE TURBO

B 54616552 1 PIPE , EXHAUST ( STANDARD )
54738752 1 PIPE , EXHAUST ( IQ )
C 35127653 1 CLAMP
D 35611235 1 SUPPORT , PIPE
E 36880995 12 SCREW
F 36879195 12 NUT
G 54616560 1 PIPE , EXHAUST
H 35307131 3 CLAMP , SEAL
J 54629589 1 STEP
K 35851351 1 CAP , RAIN
L 54629126 1 PIPE , EXHAUST
M 36799807 1 CLAMP , SEAL
N 54603204 1 MUFFLER
54662010 1 WRAP , EXHAUST
54721105 1 KIT , WRAP WIRE KIT

MANUAL NO. DRAWING NO. DATE / REV:

54757919 12 02/02 B

Book 54757919 (7/02) (73)

285 AIR END COMPLETE

P
L
J

Q K

E
C G
B

A F

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35116086 1 KEY , BUSHING

B 35307784 1 BUSHING
C 54540141 1 COUPLING
D 95941092 12 SCREW
E 54542535 2 BRACKET , AIR END
F 35584556 2 MOUNT , RUBBER
G 35375385 8 SCREW
H 35273937 2 WASHER
J 96700919 2 SCREW
K 42469809 1 AIR END ASSEMBLY
L 36754059 1 GASKET
M 36729531 1 UNLOADER ASSEMBLY
N 35375377 8 SCREW

MANUAL NO. DRAWING NO. DATE / REV:

54757919 13 08/01 A

Book 54757919 (7/02) (74)

285 AIR END ASSEMBLY

B
F

Q
K
J

E Y
A D

C X

W
U

N
M

P Z

S
R

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35271139 8 SCREW S 35300136 1 KEY

B 35367069 1 KEY T 35298470 1 GEAR SET HP--1300
C 35849348 1 COVER 36758142 1 GEAR SET P--1600
D 35299536 1 SHIM U 35300144 1 KEY
E 95358214 1 O--RING V 35851195 1 SHAFT
F 35596626 1 SEAL W 35610286 1 SPACER
G 35299775 1 LOCKNUT X 95285599 1 RETAINING RING
H 35300227 1 SPACER Y 35610591 1 BEARING
J 35299379 1 BEARING Z 35299379 1 BEARING
K 35365261 1 PIN
L 36711083 1 GEAR CASE
M 35295336 1 DOWEL
N 35299569 4 SCREW
P 35300177 1 PLATE , CLAMP
Q 35295344 18 SCREW
R 35300227 1 SPACER

MANUAL NO. DRAWING NO. DATE / REV:

54757919 14 08/01 A

Book 54757919 (7/02) (75)

285 AIR END ASSEMBLY

D
R

C M
L

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35293869 4 SCREW
B 35610609 1 BEARING
C 35373877 1 PLATE , CLAMP
D 35820646 1 GASKET
E 36754141 1 HOUSING , FRONT BEARING
F 35365279 2 PIN
G 36711109 1 HOUSING , ROTOR
H 35272533 18 SCREW
J 35365279 1 DOWEL
K 35820661 1 GASKET
L 36760890 1 HOUSING , REAR BEARING
M 39101472 18 SCREW
N 35092246 1 ROTOR SET
P 35295336 1 DOWEL
Q 35305325 1 DOWEL
R 35820653 1 GASKET

MANUAL NO. DRAWING NO. DATE / REV:

54757919 15 08/01 A

Book 54757919 (7/02) (76)

285 AIR END ASSEMBLY

A D
K

N
L

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35299510 SET SHIM

B 35299403 2 BEARING
C 35610278 1 PLATE , CLAMP
D 35299569 4 SCREW
E 35373141 SET SHIM
F 95358446 1 O--RING
G 35321520 8 SCREW
H 36504330 1 CAP
J 95870432 1 O--RING
K 36504355 1 CAP
L 35373133 SET SHIM
M 35606920 1 PLATE , CLAMP
N 35299429 2 BEARING
P 35299528 SET SHIM

MANUAL NO. DRAWING NO. DATE / REV:

54757919 16 08/01 A

Book 54757919 (7/02) (77)

UNLOADER ASSEMBLY

Y
X Q R
W P
U
V N
U
M
M

E
T D
S C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35594878 1 SPRING , PISTON W 35332626 1 SPACER

B 35594910 1 SPRING , VALVE X 39102355 1 O--RING
C 35594829 1 PISTON Y 35280528 1 PLUG
D 35594837 1 DIAPHRAGM
E 35332618 1 WASHER , PISTON
F 35A2D217 1 SCREW
G 35594811 1 COVER , PISTON
H 35374834 8 SCREW
J 36729416 1 BODY , UNLOADER
K 34A7SZ4 1 PLUG
L 35594860 1 VALVE , UNLOADER
M 35332659 1 BUSHING
N 35332675 1 STEM , VALVE
P 35332634 1 BUSHING , HOUSING
Q 35332642 1 SEAL
R 35594845 1 GASKET
S 36729465 1 HOUSING , PISTON
T 35374842 12 SCREW
U 35331586 2 GROMMET
V 35328210 1 VALVE

MANUAL NO. DRAWING NO. DATE / REV:

54757919 17 08/01 A

Book 54757919 (7/02) (78)

STARTING AID ASSEMBLY

J
H

L G
E
K
D

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35103498 1 ELBOW
B 35132166 1 TUBING ( 84 INCHES )
C 35602812 1 ATOMIZER
D 35322908 4 SCREW
E 35103506 1 CLAMP
F 35357052 1 VALVE AND BRACKET ASSEMBLY
G 95043196 4 WASHER
H 92304500 4 NUT
J 35112911 1 CYLINDER , ETHER
K 95930301 1 BUSHING
L 54720719 1 ADAPTER ( TO ENGINE CHARGE AIR RETURN )

MANUAL NO. DRAWING NO. DATE / REV:

54665302 18 04/01 A

Book 54757919 (7/02) (79)

RADIATOR AND OIL COOLER

L
P

F
K

E J
G
C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54501085 1 FAN GUARD ASSEMBLY

B 54661426 4 PLATE , COVER
C 54661459 2 BRACKET
D 54507488 1 ORIFICE , L.H. FAN
E 54507470 1 ORIFICE , R.H. FAN
F 54507454 1 SUPPORT , R.H. SHROUD
G 54507447 1 SUPPORT , BOTTOM SHROUD
H 54507462 1 SUPPORT , L.H. SHROUD
J 54521422 1 SUPPORT , L.H. REAR SHROUD
K 54501439 1 SUPPORT , TOP SHROUD
L 54521430 1 SUPPORT , R.H. REAR SHROUD
M 54521448 1 SUPPORT , TOP REAR SHROUD
N 54501846 1 COOLER , A/C FUEL
P 54501838 1 RADIATOR
Q 54501853 2 COOLER , OIL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 19 08/01 A

Book 54757919 (7/02) (80)

RADIATOR PIPING

E
D
M

C
F
H

G
J

K
N

L
P
B H

S
R

A
N

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54642350 1 TUBE , LOWER RADIATOR

B 36767903 1 HOSE , REDUCER
C 54642343 1 TUBE , UPPER RADIATOR
D 35330570 3 HOSE , CONNECTOR
E 54501838 1 RADIATOR
F 95235131 2 CLAMP
G 35135458 1 HOSE , BY--PASS ( 55 INCHES )
H 35363662 1 FITTING , BARBED
J 43212216 1 ADAPTER
K 35285600 1 HOSE , VENT ( 52 INCHES )
L 95264776 2 CLAMP
M 35222017 8 CLAMP
N 35366665 1 ELBOW
P 35326578 1 HOSE , DRAIN ( 115 INCHES )
Q 35576115 1 VALVE , BALL
R 95953949 1 ADAPTER
S 95220844 2 CLAMP
54474572 1 SWITCH , LEVEL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 20 08/01 A

Book 54757919 (7/02) (81)

FUEL TANK VENT PIPING

F
G
E G
F D

E C H F

D
B E
C D
C H

B G

F
B D
E

J K
C

A K

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54594098 1 TANK , R.H. FUEL

B 35369354 1 ELBOW
C 35356484 1 TUBING ( 23 INCHES )
D 92368687 1 SCREW
E 35253038 1 CLAMP
F 35369339 1 REDUCER
G 35322395 1 BREATHER
H 35356484 1 TUBING ( 40 INCHES HSRG )
J 54594080 1 TANK , L.H. FUEL
K 35279025 12 SCREW

MANUAL NO. DRAWING NO. DATE / REV:

54757919 21 08/01 A

Book 54757919 (7/02) (82)

FUEL PIPING

H
G

F
A

C
B

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35279081 ELBOW1
B 35305499 1 HOSE ASSEMBLY
C OUT OF FUEL PUMP ON ENGINE
D INTO FUEL PUMP ON ENGINE
E 35136548 1 HOSE ASSEMBLY ( HSRG )
35325083 1 HOSE ASSEMBLY ( WAGON WHEEL )
F 35286756 1 ELBOW
G 22060156 1 HOSE ASSEMBLY ( HSRG )
22060149 1 HOSE ASSEMBLY ( WAGON WHEEL )
H 35309210 1 ELBOW
36845014 1 CAP , FUEL TANK
54672811 1 SENDER , FUEL LEVEL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 22 08/01 A

Book 54757919 (7/02) (83)

AIR INTAKE AND FILTERS

M
V
L

W B C K

U
J
T
R
H
S

G
P

D
E

A B C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36879815 1 BRACKET , AIR CLEANER

B 36880995 12 SCREW
C 36879195 12 NUT
D 35161025 1 CLAMP
E 54599956 1 ELBOW , RUBBER
F 35112648 1 TUBE
G 35509074 1 ELBOW , RUBBER
H 35123272 1 TUBE
J 35112630 1 ELBOW , RUBBER
K 35505866 1 TUBE
L 35119858 1 CLAMP
M 35141290 1 HOSE , HUMP
N 35129071 1 CLAMP
P 35129071 4 CLAMP
Q 36862886 2 ELBOW , RUBBER
R 35300110 1 TUBE
S 36867778 2 EVACUATOR
T 36864361 2 ELEMENT , PRIMARY
U 36864379 2 ELEMENT , SAFETY
V 35388982 2 NUT , WING
W 36864346 2 AIR CLEANER ASSEMBLY
36847838 2 SWITCH , AIR FILTER

MANUAL NO. DRAWING NO. DATE / REV:

54757919 23 08/01 A

Book 54757919 (7/02) (84)

SEPARATOR TANK ASSEMBLY

R
X

Y
Q

A1 W

M
N
K
V J
A2
U

T
L
G
H
S
E F

A
D
B

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 95219747 1 CONNECTOR 36898922 1 PROBE , TEMPERATURE

B 36878254 1 HOSE ASSEMBLY
C 35294750 1 ELBOW
D 36879203 2 NUT
E 54629464 1 GLASS , SIGHT
F 54627799 2 ELBOW
G 36877793 2 SCREW
H 36765121 8 SCREW
J 36786283 1 GASKET
K 54612437 1 DISCHARGE HOSE ASSEMBLY
L 36765121 8 SCREW
M 36856656 1 GASKET
N 36754414 1 LINER , SHELL
P 36754406 1 ELEMENT , SEPARATOR
35610617 1 GASKET
Q 54612429 1 COVER , TANK
R 95934170 16 SCREW
S 54612403 1 TANK , SEPARATOR
T 35277797 1 O--RING
U 35802933 1 PLUG , OIL FILL
V 95954285 1 TEE
W 95942108 1 ADAPTER
X 36764371 1 VALVE , SAFETY
Y 95953311 1 ELBOW
Z 36764389 1 ADAPTER
A1 35192178 1 CLAMP
A2 54744149 1 PIPE , SAFETY VALVE
MANUAL NO. DRAWING NO. DATE / REV:
54757919 24 07/02 B

Book 54757919 (7/02) (85)

AIR PIPING

C7

C4 C6
C2
C1
C8

C3 C3 C5
B9

C9 D2
D1
A6 B8
B6

D3 D7
B7

B5 D4

B3
B4 D6 D5 D8

SEPARATOR
A4
A3 TANK
A9 B1
Y Z B2
A1
A2
A5

R Q X A8
U
V A7
D9
W PRESSURE GAUGE
U
T
P
E1

N L
S

M
K E2
J
G
E E4 E3
AIR END
C E5
F H E6
E7
D

C E8

MANUAL NO. DRAWING NO. DATE / REV:

54757919 25 08/01 A

Book 54757919 (7/02) (86)

AIR PIPING

A 35132299 SILENCER B2 35287911 ELBOW

B 95989554 COUPLING B3 35298512 HOSE ASSEMBLY

C 35290147 CONNECTOR B4 95944625 BUSHING

D 35282987 HOSE ASSEMBLY B5 95944575 NIPPLE

E 35335017 VALVE , BLOWDOWN B6 36854495 REGULATOR

F 95944575 NIPPLE B7 35290253 ELBOW

G 95944633 BUSHING B8 35282953 HOSE ASSEMBLY

H 35279116 ADAPTER B9 35283092 TEE

J 35283126 CONNECTOR C1 35290253 ELBOW

K 35298512 HOSE ASSEMBLY C2 35123124 ORIFICE

L 35248145 VALVE , CHECK C3 95940748 BUSHING

M 95954095 ELBOW C4 36840841 VALVE , SOLENOID

N 95930301 BUSHING C5 95944690 TEE

P 95287629 ADAPTER C6 95930301 BUSHING

Q 35283241 HOSE ASSEMBLY C7 54496773 REDUCER

R 95287629 ADAPTER C8 35279934 ELBOW

S 36840460 VALVE , CHECK C9 35282961 HOSE ASSEMBLY

T 35294453 ELBOW D1 35283084 TEE

U 95940748 BUSHING D2 35283068 ELBOW

V 36840841 VALVE , SOLENOID D3 35321165 REDUCER

W 35279835 ELBOW D4 35287739 TEE

X 95944575 NIPPLE D5 35330117 TEE

Y 95954194 TEE D6 36863702 ADAPTER

Z 35283050 TEE D7 22061394 VALVE , SAFETY

A1 95944690 TEE D8 95954111 ELBOW

A2 35322346 ORIFICE , .156 D9 35280098 ELBOW

A3 95930301 BUSHING E1 35282979 HOSE ASSEMBLY

A4 36920825 REDUCER E2 36852499 ELBOW

A5 36841815 TUBE ASSEMBLY E3 35283001 HOSE ASSEMBLY

A6 35284538 HOSE ASSEMBLY E4 35283092 TEE

A7 35280510 ADAPTER E5 35282961 HOSE ASSEMBLY

A8 95944617 BUSHING E6 35336139 FITTING , BULKHEAD

A9 35330117 TEE E7 35367846 CONNECTOR

B1 35365774 REDUCER E8 35324839 VALVE , BALL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 26 08/01 A

Book 54757919 (7/02) (87)

285 OIL PIPING

M L

P
J
K
H

F E

D
B

A
C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35335124 1 CONNECTOR
B 36897346 1 ELEMENT , FILTER
C 95286910 1 ELBOW
D 54625348 1 TUBE ASSEMBLY
E 36506756 1 CLAMP
F 35296409 1 CONNECTOR
G 39871306 1 HEAD , FILTER
H 54625173 1 BRACKET , FILTER
J 36756906 1 TEE
K 54628185 1 TUBE ASSEMBLY
L 54625363 1 TUBE ASSEMBLY
M 54628177 1 TUBE ASSEMBLY
N 54625355 1 TUBE ASSEMBLY

MANUAL NO. DRAWING NO. DATE / REV:

54757919 27 08/01 A

Book 54757919 (7/02) (88)

MINIMUM PRESSURE CHECK VALVE ASSEMBLY

F
B

A
E

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54699731 1 BODY , CHECK VALVE

B 36792380 1 CHECK VALVE ASSEMBLY
C 54699749 1 SPRING , CHECK VALVE
D 36792927 1 PISTON
E 54699756 1 O--RING
F 36794790 1 SPRING , MAIN
G 36794808 1 CAP

MINIMUM PRESSURE CHECK VALVE ASSEMBLY 54642152

MANUAL NO. DRAWING NO. DATE / REV:

54757919 28 08/01 A

Book 54757919 (7/02) (89)

OIL TEMPERATURE BY--PASS VALVE ASSEMBLY

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 95920674 4 SCREW
B 35307537 1 BODY , VALVE
C 35307545 1 SEAT , VALVE
D 35307552 1 SLEEVE , VALVE
E 35307560 1 SEAL , VALVE
F 35307578 1 ELEMENT , VALVE
G 35307586 1 GASKET , VALVE

35825595 -- OIL TEMPERATURE BY--PASS VALVE ASSEMBLY

MANUAL NO. DRAWING NO. DATE / REV:

54757919 29 08/01 A

Book 54757919 (7/02) (90)

INSTRUMENT PANEL ASSEMBLY

BEGINS WITH SERIAL NO. 330945 V

X U

Y
R

Q
W

N K

M
J

F
H

E
D
C

B
G A

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 22053896 1 SWITCH , LAMPS M 36841153 1 GAGE , VOLTAGE

B 22054050 1 SWITCH , HEATER N 22105613 1 GAGE , AIR DISCHARGE
C 22054142 5 PLUG , SWITCH P 22105571 1 PANEL , INSTRUMENT
D 22054076 1 SWITCH , AFTER WARM--UP Q 22055883 1 TACHOMETER
E 36844124 3 SCREW , QUARTER TURN R 22105639 1 GAGE , 300 PSI PRESSURE
F 35369180 3 RETAINER S 54766704 1 HOURMETER
G 22055800 1 OVERLAY , MODULE T 36852622 1 LIGHT , PANEL
H 36870590 1 GAGE , OIL PRESSURE 22113880 1 BULB , LIGHT
J 22127385 1 SWITCH ASSEMBLY U 54688411 1 MODULE , WEDGE
22127377 1 SWITCH , START V 95928800 4 NUT
22134118 1 KNOB ASSEMBLY W 36840908 1 HINGE
K 22105621 1 GAGE , WATER TEMPERATURE X 35144492 3 NUT
L 22050991 1 GAGE , FUEL LEVEL Y 35365386 3 SCREW
22137426 7 BULB , GAGE LIGHT
MANUAL NO. DRAWING NO. DATE / REV:
54757919 30A 7/02 A

Book 54757919 (7/02) (91)

INSTRUMENT PANEL ASSEMBLY

U
R
T

Q
W

V S
P

M N

L
X

K
Y
H J

F
G
A

B C E
D

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54755590 1 PANEL , INSTRUMENT

B 36844124 3 SCREW , QUARTER TURN
C 35369180 3 RETAINER
D 22053896 1 SWITCH , LAMPS
E 22054050 1 SWITCH , HEATER
F 22054076 1 SWITCH , AFTER WARM--UP
G 22054068 1 SWITCH , ETHER
H 54774104 1 COVER , KEY
J 22054167 1 KEY , SWITCH
K 92086719 1 SWITCH , START
L 54766704 1 METER , HOUR
M 22054142 4 PLUG , SWITCH
N 22050991 1 GAUGE , FUEL LEVEL
P 22056394 1 GAUGE , 4 IN 1
Q 36861177 1 TACHOMETER
R 36840767 1 GAUGE , PRESSURE
S 54688411 1 MODULE , WEDGE
T 95928800 4 NUT
U 35144492 3 NUT
V 35365386 3 SCREW
W 36840908 1 HINGE
X 36841252 1 LIGHT , PANEL
Y 22055800 1 OVERLAY , MODULE

MANUAL NO. DRAWING NO. DATE / REV:

54757919 30 08/01 A

Book 54757919 (7/02) (92)

INSTRUMENT PANEL ASSEMBLY

A D

B E

J
L
D

G F

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 95923314 1 NUT
B 95934998 1 WASHER
C 35327311 1 SPRING
D 92368687 7 SCREW
E 35327303 1 EYEBOLT
F 36738565 1 DOOR , INSTRUMENT PANEL
G 36740405 1 HINGE
H 35357995 1 STUD
J 35603349 1 HOLDER , DOOR
K 95935037 1 WASHER
L 35273366 1 NUT
M 54576939 1 PANEL , VERTICAL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 31 08/01 A

Book 54757919 (7/02) (93)

BATTERY & MOUNTING

Q G

E
J
D
H
C

M
B
N

P
A

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36870350 1 TRAY , BATTERY

B 35225788 2 BATTERY
C 54715479 4 STUD
D 95935037 8 WASHER
E 95923322 8 NUT
F 35562156 2 FRAME
G 35108216 4 CLIP
H 54765367 1 CABLE , NEGATIVE
J 35128982 1 CABLE , JUMPER
K 54765375 1 CABLE , POSITIVE
L 36896975 1 SWITCH , MASTER CUT--OFF
M 54737400 1 BRACKET , SWITCH
N 35279025 2 SCREW
P 54765383 1 CABLE , MASTER SWITCH
Q 54706825 1 COVER , BATTERY
35578194 1 GROUND STRAP FROM STARTER
35293075 1 GROUND STRAP TO RH OF ENGINE

MANUAL NO. DRAWING NO. DATE / REV:

54757919 32 08/01 A

Book 54757919 (7/02) (94)

COMMON ENCLOSURE ASSEMBLY

S Q N

R J
K
L
N
M
E
L
D
K
F
G J

A C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36793602 5 LATCH , DOOR SLAM

B 54576871 1 BRACE , FRONT PANEL
C 54576939 1 PANEL , L.H. FRONT
54744479 1 PANEL , L.H. FRONT ( IQ UNITS )
D 54576947 1 PANEL , R.H. FRONT
22055750 1 PANEL , R.H. FRONT ( IQ UNITS )
E 36863363 1 DOOR , FRONT
F 54718184 2 BRACE , FRONT
G 54587944 1 GRILLE , L.H. FRONT SIDE
H 36863413 5 HINGE
J 36863660 1 DOOR , SIDE
K 54587969 1 PANEL , CENTER
L 36863652 1 DOOR , SIDE
M 54587977 1 PANEL , L.H. REAR SIDE
N 54663240 1 PANEL , REAR SIDE
P 54587985 1 PANEL , R.H. REAR SIDE
Q 36863371 5 ANGLE , DOOR DRIP
R 54587951 1 GRILLE , R.H. FRONT SIDE
S 36849925 5 LATCH , DOOR

MANUAL NO. DRAWING NO. DATE / REV:

54757919 33 02/02 B

Book 54757919 (7/02) (95)

TOP ENCLOSURE ASSEMBLY

U
Q R
S
N

P T

V
L

K F

G
E

A C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54576970 1 CAP , FRONT END

B 36755981 4 CAP , CORNER
C 54690110 1 CAP , L.H. FRONT SIDE
D 36755742 6 BRACKET , FILLER
E 54690128 1 CAP , L.H. REAR SIDE
F 54584784 1 CAP , REAR END
G 54747316 8 BRACE , TOP FOAM
H 54747324 8 BRACE , TOP FOAM
J 54663224 1 CAP , R.H. FRONT TOP
K 54663232 1 CAP , R.H. REAR TOP
L 54700091 2 BRACE , CENTER ROOF
M 54599915 1 PANEL , FRONT TOP
N 54599923 1 PANEL , 2ND AND 4TH TOP
P 54599931 1 PANEL , CENTER TOP
Q 54599949 1 PANEL , REAR TOP
R 54690136 1 PLATE , RADIATOR FILL
S 35131051 1 LATCH , DOOR
T 36864403 1 DOOR , ROOF
U 36864304 1 CABLE
V 36864288 1 HINGE , DOOR

MANUAL NO. DRAWING NO. DATE / REV:

54757919 34 08/01 A

Book 54757919 (7/02) (96)

FAST TRACK ENCLOSURE

F H
K

G L

E M

B N

A C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54640982 1 BAFFLE , L.H. OUTSIDE

NOTE: ALL OTHER ENCLOSURE PARTS ARE SHOWN
B 54641022 1 STRIP , SUPPORT
ON COMMON ENCLOSURE DRAWING.
C 54640966 1 BAFFLE , L.H. INSIDE
D 54640974 1 BAFFLE , R.H. INSIDE
E 54641006 1 PLATE , TIE
F 54672761 1 PANEL , R.H. REAR
G 54718184 6 STRIP , FOAM RETENTION
H 54663299 1 PANEL , R.H. REAR CORNER
J 54672779 1 DOOR , REAR
36793602 1 LATCH , DOOR SLAM
K 54692744 1 HINGE
L 54663281 1 PANEL , L.H. REAR CORNER
M 54576921 1 STRIP , PANEL SUPPORT
N 54672753 1 PANEL , L.H. REAR SIDE

MANUAL NO. DRAWING NO. DATE / REV:

54757919 35 08/01 A

Book 54757919 (7/02) (97)

WAGON WHEEL ENCLOSURE

J
N
K

H
M

A
F
B

ITEM CPN QTY DESCRIPTION

A 54688239 1 BAFFLE , R.H.

NOTE: ALL OTHER ENCLOSURE PARTS ARE SHOWN
B 54688221 1 BAFFLE , L.H.
ON COMMON ENCLOSURE DRAWING.
C 54641022 4 SUPPORT , BAFFLE
D 54688247 2 BAFFLE , OUTSIDE
E 54718184 6 STRAP , FOAM
F 54663265 1 PANEL , L.H. REAR SIDE
G 54576921 1 ANGLE , REAR MOUNTING
H 54576954 1 PANEL , L.H. REAR
J 36863363 1 DOOR , REAR
36793602 1 LATCH , SLAM
36863413 1 HINGE
K 54576962 1 PANEL , R.H. REAR
L 54663273 1 PANEL , R.H. SIDE
M 54641006 2 PLATE , TIE
N 36849925 1 HOLDER , DOOR

MANUAL NO. DRAWING NO. DATE / REV:

54757919 36 08/01 A

Book 54757919 (7/02) (98)

COMMON FOAM

N
P N
N
P

N N P
N
N
N

M G

F
F

L C
K
L
D
B
K
K
J

F
J F F
C L
K
C D
C
H J
K K E
B
L

D
A B

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54721204 1 FOAM , L.H. FRONT TOP

B 54719703 2 FOAM , DOOR
C 54719711 3 FOAM , DOOR
D 54719646 2 FOAM , CENTER PANEL
E 54719695 1 FOAM , L.H. SIDE
F 54759519 4 FOAM , R.H. / L.H. REAR SIDE
G 54759527 2 FOAM , REAR
H 54721675 1 FOAM , R.H. FRONT
J 54720065 2 FOAM , DOOR
K 54719661 5 FOAM , CENTER DOOR
L 54720057 3 FOAM , DOOR
M 54719653 1 FOAM , R.H. REAR SIDE
N 54699046 7 FOAM , TOP
P 54699087 2 FOAM , CENTER TOP
Q 54710041 1 FOAM , REAR TOP

MANUAL NO. DRAWING NO. DATE / REV:

54757919 37 08/01 A

Book 54757919 (7/02) (99)

HIGH SPEED RUNNING GEAR FOAM

F K

A H

D
E

B
A

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54675848 1 FOAM , SPLITTER BAFFLE

B 54675830 1 FOAM , SPLITTER BAFFLE
C 54675822 1 FOAM , L.H. BAFFLE
D 54675806 1 FOAM , L.H. BAFFLE
E 54675814 1 FOAM , L.H.
F 54685334 1 FOAM , R.H.
G 54685326 1 FOAM , R.H.
H 54759550 1 FOAM , BOTTOM DOOR
J 54759543 1 FOAM , CENTER DOOR
K 54759535 1 FOAM , TOP DOOR
54737606 1 FOAM , L.H. BAFFLE ( IQ UNITS )
54737598 1 FOAM , L.H. BAFFLE ( IQ UNITS )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 38 02/02 B

Book 54757919 (7/02) (100)

WAGON WHEEL FOAM

H
J L

G
E
F

B
A

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54691134 1 FOAM , L.H. SPLITTER BAFFLE

B 54691175 1 FOAM , L.H. SPLITTER BAFFLE
C 54691118 1 FOAM , SPLITTER BAFFLE
D 54691191 1 FOAM , R.H. SPLITTER BAFFLE
E 54691159 1 FOAM , R.H. SPLITTER BAFFLE
F 54691126 1 FOAM , L.H. BAFFLE
G 54691167 1 FOAM , L.H. BAFFLE
H 54691183 1 FOAM , R.H. BAFFLE
J 54691142 1 FOAM , R.H. BAFFLE
K 54670459 1 FOAM , BOTTOM DOOR
L 54760442 1 FOAM , MIDDLE DOOR
M 54760434 1 FOAM , TOP DOOR
54737606 1 FOAM , L.H. BAFFLE ( IQ UNITS )
54737598 1 FOAM , L.H. BAFFLE ( IQ UNITS )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 39 02/02 B

Book 54757919 (7/02) (101)

WIRING PARTS LISTS

VIKING ELECTRICAL COMPONENTS

PART NO. QTY DESCRIPTION PART NO. QTY DESCRIPTION
54757224 1 IQ WIRING HARNESS 35577873 1 AUXILARY START RELAY
54474572 1 COOLANT LEVEL SWITCH 54720701 1 ENG. TEMP. SENDER ADAPTOR
36896975 1 BATTERY DISCONNECT SWITCH 36841526 1 CONTROL ORIFICE HEATER
36920825 1 0--100 PSI PRESSURE TRANSDUCER 36864677 1 REGULATOR HEATER
54765946 1 0--500 PSI PRESSURE TRANSDUCER 54765367 1 NEGATIVE BATTERY CABLE
36892362 1 24V SEALED RELAY 54765375 1 POSITIVE BATTERY CABLE
36785319 1 MAG SPEED SENSOR 54765383 1 POSITIVE JUMPER BATTERY CABLE
36898922 2 THERMISTOR TEMPERATURE PROBE 35128982 1 BATTERY JUMPER
36842300 1 START / RUN SOLENOID 35578194 1 FRAME GROUND STRAP
36842318 1 COMPRESSOR SOLENOID 35293075 1 ENGINE GROUND STRAP
36840841 2 SOLENOID VALVE 54672803 1 FUEL LEVEL SENDER ( WAGON WHEEL )
36847838 2 AIR FILTER SWITCH 54672811 1 FUEL LEVEL SENDER ( HIGH SPEED )
36870608 1 ENGINE OIL PRESSURE SENDER 54688411 1 WEDGE CONTROLLER
36841138 2 ENG. & COMP. TEMP SENDER 54654918 1 W1 CHASSIS HARNESS
36757581 1 COMP. OIL PRESSURE SWITCH 54765953 1 ADDRESS PLUG
36850691 1 START--UP COMPRESSOR 54765649 1 ADDRESS PLUG
54496773 1 0--225 PSI PRESS. TRANSDUCER 36841526 1 REGULATOR--HEATER
36792083 2 FUSE 20 AMP BLADE 22060594 1 CONTROL PANEL HARNESS
22071591 2 FUSE 10 AMP BLADE
35376169 4 DIODE

IQ OPTION
PART NO. QTY DESCRIPTION

54757224 1 IQ WIRING HARNESS

54775887 1 IQ HEATER HARNESS
36841526 5 IQ ORIFICE HEATERS
36898310 1 ACTUATOR
36898922 1 THERMISTOR TEMP. PROBE
36892362 1 24V SEALED RELAY
36920643 1 TCU
36899599 1 IQ FILTER SWITCH -- 20 PSI
36899615 1 IQ FILTER SWITCH -- 25 PSI

DENOTES XHP MACHINES ONLY

DENOTES HP MACHINES ONLY
MANUAL NO. DRAWING NO. DATE / REV:
54757919 39A 3/02 B

Book 54757919 (7/02) (102)

AC HEATER KIT

AC HEATER KIT

PART NO. QTY DESCRIPTION

36851533 1 BRACKET , PRESSURE SWITCH
36880995 2 SCREW ( ATTACH BRACKET )
36879195 2 NUT ( ATTACH BRACKET )
54464607 1 AC POWERED COLD START ASSY.
54464664 1 HARNESS , PRESSURE SWITCH
54480298 1 WELL , THERMOSTAT
54464623 1 HEATER , OIL PAN
36920346 1 PAD , HEATER 8D BATTERY
36920338 1 PAD , HEATER 8D BATTERY
35283464 1 ELBOW ( IN THREADED PORT OF PRESS. SWITCH )
35114545 1 TEE ( IN ADAPTER AT ENG. OIL PORT )
35283472 1 CONNECTOR ( IN TEE FACING LIFTING BAIL )

( FOR TEMPERATURES BELOW 10 F USE IR PERFORMANCE 500 OIL 35382944 / 55 GAL. )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 39B 12/01 B

Book 54757919 (7/02) (103)

WAGON WHEEL PARKING BRAKE ASSEMBLY

G
T

K S
R

A V Q

D P

B E
U
F

C
J
N

K L

H M

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 95941100 2 SCREW
B 36847432 1 BRACKET , RH LEVER
C 36782878 1 LEVER , BRAKE
D 35603224 2 PLATE , SPACER
E ---------------- 2 FURNISHED WITH LEVER
F 35603208 1 CLEVIS , BRAKE LEVER
G 35252618 4 NUT
H 36877793 4 SCREW
J 36847440 1 BRACKET , LH LEVER
K 36879195 4 NUT
L 36786887 1 BRACKET , LH CABLE LATCH
36786895 1 BRACKET , RH CABLE LATCH
M 95916573 8 NUT
N 95934741 8 WASHER
P 36782035 2 ARM , BRAKE
Q 36783785 2 PIN , CLEVIS
R 36786697 2 BUSHING
S 95935037 2 WASHER
T 95928867 2 PIN , COTTER
U 36880995 2 SCREW
V 36783306 1 BRACKET , FRONT CABLE LATCH

MANUAL NO. DRAWING NO. DATE / REV:

54757919 44 08/01 A

Book 54757919 (10/01) (106)

WAGON WHEEL PARKING BRAKE ASSEMBLY

H
F
E

J
C C

K
B

A
L

M N

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36782878 1 LEVER , BRAKE

B 35603208 1 CLEVIS , BRAKE LEVER
C 35118728 2 NUT
D 35603182 1 ROD , LINK
E 95935086 2 NUT
F 35603216 1 EQUALIZER , CLEVIS
G 35602846 1 EQUALIZER , CABLE
H 35357151 3 PIN , CLEVIS
J 95934998 3 WASHER
K 95928867 3 PIN , COTTER
L 36783306 1 BRACKET , FRONT CABLE LATCH
M 22064141 1 CABLE , LH BRAKE
N 22064000 1 CABLE , RH BRAKE

MANUAL NO. DRAWING NO. DATE / REV:

54757919 45 08/01 A

Book 54757919 (10/01) (107)

SEPARATOR AIR PIPING

K
M

J
M

E
F
P
H D

N
A
N
Q B

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 95935003 4 WASHER
B 95922902 4 NUT
C 54668314 1 SUPPORT , PIPE
D 35130293 4 SCREW
E 36898120 1 PIPE
F 95927273 8 SCREW
G 54642152 1 VALVE , MINIMUM PRESSURE
H 36799419 1 CLAMP
J 35586288 1 CLAMP
K 54642137 1 PIPE
L 95929089 4 SCREW
M 95358040 1 O--RING
N 95940946 2 NIPPLE
P 36922995 1 VALVE , BALL
Q 95916581 1 ELBOW

MANUAL NO. DRAWING NO. DATE / REV:

54757919 46 08/01 A

Book 54757919 (10/01) (108)

AIR CHARGE PIPING

B
C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54632690 1 TUBE , BOTTOM A/C

B 54501846 1 COOLER , AIR CHARGE
C 54444427 8 CLAMP
D 54632682 1 TUBE , UPPER A/C
E 54422522 4 HOSE , RIBBED

MANUAL NO. DRAWING NO. DATE / REV:

54757919 47 08/01 A

Book 54757919 (10/01) (109)

IQ AIR PIPING

P
X Y
A1
Q

A2 R S
N
T U
A3
V
M

W A6
L

F G
K D

A B C
A4 E H

K A7

A5
Q Q

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36799419 2 U--BOLT A4 54741087 1 PIPE , MANIFOLD

B 95935003 8 WASHER A5 54668314 1 SUPPORT , PIPE
C 95922902 8 NUT A6 95929089 32 SCREW
D 35586288 2 CLAMP A7 95916581 2 ELBOW
E 36898120 2 PIPE , SERVICE
F 54642152 2 VALVE , MINIMUM PRESSURE
G 95927273 36 SCREW
H 35130293 8 SCREW
J 95358040 11 O--RING
K 36922995 3 VALVE , BALL
L 54735055 1 PIPE
M 35113646 1 CLAMP
N 54734983 1 PIPE
P 36893220 3 ADAPTER , FLANGE
Q 95940946 8 NIPPLE
R 54738984 1 FILTER , SECONDARY
S 54739065 1 ELEMENT , FILTER
T 54738976 1 FILTER , PRIMARY
U 54739057 1 ELEMENT , FILTER
V 54738968 1 SEPARATOR , WATER
W 54734090 1 PIPE
X 54739016 1 KIT , BRACKET / WEDGE
Y 54739024 1 KIT , WEDGE
Z 54732250 1 BRACKET , FILTERS
A1 54699129 1 COOLER ASSEMBLY
A2 54700943 1 LOUVER ASSEMBLY
A3 547482490 1 PIPE
MANUAL NO. DRAWING NO. DATE / REV:
54757919 48 08/01 A

Book 54757919 (10/01) (110)

IQ COOLER PIPING

AFTERCOOLER

G G

F F H

J E E

D
K K

C
A

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A TO AIR END INLET HOUSING AT REAR

B 95365078 1 CONNECTOR
C 36844074 1 HOSE ASSEMBLY
D 35294701 1 HOSE ASSEMBLY
E 35322379 1 VALVE , BLOWDOWN
35379064 1 DIAPHRAM KIT
F 35367846 1 REDUCER
G 35284082 1 CONNECTOR
H 35283050 1 TEE
J 35279934 1 ELBOW
K 35248319 1 ORIFICE , .094
36898922 1 PROBE , TEMPERATURE

MANUAL NO. DRAWING NO. DATE / REV:

54757919 49 08/01 A

Book 54757919 (10/01) (111)

IQ FILTER PIPING

SECONDARY FILTER PRIMARY FILTER

EXHAUST PIPE

WATER SEPARATOR
Q P

B B B
C C C N

D D D

E E E
F F
F
G M
J J L

R
G K H

H G G

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54738968 1 SEPARATOR , WATER

B 95245353 1 ADAPTER
C 95772562 1 NIPPLE
D 36844579 1 Y--STRAINER
E 95940748 1 ADAPTER
F 37081528 1 REDUCER
G 35283472 1 CONNECTOR
H 36882223 1 TEE
J 95452025 1 NIPPLE
K 35310960 1 HOSE ASSEMBLY
L 35284082 1 CONNECTOR
M 35296110 1 HOSE ASSEMBLY
N 35321983 1 CONNECTOR
P 54738976 1 FILTER , PRIMARY
Q 54738984 1 FILTER , SECONDARY
R 35283241 1 HOSE ASSEMBLY

MANUAL NO. DRAWING NO. DATE / REV:

54757919 50 08/01 A

Book 54757919 (10/01) (112)

IQ INDICATOR PIPING

D A K E

J
B

A B

H
F

E
B

M A L E G

B C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36898401 1 CONNECTOR
B 35290352 1 ELBOW
C 35310226 1 HOSE ASSEMBLY
D 36899599 1 INDICATOR , 20 PSI
E 35283464 1 ELBOW
F 35310960 1 HOSE ASSEMBLY
G TO WATER SEPARATOR TUBE
H TO FILTER CROSSOVER TUBE
J TO FILTER OUTLET TUBE
K 35323757 1 HOSE ASSEMBLY
L 35323591 1 TEE
M 36899615 1 INDICATOR , 25 PSI
N 36920650 1 HOSE ASSEMBLY

MANUAL NO. DRAWING NO. DATE / REV:

54757919 51 08/01 A

Book 54757919 (10/01) (113)

ENGINE OIL DRAIN PIPING

ENGINE OIL PAN D E F

FRAME

A B C PLUG

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35294750 1 ELBOW
B 35323880 1 HOSE ASSEMBLY
C 95219747 1 CONNECTOR
D 35576115 1 VALVE , BALL
E 95647939 1 NIPPLE
F 95928172 1 ELBOW

MANUAL NO. DRAWING NO. DATE / REV:

54757919 52 08/01 A

Book 54757919 (10/01) (114)

FUEL TANK DRAIN PIPING

R.H. FUEL TANK

D
K L M N
E

G H J FRAME

PLUG

L.H. FUEL TANK

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 95953535 2 NIPPLE
B 95937454 1 CONNECTOR
C 54762190 2 FITTING , HOSE
D 54762182 1 HOSE ( 19 INCHES )
E 35221662 2 CLAMP
F 95954285 1 TEE
G 95953873 1 REDUCER
H 95219747 1 CONNECTOR
J 36893828 1 HOSE ASSEMBLY
K 95219747 1 CONNECTOR
L 35576115 1 VALVE , BALL
M 95647939 1 NIPPLE
N 95928172 1 ELBOW

MANUAL NO. DRAWING NO. DATE / REV:

54757919 53 08/01 A

Book 54757919 (10/01) (115)

RADIATOR DRAIN PIPING

BOTTOM OF RADIATOR

E F G H

FRAME
D
C PLUG

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35366665 1 ELBOW
B 95220844 2 CLAMP
C 35326578 1 HOSE ( 115 INCHES )
D 35326560 1 FITTING , HOSE
E 95953949 1 REDUCER
F 35576115 1 VALVE , BALL
G 95647939 1 NIPPLE
H 95928172 1 ELBOW

MANUAL NO. DRAWING NO. DATE / REV:

54757919 54 08/01 A

Book 54757919 (10/01) (116)

SEPARATOR TANK DRAIN PIPING

BOTTOM OF SEPARATOR TANK

D E F

FRAME

PLUG
A B C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 35294750 1 ELBOW
B 36878254 1 HOSE ASSEMBLY
C 95219747 1 CONNECTOR
D 35576115 1 VALVE , BALL
E 95647939 1 NIPPLE
F 95928172 1 ELBOW

MANUAL NO. DRAWING NO. DATE / REV:

54757919 55 08/01 A

Book 54757919 (10/01) (117)

DECAL LOCATION

Q
J

M K
N
J

H
L

E
C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54568803 1 TOWING DECAL ( HIGH SPEED RUNNING GEAR )

B 54629902 1 3--PART WARNING DECAL
C 22055701 1 TOWING DECAL ( WAGON WHEEL )
D 54568787 1 IMPROPER OPERATION DECAL
E 54568779 4 ROTATING FAN DECAL
F 54749205 4 NO WELD DECAL
G 54604939 4 FALL OFF UNIT DECAL
H 36514602 1 NOISE EMISSION DECAL
J 54568761 2 HIGH PRESSURE FLUID DECAL
K 54604962 1 RADIATOR FILL DECAL
L 54699400 2 LIFT POINT DECAL
M 22053847 1 OIL LEVEL DECAL
N 54604970 1 OIL FILL DECAL
P 54568795 1 HIGH PRESSURE AIR DECAL
Q 22054365 1 IQ OPERATION DECAL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 56 01/02 B

Book 54757919 (10/01) (118)

 C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54604988 1 DOOR UNDER PRESSURE DECAL

B 54625207 2 DIESEL FUEL DECAL
C 54568753 1 BATTERY GAS DECAL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 57 08/01 A

Book 54757919 (10/01) (119)

FAST TRACK FRAME ASSEMBLY

C B

ITEM CPN QTY DESCRIPTION CPN QTY DESCRIPTION

A 54760202 1 FRAME ASSEMBLY LESS RUNNING GEAR OPTION ( PARTS )

B 54542543 1 BAIL , LIFTING 22053870 2 MIDDLE SUPPORT ASSEMBLY
C 96720610 4 SCREW 22053888 4 LARGE EDGE SUPPORT ASSEMBLY
96727896 4 SCREW ( THRU EDGE ASSY. TO FRAME )
36879203 4 NUT ( THRU EDGE ASSY. TO FRAME )
36879492 8 SCREW ( THRU SIDES OF EDGE SUPPORTS )
36879203 8 NUT ( THRU SIDES OF EDGE SUPPORTS )
22054118 2 LARGE FRONT SUPPORT ASSY.
95939914 8 SCREW ( THRU SLOTS OF THE SUPPORT )
95941084 8 NUT ( TO SCREWS THRU SUPPORTS )
54594098 1 TANK , R.H. FUEL
35279025 24 SCREW ( FUEL TANKS TO FRAME )
54594080 1 TANK , L.H. FUEL
22060156 1 HOSE ASSY. ( FUEL COOLER TOP TO L.H. TANK )
35136548 1 HOSE ASSY. ( R.H. TANK PICK--UP TO ENGINE )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 2 12/01 B
WAGON WHEEL FRAME ASSEMBLY

C B

ITEM CPN QTY DESCRIPTION CPN QTY DESCRIPTION

A 54501796 1 FRAME ASSEMBLY LESS RUNNING GEAR OPTION ( PARTS )

B 54542543 1 BAIL , LIFTING 22051304 4 SUPPORT ( BETWEEN FRAME )
C 96720610 4 SCREW 39179072 16 BOLT ( SUPPORTS TO FRAME )
96701750 16 NUT ( SUPPORTS TO FRAME )
22053706 2 CROSSMEMBER ( BETWEEN SUPPORTS )
39179072 8 BOLT ( CROSSMEMBER TO SUPPORT LEGS )
96701750 8 NUT ( CROSSMEMBER TO SUPPORT LEGS )
54594114 1 TANK , R.H. FUEL TANK
35279025 12 SCREW ( FUEL TANK TO FRAME )
54594106 1 TANK , L.H. FUEL TANK
22060149 1 HOSE ASSEMBLY ( FUEL COOLER TOP TO L.H. TANK )
35325083 1 HOSE ASSEMBLY ( RH FUEL PICK--UP TO ENGINE )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 3 12/01 B
HIGH SPEED RUNNING GEAR

X Y

P Q R S T U V W

E F G H J K L M N
C D

A B

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36877991 4 TIRE
B 22077515 4 WHEEL
36878049 4 CLAMP , PLATE
C 35272150 8 STUD
D 36880276 8 NUT
E 36853091 4 NUT
F 36853109 2 WASHER
G 36853117 2 WASHER , LOCK
H 36851624 1 INNER BEARING CUP
J 36851616 1 OUTER BEARING CUP
K 36851608 1 INNER BEARING
L 36851590 1 OUTER BEARING
M 36851632 1 SEAL
N 36776813 8 CAP , DUST
P 36880268 4 HUB ASSEMBLY
Q 36880292 2 L.H. ELECTRIC BRAKE
R 36880300 2 R.H. ELECTRIC BRAKE
S 36880318 4 SHIELD , BOTTOM DUST
T 36880326 4 SHIELD , TOP DUST
U 36880334 7 BOLT
V 95939955 7 WASHER , LOCK
W 36880342 7 LOCKNUT
X 35603190 2 CHOCK , WHEEL
Y 35333830 2 STRAP , RUBBER

MANUAL NO. DRAWING NO. DATE / REV:

54757919 5 01/02 B
WAGON WHEEL RUNNING GEAR

V
M

G
W
K L
X Y

F J

Z H

A2 A1

A3

D A4
Q
R
C P
A8 A9
A A1

A5 B

A6 S

A7 T

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36504389 2 ROD , TIE X 95934956 2 WASHER

B 36140730 2 NUT , JAM Y 36719557 1 DRAWBAR
C 35588961 2 BALL JOINT , OUTER Z 35107168 1 PIN , HINGE
D 35221894 2 FITTING , LUBE A1 95201455 2 PIN , COTTER
E 36753259 1 AXLE , FRONT A2 36753242 1 ARM , CENTER
F 95717369 1 PIN , ROLL A3 35588953 2 BALLJOINT , INNER
G 35221894 1 FITTING , LUBE A4 35140722 2 NUT , JAM
H 95338554 2 PIN , ROLL A5 36719219 1 LATCH
J 95239927 4 WASHER A6 35141167 1 SPRING
K 36851566 1 L.H. KNUCKLE ASSEMBLY A7 95098703 2 PIN , ROLL
L 36851574 1 R.H. KNUCKLE ASSEMBLY A8 36851376 1 FRONT AXLE ASSEMBLY
M 95673042 2 PIN , ROLL A9 36851384 1 REAR AXLE ASSEMBLY
N 35319045 2 PIN , KING B1 36853042 2 TIE ROD ASSEMBLY
P 95018982 2 PIN , COTTER ( INCLUDES A,B,C,A3,A4 )
Q 36719169 2 BRACKET 22077515 4 WHEEL
R 36719466 2 SPRING 36877991 4 TIRE
S 36719177 2 BRACKET 36878049 4 RING , CLAMP
T 35111590 2 BOLT , SHACKLE
U 95318556 2 FITTING , LUBE
V 35588755 1 PIN , CENTER
W 95717377 2 PIN , ROLL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 9 01/02 B
EXHAUST ASSEMBLY

L
J

E F N H

D E F
B

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54603774 1 PIPE , ENGINE TURBO

B 54616552 1 PIPE , EXHAUST ( STANDARD )
54738752 1 PIPE , EXHAUST ( IQ )
C 35127653 1 CLAMP
D 35611235 1 SUPPORT , PIPE
E 36880995 12 SCREW
F 36879195 12 NUT
G 54616560 1 PIPE , EXHAUST
H 35307131 3 CLAMP , SEAL
J 54629589 1 STEP
K 35851351 1 CAP , RAIN
L 54629126 1 PIPE , EXHAUST
M 36799807 1 CLAMP , SEAL
N 54603204 1 MUFFLER
54662010 1 WRAP , EXHAUST
54721105 1 KIT , WRAP WIRE KIT

MANUAL NO. DRAWING NO. DATE / REV:

54757919 12 02/02 B
COMMON ENCLOSURE ASSEMBLY

S Q N

R J
K
L
N
M
E
L
D
K
F
G J

A C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 36793602 5 LATCH , DOOR SLAM

B 54576871 1 BRACE , FRONT PANEL
C 54576939 1 PANEL , L.H. FRONT
54744479 1 PANEL , L.H. FRONT ( IQ UNITS )
D 54576947 1 PANEL , R.H. FRONT
22055750 1 PANEL , R.H. FRONT ( IQ UNITS )
E 36863363 1 DOOR , FRONT
F 54718184 2 BRACE , FRONT
G 54587944 1 GRILLE , L.H. FRONT SIDE
H 36863413 5 HINGE
J 36863660 1 DOOR , SIDE
K 54587969 1 PANEL , CENTER
L 36863652 1 DOOR , SIDE
M 54587977 1 PANEL , L.H. REAR SIDE
N 54663240 1 PANEL , REAR SIDE
P 54587985 1 PANEL , R.H. REAR SIDE
Q 36863371 5 ANGLE , DOOR DRIP
R 54587951 1 GRILLE , R.H. FRONT SIDE
S 36849925 5 LATCH , DOOR

MANUAL NO. DRAWING NO. DATE / REV:

54757919 33 02/02 B
HIGH SPEED RUNNING GEAR FOAM

F K

A H

D
E

B
A

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54675848 1 FOAM , SPLITTER BAFFLE

B 54675830 1 FOAM , SPLITTER BAFFLE
C 54675822 1 FOAM , L.H. BAFFLE
D 54675806 1 FOAM , L.H. BAFFLE
E 54675814 1 FOAM , L.H.
F 54685334 1 FOAM , R.H.
G 54685326 1 FOAM , R.H.
H 54759550 1 FOAM , BOTTOM DOOR
J 54759543 1 FOAM , CENTER DOOR
K 54759535 1 FOAM , TOP DOOR
54737606 1 FOAM , L.H. BAFFLE ( IQ UNITS )
54737598 1 FOAM , L.H. BAFFLE ( IQ UNITS )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 38 02/02 B
WAGON WHEEL FOAM

H
J L

G
E
F

B
A

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54691134 1 FOAM , L.H. SPLITTER BAFFLE

B 54691175 1 FOAM , L.H. SPLITTER BAFFLE
C 54691118 1 FOAM , SPLITTER BAFFLE
D 54691191 1 FOAM , R.H. SPLITTER BAFFLE
E 54691159 1 FOAM , R.H. SPLITTER BAFFLE
F 54691126 1 FOAM , L.H. BAFFLE
G 54691167 1 FOAM , L.H. BAFFLE
H 54691183 1 FOAM , R.H. BAFFLE
J 54691142 1 FOAM , R.H. BAFFLE
K 54670459 1 FOAM , BOTTOM DOOR
L 54760442 1 FOAM , MIDDLE DOOR
M 54760434 1 FOAM , TOP DOOR
54737606 1 FOAM , L.H. BAFFLE ( IQ UNITS )
54737598 1 FOAM , L.H. BAFFLE ( IQ UNITS )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 39 02/02 B
WIRING PARTS LISTS

VIKING ELECTRICAL COMPONENTS

PART NO. QTY DESCRIPTION PART NO. QTY DESCRIPTION
54757224 1 IQ WIRING HARNESS 35577873 1 AUXILARY START RELAY
54474572 1 COOLANT LEVEL SWITCH 54720701 1 ENG. TEMP. SENDER ADAPTOR
36896975 1 BATTERY DISCONNECT SWITCH 36841526 1 CONTROL ORIFICE HEATER
36920825 1 0--100 PSI PRESSURE TRANSDUCER 36864677 1 REGULATOR HEATER
54765946 1 0--500 PSI PRESSURE TRANSDUCER 54765367 1 NEGATIVE BATTERY CABLE
36892362 1 24V SEALED RELAY 54765375 1 POSITIVE BATTERY CABLE
36785319 1 MAG SPEED SENSOR 54765383 1 POSITIVE JUMPER BATTERY CABLE
36898922 2 THERMISTOR TEMPERATURE PROBE 35128982 1 BATTERY JUMPER
36842300 1 START / RUN SOLENOID 35578194 1 FRAME GROUND STRAP
36842318 1 COMPRESSOR SOLENOID 35293075 1 ENGINE GROUND STRAP
36840841 2 SOLENOID VALVE 54672803 1 FUEL LEVEL SENDER ( WAGON WHEEL )
36847838 2 AIR FILTER SWITCH 54672811 1 FUEL LEVEL SENDER ( HIGH SPEED )
36870608 1 ENGINE OIL PRESSURE SENDER 54688411 1 WEDGE CONTROLLER
36841138 2 ENG. & COMP. TEMP SENDER 54654918 1 W1 CHASSIS HARNESS
36757581 1 COMP. OIL PRESSURE SWITCH 54765953 1 ADDRESS PLUG
36850691 1 START--UP COMPRESSOR 54765649 1 ADDRESS PLUG
54496773 1 0--225 PSI PRESS. TRANSDUCER 36841526 1 REGULATOR--HEATER
36792083 2 FUSE 20 AMP BLADE 22060594 1 CONTROL PANEL HARNESS
22071591 2 FUSE 10 AMP BLADE
35376169 4 DIODE

IQ OPTION
PART NO. QTY DESCRIPTION

54757224 1 IQ WIRING HARNESS

54775887 1 IQ HEATER HARNESS
36841526 5 IQ ORIFICE HEATERS
36898310 1 ACTUATOR
36898922 1 THERMISTOR TEMP. PROBE
36892362 1 24V SEALED RELAY
36920643 1 TCU
36899599 1 IQ FILTER SWITCH -- 20 PSI
36899615 1 IQ FILTER SWITCH -- 25 PSI

DENOTES XHP MACHINES ONLY

DENOTES HP MACHINES ONLY
MANUAL NO. DRAWING NO. DATE / REV:
54757919 39A 3/02 B
DECAL LOCATION

Q
J

M K
N
J

H
L

E
C

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 54568803 1 TOWING DECAL ( HIGH SPEED RUNNING GEAR )

B 54629902 1 3--PART WARNING DECAL
C 22055701 1 TOWING DECAL ( WAGON WHEEL )
D 54568787 1 IMPROPER OPERATION DECAL
E 54568779 4 ROTATING FAN DECAL
F 54749205 4 NO WELD DECAL
G 54604939 4 FALL OFF UNIT DECAL
H 36514602 1 NOISE EMISSION DECAL
J 54568761 2 HIGH PRESSURE FLUID DECAL
K 54604962 1 RADIATOR FILL DECAL
L 54699400 2 LIFT POINT DECAL
M 22053847 1 OIL LEVEL DECAL
N 54604970 1 OIL FILL DECAL
P 54568795 1 HIGH PRESSURE AIR DECAL
Q 22054365 1 IQ OPERATION DECAL

MANUAL NO. DRAWING NO. DATE / REV:

54757919 56 01/02 B
SEPARATOR TANK ASSEMBLY

R
X

Y
Q

A1 W

M
N
K
V J
A2
U

T
L
G
H
S
E F

A
D
B

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 95219747 1 CONNECTOR 36898922 1 PROBE , TEMPERATURE

B 36878254 1 HOSE ASSEMBLY
C 35294750 1 ELBOW
D 36879203 2 NUT
E 54629464 1 GLASS , SIGHT
F 54627799 2 ELBOW
G 36877793 2 SCREW
H 36765121 8 SCREW
J 36786283 1 GASKET
K 54612437 1 DISCHARGE HOSE ASSEMBLY
L 36765121 8 SCREW
M 36856656 1 GASKET
N 36754414 1 LINER , SHELL
P 36754406 1 ELEMENT , SEPARATOR
35610617 1 GASKET
Q 54612429 1 COVER , TANK
R 95934170 16 SCREW
S 54612403 1 TANK , SEPARATOR
T 35277797 1 O--RING
U 35802933 1 PLUG , OIL FILL
V 95954285 1 TEE
W 95942108 1 ADAPTER
X 36764371 1 VALVE , SAFETY
Y 95953311 1 ELBOW
Z 36764389 1 ADAPTER
A1 35192178 1 CLAMP
A2 54744149 1 PIPE , SAFETY VALVE
MANUAL NO. DRAWING NO. DATE / REV:
54757919 24 07/02 B
INSTRUMENT PANEL ASSEMBLY

BEGINS WITH SERIAL NO. 330945 V

X U

Y
R

Q
W

N K

M
J

F
H

E
D
C

B
G A

ITEM CPN QTY DESCRIPTION ITEM CPN QTY DESCRIPTION

A 22053896 1 SWITCH , LAMPS M 36841153 1 GAGE , VOLTAGE

B 22054050 1 SWITCH , HEATER N 22105613 1 GAGE , AIR DISCHARGE
C 22054142 5 PLUG , SWITCH P 22105571 1 PANEL , INSTRUMENT
D 22054076 1 SWITCH , AFTER WARM--UP Q 22055883 1 TACHOMETER
E 36844124 3 SCREW , QUARTER TURN R 22105639 1 GAGE , 300 PSI PRESSURE
F 35369180 3 RETAINER S 54766704 1 HOURMETER
G 22055800 1 OVERLAY , MODULE T 36852622 1 LIGHT , PANEL
H 36870590 1 GAGE , OIL PRESSURE 22113880 1 BULB , LIGHT
J 22127385 1 SWITCH ASSEMBLY U 54688411 1 MODULE , WEDGE
22127377 1 SWITCH , START V 95928800 4 NUT
22134118 1 KNOB ASSEMBLY W 36840908 1 HINGE
K 22105621 1 GAGE , WATER TEMPERATURE X 35144492 3 NUT
L 22050991 1 GAGE , FUEL LEVEL Y 35365386 3 SCREW
22137426 7 BULB , GAGE LIGHT
MANUAL NO. DRAWING NO. DATE / REV:
54757919 30A 7/02 A
AC HEATER KIT

AC HEATER KIT

PART NO. QTY DESCRIPTION

36851533 1 BRACKET , PRESSURE SWITCH
36880995 2 SCREW ( ATTACH BRACKET )
36879195 2 NUT ( ATTACH BRACKET )
54464607 1 AC POWERED COLD START ASSY.
54464664 1 HARNESS , PRESSURE SWITCH
54480298 1 WELL , THERMOSTAT
54464623 1 HEATER , OIL PAN
36920346 1 PAD , HEATER 8D BATTERY
36920338 1 PAD , HEATER 8D BATTERY
35283464 1 ELBOW ( IN THREADED PORT OF PRESS. SWITCH )
35114545 1 TEE ( IN ADAPTER AT ENG. OIL PORT )
35283472 1 CONNECTOR ( IN TEE FACING LIFTING BAIL )

( FOR TEMPERATURES BELOW 10 F USE IR PERFORMANCE 500 OIL 35382944 / 55 GAL. )

MANUAL NO. DRAWING NO. DATE / REV:

54757919 39B 12/01 B