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Ingersoll-Rand XHP900WCAT Operating & Maintenance Manual
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Ingersoll-Rand XHP900WCAT Operating & Maintenance Manual

Ingersoll-Rand XHP900WCAT Operating & Maintenance Manual

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Operating & Maintenance Manual
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.
Utility Equipment
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
Revised (10-12)
Book: 22464945 (01/07)
Compressor Models
XHP900WCAT
Code: B
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.

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Summary of Contents for Ingersoll-Rand XHP900WCAT

  • Page 1 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, Utility Equipment service marks, logos, or other proprietary identifying marks belonging P.O.
  • Page 2 QUALITY POLICY We will supply products and services that consistently meet the requirements of our customers and each other. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
  • Page 3 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.
  • Page 4 Swan Lane, Hindley Green 501 Sanford Avenue Wigan WN2 4EZ Represented In EC By: Mocksville, North Carolina 27028 United Kingdom Declare that, under our sole responsibility for manufacture and supply, the product(s) HP1300WCU VHP825WCU XHP900WCAT VHP750WCAT XHP1170WCU XP1400WCU HP935WCU XHP650WCAT VHP850WCAT XHP1070WCU P1600WCU...
  • Page 5 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.
  • Page 6 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.
  • Page 7 TABLE OF CONTENTS SECTION 1 ....SAFETY SECTION 2 ....NOISE EMISSION SECTION 3 .
  • Page 8 SECTION 1- - SAFETY SAFETY PRECAUTIONS Compressed air must not be used for a feed to any form of breathing apparatus or mask. General Information The discharged air contains a very small percentage Ensure that the operator reads and understands the of compressor lubricating oil and care should be taken decals and consults the manuals before maintenance to ensure that downstream equipment is compatible.
  • Page 9 This machine may include such materials as oil, diesel Use care to avoid contacting hot surfaces (engine fuel, antifreeze, brake fluid, oil/air filters and batteries exhaust manifold and piping, air receiver and air which may require proper disposal when performing discharge piping, etc.).
  • Page 10 SAFETY LABELS Look for these signs on machines shipped to international markets outside North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform you supervisor. Hot Surface Corrosion risk Lifting point...
  • Page 11 Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken. WARNING - - Maintain correct tire pressure. (Refer to the GENERAL INFORMATION section of this manual). WARNING: Consult the operation and maintenance manual before performing any maintenance. Rough Service Designation Wet Location Operation Do not stack...
  • Page 12 Oil Drain km/h WARNING undertake Do not exceed the speed limit. maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved. Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken Do not remove the Operating and Maintenance manual and manual holder from this machine.
  • Page 13 Look for these signs on machines shipped to markets in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform you supervisor. Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored.
  • Page 14 km/h WARNING WARNING Improper operation of this equipment. Collapsing jackstand. Can cause serious injury or death. Can cause serious injury. Read Operator’s Manual supplied with this machine before operation or Insert locking pin completely. servicing. Excessive towing speed. Modification or alteration of this machine. Can cause serious injury or death.
  • Page 15 CAUTION WARNING DO NOT USE ETHER. High pressure air. Can cause serious ENGINE DAMAGE WILL OCCUR. injury or death. This engine is equipped with an Relieve pressure before electric heater starting aid. removing filler plugs/caps, fittings or covers. NOTICE COOLANT FILL INSTRUCTIONS Adding: USE DIESEL Remove radiator cap.
  • Page 16 SECTION 2 - - NOISE EMISSION This section pertains only to machines distributed with- in the United States. WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or re- placement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
  • Page 17 NOISE EMISSION CONTROL MAINTENANCE LOG COMPRESSOR MODEL SERIAL NO. USER UNIT NO. UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Engine Make & Model: Serial No.: Purchaser or Owner: Address: Date Purchased: The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations, specifically the following acts or the causing thereof: (1) the removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replace- ment, of any device or element of design incorporated into new compressor for the purpose of noise control prior...
  • Page 18 MAINTENANCE SCHEDULE ITEM AREA PERIOD Compressed Air Leaks As Detected Safety and Control Systems As Detected Acoustic Materials Daily Fasteners 100 hours Enclosure Panels 100 hours Air Intake & Engine Exhaust 100 hours Cooling Systems 250 hours Isolation Mounts 250 hours Engine Operation See Operator’s Manual Fuels &...
  • Page 19 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK HOURMETER MAINT/ LOCATION CITY/ WORK DONE BY READING STATE (NAME) INSPECT DATE Book 22464945 (1/07)
  • Page 20 SECTION 3 - - General Data Models Rated Delivery: --cfm (--litres/sec) 900(425) Rated Pressure: --psi (--kPa) 350(2400) Engine Caterpillar (Diesel) 3406TA Full Load Speed -- rpm 1800 1200 No Load Speed -- rpm Electrical System -- volt Weights - - pounds(kilograms) 14900(6765) Fluid Capacities - - U.S.
  • Page 21 SECTION 4 - - OPERATING INSTRUCTIONS Instrument Control Panel OPERATING CONTROLS & INSTRUMENTS Engine Oil Pressure Gauge - - See Engine Op- eration Manual for normal range. 7. Hourmeter - - Records running time for mainte- nance purposes. Voltmeter - - Indicates battery condition. Engine Water Temperature Gauge - - Indi- cates coolant temperature, with normal operating...
  • Page 22 When the unit is to be operated out- -of- -level it is WARNING important: (1) To keep the engine crankcase oil level near the high Do not climb on top of unit. The lifting eye can be level mark (with the unit level), reached through the roof door ONLY from INSIDE (2) To have the compressor oil level gauge show no of the unit.
  • Page 23 WARNING CAUTION No smoking, sparks, or open flame near fuel. Unrestricted air flow from a hose will result in a whipping motion of the hose which can cause • Check the fuel level. Add only CLEAN DIESEL fuel serious injury or death. A safety device must be attached to the hose at the source of supply to for maximum service from the engine.
  • Page 24 • Compressor is now ready to furnish air when the If equipped with 24 volt compressor (Cold Start service valve is opened. Option) STOPPING S Press and hold the BYPASS button for ten (10) to fif- • Close air service valve (s). teen (15) seconds.
  • Page 25 In a shutdown situation, the function of the panel lamps EQUIPMENT PROTECTION is to indicate what specific failure caused the unit to shut down. These lamps will remain illuminated until NOTICE the Power Switch is turned “OFF”. Note: None of the panel lamps should be glowing when machine is operating.
  • Page 26 SPEED AND PRESSURE REGULATION XHP 900 Units ONLY: Adjust spring so it is full Adjustment Instructions stretched, and nut (F) is at far end of rod, closest to spring (G). Tighten nuts. The operating pressure of this unit was set at the facto- ry to the maximum rating (at full speed).
  • Page 27 SECTION 5 - - MAINTENANCE NOTICE: Holes or cracks downstream of the air cleaner housing will cause the restriction indicators to GENERAL be ineffective. In addition to periodic inspections, many of the The air filters restricted sensor will automatically reset components in these units require periodic servicing to after the main power switch is flipped to “OFF.”...
  • Page 28 The air cleaner system (housing and piping) should be AUTOMATIC SHUTDOWN SYSTEM inspected every month for any leakage paths or inlet The discharge air temperature switches will require obstructions. Make sure the air cleaner mounting approximately 248°F (120°C) to actuate. The engine bolts and clamps are tight.
  • Page 29 To ensure freedom from air leaks, all rubber hose joints and the screw--type hose clamps must be abso- lutely tight. Regular inspection of these connections In the event foreign deposits, such as sludge and lac- quer, accumulate in the oil cooler to the extent that its for wear or deterioration is a definite “must”...
  • Page 30 NOTICE Excessive grease in the hub or grease cap serves FASTENERS no purpose due to the fact that there is no way to Visually check entire unit in regard to bolts, nuts and force the grease into the bearing. The manufactur- screws being properly secured.
  • Page 31 RECEIVER- -SEPARATOR SYSTEMS * Remove scavenge tube from tank cover. WARNING * Disconnect service line from cover. High pressure air can cause serious injury or death from hot oil and flying parts. Always relieve * Remove cover, element and inner shell. pressure before removing caps, plugs, covers or other parts from pressurized air system.
  • Page 32 cut line if necessary SCAVENGE LINE NOTICE Excessive oil carry- -over may be caused by an oil- - WARNING logged separator element. Do not replace element without first performing the following mainte- High pressure air can cause serious injury or nance procedure: death from hot oil and flying parts.
  • Page 33 Apply 2 medium - - wet coats of Duponts 222S Adhesion Promoter over the entire EXTERIOR FINISH CARE area to be painted, with a 5 minute flash in between coats. This unit was painted and heat cured at the factory with a high quality, thermoset polyester powder To apply the texture coat, use Duponts coating.
  • Page 34 BRAKE SYSTEMS (Hydraulic Only) Whenever a brake line hose, tube or fitting is removed/ This compressor is equipped with mechanical parking replaced, the hydraulic brake system must be bled of brakes and hydraulic surge brakes. The maintenance air to ensure proper brake operation. Bleed the of these brake systems is required to ensure safe op- brakes, at each wheel cylinder, in the following order: eration of this compressor.
  • Page 35 NOTE: New cables will stretch and therefore should be readjusted after the first week of use. Every six months, apply a multi--purpose grease to the fittings on the brake actuator. Electric Brake Adjustment: Brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have “seated”, (2) at 3000 mile intervals, (3) or as use and performance requires.
  • Page 36 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. LARGE UNITS 500 hours 1000 hours 2000 hours **Hydraulic Oil Level Compressor Oil Level Engine Oil Level **Radiator Coolant Level...
  • Page 37 SECTION 6 - - LUBRICATION GENERAL INFORMATION Lubrication is an essential part of preventive mainte- If the unit has been operated for the time/ hours men- nance, affecting to a great extent the useful life of the tioned above, it should be completely drained of oil. If unit.
  • Page 38 Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid RATED OPERATING PRESSURE required. Note that the selection of fluid is dependent on 350 PSI 100 - - 300 PSI the design operating pressure of the machine and the 125_F ambient temperature expected to be encountered 50_C...
  • Page 39 SECTION 7 - - TROUBLE SHOOTING Bold Headings depict the COMPLAINT - - Subheadings suggest the CAUSE Note: Subheadings suggest sequence to follow troubleshooting. Corrective Action Unit Shutdown: Out of Fuel Add CLEAN diesel Fuel Compressor Oil Temp. Too High See Complaint 10 Engine Water Temp.
  • Page 40 Engine Oil Pressure Lamp Stays On: Corrective Action Low Oil Level Add oil. Out of Level >15 degrees Relocate or reposition. Wrong Lube Oil See Engine Oil Spec. Change oil. Clogged Oil Filter Element(s) Replace element(s). Engine Malfunctioning See Trouble Shooting in Engine Manual. Loose Wire Connection.
  • Page 41 Excessive Compressor Oil Temperature: Corrective Action Ambient Temp. > 125_F (52_C) Above spec limit. Out of Level > 15 degrees Relocate or reposition unit. Low Oil Level Add oil. Look for any leaks. Wrong Lube Oil Check spec in this manual. Dirty Cooler Clean exterior surfaces.
  • Page 42 Short Air Cleaner Life: Corrective Action 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. Oil Pump Drive Coupling Inspect coupling. If necessary, replace coupling. Excessive Oil In Air: High Oil Level Read procedure in this manual.