Ingersoll-Rand XHP900CM Operating, Maintenance & Parts Manual
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Ingersoll-Rand XHP900CM Operating, Maintenance & Parts Manual

Ingersoll-Rand XHP900CM Operating, Maintenance & Parts Manual

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Portable Compressor Division
P. O. Box 868
Mocksville, NC 27028
OPERATING, MAINTENANCE, PARTS
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.
Revised (01-13)
Co. 2001
©
INGERSOLL-RAND
Manual No. 54771142 (7/01)
MANUAL
COMPRESSOR MODEL
XHP900CM
1
(
)
Revision A
07/2001
07/18/01

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Summary of Contents for Ingersoll-Rand XHP900CM

  • Page 1 COMPRESSOR MODEL XHP900CM 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...
  • Page 2 QUALITY POLICY We will supply products and services that consistently meet the requirements of our customers and each other. Manual No. 54771142 (7/01) 07/18/01...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 ..SAFETY SECTION 2 ..WARRANTY SECTION 3 ..WARRANTY REGISTRATION SECTION 4 ..SYSTEM DESCRIPTION SECTION 5 ..INSTALLATION SECTION 6 .

  • Page 4: Section 1

    SECTION 1 - SAFETY IMPORTANT SAFETY INSTRUCTIONS Look for these signs 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 your supervisor. Indicates the presence of a hazard which WILL cause severe injury, death or property damage, if ignored.
  • Page 5 Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. DANGER Air discharged from this machine may contain carbon monoxide or other contaminants which will cause severe injury or death.
  • Page 6 WARNING WARNING Never inspect or service unit without first This machine produces loud noise with the relieving pressure from the air start reservoir doors open or service valve vented. Extended to prevent accidental starting. exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are Do not remove the pressure cap from a HOT open or service valve is vented.
  • Page 7 WARNING WARNING Hot pressurized fluid. Can cause severe burns. Do not open radiator while hot. Rotating fan blade. Can cause severe injury. Do not operate without guard in place. CAUTION Use extreme care to avoid contacting hot surfaces. CAUTION Air receiver and air discharge piping, etc. Never allow the unit to sit stopped with pressure in Do not connect the air discharge on this unit onto a the receiver separator system.
  • Page 8 Hazardous Substance Precaution The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly. SUBSTANCE PRECAUTION Compressor Oil Avoid ingestion, skin contact and breathing fumes. Preservative Grease Avoid ingestion, skin contact and breathing fumes. Rust Preventative Avoid ingestion, skin contact and breathing fumes.
  • Page 9 SAFETY CARD Manual No. 54771142 (7/01) 07/18/01...

  • Page 10: Section 2

    1,000 hours of service by, the initial user. Downhole Drills - In lieu of the repair or replacement of defective parts, Ingersoll-Rand may elect to issue full or partial credit toward the purchase of a new part.
  • Page 11 Warranty The remedies of the user set forth under the provisions of warranty outlined above Ingersoll-Rand will provide a new part or are exclusive and the total liability of repaired part, at its election, in place of Ingersoll-Rand or its distributors with...
  • Page 12 2000 major components 25-36 mo/3000 hrs parts only Vanguard no limit  White 2000 MANUFACTURER MONTHS HOURS COMMENTS PARTS WARRANTY Ingersoll-Rand no limit parts only AIREND TYPE MONTHS HOURS COMMENTS AIREND EXCHANGE Vane 1000 parts & labor WARRANTY Screw 2000 parts &...
  • Page 13 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 668 Mocksville, North Carolina 27028 Attn: Warranty Department Note: Completion of this form validates the warranty.
  • Page 14 The warranty and limitation of liability has been reviewed and understood by the owner/user. 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.
  • Page 15 - - - - - - - - - - - - - - - - - - - - - fold - - - - - - - - - - - - - - - - - - - Manual No.
  • Page 16 SECTION 4 – SYSTEM DESCRIPTION General The CM air compressors are semi-packaged, air cooled units designed for power take-off applications. Each unit is designed to operate at ambient temperatures from - 10°F to 125°F (-23.3°C to 51.7°C). For the actual delivery of each unit at its rated operating pressure, refer to the typical General Data Decal supplied with each unit, and to the table in Section 5.
  • Page 17 SECTION 5 - INSTALLATION Location After the type of drive is determined, satisfactory installation depends upon the ability of the installer. Refer to the appropriate foundation plan located in the back of this manual for the dimensions of the compressor package and the appropriate separator foundation plan for the dimensions of the combination primary oil separator tank-air receiver (hereafter called the receiver separator).
  • Page 18 PIPING General As CM Series compressors are comprised of two modules (compressor and separator), there is necessarily interconnecting piping between the two. These hoses are not provided with the units, as the required lengths of the hoses are dependent on the relative location of the two modules in their installed location.
  • Page 19 Receiver separator Discharge Piping The receiver separator discharge piping must be furnished by the customer. Refer to the appropriate separator fitting location for a typical piping arrangement for these units. A minimum pressure valve and a manual shut-off valve is supplied with each unit and must be piped into the customer’s system as indicated.
  • Page 20 The standard regulation system supplied with CM Series Compressors is designed to provide capacity control for the compressor only. Variable speed control of a driver engine is possible with additional equipment. Consult Ingersoll-Rand Company, Specialty Products Department for technical assistance for these applications.

  • Page 21: Section 6

    SECTION 6 - OPERATING INSTRUCTIONS 3. –HR2: Disconnect the hose going to the seal and inject 7 gallons (26L) into the SETTING-UP manifold tubing. --HR2.5: Remove cap on manifold tube • Place the unit in an open, well-ventilated between pump and filter and inject 7 gallons area.
  • Page 22 Be sure no one is IN or ON the compressor High Discharge Air Temperature- unit. (1) At the airend outlet. Do NOT operate machine with guards removed. (2) In the safety valve connection on the separator tank. Do NOT operate machine with any access panel open.
  • Page 23 Pressure Regulation Adjusting Instructions 8. With service valve closed, adjust Adjustment Instructions pressure regulator (PR) to rated pressure (*) plus 10 psi (70kPa) as follows: The operating pressure of this unit was set at the 9. Loosen locknut (M) counterclockwise. Turn factory to the maximum rating (at full speed) adjustment cap (N) clockwise to increase See General Data.
  • Page 24 TROUBLESHOOTING (2) Has similar trouble occurred before? INTRODUCTION (3) What previous maintenance work has been Troubleshooting for a portable air compressor done? is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. B.
  • Page 25 TROUBLESHOOTING CHART Bold Headings depict the COMPLAINT - Subheadings depict the CAUSE Note: Subheadings suggest order to follow in cause of troubleshooting. Short Air Cleaner Life: Excessive Compressor Oil Temperature: Dirty Operating Conditions Ambient Temperature Too High Inadequate Element Cleaning Out of Level >...
  • Page 26 SECTION 7 – GENERAL DATA Compressor Model ......................XHP900CM Rated Delivery - CFM (litres/sec.)..................900 (425) Rated Pressure - PSI (kPa) ....................350 (2413) Compressor Lube Capacity (Refill) – U.S. gal. (litres)............44 (167) Compressor Oil Filter Element ..................36860336 Compressor Oil Separator Element...................

  • Page 27: Section 8

    SECTION 8 - MAINTENANCE COMPRESSOR OIL LEVEL CAUTION The oil level should be checked before the unit is Any unauthorized modification or failure to operated. The optimum operating level is midway maintain this equipment may make it unsafe and of the sight tube on the side of the receiver tank. out of factory warranty.
  • Page 28 COMPRESSOR OIL COOLER Install cleaned or new elements in the The compressor lubricating and cooling oil is reverse order to the above. Tighten wing cooled by means of a fin and tube-type oil cooler. nuts firmly and replace cotter pin. The lubricating and cooling oil, flowing internally Inspect to ensure that the end cap seals through the core section, is cooled by the air...
  • Page 29 NOTICE NOTICE Piping systems operating at less than 150 psi If there is any indication of formation of varnishes, (1050 kPa) may use a special nylon tubing. The shellacs or lacquers on the oil filter element, it is a associated fittings are also of a special “push-in” warning the compressor lubricating oil has design.
  • Page 30 RECEIVER SEPARATOR SYSTEMS WARNING High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or other parts from pressurized air system. Open service valve. • Ensure pressure is relieved, with BOTH: •...
  • Page 31 The life of the oil separator element is dependent • Place a straightedge across top of element upon the operating environment (soot, dust, etc.) and measure from bottom of straightedge to and should be replaced every twelve months or bottom of element. (See drawing below) 2000 hours.
  • Page 32 SCAVENGE LINE If grease removal is needed, a fast evaporating alcohol chlorinated WARNING solvent can be used. Note: This may cause some dulling of the paint finish. High pressure air can cause severe injury or If the paint has faded or chalked, the death from hot oil and flying parts.
  • Page 33 PREVENTIVE MAINTENANCE SCHEDULE If operating in extreme environments (very hot, cold, dusty or wet), these time periods should be reduced. 500 hrs 1000 hrs 2000 hrs Daily Weekly Monthly /3 mos. /6 mos. /12 mos. Compressor Oil Level Gauges/Lamps *Air Cleaner Service Indicators Air Cleaner Precleaner Dumps Hoses (Oil, Air, Intake Hydraulic) Automatic Shutdown System...
  • Page 34 LUBRICATION Both compressor lubrication and cooling are accomplished by the compressor lubricating oil. The oil is forced from the oil storage reservoir, under system pressure, through an oil cooler and an oil filter directly to the compressor. When the compressor is operating at low capacity, some of the oil may bypass the cooler through a thermostatically controlled bypass valve.
  • Page 35 Relatively cool lubricating oil is admitted under pressure to the compressor bearings and is also injected in metered amounts, directly to the rotor chamber. All of the oil thus introduced mixes with, and passes on with the air being compressed, thus removing the heat of compression to a large degree. On its way to the final discharge connection, the air passes through a receiver/separator.
  • Page 36 FLUIDS AND LUBRICANTS TABLE Design Operating Pressure Ambient Specification Temperature 100 psi to 300 psi IR Pro -10°F to 125°F • (-23°C to 52°C) Mil PRF 2104G SAE 10W 100 psi to 300 psi IR Performance 500 -40°F to 125°F (-40°C to 52°C) Mil PRF 46167 350 psi...
  • Page 37 CAUTION Shorter oil change intervals may be necessary if unit is operated under adverse conditions. WARNING Do not, under any circumstances, open any drain cocks, remove any plugs or the oil filler plug from the compressor lubricating and cooling oil system without making sure the air receiver system had been completely relieved of all air pressure.
  • Page 38 NOTICE unit as the front. Standing at the rear of the unit facing the drive end (front) will determine the Ingersoll-Rand Company can bear no right and left sides. responsibility for injury or damages resulting directly from the use of non- FASTENERS approved repair parts.
  • Page 39 Ingersoll-Rand Company used and find illustration page number. (“Company”) in writing. No additional or contrary terms will be binding upon the Company unless Locate the desired part on the illustration expressly agreed to in writing.
  • Page 40 AIREND EXCHANGE PROGRAM Warranty: The Company warrants that parts manufactured by it will be as specified and will be Your Ingersoll-Rand Company Construction free from defects in materials and workmanship. Equipment Group Sales Offices and authorized The Company’s liability under this warranty shall...

  • Page 41: Section 10

    SECTION 10 – PARTS LIST Page No Frame & Enclosure 41-43 Air End & Components 44-49 Cooling Fan 50-52 Oil Cooler Shutter Assembly Air Filters 55-56 Instrumentation Separator Tank Assembly 58-60 Air & Oil Piping 61-66 Decals 67-71 xhp900cm.doc (41) 07/18/01...
  • Page 42 7/18/2001...
  • Page 43 ENCLOSURE ITEM PART NUMBER DESCRIPTION 36892677 Latch (4) 43211820 Door Pull (4) 43213446 Door Catch Assembly (2) (See next page for detail) xhp900cm.doc 7/18/2001...
  • Page 44 ENCLOSURE F, G ITEM PART NUMBER DESCRIPTION 43213032 Bracket, Catch 43213024 Catch Arm 43213040 Spring 36785327 Screw, Pivot 36769032 Nut Lkg. 35144328 Screw (2/Catch Assy) 35144492 Nut (2/Catch Assy) xhp900cm.doc 7/18/2001...
  • Page 45 (see Dwg. 36735967 for parts breakdown) Check Valve 36843720 Gasket (2) 95225116 Bolt (8) 35376094 Washer (8) 11A5G8 Support RH 43212026 Support LH (Opposite Side) 43212018 Bolt (7) 35375591 Bolt (4) 35252568 Nut (4) 35252618 Switch, Disch. Temp. 36790780 xhp900cm.doc 7/18/2001...
  • Page 46 AIR END B C D ITEM PART NUMBER DESCRIPTION 43211937 Plate A/E Support 95934386 Bolt (4) 95935011 Washer (4) 95922928 Nut (4) 35375377 Bolt (4)(Plate to A/E-not shown) 43212059 Discharge Pipe 43212042 Flange, Air Inlet xhp900cm.doc 7/18/2001...
  • Page 47 Bushing 35288893 Pivot Bolt 95934998 Washer 95923314 35264951 Control Lever 35607910 Lever 35300532 Rod End 95926028 Nut Jam 95934626 Bolt 95923330 95934907 Washer 35605799 Adjusting Rod 35145077 35605799 Spring 35375963 Bolt (8) 36884112 Valve, Butterfly 36754059 Gasket (2) xhp900cm.doc 7/18/2001...
  • Page 48 7/18/2001...
  • Page 49 7/18/2001...
  • Page 50 7/18/2001...
  • Page 51 COOLING FAN ITEM PART NUMBER DESCRIPTION 43211713 Fan, 36” 43211614 Hub, Drive 35103852 Bushing 35321108 Screw (6) Fan to Hub (Not shown) xhp900cm.doc 7/18/2001...

  • Page 52: Cooling Fan

    COOLING FAN ITEM PART NUMBER DESCRIPTION 36870004 Fan Guard 35374834 Screw (6) 36895746 Nutsert (6) in End Panel xhp900cm.doc 7/18/2001...
  • Page 53 COOLING FAN ITEM PART NUMBER DESCRIPTION 43212356 Guard, RH 43212364 Guard, LH (Opposite side shown) 43212372 Guard, Center 35144344 Bolt (4) 35145077 Nut (4) 36763670 Bolt (4) 36898450 Spacer (2) Cut in Half for Correct Length xhp900cm.doc 7/18/2001...

  • Page 54: Oil Cooler

    OIL COOLER ITEM PART NUMBER DESCRIPTION 43211739 Oil Cooler 35252758 Bolt (8) 3252618 Nut (8) xhp900cm.doc 7/18/2001...

  • Page 55: Shutter Assembly

    SHUTTER ASSEMBLY ITEM PART NUMBER DESCRIPTION 43212273 Shutter Assembly 43211978 Spring (2) 95942603 Screw SS (4) 95923124 Nut (4) xhp900cm.doc 7/18/2001...
  • Page 56 Air Filter 35384619 Element Primary 35384627 Element Safety 35384635 Cover 35384650 Gasket 35380856 Wingnut (cover) 35380864 Retainer (cover) 35380815 Wingnut (primary) 35384643 Nut Assembly (safety) 35380823 Valve Vacuator 35803147 Mounting Band (4) 35144344 Bolt (8) 35145077 Nut (8) xhp900cm.doc 7/18/2001...

  • Page 57: Air Filters

    G H J ITEM PART NUMBER DESCRIPTION 43211986 Plenum 35135300 Elbow (2) 35161025 Clamp (4) 35112630 Elbow (2) 35119858 Clamp (4) 36794964 Tube 95956199 Elbow 1/8p x 45 95287629 Adapter 1/8p x 4 35291269 Hose – 4 (to indicator) xhp900cm.doc 7/18/2001...

  • Page 58: Instrumentation

    INSTRUMENTATION ITEM PART NUMBER DESCRIPTION 36841468 Gauge, Disch. Pressure 36765790 Gauge, Disch. Temperature 35107390 Indicator, Service – Air Cleaners 35107408 Flange 95287629 Adapter Hose (in back of Flange) 35144328 Screw (2) 35144492 xhp900cm.doc 7/18/2001...

  • Page 59: Separator Tank Assembly

    Separator Tank & Cover Assembly 36762250 Element, Separator 95935201 Bolt, Cover to Tank (12) 43204742 Bracket, Tank (2) 35802933 Plug, Oil Filter 36860468 Fittings, Sight Glass 35324649 Gasket, Sight Gauge 36845444 Tube, Sight Gauge 36877793 Bolt (4) 36879203 Nut (4) xhp900cm.doc 7/18/2001...
  • Page 60 SEPARATOR TANK ASSEMBLY B, C ITEM PART NUMBER DESCRIPTION 35596733 Safety Valve 95953410 95928040 Nipple (Tee to Tank) 95953949 Bushing 36865756 Switch, Temperature 95944104 Elbow, 90° ° ° ° ST 36762821 Nipple 35261155 Clamp 36764868 Pipe xhp900cm.doc 7/18/2001...
  • Page 61 SEPARATOR TANK ASSEMBLY ITEM PART NUMBER DESCRIPTION 36762268 Minimum Pressure Valve 36893220 Flange, Adapter 95951398 Bushing, Reducing 95091625 Nipple, 2” NPT 35602473 Ball Valve, 2” NPT 95358040 O-Ring xhp900cm.doc 7/18/2001...
  • Page 62 7/18/2001...
  • Page 63 7/18/2001...
  • Page 64 7/18/2001...
  • Page 65 OIL PIPING B, C ITEM PART NUMBER DESCRIPTION 43212992 Bracket, Oil Temp. Bypass Valve 35261155 Clamp (2x) 95094306 Washer (4x) xhp900cm.doc 7/18/2001...

  • Page 66: Air & Oil Piping

    C D E ITEM PART NUMBER DESCRIPTION 36842532 Bracket, Blowdown Valve 35134550 Screw Tapping (2) 95934618 Bolt (2-Bldn valve to brkt) 95935037 Washer (2-Bldn valve to brkt) 35145077 Nut (2-Bldn valve to brkt) 35166404 U-Bolt (2) 35144492 Nut (4) xhp900cm.doc 7/18/2001...
  • Page 67 AIR PIPING ITEM PART NUMBER DESCRIPTION 36842565 Bracket 35166404 U-Bolt 35144492 Nut (2) xhp900cm.doc 7/18/2001...

  • Page 68: Decals

    DECALS ITEM PART NUMBER DESCRIPTION 43212349 Interface Markings Decal 43212604 Warning/Notice: Door Under Pressure 36534832 Service Decal 36522035 Warning: Improper Operation 36520310 Notice: Dropping 36522050 Warning: Rotating Fan (2) 36513026 Lift Decal (4) xhp900cm.doc 7/18/2001...
  • Page 69 DECALS ITEM PART NUMBER DESCRIPTION 36532018 Danger/Warning: 3 part Decal 36534956 Oil Fill Decal (this location) 36512739 Oil Level Decal 36535185 Pro-Tec Lubricant Decal (this location) 36534840 Extended Warranty (this location) xhp900cm.doc 7/18/2001...
  • Page 70 DECALS ITEM PART NUMBER DESCRIPTION 36522290 Safety Card 43215102 General Data Decal xhp900cm.doc 7/18/2001...
  • Page 71 DECALS ITEM PART NUMBER DESCRIPTION 36522050 Warning: Rotating Fan (2) DECALS xhp900cm.doc 7/18/2001...
  • Page 72 ITEM PART NUMBER DESCRIPTION 36527810 I-R Signature (1 ea. Side)) xhp900cm.doc 7/18/2001...

  • Page 73: Section 11

    ¾”-10 UNC-2A x 2 ½” Hex Head 35A2D382 ¾”-10 UNC-2A x 3” Hex Head 35A2D384 ¾”-10 UNC-2A x 3 ½” Hex Head Whiz-Lock® is a Registered T.M. of MacLean-Fogg Nut Co. (Alternate Suppliers are Acceptable for this Part Number) xhp900cm.doc 7/18/2001...
  • Page 74 SAE/Inch Capscrews Grade Identification *Due to their material and hardness, grade 8 capscrews are not suitable for use on the pressurized air systems on an Ingersoll-Rand Portable Air Compressor. On uses other than pressure application, grade 8 capscrews are acceptable. xhp900cm.doc...
  • Page 75 *Due to the material and hardness, class 10.9 and 12.9 capscrews are not suitable for use on the pressurized air systems on an Ingersoll-Rand Portable Air Compressor. On uses other than pressure applications, class 10.9 and 12.9 capscrews are acceptable.
  • Page 77 (77) 07/18/01...

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