Ingersoll-Rand XHP1170 FRAME CAT Operating & Maintenance Manual
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Ingersoll-Rand XHP1170 FRAME CAT Operating & Maintenance Manual

Ingersoll-Rand XHP1170 FRAME CAT 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.
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.
Utility Equipment
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
Book: 22878086 (3-29-07) Rev. A
Revised (10-12)
Compressor Models
XHP1170 FRAME CAT
Code:

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Summary of Contents for Ingersoll-Rand XHP1170 FRAME CAT

  • Page 1 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 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: Table Of Contents

    TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE FOREWORD ............. . 7 SAFETY .
  • Page 4 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE lnspection ..............46 Reassembly .
  • Page 5 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE Figure 8-1 Harness System Schematic Figure 8-2 Wedge to Engine Interface Figure 8-3 Can Communication Figure 8-4 Control System Schematic Diagram...
  • Page 6 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 7: Foreword

    Foreword Book: 22878086 (3-29-07) Rev. A...
  • Page 8 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.
  • Page 9 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.
  • Page 10 Operating & Maintenance Manual Foreword **Always use Ingersoll-Rand Replacement Parts** Book: 22878086 (3-29-07) Rev. A...

  • Page 11: Safety

    Safety Book: 22878086 (3-29-07) Rev. A...

  • Page 12: Safety Precautions

    Operating & Maintenance Manual Safety Safety Safety Precautions General Information Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

  • Page 13: Compressed Air

    Safety Operating & Maintenance Manual Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, blow gun tips, etc. well away from moving parts. Compressed Air Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.

  • Page 14: Materials

    Operating & Maintenance Manual Safety Materials The following substances may be produced during the operation of this machine: • engine exhaust fumes WARNING Avoid inhalation Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times.

  • Page 15: Battery

    Safety Operating & Maintenance Manual This machine may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authorities for proper disposal of these materials. Battery A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive.

  • Page 16: Decals

    Operating & Maintenance Manual Safety Decals Decals are located on the machine to point out potential safety hazards. Read and follow these instructions. If you do not understand the instructions, inform your supervisor. Note that there are different decal headings: DANGER (Red Background) Indicates the presence of a hazard which WILL cause serious injury,...
  • Page 17 Safety Operating & Maintenance Manual 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.
  • Page 18 Operating & Maintenance Manual Safety **Always Use Ingersoll-Rand Replacement Parts** Book: 22878086 (3-29-07) Rev. A...

  • Page 19: General Data

    General Data Book: 22878086 (3-29-07) Rev. A...
  • Page 20 Operating & Maintenance Manual General Data General Data MODELS XHP1070CWCAT XHP1170AWCAT Air Delivery - cfm (litres/sec) 1070 (505) 1170 (553) COMPRESSOR Rated Operating Pressure - psi 150-350 (1034- 150-350 (1034- (kPa) 2412) 2412) ENGINE (Diesel) Manufacturer Caterpillar Caterpillar Model Rated Horsepower at 1800 rpm Electrical System 24VDC 24VDC...
  • Page 21 General Data Operating & Maintenance Manual EXPENDABLE SERVICE PARTS Part Number Description Where Used Quantity 36860336 ....... Filter, Oil ........Airend ....... 2 36762250 ......Separator, Oil HP ....... Airend ....... 1 36864361 ....... Filter, Inlet Primary ..... Engine & AE inlet ....2 36864379 .......
  • Page 22 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 23: Operating Instructions

    Operating Instructions Book: 22878086 (3-29-07) Rev. A...

  • Page 24: Operating Controls And Instruments

    Operating & Maintenance Manual Operating Instructions Operating Instructions Operating Controls and Instruments The operating controls and instruments are arranged on the control panel as shown above. A description of each panel device is as follows: 1. Panel Light: Illuminates instrument and control panel. Controlled by Switch 14. 2.
  • Page 25 Operating Instructions Operating & Maintenance Manual 7. Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to dirty IQ air filters (if equipped). 8. Low Fuel Level: NA 9. Compressor Malfunction: Fault indicator lamp. Indicates shutdown due to compressor system fault. Refer to Fault Code List. 10.

  • Page 26: Lifting Unit

    It is necessary to isolate the compressor package from the carrier base with a flexible mounting system. Such a system must also prevent detachment of the package from the carrier base in the event the isolators fail. Contact Ingersoll-Rand representative for flexible mounting kits.
  • Page 27 Operating Instructions Operating & Maintenance Manual WARNING Unrestricted air flow from a hose will result in a whipping motion of the hose which can cause serious injury or death. A safety device must be attached to the hose at the source of supply to reduce pressure in case of hose failure or other sudden pressure release.

  • Page 28: Before Starting

    Operating & Maintenance Manual Operating Instructions Before Starting Open manual blowdown valve to ensure the separator has been vented of all pressure. Close the valve before starting. Inspect the complete installation including remote fuel lines (if any) and air hose routing and connections.
  • Page 29 Operating Instructions Operating & Maintenance Manual NOTE: This machine will not allow engine starting if engine coolant is low. NOTICE If the appropriate mixture of antifreeze is not used during freezing temperatures, failure to drain the engine may cause costly engine damage.

  • Page 30: Starting

    Operating & Maintenance Manual Operating Instructions Starting NOTICE This unit is equipped with a battery disconnect switch which removes power from the machine controller for long term storage. The switch is located on the side of the engine near the battery. This switch must be turned ON to provide power to the control panel for starting this unit.

  • Page 31: Normal Operation

    Operating Instructions Operating & Maintenance Manual Normal Operation The Operator may observe and monitor operating parameters using the gages on the panel. In the event the machine controller detects a parameter outside normal operating limits, the unit will shutdown. In the event the machine controller detects a parameter at a dangerously high or low level, the machine will be automatically be stopped with the cause of the SHUTDOWN shown on the diagnostic lights and display.

  • Page 32: Air Aftercooler Option

    Operating & Maintenance Manual Operating Instructions Air Aftercooler Option The optional Aftercooling System is a complete, self-contained system which provides cooler, dryer air than from a standard portable compressor. The system utilizes an integral aftercooler, and a liquid, condensate separation system to provide the cool air. The condensate handling system directs all liquid condensed from the moisture separator into a common drain port for customer routing and disposal.

  • Page 33: Theory Of Operation

    Operating Instructions Operating & Maintenance Manual Theory of Operation The compressed air exits the separator tank through the top cover piping, and can then travel along one of two paths, selectable via a three way manual positioned valve. One path allows Standard Operation, which bypasses the aftercooler, and delivers air quality equivalent to a standard oil-flooded portable compressor.
  • Page 34 Operating & Maintenance Manual Operating Instructions Daily Maintenance: Observe the discharge from the condensate line when operating the aftercooler. If water and or air are not discharging, shut down the unit and remove the cause for obstruction. Weekly Maintenance: • Remove Y-strainer screens at the bottom of the moisture separator and both filters and clean out any residue.

  • Page 35: Pressure Regulation

    Operating Instructions Operating & Maintenance Manual Pressure Regulation Normally, regulation requires no adjusting; but if proper adjustment is lost, proceed as follows: Adjustment Instructions (for XHP units with Tier II and Tier III Electronic Control Caterpillar Engines. The operating pressure of this unit was set at the factory to the maximum rating (at full speed). See General Data.
  • Page 36 Operating & Maintenance Manual Operating Instructions Start unit and monitor separator tank pressure. 11. The target pressure is 50 to 80 psi while operating at start pressure. 12. If the pressure exceeds 80 psi: Loosen jam nut (H) , turn rod (L) 1/4 to 1/2 turn CCW (as viewed from rod end) to lightly close butterfly, and secure jam nut (H).
  • Page 37 Operation of the Air Inlet Shutoff Valve The air inlet shutoff valve will close if the engine speed reaches 2100 rpm in normal operation. After engine shutdown, the Wedge controller will display engine fault code 35 - Engine Overspeed Shutdown. Reset the ECM and the air inlet valve before attempting to restart the engine.
  • Page 38 Operating & Maintenance Manual Operating Instructions Book: 22878086 (3-29-07) Rev. A...

  • Page 39: Maintenance

    Maintenance Book: 22878086 (3-29-07) Rev. A...
  • Page 40 Operating & Maintenance Manual Maintenance Maintenance Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months 500 hrs. 1000 hrs. /850 km 2000 hrs. Compressor Oil Level Engine Oil Level *Radiator Coolant Level Gauges/Lamps *Air Cleaner Service Indicators Fuel Tank (Fill at end of day) *Fuel/Water Separator Drain Oil Leaks Fuel Leaks...
  • Page 41 Maintenance Operating & Maintenance Manual Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months Months 500 hrs. 1000 hrs /850 km 2000 hrs 3000 hrs *Fue/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease.

  • Page 42: Routine Maintenance

    Operating & Maintenance Manual Maintenance Initial 3 Months 6 Months 500 miles Daily Weekly Monthly Months 500 hrs. 1000 hrs /850 km 2000 hrs Scavenge line * Engine breather element Separator tank (2) exterior *Lubricator (Fill) 2 Yrs 4 Yrs 6 Yrs Safety valve Hoses...

  • Page 43: Prior To Attempting Any Maintenance Work, Ensure That

    Maintenance Operating & Maintenance Manual Prior to attempting any maintenance work, ensure that:- • all air pressure is fully discharged and isolated from the system. If the automatic blowdown valve is used for this purpose, then allow enough time for it to complete the operation.

  • Page 44: Protective Shutdown System

    Operating & Maintenance Manual Maintenance Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:- • the machine is suitably tested. • all guards and safety protection devices are refitted. • all panels are replaced, canopy and doors closed. •...

  • Page 45: Compressor Oil Filter

    Maintenance Operating & Maintenance Manual Compressor Oil Filter Refer to the MAINTENANCE CHART in this section for the recommended servicing intervals. Removal WARNING Do not remove the filter(s) without first making sure that the machine is stopped and the system has been completely relieved of all air pressure. (Refer to STOPPING THE MACHINE in the OPERATING INSTRUCTIONS section of this manual) Clean the exterior of the filter housing and remove the spin-on element.

  • Page 46: Reassembly

    Operating & Maintenance Manual Maintenance Reassembly Clean the filter gasket contact area and install the new element.Tighten until the gasket makes contact with the filter housing. Tighten an additional 1/2 to 3/4 of a revolution. CAUTION Start the machine (refer to PRIOR TO STARTING and STARTING THE MACHINE in the OPERATING INSTRUCTIONS section of this manual) and check for leakage before the machine is put back into service.

  • Page 47: Reassembly

    Maintenance Operating & Maintenance Manual Reassembly Thoroughly clean the orifice/drop tube and filter gasket contact area before reassembly. Install the new element. WARNING DO not remove the staple from the anti-static gasket on the separator element since it serves to ground any possible static build-up. Do not use gasket sealant since this will affect electrical conductance.

  • Page 48: Air Filter Elements

    Operating & Maintenance Manual Maintenance WARNING Follow the instructions provided by the antifreeze supplier when adding or draining the antifreeze solution. It is advisable to wear personal protective equipment to prevent skin and eye contact with the antifreeze solution. Air Filter Elements The air filter element should be replaced regularly (refer to the MAINTENANCE CHART) or when the restriction indicator shows red, whichever comes first.

  • Page 49: Fuel System

    Maintenance Operating & Maintenance Manual Fuel System The fuel tank should be filled daily or every eight hours. To minimise condensation in the fuel tank(s), it is advisable to top up after the machine is shut down or at the end of each working day.

  • Page 50: Pressure System

    Operating & Maintenance Manual Maintenance Pressure System Regularly, it is necessary to inspect the external surfaces of the system (from the airend through to the discharge valve(s)) including hoses, tubes, tube fittings and the separator tank, for visible signs of impact damage, excessive corrosion, abrasion, tightness and chafing. Any suspect parts should be replaced before the machine is put back into service.

  • Page 51: Compressor Lubricating Oil

    Maintenance Operating & Maintenance Manual Compressor Lubricating Oil Refer to the MAINTENANCE CHART in this section for service intervals. NOTE: If the machine has been operating under adverse conditions, or has suffered long shutdown periods, then more frequent service intervals will be required.
  • Page 52 Torque Values **Always use Ingersoll-Rand Replacement parts!** Book: 22878086 (3-29-07) Rev. A...
  • Page 53 Maintenance Operating & Maintenance Manual TABLE 3 Wheel Torque Chart - Inch Wheel Torque Chart - Metric 1/2” lug nuts Torque (ft-lbs) Torque Torque (n-M) (ft-lbs) 13” Wheel 80-90 15” Wheel 105-115 M12 Bolts 85-95 62-70 16” Wheel 105-115 M14 Bolts 145-155 107-115 16.5”...
  • Page 54 Operating & Maintenance Manual Maintenance Book: 22878086 (3-29-07) Rev. A...

  • Page 55: Lubrication

    Lubrication Book: 22878086 (3-29-07) Rev. A...

  • Page 56: General Information

    Maintenance Section. All filters and filter elements for air and compressor lubricant must be obtained through Ingersoll-Rand to assure the proper size and filtration for the compressor. Compressor Oil Change These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit for approximately 6 months or 1000 hours, whichever comes first.
  • Page 57 Add oil in the specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil. Check the oil level. DO NOT OVERFILL. NOTICE Ingersoll-Rand provides compressor oil specifically formulated for Portable Compressors and requires the use of these fluids in order to obtain extended limited airend warranty.

  • Page 58: Portable Compressor Fluid Chart

    Preferred: XHP605 IR XHP1001 Preferred Ingersoll-Rand Fluids - Use of these fluids with original I-R filters can extend airend warranty. Refer to operator’s manual warranty section for details or contact your I-R representative. Ingersoll-Rand 1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Litre) Preferred Fluids IR Pro-Tec™...

  • Page 59: Trouble Shooting

    Trouble Shooting Book: 22878086 (3-29-07) Rev. A...

  • Page 60: Introduction

    Operating & Maintenance Manual Trouble Shooting Trouble Shooting Introduction Trouble shooting for a portable air compressor is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The trouble shooting chart that follows includes some of the problems that an operator may encounter during the operation of a portable compressor.
  • Page 61 Trouble Shooting Operating & Maintenance Manual NOTE: General Information The WEDGE controller records and displays diagnostic fault codes for the compressor system and the electronic engine. These codes are displayed on the 4-digit LED display on the machine control panel. Two of the ten LED diagnostic lamps on the control panel are used with fault codes display.
  • Page 62 Operating & Maintenance Manual Trouble Shooting Fault Caterpillar Model C15 Engine Diagnotic Codes Code Engine Speed Signal abnormal Secondary Engine Speed Signal abnormal Engine Overspeed Warning Engine Overspeed Shutdown Fuel Pressure open/short + battery Fuel Pressure short to ground Intake Manifold Air Temperature open/short + battery Intake Manifold Air Temperature short to ground Injector Actuation Pressure Signal Erratic Injector Actuation Pressure Voltage High...
  • Page 63 Trouble Shooting Operating & Maintenance Manual Fault Caterpillar Model C15 Engine Diagnotic Codes Code High Inlet Air Temperature Warning High Inlet Air Temperature Shutdown High Fuel Temperature Warning High Fuel Temperture Derate High Fuel Temperature Shutdown Injector Cylinder #1 Fault Injector Cylinder #2 Fault Injector Cylinder #3 Fault Injector Cylinder #4 Fault...

  • Page 64: Wedge Diagnostic Display Codes

    Operating & Maintenance Manual Trouble Shooting Wedge Diagnostic Display Codes Alert/Shutdown List If the fault indicator lamp is illuminated, refer to the If the Engine Diagnostic List fault indicator lamp is illuminated, refer to the ALERT/SHUTDOWN CONDITIONS Alert Shutdown Dedicated Lights Code Light (Blinks) Code...
  • Page 65 Trouble Shooting Operating & Maintenance Manual ALERT/SHUTDOWN CONDITIONS Dedicated Lights Code Light (Blinks) Code Delay LIght (Steady) (sec). Serial Comm. Problem CPRSR Malf. CAN Bus Problem CPRSR Malf. Auto Start/Stop Module Failure - no CPRSR Malf. comm for 17 sec. Low Fuel Level fuel level fuel level...

  • Page 66: Trouble Shooting Chart

    Operating & Maintenance Manual Trouble Shooting 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 6 Engine Water Temp.
  • Page 67 Trouble Shooting Operating & Maintenance Manual 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).
  • Page 68 Operating & Maintenance Manual Trouble Shooting 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 7, 11, 12 Engine idle speed too low.
  • Page 69 **Always use Ingersoll-Rand Replacement parts!** Book: 22878086 (3-29-07) Rev. A...
  • Page 70 Operating & Maintenance Manual Trouble Shooting Book: 22878086 (3-29-07) Rev. A...

  • Page 71: Electrical

    Electrical Book: 22878086 (3-29-07) Rev. A...

  • Page 72: General Information And Operational Theory

    Operating & Maintenance Manual Electrical Electrical General Information and Operational Theory General The XHP1070/1170 machine has an electronic monitor and control system to provide discharge air pressure control and engine and package monitor functions. The system uses the WEDGE controller to perform these functions. The electrical system connects all the necessary switches, sensors and transducers to the WEDGE controller in order for it to perform the monitor and control functions.

  • Page 73: Sensors And Transducers

    Electrical Operating & Maintenance Manual Sensors and Transducers The electronics system contains sensors and transducers that are used to collect process data from the compressor. Compressor temperatures are measured by thermistors. These devices exhibits a change in resistance as the temperature changes. The resistance causes an input voltage change to the WEDGE controller input and is interpreted as a temperature change.

  • Page 74: Electronic Engine

    Operating & Maintenance Manual Electrical Electronic Engine The XHP1070/1170 machine contains an emissions certified diesel engine. In order to meet the emissions requirements, the engine has an electronic control system. The control system handles all the monitor, alarm and control functions for the engine. The WEDGE controller communicates with the engine controller over the J1939 CAN network.

  • Page 75: Trouble Shooting Flow Chart

    Electrical Operating & Maintenance Manual Trouble Shooting Flow Chart PROBLEM CHECK LIST Control panel key is turned to “ON’ Check F1 fuse position, WEDGE controller Check operation of switch S1 annuciator lamps and 4 digit LED Check wiring from S1 to WEDGE display do not come on controller Checking battery voltage, ensure...
  • Page 76 **Always use Ingersoll-Rand Replacement parts!** Book: 22878086 (3-29-07) Rev. A...

  • Page 77: Electrical Schematics

    Electrical Schematics Book: 22878086 (3-29-07) Rev. A...
  • Page 78 Operating & Maintenance Manual Electrical Schematics Book: 22878086 (3-29-07) Rev. A...
  • Page 79 Electrical Schematics Operating & Maintenance Manual Book: 22878086 (3-29-07) Rev. A...
  • Page 80 Operating & Maintenance Manual Electrical Schematics Book: 22878086 (3-29-07) Rev. A...
  • Page 81 Electrical Schematics Operating & Maintenance Manual Figure 8-4 Book: 22878086 (3-29-07) Rev. A...
  • Page 82 Book: 22878086 (3-29-07) Rev. A...
  • Page 83 © 2004 Ingersoll-Rand Company, Printed in the USA...

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