Ingersoll-Rand CSAXHP1070WCAT Operating & Maintenance Manual
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Ingersoll-Rand CSAXHP1070WCAT Operating & Maintenance Manual

Ingersoll-Rand CSAXHP1070WCAT 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
Book: 23012958 (2-16-07) Rev. A
Compressor Models
CSA XHP1070WCAT
Code: B

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Summary of Contents for Ingersoll-Rand CSAXHP1070WCAT

  • Page 1 Operating & Maintenance Manual Compressor Models CSA XHP1070WCAT Code: B 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.

  • 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 Reassembly ..............48 Compressor Oil Separator Element .
  • Page 5 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE...
  • Page 6 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 7: Foreword

    Foreword Book: 23012958 (2-16-07) 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 **Always use Ingersoll-Rand Replacement parts!** Book: 23012958 (2-16-07) Rev. A...

  • Page 11: Safety

    Safety Book: 23012958 (2-16-07) 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: • brake lining dust • 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: Transport

    Operating & Maintenance Manual Safety Transport When loading or transporting machines ensure that the specified lifting and tie down points are used. When loading or transporting machines ensure that the towing vehicle, its size, weight, towing hitch and electrical supply are all suitable to provide safe and stable towing at speeds either, up to the legal maximum for the country in which it is being towed or, as specified for the machine model if lower than the legal maximum.

  • Page 17: Decals

    Safety Operating & Maintenance Manual 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 18 Operating & Maintenance Manual Safety 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 19: General Data

    General Data Book: 23012958 (2-16-07) Rev. A...
  • Page 20 Operating & Maintenance Manual General Data General Data MODELS XHP1070BWCAT Air Delivery - cfm (litres/sec) 1070 (505) COMPRESSOR Rated Operating Pressure - psi (kPa) 350 (2400) ENGINE (Diesel) Manufacturer Caterpillar Model 3406TA Full Load Speed - rpm 1800 No Load Speed - rpm 1350 Electrical System 24VDC...
  • Page 21 General Data Operating & Maintenance Manual RUNNING GEAR Low Speed Tire Size/Load Range 8.25 x 15TR Load Range “F” Inflation Pressure (cold) psi (kPa) 105 (720) Towing Speed (Maximum) mph (km/hr) 20 (32) CAUTION Any departure from the specifications may make this equipment unsafe. Book: 23012958 (2-16-07) Rev.
  • Page 22 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 23: Operating Instructions

    Operating Instructions Book: 23012958 (2-16-07) 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. Compressor Disch. Pressure Gauge: Indicates pressure in receiver tank, normally from 0 psi (kPa) to the rated pressure of the machine.

  • Page 25: Lifting Unit

    Operating Instructions Operating & Maintenance Manual 7. Hourmeter: Records running time for maintenance purposes. 8. Voltmeter: Indicates battery condition. 9. Engine Water Temperature Gauge: Indicates coolant temperature with normal operating range from 180°F (82°C) to 210°F (99°C). 10. Power Switch: Flip “ON” to operate, “OFF” to stop. 11.

  • Page 26: Before Towing

    Operating & Maintenance Manual Operating Instructions Before Towing Ensure that the tires, wheels and running gear are in good condition and secure. Towing Do not tow this unit in excess of 20 mph (32km/hr). Use a tow vehicle whose towing capacity is greater than the gross weight of this unit.

  • Page 27: Before Starting

    Operating Instructions Operating & Maintenance Manual Air hose restraining cable installation: Secure hose restraining cable at each end to prevent accidental hose whipping. At the machine-side of the air hose, install and secure one end of the hose restraining cable on the 3”...
  • Page 28 Operating & Maintenance Manual Operating Instructions WARNING Do not remove the cap from a HOT engine radiator. The sudden release of pressure from a heated cooling system can result in a loss of coolant and possible severe personal injury. WARNING Hot pressurized fluid can cause serious burns.

  • Page 29: Starting

    Operating Instructions Operating & Maintenance Manual NOTE: This machine will not allow engine starting if the fuel level is below the minimum fuel shut off level. WARNING This machine produces loud noise with doors open. Extended exposure to loud noise can cause hearing loss. Wear hearing protection when doors or valve(s) are open.

  • Page 30: Normal Operation

    Operating & Maintenance Manual Operating Instructions CAUTION Ether is an extremely volatile, high flammable gas. Use Sparingly! If too much is injected, the uncontrolled explosion may result in costly damage to the engine. 4. In cold weather, as required, press the ETHER INJECT button once or twice only while the engine is cranking.

  • Page 31: Stopping

    Operating Instructions Operating & Maintenance Manual Stopping • Close air service valve(s). • Allow the unit to run at “IDLE” for 3 to 5 minutes to reduce the engine temperatures. • Turn the keyswitch to the “OFF” position. NOTICE Failure to allow turbo cool down prior to stopping can cause turbocharger damage.

  • Page 32: Pressure Regulation

    Operating & Maintenance Manual Operating Instructions Pressure Regulation Normally, regulation requires no adjusting; but if proper adjustment is lost, proceed as follows: Before Starting Unit - 1. WITH UNIT STOPPED, disconnect rod end bearing on governor cable (GC) at engine governor lever. 2.
  • Page 33 Operating Instructions Operating & Maintenance Manual 10. Take slack out of spring (G) by moving nuts (E) and (F). Tighten nuts. 11. Start unit and allow to warm up for 3 to 5 minutes. 12. The target pressure is 50 to 80 psi while operating at start pressure. 13.
  • Page 34 **Always use Ingersoll-Rand Replacement parts!** Book: 23012958 (2-16-07) Rev. A...

  • Page 35: Trouble Shooting

    Trouble Shooting Book: 23012958 (2-16-07) Rev. A...

  • Page 36: 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 37: Trouble Shooting Chart

    Trouble Shooting Operating & Maintenance Manual 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 38 Operating & Maintenance Manual Trouble Shooting 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 39 Trouble Shooting Operating & Maintenance Manual 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 40 **Always use Ingersoll-Rand Replacement parts!** Book: 23012958 (2-16-07) Rev. A...

  • Page 41: Maintenance

    Maintenance Book: 23012958 (2-16-07) Rev. A...
  • Page 42 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 43 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 44: 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 45: 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 46: Protective Shutdown System

    Operating & Maintenance Manual Maintenance • warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen. Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:- •...

  • Page 47: 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.

  • Page 48: 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 49: 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 50: 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 51: 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 52: 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.

  • Page 53: 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. WARNING DO NOT, under any circumstances, remove any drain plugs or the oil filler-plug from the compressor lubricating and cooling system...
  • Page 54 **Always use Ingersoll-Rand Replacement parts!** Book: 23012958 (2-16-07) Rev. A...

  • Page 55: Lubrication

    Lubrication Book: 23012958 (2-16-07) 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 Llitre) Preferred Fluids IR Pro-Tec™...
  • Page 59 © 2004 Ingersoll-Rand Company, Printed in the USA...

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