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

Ingersoll-Rand CSA 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
Book: 23010598 (2-16-07) Rev. A
Compressor Model
CSA XHP900WCAT
Code: A

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  • Page 1 Operating & Maintenance Manual Compressor Model CSA XHP900WCAT Code: A 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 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 Reassembly ..............46 Ventilation .
  • Page 5 **Always use Ingersoll-Rand Replacement parts!**...
  • Page 6 TABLE OF CONTENTS Operating & Maintenance Manual TITLE PAGE...

  • Page 7: Foreword

    Foreword Book: 23010598 (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: 23010598 (2-16-07) Rev. A...

  • Page 11: Safety

    Safety Book: 23010598 (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: 23010598 (2-16-07) Rev. A...
  • Page 20 Operating & Maintenance Manual General Data General Data MODELS XHP900CWCAT Air Delivery - cfm (litres/sec) 900 (425) COMPRESSOR Rated Operating Pressure - psi (kPa) 350 (2400) ENGINE (Diesel) Manufacturer Caterpillar Model 3406TA Electrical System 24VDC Full Load Speed - rpm 1800 No Load Speed - rpm 1200...
  • Page 21 General Data Operating & Maintenance Manual SERVICE PARTS Part Number Description 36860336 ....... Compressor Oil Filter Element 22402242 ......Compressor Oil Separator Element 36864361 ....... Air Cleaner Element (Outer) 36864379 ....... Air Cleaner Element (Inner) 36864361 ......Engine Cleaner Element (Outer) 36864379 .......
  • Page 22 **Always use Ingersoll-Rand Replacement parts!**...

  • Page 23: Operating Instructions

    Operating Instructions Book: 23010598 (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 Discharge Pressure Gauge: Indicates pressure in receiver tank, normally from 0 psi (kPa) to the rated pressure of the machine.

  • Page 25: Before Towing

    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: Set-Up

    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 Disconnect Engage parking brakes and chock wheels of both tow vehicle and compressor. Stand aside while: • Withdraw pin, swing jack down and fully insert pin to lock in down position. • Disconnect safety chains from tow vehicle. •...

  • Page 28: Before Starting

    Operating & Maintenance Manual Operating Instructions Before Starting All checks should be made while unit is level. • Open service valve(s) to ensure pressure is relieved in receiver-separator system. • Close valve(s) in order to build up full air pressure and ensure proper oil circulation. •...
  • Page 29 Operating Instructions Operating & Maintenance Manual Check coolant to assure coolant level by removing the radiator top cap and looking for coolant in the filler neck of the radiator. Add coolant as required. Insure that radiator cap is installed properly and tightened. Check engine coolant level on coolant recovery bottle on inside of rear door.

  • Page 30: Starting

    Operating & Maintenance Manual Operating Instructions • Close the side doors to maintain a cooling air 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. •...

  • Page 31: In Cold Weather

    Operating Instructions Operating & Maintenance Manual 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. In cold weather: In cold weather, as required, press the ETHER INJECT button once or twice only while the engine is cranking.

  • Page 32: Equipment Protection

    Operating & Maintenance Manual Operating Instructions CAUTION Never allow the unit to sit stopped with pressure in the receiver-separator system. As a precaution, open the service valve. WARNING Even after pressure is relieved from the piping system, any air supply line from the compressor to a tool or machine could remain under pressure and cause serious personal injury or death.
  • Page 33 Operating Instructions Operating & Maintenance Manual Automatic Shutdown/Diagnostics Should any of these problem situations occur, the unit will automatically shutdown and stop. BEFORE restarting the unit or flipping the POWER switch to “OFF”, check the DIAGNOSTICS area on the instrument panel. In a shutdown situation, the function of the panel lamps is to indicate what specific failure caused the unit to shutdown.

  • Page 34: Pressure Regulation

    Operating & Maintenance Manual Operating Instructions Pressure Regulation Adjustment Instructions Normally, regulation requires no adjusting; but if proper adjustment is lost, proceed as follows: The operating pressure of this unit was set at the factory to the maximum rating (at full speed). See General Data.
  • Page 35 Operating Instructions Operating & Maintenance Manual 11. With service air valve closed, adjust pressure regulator (PR) to rated pressure (*) plus 10 psi (70 kPa) as follows: 12. Loosen locknut (M) counterclockwise. Turn adjustment cap (N) clockwise to increase pressure, counterclockwise to decrease pressure. 13.
  • Page 36 **Always use Ingersoll-Rand Replacement parts!** Book: 23010598 (2-16-07) Rev. A...

  • Page 37: Maintenance

    Maintenance Book: 23010598 (2-16-07) Rev. A...
  • Page 38 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 39 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 40: 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 41: 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 42: 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 43: 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 44: 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 45: 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 46: 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 47: 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 48: 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 49: 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 50 **Always use Ingersoll-Rand Replacement parts!** Book: 23010598 (2-16-07) Rev. A...

  • Page 51: Lubrication

    Lubrication Book: 23010598 (2-16-07) Rev. A...

  • Page 52: 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 53: Trouble Shooting

    Trouble Shooting Book: 23010598 (2-16-07) Rev. A...

  • Page 54: 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 55: Double Check Before Disassembly

    Trouble Shooting Operating & Maintenance Manual C. Double Check Before Disassembly The source of most compressor troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a compressor can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly.

  • Page 56: 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 10 Engine Water Temp.
  • Page 57 Trouble Shooting Operating & Maintenance Manual 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 58 Operating & Maintenance Manual Trouble Shooting Incorrect Linkage Adjustment Make adjustment per Section 4. Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve. Make adjustment per Section 4. Wrong Air Filter Element Install correct element. 10. Short Air Cleaner Life: Dirty Operating Conditions Move unit to cleaner environment.
  • Page 59 © 2004 Ingersoll-Rand Company, Printed in the USA...

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