Ingersoll-Rand 25/300 XHP1070AWCAT Installation and operation manual

Operating & Maintenance Manual
Compressor Models
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.
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
Book 22481881 (12/05)
25/300
XHP1070AWCAT
XHP1070DWCAT
25/330
XHP11
XHP1170BWCAT
70WCAT
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 (10-12)

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.

22481881 1
Foreword

Operation & Maintenance Manual Foreword
222481881
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. Any
modification to any part is absolutely prohibited and would result in the CE certification and
marking being rendered invalid. A declaration of that conformity follows:

Foreword Operation & Maintenance Manual
22481881 3
25/300
25/330
XHP1070AWCAT
XHP1070DWCAT XHP1170WCAT
XHP1170BWCAT

Operation & Maintenance Manual Foreword
422481881
Nothing contained in this document is intended to extend any promise, warranty or
representation,expressedorimplied,regardingtheIngersoll-Randproductsdescribedherein.
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.
This manual contains instructions and technical data to cover all routine operation and
scheduled maintenance tasks by operation and maintenance staff. Major overhauls are
outside the scope of this manual and should be referred to an authorized Ingersoll-Rand
service department.
All components, accessories, pipes and connectors added to the compressed air system
should be:
• of good quality, procured from a reputable manufacturer and, wherever possible, be
of a type approved by Ingersoll-Rand.
• clearly rated for a pressureat least equalto the machine maximum allowable working
pressure.
• compatible with the compressor lubricant/coolant.
• accompanied with instructions for safe installation, operation and maintenance.
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.
Ingersoll-Rand reserves the right to make changes and improvements to products without
notice and without incurring any obligation to make such changes or add such improvements
to products sold previously.
The intended uses of this machine are outlined below and examples of unapproved usage are
also given. However, Ingersoll-Rand cannot anticipate every application or work situation that
may arise. If in doubt, consult supervision.
This machine has been designed and supplied for above ground operation to be used for
compression of normal ambient air containing no additional gases, vapors or particles within
the ambient temperature range specified in the general data section of this manual.
This machine should not be used:
A. For direct or indirect human consumption of the compressed air.
B. Outside the ambient temperature range specified in the general data section of
this manual.
C. When an actual or foreseeable risk of hazardous levels of flammable gases or
vapors exists.
D. With other than Ingersoll-Rand approved components.
E. With guards, or controls or switches missing or disabled.
F. For storage or transportation of materials inside or on the enclosure.

Foreword Operation & Maintenance Manual
22481881 5
This company accepts no responsibility for errors in translation of this manual from the original
Englishversion.Youas the customer areexpectedtoprovidecertain service and maintenance
items. Your Ingersoll-Rand dealer can provide all other more detailed service and
maintenance items on a special preventive maintenance schedule for each machine. It is very
important that the minimum service and maintenance requirements explained in this manual
be performed at the required intervals. Exceeding these intervals may reduce the reliability of
the machine. The purpose of this manual is to train the operator with functions, operation, and
basic service and maintenancerequirements ofthe compressor. During the preparation of this
manual, every effort was made to ensure the adequacy and accuracy of the contents.
Before starting the compressor, this manual and instructions shouldbe carefully read to obtain
a thorough knowledge of the duties to be performed. Please take pride in the compressor,
keep it clean, and in good mechanical condition.

Operation & Maintenance Manual Foreword
622481881

1 - 1
TABLE OF CONTENTS
Manual-Name
TITLE PAGE
SECTION 1 - INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
HOW THIS MANUAL IS ORGANIZED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Where To Find Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
DANGER, WARNING, CAUTION, NOTICE and NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
PROCEDURE WHEN RECEIVING THE T3W WATERWELL DRILL . . . . . . . . . . . . . . . . . . 1-5
IDENTIFICATION DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
T3W WATERWELL DRILL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
T3W WATERWELL DRILL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
DERRICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
OPERATORS CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SERVICEABILITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
STANDARD FEATURES ON T3W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
DRILL LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
SECTION 2 - SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 - SAFETY AND HEALTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
GENERAL SAFETY AND HEALTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety And Health Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 - SAFETY PRECAUTIONS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
DRILL APPLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
PERSONNEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
GENERAL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
GENERAL RULES FOR INGERSOLL-RAND DRILLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
PRE-START INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
OPERATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
MAINTENANCE SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
WARNING OF SPECIAL DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

1 - 2
TABLE OF CONTENTS
Manual-Name
TITLE PAGE
INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 - INSTRUMENTS AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
T3W INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
UPPER CONSOLE, 900/350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
UPPER CONSOLE, 1070/350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
MIDDLE CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
LOWER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
UNDER CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
HELPER'S CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
IN/OUT BOX ACTUATION CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
SERVICE PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
RECEIVER OIL LEVEL GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
HYDRAULIC TANK GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
FUEL TANK GAUGE AND FILLER CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
SECTION 6 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 - SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
MAINTENANCE SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 - MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3 - REFILL CAPACITIES AND SUBSTANCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
FILTER ELEMENTS AND KITS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
FLUID CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

22481881 1
Section A - Safety

Operation & Maintenance Manual Safety
222481881
Safety
SAFETY PRECAUTIONS
General Information
Ensure that the operator reads and
understands the decals and consults the
manuals before maintenance or operation.
NOTICE
Do not paint over safety warnings
or instructional decals. If safety
warning decals become illegible,
immediately order replacements
from the factory.
Part numbers for original individual decals
and their mounting locations are shown
withinPartsListSection.Theseareavailable
as long as a particular model is in production.
Ensure that the Operation and Maintenance
manual, and the manual holder if equipped,
are not removed permanently from the
machine.
Ensure that maintenance personnel are
adequately trained, competent and have
read the manuals.
Make sure that all protective covers are in
place and that the canopy/doors are closed
during operation.
The specification of this machine is such that
the machine is not suitable for use in
flammable gas risk areas. If such an
application is required then all local
regulations, codes of practice and site rules
must be observed. To ensure that the
machine can operate in a safe and reliable
manner, additional equipment such as gas
detection, exhaust spark arrestors, and
intake (shut-off) valves may be required,
dependent on local regulations or the degree
of risk involved.
Air discharged from this machine may
contain carbon monoxide or other
contaminants which will cause serious injury
or death. Do not breathe this air.
Compressed air can be dangerous if
incorrectly handled. Before doing any work
on the unit, ensure that all pressure is vented
fromthesystemandthatthemachinecannot
be started accidentally.
Ensure that the machine is operating at the
rated pressure and that the rated pressure is
known to all relevant personnel.
All air pressure equipment installed in or
connected to the machine must have safe
working pressure ratings of at least the
machine safety valve rating.
If more than one compressor is connected to
one common downstream plant, effective
check valves and isolation valves must be
fitted and controlled by work procedures, so
that one machine cannot accidentally be
pressurized or over pressurized by another.
Compressed air must not be used for a feed
to any form of breathing apparatus or mask.
The discharged air contains a very small
percentage of compressor lubricating oil and
care should be taken to ensure that
downstream equipment is compatible.
If the discharged air is to be ultimately
released into a confined space, adequate
ventilation must be provided.
When using compressed air, always use
appropriate personal protective equipment.
All pressure containing parts, especially
flexible hoses and their couplings, must be
regularly inspected, be free from defects and
be replaced according to the Manual
instructions.
Avoid bodily contact with compressed air.
Never operate unit without first observing all
safety warnings and carefully reading the

Safety Operation & Maintenance Manual
22481881 3
operation and maintenance manual shipped
from the factory with this machine.
Never operate the engine of this machine
inside a building without adequate
ventilation. Avoid breathing exhaust fumes
whenworkingonornearthemachine.Donot
alter or modify this machine.
A battery contains sulfuric acid and can give
off gases which are corrosive and potentially
explosive. Avoid contact with skin, eyes and
clothing. In case of contact, flush area
immediately with water.
Exercise extreme caution when using
booster battery. To jump battery, connect
ends of one booster cable to the positive (+)
terminal of each battery. Connect one end of
other cable to the negative (-) terminal of the
booster battery and other end to a ground
connection away from dead battery (to avoid
a spark occurring near any explosive gases
that may be present). After starting unit,
always disconnect cables in reverse order.
This machine may include such materials as
oil, diesel fuel, antifreeze, brake fluid, oil/air
filtersandbatterieswhichmayrequireproper
disposal when performing maintenance and
service tasks. Contact local authorities for
proper disposal of these materials.
HighPressureAircancauseseriousinjuryor
death. Relieve pressure before removing
filler plugs/caps, fittings or covers.
Air pressure can remain trapped in air supply
line which can result in serious injury or
death. Always carefully vent air supply line at
tool or vent valve before performing any
service.
This machine produces loud noise with the
doors open or service valve vented.
Extended exposure to loud noise can cause
hearingloss.Alwayswearhearingprotection
when doors are open or service valve is
vented.
Never inspect or service unit without first
disconnecting battery cable(s) to prevent
accidental starting.
Do not remove the pressure cap from a HOT
radiator. Allow radiator to cool down before
removing pressure cap.
Do not use petroleum products (solvents or
fuels) under high pressure as this can
penetrate the skin and result in serious
illness. Wear eye protection while cleaning
unit with compressed air to prevent debris
from injuring eye(s).
Disconnected air hoses whip and can cause
serious injury or death. Always attach a
safety flow restrictor to each hose at the
sourceofsupplyorbranchlineinaccordance
with OSHA Regulation 29CFR Section
1926.302(b).
Hot pressurized fluid can cause serious
burns. Do not open radiator while hot.
Rotating fan blade can cause serious injury.
Do not operate without guard in place.
Use care to avoid contacting hot surfaces
(engine exhaust manifold and piping, air
receiver and air discharge piping, etc.).
Ether is an extremely volatile, highly
flammable gas. USE SPARINGLY! Do NOT
use ETHER if unit has GLOW Plug starting
aid. Engine damage will result.
Never allow the unit to sit stopped with
pressure in the receiver-separator system.
As a precaution, open the manual blowdown
valve.
Never operate unit with guards, covers or
screens removed. Keep hands, hair,
clothing, tools, blow gun tips, etc. well away
from moving parts.
Make sure wheels, tires and tow bar
connectors are in safe operating condition
and tow bar is properly connected before
towing.
Wheneverthemachine is stopped, air will flow
backintothecompressorsystemfromdevices
orsystemsdownstreamofthemachineunless
the service valve is closed. Install a check
valve at the machine service valve to prevent
reverse flow in the event of an unexpected
shutdown when the service valve is open.

Operation & Maintenance Manual Safety
422481881
Hazardous Substance Precaution
The following substances are used in the
manufacture of this machine and may be
hazardous to health if used incorrectly.
Precaution: Avoid ingestion, skin contact
and breathing fumes for the following
substances: Antifreeze, Compressor Oil,
EngineLubricatingOil, Preservative Grease,
Rust Preventative, Diesel Fuel and Battery
Electrolyte.
The following substances may be produced
duringtheoperationofthismachineandmay
be hazardous to health:
Avoid build-up of Engine Exhaust Fumes in
confined spaces.
Avoid breathing Exhaust Fumes.
Avoid breathing Brake Lining Dust during
maintenance.

Safety Operation & Maintenance Manual
22481881 5
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 your supervisor.

Operation & Maintenance Manual Safety
622481881

Safety Operation & Maintenance Manual
22481881 7

Operation & Maintenance Manual Safety
822481881
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 your
DANGER
!
WARNING
!
CAUTION
!
NOTICE
Indicates the presence of a hazard which WILL cause
serious injury, death or property damage, if ignored.
Indicates the presence of a hazard which CAN cause
serious injury, death or property damage, if ignored.
Indicates the presence of a hazard which WILL or can
cause injury or property damage, if ignored.
Indicates important set-up, operating or maintenance
information.
(Red Background)
(Orange Background)
(Yellow Background)
(Blue Background)
supervisor.

Safety Operation & Maintenance Manual
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Operation & Maintenance Manual Safety
10 22481881