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