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Ingersoll-Rand XHP1070WCAT User manual

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1()
Book 22087159 (05/02)
OPERATING, MAINTENANCE,
PARTS MANUAL
COMPRESSOR MODELS
!
Portable Power
P.O. Box 868 – 501 Sanford Ave
Mocksville, N.C. 27028
XHP1070WCAT (25/300)
XHP1170WCAT (25/330)
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.
Code:
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)
2()
Book 22087159 (05/02)
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.
3()
Book 22087159 (05/02)
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:
4()
Book 22087159 (05/02)
H. Seddon, Q.A. Manager
Ric Lunsford
Manager of quality control
Declare that, under our sole responsibility for manufacture and supply, the product(s)
Declaration of Conformity
WITH EC DIRECTIVE
We
98/37/EC
Ingersoll–Rand Company
P.O. Box 868
501 Sanford Avenue
Mocksville, North Carolina 27028
Ingersoll–Rand Company Limited
Swan Lane, Hindley Green
Wigan WN2 4EZ
United Kingdom
Represented In EC By:
To which this declaration relates, is (are) in conformity with the provisions of the above
directives using the following principal standards
Issued at Mocksville on 1–1–95 Issued at Hindley Green on 1–1–95
EN1012–1, EN29001, EN292, EN60204–1, PN8NTC2, EN 50081, EN50082
________________________________ ________________________________
89/336/EEC
HP1300WCU
XP1400WCU
P1600WCU
XP900WCU
XHP900WCAT
XHP650WCAT
XHP750WCAT
XHP825WCAT
VHP825WCU
HP935WCU
XP1050WCU
HP825WCU
VHP750WCAT
VHP850WCAT
HP900WCAT
XP1000WCAT
XHP1070CAT
NXP1300WCU NHP1500WCU 10/425
XHP1170WCU
XHP1070WCU
HP1600WCU
HP1300WCU
XHP1070WCAT
XHP1170WCAT
5()
Book 22087159 (05/02)
Nothing contained in this document is intended to extend any promise, warranty or representation, expressed
or implied, regarding the Ingersoll–Rand products described herein. 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 pressure at least equal to 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.
This company accepts no responsibility for errors in translation of this manual from the original English
version.You as the customer are expected to provide certain 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 maintenance requirements of the 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 should be 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.
To enable proper maintenance records, Ingersoll–Rand provides a Noise Emission Control Maintenance Log
Book (PCD Form 685) with each compressor shipped from the factory. This Log Book contains a recommended
schedule and space so that the serviceman can note what service and maintenance was done, by whom, where,
and when.
6()
Book 22087159 (05/02)
TABLE OF CONTENTS
SECTION 1 SAFETY. . . . . . . . . . . . . .
SECTION 2 WARRANTY / REGISTRATION. . . . . . . . . . . . . .
SECTION 3 GENERAL DATA. . . . . . . . . . . . . .
SECTION 4 OPERATION. . . . . . . . . . . . . .
SECTION 5 MAINTENANCE. . . . . . . . . . . . . .
SECTION 6 LUBRICATION. . . . . . . . . . . . . .
SECTION 7 TROUBLESHOOTING. . . . . . . . . . . . . .
SECTION 8 ELECTRICAL. . . . . . . . . . . . . .
SECTION 9 SYSTEM DIAGRAMS. . . . . . . . . . . . . .
SECTION 10 PARTS ORDERING. . . . . . . . . . . . .
SECTION 11 PARTS LIST. . . . . . . . . . . . .
SECTION 12 ENGINE (operation, maintenance,. . . . . . . . . . . . . lubrication, troubleshooting)
7()
Book 22087159 (05/02)
SECTION 1–SAFETY
SAFETY PRECAUTIONS
General Information
Ensure that the operator reads and understands the
decals and consults the manuals before
maintenance or operation.
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 from the system and that
the machine cannot 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 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 when working on or near
the machine. Do not alter or modify this machine.
8()
Book 22087159 (05/02)
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 filters and
batteries which may require proper disposal when
performing maintenance and service tasks. Contact
local authorities for proper disposal of these
materials.
High Pressure Air can cause serious injury or 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 hearing loss. Always wear
hearing protection 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 source of supply or branch line
in accordance 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.
Whenever the machine is stopped, air will flow back
into the compressor system from devices or systems
downstream of the machine unless 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.
Hazardous Substance Precaution
The following substances are used in the
manufacture of this machine and may be hazardous
to health if used incorrectly.
9()
Book 22087159 (05/02)
Precaution: Avoid ingestion, skin contact and
breathing fumes for the following substances:
Antifreeze, Compressor Oil, Engine Lubricating Oil,
Preservative Grease, Rust Preventative, Diesel
Fuel and Battery Electrolyte.
The following substances may be produced during
the operation of this machine and may 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.
10()
Book 22087159 (05/02)
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.
Corrosion risk
Hot surface
Lifting point
WARNING: Electrical shock
risk
Parking brake
No open flame
Diesel fuel
No open flame
Do not operate the machine
without guard being fitted
Lifting point
WARNING –Flammable liquid
When parking use prop
stand, handbrake and wheel
chocks
Air/gas flow or Air discharge.
WARNING –Hot and harmful
exhaust gas
Tie down point
Do not breathe the
compressed air from this
machine