Ingersoll-Rand XHP900CM User manual

Manual No. 54771142 (7/01) (1) 07/18/01
Portable Compressor Division
P. O. Box 868
Mocksville, NC 27028
OPERATING, MAINTENANCE, PARTS
MANUAL
COMPRESSOR MODEL
XHP900CM
INGERSOLL-RAND Co. 2001 Revision A
07/2001
Revised (01-13)
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.

Manual No. 54771142 (7/01) (2) 07/18/01
QUALITY POLICY
We will supply products and services that consistently meet the
requirements of our customers and each other.

Manual No. 54771142 (7/01) (3) 07/18/01
TABLE OF CONTENTS
SECTION 1 . . . . . SAFETY
SECTION 2 . . . . . WARRANTY
SECTION 3 . . . . . WARRANTY REGISTRATION
SECTION 4 . . . . . SYSTEM DESCRIPTION
SECTION 5 . . . . . INSTALLATION
SECTION 6 . . . . . OPERATION
SECTION 7 . . . . . GENERAL DATA
SECTION 8 . . . . . MAINTENANCE/LUBRICATION
SECTION 9 . . . . . PARTS ORDERING
SECTION 10 . . . . PARTS LIST
SECTION 11 . . . . COMMON FASTENERS
SECTION 12. . . . . .DRAWINGS

Manual No. 54771142 (7/01) (4) 07/18/01
SECTION 1 - SAFETY
IMPORTANT SAFETY INSTRUCTIONS
Look for these signs 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.
(Red background)
Indicates the presence of a hazard which WILL cause
severe injury, death or property damage, if ignored.
(Orange background)
Indicates the presence of a hazard which CAN cause
severe injury, death or property damage, if ignored.
(Yellow background)
Indicates the presence of a hazard which WILL or CAN
cause injury or property damage, if ignored.
(Blue background)
Indicates important setup, operating or maintenance
information.

Manual No. 54771142 (7/01) (5) 07/18/01
Never operate unit without first observing all safety warnings and carefully reading the
operation and maintenance manual shipped from the factory with this machine.
Air discharged from this machine may contain carbon
monoxide or other contaminants which will cause severe
injury or death. Do not breathe this air.
Improper operation of this equipment CAN cause
severe injury or death. Read Operator’s Manual
supplied with this machine before operation or
service.
Modification or alteration of this machine CAN
result in severe injury or death. Do not alter or
modify this machine without the express written
consent of the manufacturer.
This machine produces loud noise with service
valve vented. Extended exposure to loud noise
can cause hearing loss. Always wear hearing
protection when service valve is vented.
WARNING
WARNING
DANGER
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. Submit orders for Safety Decals to the Mocksville Parts Service Department.
The no charge order should contain only Safety Decals. Help promote product safety! Assure
that decals are present on the machines. Replace decals that are not readable.

Manual No. 54771142 (7/01) (6) 07/18/01
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.
High pressure air.
Can cause severe 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.
Never inspect or service unit without first
relieving pressure from the air start reservoir
to prevent accidental starting.
Do not remove the pressure cap from a HOT
radiator. Allow radiator to cool down before
removing pressure cap.
Disconnected Air Hoses Whip.
Can cause severe 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).
Never run unit with guards, covers or screens
removed. Keep hands, hair, clothing, tools,
blow gun tips, etc. well away from moving parts.
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)
WARNING WARNING
WARNING
WARNING
WARNING
DANGER
DANGER

Manual No. 54771142 (7/01) (7) 07/18/01
Hot pressurized fluid.
Can cause severe burns.
Do not open radiator while hot.
Use extreme care to avoid contacting hot surfaces.
Air receiver and air discharge piping, etc.
Never allow the unit to sit stopped with pressure in
the receiver separator system. As a precaution,
open the service valve.
Rotating fan blade.
Can cause severe injury.
Do not operate without guard in
place.
Do not connect the air discharge on this unit onto a
common header with any other unit of any
description, or any other source of compressed air,
without first making sure a check-valve is used
between the header and the unit. If this unit is
connected with another unit, a safety hazard could
occur.
CAUTION
CAUTION
WARNING WARNING

Manual No. 54771142 (7/01) (8) 07/18/01
Hazardous Substance Precaution
The following substances are used in the manufacture of this machine and
may be hazardous to health if used incorrectly.
SUBSTANCE PRECAUTION
Compressor Oil Avoid ingestion, skin contact and breathing fumes.
Preservative Grease Avoid ingestion, skin contact and breathing fumes.
Rust Preventative Avoid ingestion, skin contact and breathing fumes.

Manual No. 54771142 (7/01) (9) 07/18/01
SAFETY CARD

Manual No. 54771142 (7/01) (10) 07/18/01
SECTION 2 - WARRANTY
Ingersoll-Rand, through its distributor, warrants that each item of equipment
manufactured by it and delivered hereunder to the initial user to be free of defects in
material and workmanship for a period of three (3) months from initial operation or six
(6) months from the date of shipment to the initial user, whichever first occurs.
With respect to the following types of equipment, the warranty period enumerated will
apply in lieu of the foregoing warranty period.
Aftercoolers, Drill Mountings and Klemm Rotary Heads - The earlier of six (6) months from initial
operation or nine (9) months from date of shipment to the initial user.
Portable Compressors, Portable Generator Sets (GENSET), Portable Light Towers and Abrasive
Blasting Equipment - The earlier of twelve (12) months from shipment to, or the accumulation of 2,000
hours of service by, the initial user.
All Compressor Air Ends, GENSET Generators and Paving Breakers - The earlier of twenty-four (24)
months from shipment to, or the accumulation of 4,000 hours of service by, the initial user. For Air Ends,
the warranty against defects will include replacement of the complete Air End, provided the original Air
End is returned assembled and unopened.
Pavers, Milling Machines, Pedestrian Compactors (including baseplates, upright and walk
behinds) and Rotary Drills - The earlier of (6) months from shipment to, or the accumulation of 1,000
hours of service by, the initial user.
Jackhammers, Forklifts and Self-Propelled Compactors - The earlier of twelve (12) months from
shipment to, or accumulation of 1,000 hours of service by, the initial user.
Downhole Drills - In lieu of the repair or replacement of defective parts, Ingersoll-Rand may elect to
issue full or partial credit toward the purchase of a new part. The extent of credit issued will be
determined by pro rating against the normal service life of the part in question.
Spare Parts (excluding downhill drills) - Three (3) months from date of shipment.

Manual No. 54771142 (7/01) (11) 07/18/01
Warranty
Ingersoll-Rand will provide a new part or
repaired part, at its election, in place of
any part which is found upon its
inspection to be defective in material and
workmanship during the period
prescribed above. Such part will be
repaired or replaced without charge to the
initial user during normal working hours at
the place of business of an Ingersoll-
Rand distributor authorized to sell the
type of equipment involved or other
establishment authorized by Ingersoll-
Rand. User must present proof of
purchase and date at the time of
exercising warranty.
This warranty does not apply to failures
occurring as a result of abuse, misuse,
negligent repairs, corrosion, erosion and
normal wear and tear, alterations or
modification made to the product without
express written consent of Ingersoll-
Rand; or failure to follow the
recommended operating practices and
maintenance publications.
Accessories or equipment furnished by
Ingersoll-Rand, but manufactured by
others, including, but not limited to,
engines, tires, batteries, engine electrical
equipment, hydraulic transmissions,
carriers, shall carry whatever warranty the
manufacturers have conveyed to
Ingersoll-Rand and which can be passed
on to the initial user.
This warranty is in lieu of all other
warranties (except of title), expressed
or implied, and there are no warranties
of merchantability or of fitness for a
particular purpose.
Limitation of Liability
The remedies of the user set forth under
the provisions of warranty outlined above
are exclusive and the total liability of
Ingersoll-Rand or its distributors with
respect to this sale, delivery, installation,
repair or technical direction covered by or
furnished under this sale whether based
on contract, warranty, negligence,
indemnity, strict liability or otherwise shall
not exceed the purchase price of the unit
of equipment upon which such liability is
based.
Ingersoll-Rand, its supplier(s) and its
distributors shall in no event be liable to
the user, any successors in interest or
any beneficiary or assignee relating to
this sale for any consequential, incidental,
indirect, special or punitive damages
arising out of this sale or any breach
thereof, or any defects in, or failure of, or
malfunction of the equipment under this
sale whether based upon loss of use, lost
profits or revenue, interest, lost goodwill,
work stoppage, impairment of other
goods, loss by reason of shutdown or
non-operation, increased expenses of
operation of the equipment, cost of
purchase of replacement power or claims
of users or customers of the user for
service interruption whether or not such
loss or damage is based on contract,
warranty, negligence, indemnity, strict
liability or otherwise.

Manual No. 54771142 (7/01) (12) 07/18/01
General Warranty Information
PRODUCT PACKAGE AIREND GENERATOR
Portable Compressor 1 yr/2000 hrs. 2 yr/4000 hrs. 
Portable Genset

(20-50 KW) 1 yr/2000 hrs. 2 yr/4000 hrs.
Light Tower 1 yr/2000 hrs.  1 yr/2000 hrs.
Aftercooler 6 months  
Abrasive Blast Equipment 1 year  
MANUFACTURER MONTHS HOURS EXTENDED COVERAGE
Caterpillar 12 no limit Available @ Dealer
Cummins
in service after 1 Feb 93
12
12/24
no limit
no limit/2000
Available @ Dealer major
components
2 yrs/10000 hrs.
John Deere 24 2000 Available @ Dealer
Deutz 12 no limit Available @ Dealer
Ford 12 2000 
Honda 24 no limit 
Kubota 24 2000 major components 25-36
mo/3000 hrs parts only
Vanguard 24 no limit 
White 12 2000
MANUFACTURER MONTHS HOURS COMMENTS
Ingersoll-Rand 3 no limit parts only
AIREND TYPE MONTHS HOURS COMMENTS
Vane 6 1000 parts & labor
Screw 12 2000 parts & labor
PRODUCT
WARRANTY
ENGINE
WARRANTY
PARTS
WARRANTY
AIREND
EXCHANGE
WARRANTY

Manual No. 54771142 (7/01) (13) 07/18/01
SECTION 3 - WARRANTY REGISTRATION
Complete Machine Registration
Machines shipped to locations within the United States do not require a warranty
registration unless the machine status changes (i.e. change of ownership).
Machines shipped outside the United States require notification be made to initiate the
machine warranty.
Fill out the Warranty Registration Form in this section, keep a copy for your
records and mail form to:
Ingersoll-Rand Company
Portable Compressor Division
P.O. Box 668
Mocksville, North Carolina 27028
Attn: Warranty Department
Note: Completion of this form validates the warranty.
Engine Registration:
No engine registration required. Must present Proof of Purchase whenever engine
warranty service is required.

Manual No. 54771142 (7/01) (14) 07/18/01
Warranty Registration Form
Completion of this form validates the warranty
Selling Distributor Servicing Distributor WARRANTY REGISTRATION
Name Name Owner/User Name
Address Address Address
City City City
County County County
State State State
Zip Code Zip Code Zip Code
Telephone Telephone Telephone
Complete the Applicable Blocks
Owner/User Type of Business (check one only)
Construction-Heavy Asphalt Contractor Coal Mining Other Mining
(highway, excavation, etc.)
Construction-Light Government Quarry Shallow Oil & Gas
(carpentry, plumbing, pools (municipal, state,
mason, etc.) county, etc.)
Rental Building Contractor Waterwell Utility Company
(rental center, (gas, electric, water, etc.)
rental fleet, etc.)
Industrial (plant use) Other Exploration Utility Contractor
specify
Model Unit S/N Engine S/N Date Delivered
Unit-Hours Airend S/N Truck S/N Truck Engine S/N
SERVICING DISTRIBUTOR/USER ACKNOWLEDGMENT
1 The Purchaser has been instructed and/or has read the manual and understands proper preventative
maintenance, general operation and safety precautions.
2. The warranty and limitation of liability has been reviewed and understood by the owner/user.
3. In the event that this unit is to be used within a nuclear facility, the owner/user shall notify Ingersoll-Rand of
such use so that Ingersoll-Rand may arrange for appropriate nuclear liability protection from the owner-
licensee of the facility.
4 Ingersoll-Rand reserves the right to make design changes or modifications of Ingersoll-Rand products at
anytime without incurring any obligation to make similar changes or modifications on previously sold units.
I hereby acknowledge acceptance of above.
Owner/User Date
I hereby certify that the above is accurate and complete.
Distributor/I-R Rep. Date

Manual No. 54771142 (7/01) (15) 07/18/01
- - - - - - - - - - - - - - - - - - - - - fold - - - - - - - - - - - - - - - - - - -

Manual No. 54771142 (7/01) (16) 07/18/01
SECTION 4 – SYSTEM DESCRIPTION
General
The CM air compressors are semi-packaged, air cooled units designed for power take-off applications.
Each unit is designed to operate at ambient temperatures from - 10°F to 125°F (-23.3°C to 51.7°C). For
the actual delivery of each unit at its rated operating pressure, refer to the typical General Data Decal
supplied with each unit, and to the table in Section 5.
The unit includes an oil flooded, rotary, screw-type air compressor, a compressor inlet system, a capacity
control system, a compressor lubricating oil system, a compressor discharge system as well as basic
instrumentation. The compressor inlet system includes two air intake cleaners with a service indicator.
The capacity control system includes a pressure regulator linked to a compressor inlet butterfly valve. The
compressor lubricating oil system includes an air-cooled type oil cooler, two oil filters, and oil control valve
and an oil separator tank and air receiver. The oil cooler is of the fin and tube-type construction that
requires forced draft cooling air. Basic instrumentation includes compressor discharge air pressure and
temperature gauges, and air cleaner restriction indicator.
The enclosure cabinet, in which most of the components are mounted, is of heavy gauge sheet steel and
is equipped with easy opening access panels for performing routine maintenance functions.
Compression in the screw-type air compressor is created by the meshing of two sets of helical rotors (male
and female) on parallel shafts enclosed in heavy-duty cast iron housings with air inlet and outlet ports
located at opposite ends. The airend is a two-stage type. Air is compressed to an intermediate pressure
by the first stage. The discharge of the first stage empties into the inlet of the second stage, where
compression to the final discharge pressure is accomplished. The male rotors have four lobes, 90
degrees apart and the female rotors have six grooves 60 degrees apart. The grooves of the female rotor
mesh with and are driven by the male rotor. Thrust taper roller bearings at the rear of the air end prevent
longitudinal movement of the rotors. As rotation of the compressor occurs, the rotors unmesh and free air
is drawn into the cavities or pockets between the male rotor lobes and the grooves of the female rotor.
The air is trapped in these pockets and follows the direction of rotation of each rotor. As soon as the inlet
port is closed, the compression cycle begins and the trapped air is directed to the opposite or discharge
side of the rotor housing. As the rotors mesh, the normal free volume of air is decreased and the pressure
increased until the closing pocket reaches the discharge port, (or in the case of the first stage, the
interstage cavity). Cooled lubricating oil is admitted to the compressor by being injected, in metered
amounts, directly into the rotor housing so that it passes on with the air being compressed. This removes
the heat of compression to a large degree and results in a relatively low, final discharge air temperature.
Since the CM Series compressor is of the positive displacement type, an air flow control system must be
provided to regulate the volume of air passing through the compressor to match the amount of service air
required by the customer.
Constant speed control unloads the compressor at a predetermined pressure while the driving unit
continues to operate at full speed. This is accomplished by an air operated regulator closing off the intake
to the compressor in an infinitely variable or stepless manner through the inlet butterfly valve.
The discharge air pressure can be controlled between 150 and 350 psig (1034 to 2413 kPa) by simple
readjustment of the pressure regulator adjusting screw.

Manual No. 54771142 (7/01) (17) 07/18/01
SECTION 5 - INSTALLATION
Location
After the type of drive is determined, satisfactory installation depends upon the ability of the installer. Refer
to the appropriate foundation plan located in the back of this manual for the dimensions of the compressor
package and the appropriate separator foundation plan for the dimensions of the combination primary oil
separator tank-air receiver (hereafter called the receiver separator).
Choose a clean, relatively cool location for the compressor package, and provide ample space around the
unit for general accessibility and to ensure effective heat dissipation. Extreme care must be taken in
locating an air-cooled unit of this type so there is an unrestricted supply of air to the cooling fan, which pulls
air over the oil cooler core. The fan discharge air must flow away from the unit so that it may be readily
dissipated to atmosphere without recirculating hot air to the fan intake. Any recirculation of the cooling air
may result in an excessively high compressor operating temperature. The compressor package must be
located so the compressor discharge temperature gauge and the air cleaner service indicator will be fully
visible. Included with the compressor package is a compressor discharge pressure gauge and a
discharge temperature gauge.
For the installation of the receiver separator, choose a location that is on the same level as or lower than
the compressor package. Ample space must be provided around the receiver to ensure the proper
installation of all piping connections. In addition, the receiver separator must be located so that the
separator element may be removed for inspection and service. Refer to the appropriate separator
foundation plan.
A condensate drain valve is factory supplied with the receiver separator. When installing the receiver
separator, provision should be made for easy access to this drain valve as it will be necessary to drain the
condensate daily before starting the unit.
NOTE
The condensate drain valve and line must be
located as the lowest point in the lubricating
and cooling oil system for proper condensate
removal.
The valve may also be used as a service valve for draining the lubricating and cooling oil at periodic
change intervals.
Exact level is not absolutely necessary, but it is recommended the unit be leveled with a sight glass or a
carpenter’s level set on the compressor housing. Leveling may be accomplished by shimming the unit
near the unit’s bolting holes. Be sure to use steel shims. Mounting holes are provided on the bottom of
the base and weld nuts are provided on the sides of the frame. Either may be used for mounting.
Inlet Piping
Each unit is supplied with standard air cleaners to protect the compressor from normal air-borne dust and
dirt. If necessary, the air cleaners may be removed and remotely mounted for ease in accessibility.

Manual No. 54771142 (7/01) (18) 07/18/01
PIPING
General
As CM Series compressors are comprised of two modules (compressor and separator), there is
necessarily interconnecting piping between the two. These hoses are not provided with the units, as the
required lengths of the hoses are dependent on the relative location of the two modules in their installed
location. It is left to the installer to obtain hoses of the correct type and length for each installation.
The following hoses will be needed:
LOCATION SIZE HOSE TYPE
Compressor Module to Separator
Scavenge
-6 JIC Parker-Hannifin 213, or Aeroquip
FC350, or equivalent
Compressor Module to Air
Pressure Regulator Outlet
-6 JIC Parker-Hannifin 213, or Aeroquip
FC350, or equivalent
Compressor Module to Separator
Discharge
-12 JIC Parker-Hannifin 213, or Aeroquip
FC350, or equivalent
Oil Cooler to Separator Oil Outlet -24 JIC Parker-Hannifin 213, or Aeroquip
FC350, or equivalent
Airend Discharge to
Receiver/Separator Inlet
3” Hose Stem Dana/Boston Blackjack Hose
IR P/N 43203876
NOTES:
1. All hoses terminate at marked bulkhead fittings on the left side of machine
2. All hoses terminate in Type I (SAE J516 female swivel straight), 37°JIC flare fittings on each end.
3. Airend discharge pipe is customer supplied.
Compressor Discharge Piping
The connection between the compressor package and the receiver separator must be furnished by the
customer. It is recommended the customer use a flexible line with an inside diameter of the same size, or
larger than the compressor package discharge connection. All piping must be certified safe for the
pressures and temperatures involved.

Manual No. 54771142 (7/01) (19) 07/18/01
Receiver separator Discharge Piping
The receiver separator discharge piping must be furnished by the customer. Refer to the appropriate
separator fitting location for a typical piping arrangement for these units. A minimum pressure valve and a
manual shut-off valve is supplied with each unit and must be piped into the customer’s system as
indicated. The minimum pressure valve is supplied to maintain approximately 125 psig (862 kPa) in the air
receiver tank to ensure proper oil circulation and also to prevent excessive oil carryover into the customer’s
air service system. The manual shut-off valve must be installed between the minimum pressure valve and
the customer’s air service system to serve as an isolation valve.
In addition, whenever this unit is connected to a high volume customer’s service air system, a terminal
check valve must also be installed downstream of the minimum pressure valve and the isolation valve to
prevent air from the system from bleeding back into the compressor system on shutdown.
Wiring
The compressor is protected against overheating by a thermal-type discharge air temperature switch
located in the compressor discharge piping. A “normally-closed” type thermal switch, factory set at 248°F
(120°C), is supplied as standard equipment on these units. This switch is supplied for 12/24 volt DC. As
an option, this switch may be supplied for 125 volt AC. A thermal sensor switch, also set at 248°F (120°C),
normally closed, is provided as extra protection in the receiver separator. It is to be wired in series with the
airend temperature switch by the user and then into the end user’s shutdown system. The end user’s
system must be capable of initiating shutdown of the driver engine within 3-5 seconds of opening of either
of the shutdown switches. This switch is supplied for 12/24 volts DC, with optional AC switches available
as an option.
Driver
The installation of a CM Series Compressor with any drive such as a power take-off drive or a hydraulic
motor drive is very flexible. The proper rotation of the compressor is clockwise when viewed from the
driver end.
NOTE
Because the compressor is of the axial
screw type, the rotation cannot be changed.
MODEL CAPACITY TORQUE REQUIRED POWER REQUIRED INPUT
CFM M3/MIN. POUND - FEET N.M BHP KILOWATTS RPM
XHP900 900 25.4 1152 1563 395 294 1800
Note: Power requirements include fan.
A drive shaft from the source of power take-off is used to drive the compressor. It is extremely important
that the angularity of the drive shaft, including the universal joints, be within the limits specified by the
manufacturer. The power take-off shaft and the compressor rotor drive shaft must always be parallel.
This gives the same angle at each universal joint and prevents excessive wear. The forks of the universal
joint on the drive end must be installed parallel to the forks on the driven end universal. There are many
types of universal joints that can be used. However, a constant velocity universal joint as previously
described will reduce the possibility of torsional vibration. If a slip joint or spline is used on the drive
system, it should be placed between the two universal joints for best results.
It is NOT permissible to directly belt drive this unit, or use any configuration of drive that puts side
load on the compressor drive shaft. Belt or other side loads must be supported by external
bearings.

Manual No. 54771142 (7/01) (20) 07/18/01
Regulation
The standard regulation system supplied with CM Series Compressors is designed to provide capacity
control for the compressor only. Variable speed control of a driver engine is possible with additional
equipment. Consult Ingersoll-Rand Company, Specialty Products Department for technical assistance for
these applications.
The adjustment and operation of the standard regulation system is described in Section 6, Operating
Instructions.